Removable Bushing Flange With Localized Chamfer Filling
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Solution Overview
Problem
Existing flanges for condenser cores in bushings are difficult to remove and reuse, especially when the condenser core is damaged, leading to unnecessary discarding of both the core and the flange.
Innovation Solution
A bushing flange design that incorporates an annular chamfer space between the flange and the condenser core, filled with a filler material, allowing for secure fitting without requiring a perfect diameter match and enabling easy removal and reuse of the flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermosetting resin is introduced to fill the gap between the flange and the condenser core, then the flange is securely attached to the condenser core, but the flange cannot be removed for reuse if the condenser core is damaged
Solution Approach 1:
The chamfer space is segmented from the rest of the annular space by sealing elements (O-rings), creating a isolated filling zone. This segmentation allows the filler material to be confined to a specific region that can be removed without damaging the flange, enabling the flange to be reused while maintaining secure attachment during operation
Solution Approach 2:
The filler material is applied locally only in the chamfer space between the flange and condenser core shoulder, rather than throughout the entire annular space. This localized application provides sufficient attachment strength at the critical interface while allowing the rest of the flange to remain free for potential removal and reuse
2Strength
If the flange is fitted tightly around the condenser core, then secure attachment is achieved, but manufacturing precision requirements increase due to shrinkage tolerances
Solution Approach 1:
The chamfer space acts as an intermediary zone between the flange and condenser core, filled with filler material that compensates for dimensional variations caused by shrinkage. This intermediary filling allows the flange to be securely attached without requiring extremely tight manufacturing tolerances, as the filler material accommodates the gaps created by shrinkage
Solution Approach 2:
The invention changes the physical state and distribution of the filler material in the chamfer space to accommodate dimensional variations. By allowing the filler material to flow into and fill the chamfer space, the system adapts to different shrinkage parameters, maintaining secure attachment across a range of dimensional tolerances
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 design allows for secure attachment of the flange to the condenser core without the need for precise diameter matching, facilitating easy removal and reuse of the flange, thus extending its lifespan and reducing waste.
Implementation Method 1
the filler material, in so far as it acts as a glue, will only bind the flange to the condenser core at said chamfer space
Implementation Method 2
By means of the chamfer space being delimited by the upper and (especially) lower sealing elements, e.g. O-rings, the filler material is prevented from filling any space between the flange and the condenser core outside of the chamfer space
Data Source
Figure 1~3
Figure 4~6
AI summary
The present disclosure relates to a flange to be fitted around a round cylindrical condenser core (3) of a bushing. The flange comprises an annular lower flange part (7) arranged to fit around a radial shoulder (4) of the condenser core such that a lower shoulder chamfer (5) of the shoulder rests against lower flange chamfer (28) of the lower flange part around the circumference of the condenser core; and an annular upper flange part (8) arranged to be fastened to the lower flange part and to fit around the condenser core above an upper shoulder chamfer (6) of the shoulder. An upper flange chamfer (27) of the upper flange part is arranged between an upper sealing element (25) and a lower sealing element (26), such that an annular chamfer space (21) is formed between the upper flange chamfer and the upper shoulder chamfer between the upper and lower sealing elements. The flange comprises an injection through hole (22) arranged for a filler material to be injected there through to fill the chamfer space.