Reinforced Terminal Ear for Bushing Thermal Strain

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Solution Overview

Problem

Terminal ears in glass fiber production bushing assemblies face failure due to severe thermal gradients and vibrations, leading to thermal strain and fatigue, which existing designs fail to adequately address, resulting in shortened service life.

Innovation Solution

The design incorporates elongated reinforcing members extending non-parallel to the longitudinal axis of the conductive plate, providing enhanced resistance to bending and torsional strains, and optionally contacting the bushing end wall for both mechanical and thermal support, with various geometries such as V, X, or W configurations to optimize strain field reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If terminal ears are made thin to reduce material usage and weight, then manufacturing cost and weight are reduced, but resistance to thermal strain and vibrations deteriorates, leading to warping and fatigue failure

Engineering Contradiction:

Improveweight of terminal earVSAvoidresistance to thermal strain and vibrations

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent introduces reinforcing members that extend in a direction non-parallel to the longitudinal axis of the terminal ear, adding structural support in a new dimensional orientation. This allows the terminal ear to maintain thin profile in the longitudinal direction while gaining strength through transverse reinforcement, resolving the contradiction between weight reduction and strength enhancement

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The terminal ear is constructed as a composite structure combining a thin conductive plate with separate reinforcing members. This composite design allows the thin plate to perform its electrical conduction function while the reinforcing members provide mechanical strength and resistance to thermal strain, enabling both light weight and high strength

Inventive Principle:

Principle #40Composite materials

2Strength

If terminal ears are reinforced with parallel members to increase strength, then resistance to bending improves, but resistance to torsional strains and warping deteriorates

Engineering Contradiction:

Improveresistance to bendingVSAvoidresistance to torsional strains and warping

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The reinforcing members are positioned asymmetrically relative to the terminal ear structure, extending from specific locations along the longitudinal axis at non-parallel angles. This asymmetric arrangement creates a structural configuration that provides balanced resistance to both bending and torsional loads, preventing warping while maintaining bending strength

Inventive Principle:

Principle #4Asymmetry

3Temperature

If water cooling is applied to connectors to prevent overheating, then connector temperature is controlled, but thermal gradients in terminal ears increase, causing thermal strain and cooling of bushing end walls

Engineering Contradiction:

Improveconnector temperatureVSAvoidthermal strain in terminal ears

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The patent introduces curved or angled reinforcing members that extend non-parallel to the longitudinal axis, creating a structural configuration that distributes thermal stresses more evenly throughout the terminal ear. This curved geometry helps mitigate the concentration of thermal strain that would otherwise occur in straight, rigid structures subjected to thermal gradients

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 configuration significantly prolongs the service life of terminal ears by effectively managing thermal and mechanical stresses, reducing the risk of deformation and failure under extreme conditions.

Implementation Method 1

The bushing is heated electrically by passing current through the body of the bushing from a first connector clamped to a first terminal ear, electrically coupled to a first end wall of the bushing body

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

They create substantial thermal strain in the terminal ears which are fixed at both opposite ends of the bushing body because of varying levels of thermal expansion as the temperature varies over 1000°C in a few decimeters

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS9556057B2Reinforced terminal ear for bushing

Publication Date: 2017.01.31 3B FIBERGLASS SPRL

AI summary

The present invention concerns a bushing assembly comprising terminal ears (1) coupled to opposed end walls (2) of the bushing assembly, for heating the bushing tip plate and walls, each of said terminal ears comprising: (a) an electrically conductive plate, said conductive plate comprising at least a first portion (1A) extending along a longitudinal 1D axis (X1) from a first terminal edge (1D) substantially normal to said longitudinal axis (X1) 1B and coupled to a bushing end wall (2), and further comprising a second, free terminal edge (1C) connectable to a source of power, and (b) at least one elongated reinforcing member (1B) coupled to said at least first portion (1A) of said plate to increase the bending moment of the latter, characterized in that, said at least one elongated reinforcing member (1B) extends from, or adjacent to the plate first terminal edge (1D) along a direction non parallel to said longitudinal axis (X1).