Threaded Ceramic Insulated Mechanical Connection
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Solution Overview
Problem
Existing solutions for inductive heating in oil sand production lack a mechanical-load bearing and electrically isolating connection that can withstand high temperatures and mechanical forces, particularly for inductor housings, where standard materials like rubber or PVC are insufficient.
Innovation Solution
A mechanical-load bearing and electrically isolating connection using a hollow body with conducting material and a connection element, featuring threads and an insulation-material extent to convert tensile forces into compression forces, ensuring electrical isolation and mechanical stability, suitable for high-temperature applications up to 250°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If standard insulating materials like rubber or PVC are used for electrical isolation, then electrical isolation is achieved, but they cannot withstand high temperatures up to 250°C
Solution Approach 1:
The patent uses a composite structure combining ceramic coating (for high-temperature resistance and electrical isolation) with metallic threads (for mechanical strength and load bearing). This composite approach allows the connection to withstand temperatures up to 250°C while maintaining both electrical isolation and mechanical integrity, overcoming the limitation of standard insulating materials like rubber or PVC that fail at high temperatures.
2Force
If a mechanical connection is designed to bear high mechanical forces, then mechanical stability is improved, but electrical isolation may be compromised due to direct contact
Solution Approach 1:
The patent applies different material properties to different parts of the connection: the ceramic coating provides electrical isolation and high-temperature resistance where needed, while the metallic threads provide mechanical strength for force transmission. This localized differentiation of material properties allows the connection to simultaneously bear high mechanical forces and maintain electrical isolation without direct contact between conductive parts.
Solution Approach 2:
The ceramic coating acts as an intermediary layer between the metallic threads and the environment, providing electrical isolation while allowing the metallic threads to transmit mechanical forces. This intermediary ceramic layer prevents direct electrical contact while maintaining mechanical integrity, resolving the contradiction between force transmission and electrical isolation.
3Temperature
If a connection structure is designed for high-temperature applications, then temperature resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical assembly processes with a coating application process. Instead of assembling multiple high-temperature resistant components mechanically, the ceramic coating is applied directly to the metallic threads, simplifying manufacturing while maintaining high-temperature resistance up to 250°C.
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 connection effectively transmits high mechanical forces while maintaining electrical isolation, suitable for inductive heating applications, and can be easily disassembled and reassembled, using easily manufacturable components, with ceramics providing minimal partial discharge issues.
Implementation Method 1
an insulation-material extent which is fixed between the first and the second thread lends additional mechanical support and electrically isolates the hollow body from the connection element
Implementation Method 2
no current must flow via housings of this type, since the capacitances will otherwise be electrically shorted
Data Source
AI summary
A hollow body composed of an electrically conducting material and extending longitudinally along an axis is connected at one axial end to a connection element composed of an electrically conducting material and extending along the axis. A first thread is provided on the hollow body at the one axial end running about the axis, while a second thread is provided on the connection element running about the axis, so that the second thread is mechanically supported by the first thread. An insulation-material extent between the first thread and the second thread electrically isolates the hollow body from the connection element.