Electrically Isolated Coupler With Failsafe Dielectric Coating
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Solution Overview
Problem
Metallic socket tools can corrode and create shock or spark hazards when used around electrically powered equipment, and existing isolation designs often fail under high torque loads, posing a risk of electrical contact and safety hazards.
Innovation Solution
An electrically isolated coupling device with a drive body, driven body, and insulating member, where the interface portions are coated with a dielectric material having a dielectric strength greater than 10 kV, providing secondary isolation in case the primary isolation fails, ensuring continued electrical separation even under high torque conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic socket is coated with non-conductive material to prevent corrosion and electrical hazards, then electrical isolation is improved, but the coating wears away under high torque and repeated contact, degrading tool performance
Solution Approach 1:
The socket is divided into multiple sections: metallic portions for structural strength and torque transmission, and non-metallic portions for electrical isolation. The non-conductive material is applied only to specific surfaces that require electrical isolation, while metallic surfaces remain exposed at contact points for durability and torque transmission.
Solution Approach 2:
Different portions of the socket have different material properties tailored to their specific functions. The outer surface and electrical isolation surfaces use non-conductive material, while the driven end and contact surfaces use metallic material for strength and torque transmission.
2Strength
If the driven end and drive end are made of metallic material for strength, then torque transmission is improved, but electrical contact can occur creating shock or spark hazards
Solution Approach 1:
The socket uses metallic material at the driven end for torque transmission from the fastener, while non-conductive material is applied at the drive end and intermediate surfaces to prevent electrical contact with the driving tool, creating localized material properties matched to functional requirements.
Solution Approach 2:
The socket is segmented into metallic portions for mechanical strength and torque transmission, and non-metallic portions for electrical isolation. This segmentation allows each portion to fulfill its specific function without compromising the other.
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 safe use of non-electrically isolated fastener driving components near electrical components by maintaining electrical isolation, reducing the risk of shock or spark hazards and protecting sensitive equipment from surge currents.
Implementation Method 1
The isolation coating may also include a material that adheres to metal and has a dielectric strength of greater than about 10 kV
Data Source
AI summary
An electrically isolated coupler includes a drive body, a driven body, an insulating member and an isolation coating. The drive body is made of first metallic material and has a drive end configured to interface with a fastening component. The drive body includes a first interface portion and the driven body includes a second interface portion. The driven body is made of a second metallic material and has a driven end configured to interface with a driving tool. The insulating member is molded to fit between the drive body and the driven body to electrically isolate the drive body and the driven body from each other. The isolation coating is disposed on a surface of the first interface portion or the second interface portion that contacts the insulating member and faces the second interface portion or the first interface portion, respectively. The isolation coating includes a material that adheres to metal and has a dielectric strength of greater than about 10 kV.