Hermetic Electrical Coupler for Vacuum Chamber Heater Mats
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting heater mats to power supplies in vacuum chambers for composite material curing often result in vacuum leaks, damage to components, and lengthy lay-up times due to the need for multiple layers of vacuum sealant tape and complex routing of power leads.
Innovation Solution
An electrical coupler with male and female connector portions is integrated into the heater mat, allowing hermetic extension through a flexible wall of the vacuum chamber, providing a robust and efficient electrical connection to circuitry outside the chamber, reducing the need for external sealing and minimizing component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power leads are routed out of the vacuum chamber through the interface of the vacuum bag film and composite material using multiple layers of vacuum sealant tape, then electrical connection is achieved, but vacuum leaks occur and component damage happens during debagging
Solution Approach 1:
The electrical connection system is segmented into three distinct parts: (1) an electrical connector integrated into the heater mat that hermetically seals through the vacuum bag film at a dedicated port, (2) a separate power lead that connects to the connector outside the vacuum chamber, and (3) a power supply unit. This segmentation allows the vacuum seal to be maintained at the critical interface while enabling reliable electrical connection through the sealed port, eliminating vacuum leaks and preventing component damage during debagging.
Solution Approach 2:
An electrical connector serves as an intermediary component that bridges the heater mat and the power supply system. This connector is integrated into the heater mat assembly and hermetically seals through the vacuum bag film at a dedicated port, acting as a mediator that maintains vacuum integrity while enabling electrical connection. The power leads connect to this intermediary connector outside the vacuum chamber, preventing direct penetration of the vacuum seal and eliminating leaks.
2Ease of manufacture
If complex routing of power leads through the vacuum chamber interface is used to achieve electrical connection, then electrical interconnection is established, but lay-up time increases significantly
Solution Approach 1:
The electrical connector is pre-integrated into the heater mat assembly before the composite material is placed in the vacuum chamber. This preliminary integration eliminates the need for complex routing of power leads through the vacuum chamber interface during the lay-up process. The connector is already positioned and hermetically sealed to the vacuum bag film at a dedicated port, allowing for quick connection of power leads outside the vacuum chamber and significantly reducing lay-up time.
Solution Approach 2:
The electrical connection interface is extracted from the vacuum chamber interior and relocated to the exterior. The electrical connector remains integrated into the heater mat, but the connection point for power leads is positioned outside the vacuum chamber. This extraction eliminates the need for complex routing through the vacuum interface and reduces lay-up time by allowing straightforward connection of power leads in the external environment.
3Reliability
If multiple layers of vacuum sealant tape are applied to seal the interface, then sealing is attempted, but the process becomes complex and time-consuming
Solution Approach 1:
The vacuum bag film with its integrated sealing system acts as a disposable component that provides hermetic sealing without requiring multiple layers of vacuum sealant tape. The electrical connector is designed to hermetically seal through the vacuum bag film at a dedicated port, and the entire assembly is removed after a single use. This approach eliminates the complexity of applying and managing multiple layers of sealant tape while maintaining reliable vacuum sealing.
Solution Approach 2:
The electrical connector serves as an intermediary that provides hermetic sealing through the vacuum bag film at a dedicated port, replacing the need for multiple layers of vacuum sealant tape. This connector is specifically designed to maintain vacuum integrity while enabling electrical connection, simplifying the sealing process by eliminating the complex multi-layer tape application procedure.
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 solution significantly reduces vacuum leaks, enhances durability, and simplifies the bagging and debagging processes by maintaining a leak-tight seal and allowing for efficient electrical interconnection of heater mat components with circuitry, thereby improving the efficiency of composite material curing.
Implementation Method 1
an alternative heat source, such as a heater mat (e.g., including electrical resistance wires encapsulated in silicon rubber), may be used to raise the temperature of a composite repair material to a cure temperature
Implementation Method 2
the heater mat and the composite repair material are compacted toward the damaged composite material through atmospheric pressure applied via a vacuum bag film
Data Source
AI summary
A method of supplying electricity to an electrical component inside a vacuum chamber may include positioning an electrical component inside a vacuum chamber, the electrical component having a first electrical connector portion. A second electrical connector portion may then be connected to the first electrical portion through a hole in a flexible wall of the vacuum chamber, the second electrical connector portion being electrically connected to circuitry disposed outside the vacuum chamber. The connecting step may include hermetically clamping the flexible wall of the vacuum chamber between the first and second electrical connector portions.