Electrically Isolating Gasket Coating for Thin High-Temperature Seals
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Solution Overview
Problem
Existing gaskets with electrically isolating properties face limitations such as inadequate dielectric strength, temperature limitations, structural complexity, and chemical resistance issues, leading to failures at elevated temperatures and pressures, and increased thickness due to the need for thicker materials to achieve sufficient voltage resistance.
Innovation Solution
A gasket design featuring a core gasket component coated with a dielectric material like polyimide, ceramic, or aluminum oxide on all surfaces, including grooves and protrusions, eliminating the need for glass reinforced epoxy and allowing for thinner profiles while maintaining high dielectric strength and improved chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass reinforced epoxy (GRE) is used to provide electrically isolating properties, then dielectric strength is improved, but temperature resistance deteriorates because GRE becomes soft above 250-350°F and loses strength
Solution Approach 1:
The patent uses a composite structure combining a core gasket component (metal or non-metallic material) with a coating of dielectric material (such as polyimide, ceramic, or aluminum oxide). This composite approach allows the core to provide mechanical strength and temperature resistance while the coating provides electrical isolation, resolving the contradiction between dielectric strength and temperature resistance.
Solution Approach 2:
The patent applies a thin film coating of dielectric material onto the core gasket component. This thin film provides sufficient electrical isolation without adding significant thickness, and the coating materials (polyimide, ceramic, aluminum oxide) are selected to maintain integrity at high temperatures, thus improving temperature resistance while maintaining electrical isolation.
2Reliability
If thicker gasket material is used to achieve sufficient voltage resistance, then dielectric strength is improved, but gasket thickness increases leading to installation limitations
Solution Approach 1:
The composite structure of a thin dielectric coating on a conductive or non-conductive core allows achieving high voltage resistance with minimal thickness. The coating materials have high dielectric strength properties, enabling sufficient electrical isolation in a thin layer, thus resolving the contradiction between voltage resistance and gasket thickness.
Solution Approach 2:
The patent changes the material parameters by selecting dielectric coating materials with high dielectric strength (such as polyimide, ceramic, aluminum oxide). This allows achieving the required voltage resistance with a thinner coating thickness, thus reducing overall gasket thickness while maintaining electrical isolation performance.
3Reliability
If dielectric coating is applied to all surfaces including grooves and protrusions, then electrical isolation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies a flexible thin film coating that can conform to complex surfaces including grooves and protrusions. This thin film approach allows complete surface coverage for electrical isolation while maintaining manufacturability, as the coating process can accommodate complex geometries without requiring additional manufacturing steps, thus resolving the contradiction between electrical isolation and manufacturing ease.
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 provides enhanced electrical isolation, increased temperature range, reduced thickness for easier installation, improved chemical resistance, and simplified structure, enabling the gasket to be used in a wider variety of applications, including high-temperature and high-pressure environments.
Implementation Method 1
the coating or film comprises polyimide, ceramic, or aluminum oxide
Data Source
AI summary
An electrically isolating gasket is disclosed wherein a coating layer is disposed on at least one conductive surface, and in some embodiments, on all surfaces or at least all of the conductive surfaces. The electrically isolating gasket includes a core gasket component, a ring seal component, and a non-conductive inner seal component. The coating layer can be, for example, polyimide, polyamide, ceramic, and aluminum oxide.