Electrically Isolated Coupler With Failsafe Coating for High Torque
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Solution Overview
Problem
Existing fastener driving components, such as socket tools, face challenges in electrical isolation, particularly when used near electrically charged components, as metallic materials can corrode or create shock hazards, and existing isolation designs may fail under high torque, leading to potential electrical contact and safety risks.
Innovation Solution
An electrically isolated coupling device with a drive body, driven body, insulating member, and a failsafe isolation coating is introduced, where the insulating member is molded between the drive and driven bodies to provide initial isolation, and a thin, high-dielectric-strength coating is applied to ensure continued isolation even if the primary isolation fails, preventing electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating member is molded between the drive body and driven body to provide electrical isolation, then electrical isolation is achieved, but the isolation material may fail under high torque loads creating weak points
Solution Approach 1:
The patent applies composite materials by combining the insulating member with an isolation coating system. The insulating member provides bulk electrical isolation, while the isolation coating (applied to the drive body, driven body, or both) reinforces the isolation at critical interfaces. This composite approach allows the system to withstand high torque loads without compromising electrical isolation, as the coating prevents failure at the metal-insulator interfaces where stress concentrates.
2Reliability
If a non-conductive coating is applied to the metallic socket, then electrical isolation is improved, but the coating wears away over time under high torque and repeated contact
Solution Approach 1:
The patent applies local quality by positioning the isolation coating specifically at critical interfaces rather than uniformly coating the entire socket. The coating is applied to the drive body, driven body, or both at the surfaces that contact the insulating member or face each other. This localized application ensures electrical isolation at the most critical points while reducing overall material usage and maintaining durability under torque and contact conditions.
3Force
If the ends of the socket directly contacting the driving tool or fastener remain exposed metallic surfaces, then high torque transmission is achieved, but the socket becomes a shock or spark hazard
Solution Approach 1:
The patent introduces an intermediary isolation coating between the exposed metallic surfaces and the environment. The coating is applied to surfaces that may face each other or contact the insulating member, creating a dielectric barrier. This intermediary layer prevents electrical contact and spark generation while allowing the metallic surfaces to maintain their torque transmission capabilities, effectively mediating between the conflicting requirements of force transmission and electrical safety.
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 under high torque conditions, reducing the risk of shock or spark hazards and protecting sensitive equipment from surge currents.
Implementation Method 1
The isolation coating may 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.