Electrode Holder Locking Protrusions High Temperature Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrode holders for detecting liquid levels or conductivity in metal containers face issues with insulator degradation at high temperatures, leading to potential electrode shaft dislodgment, liquid leakage, and abrasion due to differences in thermal expansion and material compatibility.
Innovation Solution
The electrode holder incorporates a metal container mounting portion with a ring-shaped seat and engagement protrusions on the electrode shaft, along with rotation stop features and a dual-layer insulator comprising heat-resistant engineering plastic and water-repellent fluorine-based resin to prevent dislodgment, leakage, and abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a synthetic resin insulator is used to electrically insulate the electrode shaft from the metal container, then electrical insulation is achieved, but the insulator cannot resist high temperatures and may be destroyed
Solution Approach 1:
The patent uses a composite insulator structure combining synthetic resin with a heat-resistant coating layer. The coating layer contains heat-resistant particles dispersed in a resin matrix, creating a composite material that maintains electrical insulation properties while withstanding high temperatures. This resolves the contradiction by integrating two material systems with complementary properties.
2Reliability
If the electrode shaft and container mounting portion are formed of metal with the insulator formed of synthetic resin, then electrical insulation is achieved, but abrasion occurs due to difference in coefficient of linear expansion and mold shrinkage factor
Solution Approach 1:
The patent modifies the insulator's dimensional parameters by adding a heat-resistant coating layer that compensates for differential thermal expansion and mold shrinkage. The coating layer's properties are specifically designed to match the thermal expansion characteristics of the metal components, reducing relative movement and abrasion between interfaces while maintaining electrical insulation.
3Reliability
If the insulator is destroyed due to high temperature, then the electrode shaft may come out of the container mounting portion, but liquid leakage occurs from the gap between electrode shaft and container mounting portion
Solution Approach 1:
The patent implements a sealing structure that provides backup protection against liquid leakage before the insulator completely fails. The sealing mechanism is designed to compensate for insulator degradation and maintain liquid tightness even when the insulator is damaged, preventing catastrophic failure and allowing for gradual replacement.
4Ease of operation
If torsional torque is applied to the electrode shaft or container mounting portion, then the insulator may rotate and cause abrasion, but liquid leakage occurs from the gap generated by abrasion
Solution Approach 1:
The patent introduces an anti-rotation protrusion on the insulator that engages with a corresponding feature on the container mounting portion. This intermediary mechanical feature prevents relative rotation between the insulator and mounting portion, eliminating abrasion caused by torsional torque while maintaining the electrical insulation function and preventing liquid leakage.
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
This design effectively prevents electrode shaft dislodgment and liquid leakage even under high-temperature conditions, maintains insulation integrity, and enhances durability by engaging protrusions and stop features, while the dual-layer insulator ensures heat resistance and water repellency.
Implementation Method 1
an outer peripheral surface of the insulator is coated with a fluorine-based resin
Implementation Method 2
a inner layer which covers a outer periphery of the electrode shaft and comes into contact with the electrode shaft, and an outer layer which covers a part of an outer periphery of the inner layer, the inner layer being formed of engineering plastic having heat resistance
Data Source
AI summary
A substantially ring-shaped seat section (8) protrudes from an inner circumference wall in a through hole (4) of a container attaching section (6) made of a metal. On an outer circumference of an electrode shaft (3) held in the through hole (4) through an insulator (5) made of a synthetic resin, locking protrusions (13, 14), which have a diameter larger than a hole diameter of the seat section (8), are provided at a distance from the seat section (8), on at least inner side or outer side of the seat section (8) in a shaft direction of the electrode shaft (3). Thus, for instance, when the inside of the metal container (2) is at a high temperature, the insulator (5) is destroyed and the electrode shaft (3) is to jump out from the container attaching section (6) to the outside or the inside of the metal container (2), the locking protrusions (13, 14) lock the seat section (8) and prevent the electrode shaft (3) from jumping out. Furthermore, since a space provided between the electrode shaft (3) and the container attaching section (6) due to the destruction of the insulator (5) is covered by having the locking protrusions (13, 14) lock the seat section (8), leakage of a liquid in the metal container (2) can be suppressed to minimum even the insulator (5) is destroyed.