Sealed electrical devices

Abstract

A hermetically sealed electrical device includes a housing and an end cap assembly. The end cap assembly includes a cap having a contact orifice and contact terminals extending through the cap via the contact orifice. An insulating member insulates the contact terminals from the cap. An angled flange connects the insulating member to the cap. The cap can be coupled to the housing to form a hermetically sealed volume.

Description

Technical Field

[0001] The present invention relates to electrical switching devices, such as contactor devices and electric fuse devices, and more particularly to improved sealed electrical switching devices. Background Technology

[0002] Many conventional devices are known for selectively connecting or disconnecting electrical installations. For example, electrical contactors (e.g., high-voltage DC contactors) and fuses (e.g., electric fuses and / or pyrotechnic fuses) are commonly available and used in electrical systems. Contactors can be configured to interrupt or complete a circuit to control power supply to or from the installation. Fuses can be used for overcurrent protection. For example, fuses can be used to prevent short circuits, overloads, and / or permanent damage to the electrical system or connected electrical installations.

[0003] Many contactors and fuses (including those used in high-voltage DC applications) utilize electrically insulated, hermetically sealed components that allow for an internal gas atmosphere within the control unit. Some conventional contactors and fuses include contact terminals, for example, brazed to a metal (e.g., aluminum) surface. However, these conventional sealing techniques and arrangements can be susceptible to premature failure, such as bursting due to pressure buildup and / or rupture under lateral loads applied to the contact terminals. These and other drawbacks in conventional installations can result in poor thermal and / or electrical performance.

[0004] Therefore, there is a need in the art for improved hermetic-sealed contactors and fuses, as well as methods for manufacturing such contactors and fuses. Summary of the Invention

[0005] The subject matter relates to improved electrical devices and methods of manufacturing such devices. In various aspects, several aspects of this disclosure relate to improved hermetic-sealed contactors and fuses incorporating an end cap assembly comprising a cap and one or more contact terminals extending through the cap. The terminals are insulated from the cap by an insulating member. In various aspects, this disclosure relates to improved hermetic-sealed contactors and fuses comprising an end cap assembly coupled to a tank or housing, for example, by resistance welding. For example, such contactors and fuses can be cheaper and / or more reliable than some existing contactors and fuses. Also in various aspects, the electrical devices described herein can be more compact than some conventional devices. Additional aspects of this disclosure relate to methods of manufacturing improved hermetic-sealed contactors and fuses. Attached Figure Description

[0006] To make it easier for someone skilled in the art to understand how to manufacture and use the disclosed systems and technologies, please refer to the following figures.

[0007] Figure 1This includes a perspective view of the electrical apparatus according to aspects of this disclosure and an exploded perspective view of a portion of the electrical apparatus.

[0008] Figure 2A It is in accordance with aspects of this disclosure along Figure 1 Section line 2-2 in the middle is cut Figure 1 A three-dimensional sectional view of the electrical equipment.

[0009] Figure 2B It is in accordance with aspects of this disclosure along Figure 1 Section line 2-2 in the middle is cut Figure 1 A sectional view of the end cap assembly of the electrical device.

[0010] Figure 3 This is a cross-sectional view of an alternative end cap assembly portion of an electrical device according to aspects of this disclosure.

[0011] Figure 4 This illustrates the manufacture of electrical devices (such as...) according to aspects of this disclosure. Figure 1 A flowchart of an aspect of the method of the electrical device shown. Detailed Implementation

[0012] This subject matter overcomes many of the prior art problems associated with hermetically sealed electrical devices. In short, aspects of this subject matter can provide improved hermetically sealed electrical devices. Some aspects of this disclosure include an improved end cap assembly for an electrical device, the end cap assembly at least partially including an insulating member disposed between the cap and contact terminals extending through the cap. Some aspects of this disclosure also describe methods of manufacturing the end cap assembly. Additional aspects of this disclosure relate to an electrical device including the end cap assembly and a method of manufacturing the improved electrical device.

[0013] Without limitations, the apparatus and techniques described herein can provide hermetic sealing devices at a lower cost than those manufactured using similar conventional methods. Furthermore, the apparatus and techniques described herein offer superior thermal and electrical performance compared to similar conventional devices. The apparatus and techniques described herein can also provide hermetic-sealed contactors and fuses using lower-cost manufacturing methods. In some cases, these methods can utilize cheaper raw materials. Moreover, some end cap assemblies described herein can be more compact than conventional assemblies, which can facilitate a reduction in the overall size of devices used with the assemblies and systems incorporating such devices.

[0014] Devices and techniques may, in addition to or alternatively, facilitate the use of different and / or more preferred materials to perform the functions required by the electrical installation. For example, but not limited to, the devices and techniques described herein may allow the use of steel for covers and / or housings. Steel can provide improved strength and / or thermal shock resistance compared to conventional materials.

