Thermocouple Junction Assembly with Segmented Metallic Sleeve
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Solution Overview
Problem
Current thermocouple transition junctions face challenges in maintaining reliable electrical connections and tensile strength at high temperatures, requiring complex precautions to prevent plastic flow during co-moulding, which can lead to defects and increased production time.
Innovation Solution
A junction assembly featuring a metallic sleeve with tapered openings to guide and secure conductors, allowing for easier welding and co-moulding, combined with an inorganic insulating coating for high-temperature resistance and an organic coating for flexibility, ensuring reliable mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic tubular sleeve is used to connect detecting rod and extension cable, then tensile strength at high temperatures is improved, but production complexity increases due to special provisions needed to hold welded ends during co-moulding
Solution Approach 1:
The junction assembly is divided into distinct functional zones: a first zone for the high-temperature detecting rod connection with inorganic insulation, and a second zone for the extension cable connection with organic insulation. The metallic sleeve is segmented with transverse openings that separate the welding area from the co-moulding area, allowing independent processing of each zone without interference.
Solution Approach 2:
The transverse openings in the metallic sleeve act as intermediaries that allow the plastic material to flow through during co-moulding, preventing pressure buildup that would otherwise displace the welded conductors. This intermediary structure enables both welding and co-moulding operations to proceed simultaneously without special positioning provisions.
2Ease of manufacture
If plastic material is injected during co-moulding, then protective casing is formed, but plastic flow can unwind wires or bring all four wires into contact making thermocouple unusable
Solution Approach 1:
The transverse openings in the metallic sleeve serve as pressure relief pathways that allow plastic material to flow through during co-moulding. This prevents accumulation of plastic pressure behind the welded ends, eliminating the force that would otherwise push the wires out of position or cause them to contact each other improperly.
Solution Approach 2:
The metallic sleeve with transverse openings is prepared in advance before the co-moulding process. This preliminary structure ensures that when plastic material is injected, it has predetermined pathways to follow, preventing uncontrolled flow that could displace wires. The openings are strategically positioned to allow plastic flow while maintaining wire separation.
3Manufacturing precision
If welded ends are held in position during co-moulding, then wire displacement is prevented, but production time increases and special provisions are required
Solution Approach 1:
The transverse openings in the metallic sleeve act as pressure relief valves during co-moulding, allowing plastic material to flow through rather than building up pressure behind the welded conductors. This eliminates the need for special clamping or holding mechanisms, as the plastic flow is naturally channeled through the openings without displacing the wires.
Solution Approach 2:
The metallic sleeve structure itself provides the function of holding wires in position during co-moulding, without requiring external fixtures or special provisions. The transverse openings enable the sleeve to serve dual purposes: maintaining wire position and allowing plastic flow, making the system self-sufficient during the co-moulding process.
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
Simplifies and accelerates the production of thermocouples by reducing assembly time and defect rates, while maintaining high tensile strength and temperature resistance, with the metallic sleeve providing structural integrity and the coatings ensuring electrical insulation.
Implementation Method 1
an insulating coating made of substantially inorganic insulating material 38 that coats and electrically insulates the first 34 and the second electrical conductor 36 from the outside and from each other
Implementation Method 2
an insulating coating made of substantially organic insulating material 43 that coats and electrically insulates the third 42 and the fourth electrical conductor 44 from the outside and from each other
Data Source
AI summary
A junction assembly having A) a first electrical cable in turn comprising a first and a second electrical conductor and an insulating coating made of insulating inorganic material, B) a second electrical cable having a third and a fourth electrical conductor and an insulating coating made of insulating organic material that coats and electrically insulates the third and fourth electrical conductor; C) a junction having a sleeve that forms two ends one of which is arranged to receive the first electrical cable and the other is arranged to receive the second electrical cable. The first and the third electrical conductor are mechanically and electrically connected together to form a first composite conductor. The second and the fourth electrical conductor are connected together to form a second composite conductor. An intermediate wall is arranged between the two.