Segmented Electrical Feedthrough for Gas-Tight Heater Connections
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Solution Overview
Problem
Existing methods for producing electrical feedthroughs for heating conductors in exhaust gas tracts are costly and complex due to the use of expensive multi-layer rod materials and significant material waste during machining.
Innovation Solution
A segmented electrical feedthrough design comprising a heating conductor and insulating portion, where the electrical conductor and insulator are arranged within an outer sleeve, connected at a predefinable angle, and produced using a method involving a joining process to reduce material waste and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer compressed rod material is used for the electrical feedthrough, then the electrical insulation and gas-tightness are improved, but the production cost and device complexity increase significantly
Solution Approach 1:
The feedthrough is divided into separate components: an outer tube made of one material and an inner core made of another material. This segmentation allows each component to be manufactured independently using simpler processes, reducing overall complexity while maintaining the functional benefits of multi-material construction for gas-tightness and electrical insulation
Solution Approach 2:
The invention uses composite construction by combining an outer tube with an inner core of different materials. The outer tube provides mechanical strength and gas-tightness, while the inner core provides electrical insulation and structural support. This composite approach achieves the required reliability without needing complex multi-layer compressed rod structures
2Manufacturing precision
If machining methods are used to trim the compressed rod material to length, then the desired projection of the electrical conductor is achieved, but approximately two-thirds of the rod material is wasted
Solution Approach 1:
The electrical conductor is pre-assembled with the inner core and outer tube in the correct configuration and length before final installation. This preliminary assembly allows the conductor to be positioned precisely without requiring subsequent trimming operations, eliminating material waste while maintaining manufacturing precision
Solution Approach 2:
The electrical conductor is nested within the inner core, which is in turn nested within the outer tube. This nested structure allows the conductor to be protected and positioned during assembly without requiring post-assembly machining, reducing material waste while achieving the desired conductor projection
3Reliability
If the electrical conductor is surrounded by insulating material within the outer tube, then electrical insulation is improved, but the production process becomes more complex and cost-intensive
Solution Approach 1:
The insulating function is merged into the inner core component, which is manufactured as a single integrated part. This eliminates the need for separate insulating material application steps and simplifies the production process while maintaining reliable electrical insulation between the conductor and outer tube
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
Facilitates a simplified, cost-effective production of electrical feedthroughs with improved durability and space efficiency, suitable for confined installations.
Implementation Method 1
the electrical conductor is electrically insulated with respect to the outer sleeve by the insulator
Implementation Method 2
which can be heated up by exploiting ohmic resistance
Data Source
AI summary
A segmented electrical feedthrough for electrically contacting a heating conductor through a housing, having a heating conductor and an insulating portion. The insulating portion has an electrical conductor, an insulator, and an outer sleeve, wherein the electrical conductor and the insulator are arranged within the outer sleeve and the electrical conductor is electrically insulated with respect to the outer sleeve by the insulator. The heating conductor is connected to the electrical conductor at a predefinable angle and the heating conductor and the insulating portion are formed from two different elements that are permanently connected to one another by a joining method, wherein the heating conductor has a recess into which the electrical conductor of the insulating portion is able to be introduced.