[0015] However, this disclosure is not limited to these improvements, and not all implementations of the apparatus and techniques described herein can be achieved with these improvements. Furthermore, while many aspects of this disclosure may be particularly useful in electrical installations such as contactors and fuses, the systems and techniques described herein may be useful in many hermetically sealed applications.

[0016] The aspects of this disclosure will now be explained in more detail with reference to the accompanying drawings.

[0017] Figure 1 This is a perspective view of an electrical device 100, which may be a contactor device, a fuse device, a pyrotechnic fuse, a pyrotechnic contactor, etc. The electrical device 100 generally includes a body or housing 102 and an end cap assembly 104 configured to cover an opening in the housing 102. In the example shown, the end cap assembly 104 is fixed to the housing 102 to seal the top opening of the housing 102.

[0018] like Figure 1 As can be seen, the end cap assembly 104 includes a plate or cap 106 and two fixed contact structures 108 extending through the cap 106. In examples, the housing 102 may be formed as a base, a "can," or a "cup," for example, defining a substantially circular opening. The assembly 104 may be, for example, an end cap that seals to the housing 102 at the circular opening to seal the interior of the housing 102. (See below for further details.) Figure 2A The housing 102 is configured to accommodate multiple internal components.

[0019] Contact structure 108 is configured to electrically connect internal components of electrical device 100 to external circuitry, such as to an electrical system or apparatus. For example, contact structure 108 may be a contact terminal configured to facilitate the connection of electrical leads (not shown). In a non-limiting example, a power source may be connected to one of the contact structures 108, and a load to be powered by the power source may be connected to another of the contact structures 108.

[0020] The housing 102 may generally comprise any suitable material that can support the structure and function of the electrical device 100. The housing 102 may be selected and / or configured to facilitate improved connection with the end cap assembly 104. For example, the housing 102 may be configured for resistance welding to the end cap assembly 104. In these examples, the housing 102 may be made of a metal such as stainless steel. Also in examples, the housing 102 may be plated, for example, by electroless nickel plating. Similarly, in embodiments of this disclosure, the cover 106 may be formed of a metallic material such as steel, including but not limited to stainless steel, low-carbon steel, and / or other materials.

[0021] The housing 102 can be configured such that its internal space (e.g., housing various internal components of the electrical device 100) is hermetically sealed. An electronegative gas can be disposed within the housing 102. This hermetically sealed configuration can help mitigate or prevent arcing between adjacent conductive elements and, in some embodiments, helps provide electrical isolation between spatially separated contacts. In some instances, the housing 102 can be under vacuum conditions and / or hermetically sealed using known methods of electrical devices that produce a hermetically sealed seal. Also, as detailed herein, in some instances, the devices and techniques detailed herein can facilitate the use of hydrogen in the housing.

[0022] like Figure 1 As shown, the end cap assembly 104 generally includes a cap 106 and multiple additional components. The cap 106 includes multiple holes or openings formed therein, including pairs of contact openings 110. Each of the contact openings 110 is sized and positioned to receive one of the contact structures 108. Figure 1 As shown, each of the contact orifices 110 is further provided with an insulating member 112 and a spacer 114.

[0023] More specifically, and as Figure 1 As best shown in the exploded view, each of the contact structures 108 has an elongated body 116 (e.g., shown in the example as a generally cylindrical body). The elongated body 116 is configured to extend through the cover 106, for example, such that the first end of the elongated body 116 (in...) Figure 1 The lower end of the orientation is provided in the volume defined by the housing 102, and the second end (in the orientation of the lower end) is provided in the volume defined by the housing 102. Figure 1 The upper end of the orientation is located outside the volume portion. In an example, the contact structure 108 also includes a flange end that extends radially relative to the elongated body 116 at the second upper end.

[0024] The insulating member 112 is shown as an annular shape. For example, the insulating member 112 may be an eyelet. The insulating member 112 has an inner surface 118 whose diameter is designed to surround the elongated body 116 of the contact terminal 108. In an embodiment of this disclosure, the diameter of the inner surface 118 of the insulating member 112 may be designed to provide a gap between the elongated body 116 and the insulating member 112. In other embodiments, the inner surface 118 may contact the elongated body 116. The insulating member 112 also has an outer surface 120. In an embodiment of this disclosure, the outer diameter of the outer surface 120 is smaller than the diameter of the contact orifice 110. Therefore, in some embodiments, the insulating member 112 may be at least partially disposed within the contact orifice 110. Without limitation, the diameter of the outer surface 120 of the insulating member 112 may provide a gap between the insulating member 112 and the associated contact orifice 110. The insulating member 112 may be a ceramic material and / or any material or blend of materials that can provide thermal and / or electrical insulation. As detailed herein, the insulating member 112 may insulate the contact structure 108 from the cover 106 and / or from the spacer 114 coupled to the cover 106.

