Electrical Feedthrough Assembly for Gas-Tight Heater Contacting
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Solution Overview
Problem
Existing methods for producing electrical feedthroughs for heatable catalytic converters are costly and complex due to the use of multi-layer compacted bar materials, resulting in significant material waste and inefficiency.
Innovation Solution
An electrical feedthrough comprising a central conductive pin, an insulating layer, and a bushing, connected through a form fit or force fit, allowing independent production and assembly with applied forces to create a durable, cost-effective connection, preventing electrical shorts and ensuring gas-tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-layer compacted bar material is used for producing electrical feedthroughs, then the feedthrough can be produced with integrated structure, but the material cost increases and significant material waste occurs due to machining removal
Solution Approach 1:
The electrical feedthrough is divided into separate components (conductive pin, insulating layer, bushing) that are produced independently and then assembled. This segmentation allows each component to be manufactured from appropriate materials with minimal waste, avoiding the need to machine away large portions of expensive multi-layer compacted bar material while still achieving the integrated functional structure.
Solution Approach 2:
The invention changes the manufacturing approach from a single integrated material (multi-layer compacted bar) to separate components with different material properties. Each component can be optimized for its specific function, reducing overall material cost and waste while maintaining the required electrical and mechanical properties.
2Ease of manufacture
If multi-layer compacted bar material with complex structure is used, then the feedthrough can be produced as a single piece, but the production complexity and cost increase significantly
Solution Approach 1:
By segmenting the feedthrough into separate components (pin, insulating layer, bushing), each component can be manufactured using simple, well-established processes. The assembly of these standardized components is more straightforward than producing a complex multi-layer compacted bar structure, thereby reducing overall production complexity despite involving multiple parts.
Solution Approach 2:
The invention combines separately manufactured components into a functional assembly that achieves the same integrated result. This merging approach allows each component to be produced independently using simpler processes, avoiding the complexity of producing a single integrated multi-layer structure while maintaining the feedthrough's functional integrity.
3Manufacturing precision
If machining methods are used to trim compacted bar material to desired dimensions, then the feedthrough can be precisely sized, but approximately two thirds of the bar material is destroyed and wasted
Solution Approach 1:
The feedthrough components are produced as separate pieces with their final dimensions established during component manufacturing rather than through extensive machining of a large compacted bar. This segmentation allows each component to be sized efficiently, minimizing material waste while achieving the required dimensional precision for the assembled feedthrough.
Solution Approach 2:
The components are pre-formed to their near-final dimensions during the manufacturing of individual parts (pin, insulating layer, bushing) before assembly. This preliminary sizing action eliminates the need for subsequent machining operations that would remove large amounts of material, thereby reducing waste while maintaining manufacturing precision.
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 solution simplifies and reduces production costs by enabling cost-effective, durable, and efficient assembly of electrical feedthroughs, minimizing material waste and ensuring long-term durability and electrical insulation.
Implementation Method 1
The components are connected to one another by a form fit and/or a force fit such that they cannot be separated non-destructively
Data Source
AI summary
An electrical feedthrough and a method for producing an electrical feedthrough for contacting a heating conductor of an electrically heatable honeycomb body, comprising an electrically conductive pin, an electrically insulating insulation layer and a bushing in which the insulation layer and the pin are at least partially accommodated. The pin is arranged centrally and at least some portions of it are completely surrounded in the circumferential direction by the insulation layer. The three elements are connected to one another by a form fit and/or a force fit such that they cannot be separated non-destructively.