Tapered Crimp Joint in Inorganic Coil Assemblies
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Solution Overview
Problem
Conventional electromagnetic coil assemblies fail at high temperatures above 260°C due to organic insulative materials' decomposition and are unsuitable for nuclear applications, as they are sensitive to radiation and prone to mechanical fatigue.
Innovation Solution
An electromagnetic coil assembly with an inorganic electrically-insulative body and a tapered crimp joint is developed, using anodized aluminum wire and ceramic materials to withstand high temperatures, and minimize mechanical stress on the magnet wire, ensuring reliable operation up to 400°C or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic insulative materials are used in electromagnetic coil assemblies, then ease of manufacture and cost are improved, but reliability at high temperatures deteriorates due to decomposition above 260°C
Solution Approach 1:
The patent changes the material parameter from organic to inorganic insulative material, enabling the coil assembly to operate reliably at high temperatures exceeding 260°C while maintaining manufacturing feasibility through established ceramic processing techniques
Solution Approach 2:
The patent employs composite material construction by combining inorganic insulative material with magnet wire and tapered crimp joints, creating a multi-material assembly that achieves both high-temperature reliability and manufacturability
2Ease of manufacture
If conventional crimp joints are used to connect lead wire to magnet wire, then ease of manufacture is improved, but reliability deteriorates due to mechanical stress and potential failure in high temperature environments
Solution Approach 1:
The patent applies preliminary action by forming the tapered crimp joint before final assembly and potting, ensuring the mechanical connection is established under controlled conditions with proper alignment and stress distribution before the assembly is sealed in the inorganic insulative material
Solution Approach 2:
The patent changes the geometric parameter of the crimp joint from conventional uniform or flared shapes to a tapered configuration, which distributes mechanical stress more evenly along the interface between lead wire and magnet wire, preventing stress concentration and improving reliability in high-temperature operation
3Ease of manufacture
If organic insulative bodies are used for electrical insulation, then ease of manufacture and cost are improved, but resistance to radiation and mechanical fatigue deteriorates
Solution Approach 1:
The patent changes the fundamental material parameter from organic to inorganic composition, providing inherent resistance to radiation and mechanical fatigue while maintaining ease of manufacture through standard ceramic processing methods
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 solution provides prolonged and reliable operation in high-temperature environments, reduces mechanical stress and radiation sensitivity, and is suitable for nuclear applications by embedding the tapered crimp joint within the inorganic insulative body, ensuring both mechanical and electrical integrity.
Implementation Method 1
an inorganic electrically-insulative body encapsulating at least a portion of the coiled magnet wire
Implementation Method 2
a first tapered crimp joint embedded within the inorganic electrically-insulative body. The first tapered crimp joint mechanically and electrically connects the lead wire to the coiled magnet wire
Data Source
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AI summary
Embodiments of an electromagnetic coil assembly (10, 100) are provided, as are embodiments of producing an electromagnetic coil assembly (10, 100). In one embodiment, the electromagnetic coil assembly (10, 100) includes a coiled magnet wire (22, 104), an inorganic electrically-insulative body (24, 112) encapsulating at least a portion of the coiled magnet wire (22, 104), a lead wire (03, 106) extending into the inorganic electrically-insulative body (24, 112) to the coiled magnet wire (22, 104), and a first tapered crimp joint (32, 102) embedded within the inorganic electrically-insulative body (24, 112). The first tapered crimp joint (32, 102) mechanically and electrically connects the lead wire (30, 106) to the coiled magnet wire (22, 104).