Conductive Media Line Assembly for Static Dissipation in ATEX Areas
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Solution Overview
Problem
Existing devices for transporting media in potentially explosive areas face challenges such as electrostatic charging leading to ignition sparks, as they require pre-assembly and cannot be cut to size, with ring-well casings being prone to damage and offering limited protection against weather and charge dissipation.
Innovation Solution
A device with an electrically conductive outer casing and inner envelope, incorporating carbon nanotubes for conductivity, a conductive cap, and a dissipative shrink tube, allowing for on-site assembly and effective charge dissipation to prevent sparks, featuring an intermediate heat-insulating layer and earthed potential equalization conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If preassembled lines with ring-well tubes are used, then charge dissipation is achieved, but the lines cannot be cut to size on-site and require complete assembly in ATEX-certified plants
Solution Approach 1:
The device is divided into separate modular components: an outer casing, an inner envelope, and intermediate layers that can be assembled on-site. This segmentation allows the system to be transported in parts and assembled at the installation location rather than requiring complete pre-assembly in certified plants.
Solution Approach 2:
The outer casing is pre-configured with conductive properties and structural features that enable charge dissipation and weather protection before assembly. The inner envelope and intermediate layers are prepared separately with their respective functions (conductive coating, heat insulation) already in place, allowing for preliminary preparation without complete assembly.
2Ease of manufacture
If ring-well casings are used, then charge dissipation is provided, but the casing is prone to damage from sharp edges and lacks long-term weather protection
Solution Approach 1:
The device employs a nested structure where the inner envelope is placed inside the outer casing, with intermediate layers between them. The outer casing provides robust mechanical protection and weather resistance, while the inner envelope with conductive coating provides charge dissipation. This nested arrangement allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
The device uses composite construction with different materials optimized for specific functions: the outer casing uses durable, weather-resistant material with conductive properties; the inner envelope uses material coated with conductive layer for charge dissipation; intermediate layers use heat-insulating materials. This composite approach combines the advantages of different materials to achieve both protection and charge dissipation.
3Ease of manufacture
If the outer casing is made thin for charge dissipation, then charge dissipation is improved, but protection against weather effects is reduced
Solution Approach 1:
The nested structure allows the outer casing to be thicker for weather protection while the inner envelope provides the charge dissipation function. The intermediate layers fill the space between, maintaining thermal and electrical properties without requiring the outer casing to be thin.
Solution Approach 2:
Different parts of the device have different thickness and material properties optimized for their specific functions. The outer casing has sufficient thickness for mechanical strength and weather resistance, while the inner envelope with conductive coating is optimized for charge dissipation. This local optimization allows each component to perform its function effectively without compromising overall system performance.
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
Enables safe and flexible assembly in explosive areas by preventing ignition sparks and providing long-term protection against weather, with enhanced durability and reliability in charge dissipation, allowing for secure operation in IIC zones.
Implementation Method 1
The outer casing (32) is configured to be electrically conductive or dissipative. The material from which the outer casing (32) is produced is produced from extruded thermoplastic urethane with a homogeneously distributed content of 1 to 6 wt % CNTs, in particular 4 wt.-% CNTs
Implementation Method 2
An intermediate layer (68) made of heat-insulating material, in particular of thermo-fleece or glass fiber fleece, or combinations thereof, is arranged between the inner and the outer envelope (38, 50)
Implementation Method 3
The inner envelope (38) is connected to a potential equalization conductor (58), in particular to an earthing system, via a conductive connection
Implementation Method 4
The inner envelope (38) is connected to a potential equalization conductor (58), in particular to an earthing system, via a conductive connection
Data Source
AI summary
A device for transporting a medium includes at least one channel which extends in an axial direction and through which the medium is guided. The channel is enclosed by an electrically conductive inner envelope that is connected to a first potential equalization conductor. An electrically conductive outer envelope is provided between the channel and an electrically conductive outer casing and is connected to an electrically conductive second potential equalization conductor. Arranged between the channel and the outer envelope is an electrically insulating intermediate layer which is produced from heat-insulating material.