Solenoid Coil Zero-Volume Encapsulation for Hazardous Locations
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Solution Overview
Problem
Existing solenoid coils for hazardous environments are heavy and costly due to the need for thick, explosion-proof enclosures and specialized materials, which compromise on weight and cost efficiency while providing inadequate protection against explosions and harsh conditions.
Innovation Solution
A solenoid coil assembly with a zero-volume enclosure filled with encapsulation material, such as transfer molded thermoset or injection molded thermoplastic, eliminating the need for flame paths and allowing a non-explosion-proof, corrosion-resistant, and physically strong enclosure, reducing size, weight, and cost while enhancing environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick, strong enclosure is used to contain explosions, then explosion protection is improved, but weight and cost increase
Solution Approach 1:
The patent removes the need for explosion containment by extracting the flammable atmosphere from the enclosure. Instead of designing the enclosure to withstand explosions, the design eliminates the possibility of explosions by filling all void spaces with encapsulation material, leaving no room for flammable material accumulation.
Solution Approach 2:
Rather than making the enclosure strong enough to contain explosions (traditional approach), the patent inverts the approach by making the enclosure incapable of supporting explosions in the first place through zero-volume design. This eliminates the need for thick, heavy explosion-proof construction.
2Reliability
If specialized flame path components and precision machining are used, then flame path requirements are met, but manufacturing complexity and cost increase
Solution Approach 1:
The patent eliminates the need for flame path components and precision machining by removing the requirement for flame path compliance. Since there is no flammable material inside the enclosure to explode, the complex flame path sealing requirements and specialized components are no longer necessary.
Data Source
AI summary
A solenoid coil assembly for hazardous environments comprises a solenoid coil and an enclosure entirely filled with encapsulation material. The encapsulation material leaves zero or almost zero volume in the enclosure for hazardous material to accumulate in any amount that could explode. This allows the solenoid coil assembly to be constructed without the usual industry standard flame paths. Additionally, the enclosure may be made of physically rigid and strong material such as metal or the like to better withstand harsh and corrosive conditions within hazardous environments without being explosion proof. The walls of such an enclosure need only have a moderate thickness and weight relative to enclosures that are explosion proof, as there is no meaningful risk of an explosion occurring within the enclosure. The combination of a rugged exterior and a zero-volume interior allows the solenoid coil assembly to reduce weight and cost while providing superior environmental protection.