High-Temperature Plug With Ceramic Insulation
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Solution Overview
Problem
Existing high-temperature plugs are either unsuitable for applications above 120°C due to thermal loads, require significant manufacturing effort, and have high space requirements, especially for multipole connections.
Innovation Solution
A high-temperature plug design featuring a metal jacket with embedded wire sections and a metal connection sleeve, where the wire ends are insulated with a ceramic compound or metal oxide, providing both thermal and electrical insulation and fixing, allowing for a compact and efficient manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic inserts are used to electrically insulate and fix contact elements, then ease of manufacture is improved at lower temperatures, but reliability deteriorates at high temperatures above 120°C
Solution Approach 1:
The patent changes the material parameter from plastic to ceramic insulation compound, which maintains its insulating properties at high temperatures. The ceramic material undergoes no significant parameter change up to 1000°C, ensuring reliable electrical insulation where plastic would fail.
Solution Approach 2:
The patent uses a composite structure combining ceramic insulation compound with metal contact elements and connection sleeve. This composite approach leverages the high-temperature stability of ceramics while maintaining the electrical conductivity needed for contact elements.
2Reliability
If individual pole connections are surrounded with PEEK housing or heat-shrinkable sleeve, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the ceramic insulation compound: electrical insulation, thermal insulation, and mechanical fixing of contact elements. This eliminates the need for separate PEEK housing or heat-shrinkable sleeves, reducing device complexity while maintaining reliability.
Solution Approach 2:
The ceramic insulation compound serves multiple functions simultaneously: it provides electrical insulation between poles, thermal insulation to protect against heat, and mechanical support to fix contact elements in position. This multi-functionality simplifies the overall plug design.
3Reliability
If connection is established for every individual pole between contact element and conductor, then reliability is improved, but volume increases
Solution Approach 1:
The patent nests the ceramic insulation compound within the metal connection sleeve, and embeds contact elements within the ceramic material. This nested arrangement allows individual pole connections to be made without increasing overall plug volume, as components are arranged concentrically rather than additively.
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 results in a compact, easily manufactured high-temperature plug with improved thermal resistance and stability, enabling efficient connections for heating elements and thermocouples without interrupting operating voltage, even at temperatures above 300°C.
Implementation Method 1
an insulation compound or a metal oxide, such that the embedding fixes the contact element in the connection sleeve
Implementation Method 2
take over electrical insulation of the individual poles and of the housing formed by the connection sleeve at least in sections
Data Source
AI summary
A high-temperature plug (10) is provided for a heating element and/or thermocouple or a temperature sensor with at least one wire section (18) embedded in an insulating manner within a metal jacket (16) with a wire end (14) led out from the metal jacket (16) on the front side. The high-temperature plug (10) has a connection sleeve (11) made of metal, into which the at least one wire section (18) embedded in an insulating manner within the metal jacket (16) opens. At least one contact element (12) is in electrical contact within the connection sleeve (11) with the wire end (14) led out from the metal jacket (16) on the front side. At least the end section, facing the at least one wire end (14), of the at least one contact element (12) is embedded in an insulating compound (13) or a metal oxide, such that the embedding fixes the contact element (12) in the connection sleeve.