Multi-Piece Ferrule Coupling to Prevent Duct Cracking
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Solution Overview
Problem
Current ferrule couplings for joining inner and outer ducts are susceptible to cracking and separation due to temperature changes and stress, and require welding, which makes them prone to rework and reduces their service life.
Innovation Solution
A multi-piece ferrule coupling system using an inner ferrule, an intermediate ferrule, and an outer ferrule, where the ferrules are mechanically joined without welding, forming an electrostatic bond path that is resistant to temperature-based stresses and maintains reliability over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join ferrules together, then the coupling strength is improved, but the reliability deteriorates due to susceptibility to cracking and separation from temperature changes and stress
Solution Approach 1:
The patent replaces the welding (thermal/mechanical) system with an electrostatic bonding system. The electrostatic bond path is formed between the inner duct and outer duct through the ferrule coupling, eliminating the need for welding and its associated vulnerabilities to temperature changes and stress-induced cracking.
Solution Approach 2:
The patent changes the bonding mechanism from thermal welding to electrostatic bonding. This parameter change in the joining method fundamentally alters how the ferrules are connected, replacing a process vulnerable to thermal stress with one that is resistant to temperature-based stresses.
2Strength
If welding is used to join ferrules, then the coupling is permanently joined, but the ease of repair deteriorates due to inability to disassemble components
Solution Approach 1:
The patent divides the coupling system into separable components (inner ferrule, outer ferrule, intermediate ferrule) that can be individually removed and reassembled. This segmentation allows for maintenance and repair while maintaining coupling strength during operation.
Solution Approach 2:
The patent replaces the permanent welding system with a mechanically separable electrostatic bonding system, enabling components to be disassembled for repair while maintaining strong operational coupling.
3Ease of manufacture
If welding is used to join ferrules, then the manufacturing process is simplified, but the duration of action deteriorates due to reduced service life
Solution Approach 1:
The patent replaces welding with electrostatic bonding, which eliminates the complex thermal processes and skill requirements of welding while producing a more durable connection with extended service life resistant to temperature-based stresses.
Solution Approach 2:
The patent changes the manufacturing process from thermal welding to electrostatic bonding, transforming both the ease of manufacture and the duration of action by creating a connection that is simpler to produce and more durable over time.
Data Source
AI summary
An apparatus comprising an inner ferrule and an outer ferrule. The inner ferrule comprises a plurality of engagement sections that define a plurality of gaps between the plurality of engagement sections. The outer ferrule is disposed around at least a portion of the inner ferrule. The outer ferrule comprises an engagement area mechanically joined to the plurality of engagement sections to join the inner ferrule to the outer ferrule.