Electrically Isolated Adapter With Overlapping Metallic Bodies
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Solution Overview
Problem
Existing socket tools and adapters made of metallic materials pose a risk of electrical shock and spark hazards when used near electrically charged components, as they can corrode and expose conductive surfaces, and previous isolation methods result in bulky designs with gaps between metallic bodies.
Innovation Solution
The adapter features overlapping metallic bodies with insulating material in between, allowing for electrical isolation while maintaining durability and reducing the adapter's size by eliminating the need for a substantial gap, using injection molding to securely bond and seal the adapter with a high-resistance insulating material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for socket tools and adapters to ensure high strength and durability, then strength is improved, but electrical shock and spark hazards are created when used around electrically powered equipment
Solution Approach 1:
The adapter combines metallic bodies (for strength and durability) with non-conductive insulating material (for electrical isolation). The metallic bodies provide the necessary mechanical strength to withstand high torque applications, while the insulating material coating or integration prevents electrical shock and spark hazards when working around electrically powered equipment.
2Object-affected harmful factors
If non-conductive coating is applied to metallic socket tools to prevent electrical hazards, then electrical safety is improved, but the coating wears away over time due to high torque and repeated contact, degrading tool performance
Solution Approach 1:
The insulating material is integrated into the adapter design from the beginning, either as a molded-in feature or as a permanent coating applied during manufacturing. This preliminary integration ensures that electrical isolation is built-in rather than added later, preventing the wear and degradation issues associated with aftermarket coatings.
3Object-affected harmful factors
If substantial gaps are introduced between metallic bodies to achieve electrical isolation, then electrical safety is improved, but the adapter becomes bulky and larger in size
Solution Approach 1:
The insulating material is applied locally at the critical interfaces where electrical isolation is needed, such as between the drive square and the socket body, or at contact points with metallic components. This localized approach provides effective electrical isolation without requiring substantial gaps throughout the entire adapter structure, maintaining a compact size.
4Object-affected harmful factors
If traditional isolation methods with gaps between metallic bodies are used, then electrical isolation is achieved, but the adapter design becomes complex and bulkier
Solution Approach 1:
The insulating material is merged with the metallic bodies to form an integrated adapter structure. Rather than being separate components that require assembly, the insulating material is molded into or coated onto the metallic body during manufacturing, creating a unified component that simplifies the overall design and reduces assembly steps.
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 design provides safe electrical isolation for socket tools, minimizing the risk of surge currents and protecting electronic components, while maintaining strength and reducing the adapter's size and weight, allowing for flexible length adjustment based on specific applications.
Implementation Method 1
an insulating material that is disposed between the drive body and the driven body
Implementation Method 2
using injection molding to securely bond and seal the adapter with a high-resistance insulating material
Data Source
Figure 1~3
Figure 4~7
Figure 8~10
AI summary
An electrically isolated adapter may include a drive body made of first metallic material extending along a common axis, a driven body made of a second metallic material extending along the common axis, and an isolation assembly formed of insulating material disposed between the drive body and the driven body. The drive body may include a drive head configured to interface with a socket or fastener. The insulating material has a resistance to electrical current that is higher than the resistance to electrical current of at least one of the first metallic material and the second metallic material. The driven body may include a drive receiver configured to interface with a protrusion of a driving tool. A portion of one of the drive body or the driven body is received inside a portion of the other of the drive body or the driven body such that the drive body and driven body overlap each other along the common axis.