Integrated Insulator Seal and Shield Assembly for Fewer Parts
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Solution Overview
Problem
Conventional corona protection devices for electrical polymer insulators require a large number of parts, leading to increased manufacturing costs and potential for incorrect installation, which can result in reduced performance and durability.
Innovation Solution
An integrated insulator sealing and shielding assembly featuring a rubber housing with radial weathersheds and a tapered end, combined with a metal end fitting and collar assembly, providing multiple sealing surfaces and a compressive sealing force to secure the connection between the rubber housing and metal end fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional corona protection devices use multiple separate parts, then sealing and shielding functions can be provided, but manufacturing costs increase and installation complexity increases
Solution Approach 1:
The patent combines multiple separate components (corona protection device, sealing elements, and shielding elements) into a single integrated assembly. The corona protection device is directly coupled to the shielded volume, which contains the sealing elements, eliminating the need for separate assembly of multiple parts and reducing installation complexity while maintaining all required functions.
2Reliability
If conventional corona protection devices use multiple separate parts, then sealing and shielding functions can be provided, but manufacturing costs increase due to secondary operations and quality checks
Solution Approach 1:
The integrated assembly allows corona protection devices to be manufactured as a single unit, eliminating secondary assembly operations and corresponding quality checks that would be required for multiple separate parts, thereby reducing manufacturing costs.
3Reliability
If conventional corona protection devices use multiple separate parts, then sealing and shielding functions can be provided, but incorrect installation may occur resulting in reduced performance and durability
Solution Approach 1:
By integrating the corona protection device, sealing elements, and shielding elements into a single pre-assembled unit, the patent eliminates installation steps where errors could occur, ensuring correct installation and maintaining optimal performance and durability.
4Reliability
If the rubber housing is tapered into the metal fitting to increase compression connection, then sealing capability is improved, but manufacturing complexity of the rubber housing increases
Solution Approach 1:
The rubber housing incorporates a tapered geometry that transitions into the metal fitting, creating a compression connection. The tapered shape allows the rubber housing to be compressed between the collar assembly and metal fitting, improving sealing capability through the compressive force while the taper provides a gradual transition that may simplify manufacturing compared to sharp angles or complex geometries.
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 integrated assembly reduces manufacturing costs by minimizing the number of parts and secondary operations, while enhancing durability and performance through improved sealing and shielding capabilities.
Implementation Method 1
The ring is compressible. The counterbore has a sealing surface so that interference of the ring with the sealing surface creates a compressive sealing force to form a seal.
Data Source
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AI summary
An integrated insulator sealing and shielding assembly includes a rubber housing having a plurality of radial weathersheds and a tapered end adjacent an endmost radial weathershed. The tapered end has an outer surface with a ring extending outward from the outer surface. The ring is compressible. A metal end fitting is disposed adjacent to the endmost radial weathershed and receives the tapered end. The tapered end is received in a counterbore in the metal end fitting. The counterbore has a sealing surface so that interference of the ring with the sealing surface creates a compressive sealing force to form a seal.