Sample Encapsulation Chamber Thermal Expansion Fit
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Solution Overview
Problem
Existing sample encapsulation systems face challenges with precise component fit due to cast manufacturing, leading to higher material mass, longer heat-up and cool-down times, and difficulties in coolant drainage, which can result in sample preparation complications such as edge rounding and handling issues.
Innovation Solution
A sample encapsulation system with a chamber/housing assembly made from dissimilar metals with different thermal expansion rates, where the chamber and inner housing are machined components that form a tight fit by exploiting thermal expansion differences, and a passive coolant drainage system using a vacuum relief check valve to facilitate quick coolant removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast components are used for chamber and housing, then manufacturing is easier, but manufacturing precision and component fit are poor
Solution Approach 1:
The housing is divided into an inner housing and an outer housing, with the chamber fitting between them. This segmentation allows each component to be manufactured separately with appropriate tolerances, and then assembled to achieve the required overall precision and tight fit.
Solution Approach 2:
The chamber is nested between the inner housing and outer housing, creating a three-component assembly. This nested structure allows the chamber to be precisely positioned and secured, achieving good component fit while allowing each part to be manufactured independently.
2Strength
If cast components with higher material mass are used, then structural strength is improved, but heat-up and cool-down times increase
Solution Approach 1:
The housing components use thin-walled constructed from aluminum or other lightweight materials that provide sufficient structural strength while minimizing mass. This reduces the thermal inertia of the system, enabling faster heat-up and cool-down cycles.
Solution Approach 2:
The system uses composite construction with the chamber made from one material (e.g., steel) and the housing from another (e.g., aluminum), combining the strength benefits of different materials while optimizing the overall mass and thermal response of the system.
3Stress or pressure
If cooling fluid is not quickly drained, then system pressure is maintained, but sample preparation quality deteriorates due to handling issues
Solution Approach 1:
The drainage system is designed to automatically and quickly drain the cooling fluid immediately after the cooling cycle completes and the sample is removed. This preliminary drainage action prevents handling issues and maintains sample preparation quality.
Solution Approach 2:
The system uses gravity-driven drainage with strategically positioned drains that automatically drain the cooling fluid without requiring external pumping or manual intervention, enabling quick and reliable fluid removal.
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 system achieves a high degree of reliability with lower mass, reduced heat-up and cool-down times, and efficient coolant drainage, ensuring precise sample preparation and handling.
Implementation Method 1
The chamber and inner housing can be formed from dissimilar metals having different rates of thermal expansion
Implementation Method 2
A cooling assembly is in communication with the chamber and adapted for cooling the sample following the encapsulation cycle
Implementation Method 3
A heating assembly is positioned at least in part in the inner housing
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A sample encapsulation system (10) includes a fixture, a base (12), a chamber (14) having an inlet and a chamber housing (16). The housing (16) has inner (36) and outer (38) housings. The chamber (14) is fixedly mounted in the inner housing (36). The base, chamber (14) and housing (16) are affixed relative to one another and movable relative to the fixture. The system includes a cap (78) and a first ram (80) operably mounted to the cap (78) for engaging the chamber inlet. A second ram (24) is positioned in the chamber (14) opposite the inlet and moves toward and away from the first ram (80). The second ram (24) is driven by a cylinder. A heating assembly is positioned in the inner housing (36) and a cooling assembly which includes a cooling jacket (50) defined in part by the inner housing (36) and the outer housing (38) includes a manifold (60). The chamber (14), chamber housing (16) and base (12) are movable toward the cap (78) for engaging the first ram (80) with the chamber inlet during an encapsulation cycle and away from the cap (78), disengaging the first ram (80) from the chamber inlet following an encapsulation cycle. The cooling system includes a vacuum breaker (62) to self-drain following cooling.