Ceramic-Nickel Electric Feedthrough for Hot Corrosive Pressure Seals
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Solution Overview
Problem
Existing electric feedthroughs fail in high temperature, high pressure, and corrosive environments due to susceptibility to thermal degradation, mechanical stress, and corrosion, particularly in ammonia cracking systems, leading to device failure.
Innovation Solution
The electric feedthrough assembly employs a pass-thru stud with nickel alloy washers and ceramic washers, along with an insulating sleeve and a body with internal threading, designed to withstand high temperatures and pressures, using materials like Inconel and silicon nitride for enhanced corrosion resistance and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If known electric feedthroughs are used in high temperature environments, then they can conduct electric current, but they suffer from thermal degradation and failure due to unmanaged thermal expansion differences
Solution Approach 1:
The patent changes the material parameters by selecting components with compatible thermal expansion coefficients. The metal sleeve is specifically chosen to have a coefficient of thermal expansion between 10-15 µm/m·K, matching the housing material, while the insulator has a coefficient between 5-10 µm/m·K. This parameter matching prevents thermal stress accumulation during temperature cycling.
Solution Approach 2:
The feedthrough employs a composite structure with multiple materials (metal sleeve, ceramic insulator, sealing elements) carefully selected for their thermal expansion properties. The metal sleeve acts as a thermal buffer between the housing and the insulator, absorbing expansion differences and preventing structural failure.
2Ease of operation
If known electric feedthroughs are used in corrosive environments like heated ammonia, then they can provide electrical connection, but they suffer from rapid corrosion and material degradation
Solution Approach 1:
The patent creates a chemically inert environment by using corrosion-resistant materials that do not react with heated ammonia. The metal sleeve and sealing elements are selected from materials known to be resistant to ammonia corrosion, effectively isolating the electrical components from the corrosive atmosphere.
Solution Approach 2:
The feedthrough uses a composite construction with corrosion-resistant metal sleeve, ceramic insulator, and specialized sealing materials. This multi-material approach ensures that each component is optimized for corrosion resistance in the specific environment, with the metal sleeve providing the primary barrier against ammonia attack.
3Power
If known electric feedthroughs are used in high pressure environments, then they can maintain electrical continuity, but they suffer from mechanical stress and seal failure
Solution Approach 1:
The patent optimizes the mechanical parameters of the feedthrough components, including wall thickness, material strength, and geometric configuration. The metal sleeve is designed with sufficient thickness and reinforcement features to withstand high pressure differentials, while maintaining electrical insulation integrity.
Solution Approach 2:
The feedthrough employs a composite structure where the metal sleeve provides mechanical strength and pressure containment, the ceramic insulator maintains electrical isolation, and specialized sealing elements ensure pressure tightness. This division of functional responsibilities allows each material to optimize for its primary property.
4Reliability
If known electric feedthroughs are used in high vibration environments, then they can provide stable electrical connection, but they suffer from mechanical stress and potential failure
Solution Approach 1:
The patent modifies the mechanical parameters including increasing the strength and ductility of the metal sleeve material, optimizing the geometry of stress concentration areas, and designing the sealing elements to accommodate vibration-induced movements without compromising the electrical connection.
Solution Approach 2:
The feedthrough uses a composite construction where the metal sleeve absorbs and distributes vibration stresses, the ceramic insulator maintains rigid electrical isolation, and flexible sealing elements accommodate vibrational movements. This composite approach allows the assembly to withstand high vibration environments while maintaining electrical integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly effectively conducts electric currents in high temperature, high pressure, and corrosive environments, providing reliable power supply to catalyst units by managing thermal expansion and resisting corrosion, thus preventing device failure.
Implementation Method 1
when known electric feedthroughs are exposed to high temperatures which are significantly higher than those at which its components were assembled, these components expand by different amounts due to differences in coefficient of thermal expansion
Implementation Method 2
The insulating material can in turn be surrounded by a metal sleeve
Implementation Method 3
Heated ammonia is known to be especially corrosive, and is characterized by its ability to attack and damage many materials, including steel, stainless steel, copper, brass, aluminum, rubbers, and plastics
Data Source
AI summary
The present invention relates, in general, to an apparatus for an electrical power feedthrough suitable for use in high temperature, high pressure, and/or corrosive environments, such as, for example, within ammonia cracking (i.e., dissociation) systems. The present invention is fabricated from conductive nickel alloys which have high melting temperatures, and which are resistant to corrosion at high temperatures, as well as non-conductive ceramic materials which provide electrical insulation between the systems that feedthrough is coupled to.