Electrically Heated Heat Shrink Component for Fast Flame-Free Assembly
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Solution Overview
Problem
Existing heat shrink components require lengthy installation times and pose safety risks due to the use of open flames, and existing heating systems are inefficient or costly, particularly for high-voltage applications where temperatures above 120°C are needed.
Innovation Solution
A heat shrink component with an electrically conductive lead made of copper and/or aluminum, providing a heating unit in thermal contact with the heat shrink layer, capable of reaching temperatures above 120°C using electrical energy, thereby reducing installation time and eliminating the need for open flames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If open flames or hot air guns are used for heat shrinkage, then the heat shrink component can be shrunk, but the installation time becomes excessively long (greater than 15 minutes) and safety risks increase
Solution Approach 1:
The patent replaces the mechanical/chemical heating system (open flames, hot air guns) with an electrical heating system. The heat shrink component includes an electrically conductive layer that converts electrical energy directly into heat through resistive heating, eliminating the need for external flame sources and significantly reducing installation time while improving safety.
Solution Approach 2:
The patent changes the heating parameter from external thermal source (flame/hot air) to internal electrical energy conversion. The electrically conductive layer is designed with specific electrical conductivity properties to generate heat efficiently when electrical current passes through it, enabling rapid heating and shrinking within 15 minutes or less.
2Productivity
If open flames are used for heat shrinkage, then the component can be shrunk, but energy consumption increases and safety hazards are created
Solution Approach 1:
The patent substitutes external thermal energy sources (open flames, hot air guns) with an internal electrical heating system. The electrically conductive layer converts electrical energy directly into thermal energy at the location where heat is needed, eliminating energy losses associated with external heating methods and improving overall heating efficiency.
Solution Approach 2:
The heat shrink component performs its own heating function through the electrically conductive layer that generates heat internally when electrical current is applied. This self-heating capability eliminates the need for external energy sources and reduces energy consumption by directing energy precisely where it is needed.
3Reliability
If conventional heating systems are used, then heat shrinkage can be achieved, but the installation process becomes complex and costly
Solution Approach 1:
The patent merges the heating function directly into the heat shrink component by incorporating an electrically conductive layer within the insulation layer. This integration eliminates the need for separate external heating devices and complex heating systems, simplifying the overall installation process while maintaining reliable heating performance.
Solution Approach 2:
The patent replaces complex mechanical heating systems (hot air guns, tunnel heaters, ceramic radiation features) with a simple electrical heating system. The electrically conductive layer provides reliable heating through resistive heating when electrical current is applied, significantly reducing system complexity while maintaining or improving heating reliability.
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 enables rapid and safe heat shrinkage of components, reducing installation time to under 10 minutes and lowering energy consumption, while being cost-effective for high-voltage applications by efficiently distributing heat across the component.
Implementation Method 1
an electrically conductive lead formed of copper and/or aluminum and having an electrical conductivity of more than 3·107 S/m
Implementation Method 2
Heat shrink components are articles made from material which shrinks from an expanded state into a shrunk state with much smaller dimensions by applying a sufficient amount of heat
Data Source
AI summary
A heat shrink component includes a heat shrink layer and a heating unit in thermal contact with at least a part of the heat shrink layer and heating the heat shrink layer to a heat shrink temperature. The heating unit includes an electrically conductive lead formed of copper and/or aluminum and having an electrical conductivity of more than 3·107 S/m. The heat shrink component has a first dimension in an expanded state and a second dimension in a shrunk state after heating. The first dimension is larger than the second dimension.