Segmented Sleeve Bearing Assembly for Tubular Electrode Mounting
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Solution Overview
Problem
The existing end block assemblies face challenges in precisely fitting and securely mounting tubular electrodes due to production tolerances, leading to potential jamming and incomplete electrical contact, which affects the stability and efficiency of coating processes.
Innovation Solution
The end block assembly incorporates a sleeve formed from multiple segments of dissimilar materials, with carefully aligned external faces to ensure a flush and precise fit, supported by a bearing assembly that includes a rotatable shaft and electrical contact structure, allowing for reliable mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-material sleeve is used to mount the tubular electrode, then the manufacturing process is simple, but production tolerances cause improper fitting and unreliable electrical contact
Solution Approach 1:
The sleeve is divided into multiple segments (first sleeve segment and second sleeve segment) that can be independently manufactured and then assembled. This segmentation allows each segment to be precision-machined separately to compensate for production tolerances, ensuring proper fitting and reliable electrical contact while maintaining a relatively simple overall structure.
Solution Approach 2:
The sleeve uses composite construction with at least two different materials - a first material for the first sleeve segment and a second material for the second sleeve segment. This composite approach enables optimization of each segment's material properties for its specific function (e.g., electrical conductivity, mechanical strength, thermal properties) while achieving precise fitting through controlled material combinations.
2Reliability
If tight tolerances are applied to ensure precise fitting, then mounting reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
By segmenting the sleeve into multiple independently manufacturable parts, the invention achieves high mounting reliability through precise assembly of standardized components rather than requiring extremely tight tolerances on a single complex piece, thereby improving ease of manufacture.
Solution Approach 2:
The invention changes the material parameter by using at least two different materials for different sleeve segments, allowing each segment to be manufactured with standard tolerances using appropriate materials, thus achieving reliable mounting without excessive manufacturing complexity.
3Adaptability or versatility
If dissimilar materials are used for different sleeve segments, then functional performance improves, but manufacturing precision requirements increase
Solution Approach 1:
The use of composite materials (first material and second material) allows each sleeve segment to be optimized for its specific functional requirements. The manufacturing precision is maintained through standardized interface designs that accommodate material differences, enabling functional adaptability without excessive alignment precision requirements.
Solution Approach 2:
Different materials are applied to different segments of the sleeve based on local functional requirements. This local quality approach allows each segment to have optimal material properties for its specific role while maintaining overall assembly precision through standardized connection interfaces.
Data Source
AI summary
In various embodiments, an end block assembly for rotatably mounting a tubular electrode in a processing chamber is provided. The end block assembly includes a receptacle region for receiving a bearing assembly which has a coupling region for coupling the tubular electrode thereto, the bearing assembly of which the coupling region is supported by a sleeve of the bearing assembly. The sleeve is plug-fitted into the receptacle region. The sleeve is joined together from a plurality of segments, the external faces thereof forming a lateral surface of the bearing assembly and at least two segments thereof being formed from dissimilar materials. The external faces of the two segments are mutually aligned such that they are flush with one another.