Multi-Material Insulating Body for Field Device Connectors

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Solution Overview

Problem

Existing connecting elements for electrical modules in field devices, particularly in explosion-endangered regions, face challenges with form stability and sealing due to the use of ceramic materials, which are sensitive to mechanical loads and do not adequately meet the requirements for both high modulus of elasticity and low tensile strength.

Innovation Solution

A connecting element with a multi-membered insulating body composed of two synthetic materials, where the end segments have a high modulus of elasticity for form retention and the intermediate segment has a low modulus for sealing, featuring passageways for contact areas of conductor elements, allowing for secure electrical connection and sealing between modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If ceramic materials are used for the insulating body, then high modulus of elasticity and form stability are achieved, but tensile strength is insufficient and sensitivity to mechanical loads increases

Engineering Contradiction:

Improveform stabilityVSAvoidtensile strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The insulating body is divided into multiple segments (first insulating body segment, second insulating body segment, and third insulating body segment), where different segments can be made from different materials optimized for their specific functions. This segmentation allows the first and second segments to provide form stability while the third segment provides sealing capability without compromising overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs composite material construction for the insulating body, combining materials with high modulus of elasticity (for form stability) with materials possessing good tensile strength and sealing properties. This composite approach resolves the contradiction by integrating the advantages of different materials into a unified insulating body structure.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If the connection space is opened for cable connection, then ease of operation is improved, but risk of contact with conductor elements increases

Engineering Contradiction:

Improveease of cable connectionVSAvoidrisk of contact

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The insulating body acts as an intermediary barrier between the conductor elements and the external environment. It provides passageways for cable access while maintaining electrical insulation and physical protection, allowing operation without direct contact with conductor elements even when the connection space is opened.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The conductor elements are nested within the insulating body structure, which is itself integrated into the housing. This nested arrangement allows the insulating body to protect the conductor elements while still permitting access through controlled passageways, reducing the risk of contact during cable connection operations.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of operation

If conductor elements are exposed for connection, then ease of connection is improved, but sensitivity to mechanical loads and bending increases

Engineering Contradiction:

Improveease of electrical connectionVSAvoidsensitivity to mechanical loads

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The insulating body is pre-formed with integrated passageways and connection interfaces that guide and protect the conductor elements before connection occurs. This preliminary preparation allows for easy connection while the insulating body continuously supports and protects the conductor elements from mechanical loads throughout the device lifecycle.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11467009B2Connecting element and transmitter housing with connecting element inserted therein

Publication Date: 2022.10.11 ENDRESS & HAUSER GMBH & CO KG

AI summary

The present disclosure relates to a connecting element for electrical connecting two electrical modules arranged in a transmitter housing of a field device, into which transmitter housing the connecting element is insertable, the connecting element including: at least two essentially rod-shaped metal conductor elements, each with two opposing end sections, wherein the conductor elements are arranged in a defined separation relative to one another; and surrounding the conductor elements and electrically insulating them from one another, a multi-membered insulating body including two insulating body end segments of at least a first synthetic material and an insulating body intermediate segment of a second synthetic material different from the first synthetic material, wherein the first synthetic material has a modulus of elasticity greater than a modulus of elasticity of the second synthetic material.