Mineral-Insulated Socket Compression for Exhaust Gas Ducts
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Solution Overview
Problem
The existing manufacturing processes for mineral-insulated sockets, especially for electrical feedthroughs in exhaust gas ducts of motor vehicles, face challenges such as high costs, mechanical instability, and leakage issues due to non-uniform compression and material breakage, which affect their ability to withstand mechanical loads and maintain low leakage rates.
Innovation Solution
A process involving the compression of a metallic inner part, electrically insulating mineral material, and outer pipe to form a composite, followed by the removal of a complete section to produce a mineral-insulated socket module, ensuring uniform compression and increased mechanical stability, with options for varying material densities and structural modifications to enhance resistance and reduce leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual mounting and compression of electrical feedthroughs is performed, then the socket can be assembled, but the compression becomes non-uniform decreasing toward ends, reducing mechanical stability and increasing leakage risk
Solution Approach 1:
Multiple electrical feedthroughs are compressed simultaneously as a group rather than individually. The compression device applies force to compress multiple sockets at once, ensuring uniform compression across all feedthroughs and eliminating the gradient effect where compression decreases toward the ends.
Solution Approach 2:
The compression process is segmented into two distinct stages: first compressing the inner conductor and insulating pipe together, then separately compressing the outer pipe. This segmented approach ensures each layer achieves optimal compression uniformity without the negative effects of sequential individual compression.
2Length of moving object
If the outer pipe length is reduced to meet installation space requirements, then installation space is optimized, but mechanical stability against impacts, knocks, tension, torsion, and vibration is reduced
Solution Approach 1:
The density and compression uniformity of the insulating material are optimized to enhance mechanical stability. By achieving uniform high-density compression throughout the insulating pipe, the structural strength is maximized within the constrained length, providing superior resistance to mechanical loads without requiring increased length.
3Ease of manufacture
If compression force is applied to assemble the feedthrough, then the components are joined, but insulating material breaks off from end surfaces, reducing surface area and mechanical resistance
Solution Approach 1:
The inner conductor and insulating pipe are compressed together first to form a stable preliminary assembly. This preliminary compression establishes proper positioning and stress distribution before the outer pipe is added and compressed, preventing material breakage during the final compression stage.
4Reliability
If expensive materials like NiCr8020 are used for the electrical conductor, then electrical performance is achieved, but manufacturing costs increase
Solution Approach 1:
The density and microstructure of the expensive NiCr8020 material are optimized through controlled compression to achieve maximum electrical performance. By extracting and utilizing the full potential of the material through proper density control, the required amount of expensive material is minimized while maintaining superior electrical conductivity.
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 process results in mineral-insulated sockets with improved mechanical stability and reduced leakage rates, effectively addressing issues of non-uniform compression and material breakage, while allowing for universal application in various feedthrough configurations.
Implementation Method 1
compressed, which reduces its cross section, so that the electrical feedthrough is produced
Data Source
AI summary
Provided is a process for the manufacture of a mineral-insulated socket, especially as a module for the manufacture of an electrical feedthrough and especially for use in an exhaust gas duct of a motor vehicle. The mineral-insulated socket has a metallic inner part arranged in a metallic outer pipe and electrically insulated from this metallic outer pipe by an electrically insulating, mineral material. In a process, the metallic inner part, the electrically insulating material, and the outer pipe are compressed to form a composite and in a subsequent step, the mineral-insulated socket is produced by removing at least one complete section of the compressed composite.