Isolated Torque Coupler With Non-Conductive Transfer Assembly
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Solution Overview
Problem
Existing fastener driving tools, such as socket wrenches, face challenges in safely operating near electrically charged components due to the risk of spark or shock hazards from metallic materials, and existing isolation designs often fail under high torque loads, compromising safety and performance.
Innovation Solution
An electrically isolated coupling device with a torque transfer assembly made of non-conductive material, maintaining a separation of at least 0.400″ between metallic components, which allows for safe use near high voltage applications while transferring torque effectively, using a combination of rigid and non-conductive materials to reinforce the coupling without sacrificing isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for sockets to provide high strength and durability, then the strength and durability are improved, but spark or shock hazards are created when used around electrically powered equipment
Solution Approach 1:
The socket is divided into multiple segments: metallic portions at the driving end and driven end for strength, and a non-conductive isolation material portion in the middle for electrical isolation. This segmentation allows each part to fulfill its specific function without compromising the overall performance.
Solution Approach 2:
The socket combines metallic materials (for strength and durability at contact points) with non-conductive isolation material (for electrical isolation). This composite structure allows the socket to simultaneously achieve mechanical strength and electrical safety, resolving the contradiction between strength and hazard prevention.
2Object-affected harmful factors
If non-conductive material is used to coat metallic socket for electrical isolation, then electrical isolation is improved, but the material wears away under high torque and repeated contact
Solution Approach 1:
Instead of coating the entire socket with non-conductive material, the design segments the socket so that only the middle portion is made of non-conductive isolation material, while the driving end and driven end remain metallic. This prevents wear at contact points while maintaining electrical isolation where needed.
Solution Approach 2:
The non-conductive material is applied locally only to the isolation portion of the socket that does not contact the driving tool or fastener, rather than coating the entire socket. This localized application maintains electrical isolation properties while avoiding wear issues at contact surfaces.
3Object-affected harmful factors
If isolation material is placed between opposing metal portions for electrical isolation, then electrical isolation is improved, but weak points are created where isolation material is unsupported and can fail under high torque loads
Solution Approach 1:
The non-conductive isolation material acts as an intermediary element between the metallic driving end and driven end portions. This intermediary provides electrical isolation while the overall socket structure maintains structural integrity to handle high torque loads without creating weak points.
Data Source
AI summary
An electrically isolated coupler includes a drive body, a driven body, and a torque transfer assembly. 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 torque transfer assembly is disposed between the drive body and the driven body to electrically isolate the drive body and the driven body from each other and transfer torque between the drive body and the driven body. The torque transfer assembly includes non-conductive material configured to maintain separation between the drive body and the driven body of at least about 0.400″.