[0025] Spacer 114 is configured to attach insulating member 112 to cover 106. In embodiments of this disclosure, spacer 114 is a flanged or curved spacer comprising a first portion 122 and a second portion 124 curved or angled relative to the first portion 122. In the illustrated embodiment, the first portion 122 is substantially cylindrical, the axis of which generally corresponds to the axis of one of the contact orifices. The second portion 124 is substantially perpendicular to the first portion 122 (e.g., at a 90-degree angle relative to the first portion or formed within a threshold angle of 90 degrees). As will be understood, the spacer 114 is shaped such that the edge 126 of spacer 114 is spaced apart from the second portion 124 of spacer 114, for example, spaced apart from the longitudinal extent of the first portion 122. As further detailed herein, the edge 126 of spacer 114 may be attached to the insulating member, for example, to a radial surface of the insulating member, and the second portion 124 may be attached to cover 106.

[0026] In embodiments of this disclosure, spacer 114 may be metallic, such as low-carbon steel. Spacer 114 may be formed using known processes, including cold forming. In embodiments, spacer 114 may be attached to the surfaces of insulating member 112 and / or cap 106 using conventional techniques such as brazing, welding, etc. In embodiments, the surface to which spacer 114 of insulating member 112 may be a metallized surface, for example, a thin metal layer formed on insulating member 112 to facilitate metal-to-metal bonding. Insulating member 112 may also include a second metallized surface to which contact structure 108 is attached. Thus, components of end cap assembly 104 may be relatively simple components made of relatively common materials and processes.

[0027] In the arrangement described herein, each of the contact structures 108 is coupled to an insulating member 112, which is coupled to the spacer 114, for example, at the edge 126 of the spacer 114, and the spacer 114 is coupled to the cover 106. Thus, the insulating member 112 is thermally and / or electrically positioned “between” the contact structure 108 and the spacer 114 / cover 106. In examples, the contact structure 108 may be made of a high-current-capacitive material such as copper. However, the contact structure 108 must be insulated from the cover 106 and / or the housing 102. Conventionally, insulating materials such as ceramics, alumina, and / or other dielectric materials have been used for the cover 106. However, these materials may be expensive, difficult to process, and / or have other disadvantages. For example, alumina may not be robust enough because it may be prone to cracking and / or fissures under higher pressures. Alternatively, in the examples of this disclosure, the insulating member 112 may facilitate the use of a more robust material, such as steel, for the cover 106.

[0028] For example Figure 1 As shown, the cover 106 may include a plurality of additional openings through which other or additional components may extend into the sealing space defined by the housing 102 and the end cap assembly 104. For example, Figure 1 Multiple feedthroughs 128 are shown. Figure 1 (There are four in total), these multiple through-holes extend through the corresponding feedthrough apertures 130 in the cover 106. In an example, the through-holes 128 can be electrical leads, etc. Also as shown, a glass seal 132 can be provided in the feedthrough aperture 130, through which the through-holes 128 pass. In an example, the glass seal 132 can facilitate sealing the through-holes 128 to the cover 106 at the feedthrough aperture 130 via a glass-metal seal. Although in Figure 1 Four through-pieces 128 are shown, but more or fewer through-pieces may be provided.

[0029] End cap assembly 104 is also shown including a tube 134 passing through cap 106. More specifically, cap 106 includes a tube orifice 136 sized to receive tube 134. For example, tube 134 can be used to vent air from housing 102 (e.g., during a sealing process), to vent excess air from housing 102 (e.g., during a failure event), to supply gas (such as an electronegative gas, like hydrogen) to housing 102, and so on. Although only one tube 134 is shown, assembly 104 may include additional tubes (or may not include tubes).

[0030] Figure 2A and Figure 2B It is along Figure 1 The electrical device 100 is shown in section line 2-2. Figure 2A A contact structure 108 is shown extending through the cover 106 and into the interior 202 of the housing 102. As detailed herein, several aspects of this disclosure allow for a hermetically sealed interior 202 of the housing 102. For example, at least a portion of the interior 202 may be an arc chamber. The arc chamber may be filled with a gas that promotes arc suppression, such as hydrogen.

[0031] Several internal components within interior 202 are also shown. For example, Figure 2A A movable contact 204 is shown disposed at the distal end of a movable shaft 206. As is conventional in the art, shaft 206 can be selectively movable to position the movable contact 204 in a first position of contact structure 108 (e.g., to allow current to flow between contact structures 108) and a second position (shown) spaced apart from contact structure 108. In the illustrated example, the end of shaft 206 opposite to the movable contact 204 includes a plunger 208. The plunger 208 extends into an opening defined by a coil 210 (e.g., an electromagnetic coil). The electromagnetic coil 210 can be selectively energized to move the plunger 208 (and thus the shaft 206 and the movable contact 204) relative to contact structure 108. In the illustrated example, coil 210 is shown disposed within housing 102, for example, in a hermetically sealed environment. Other electrical devices are known, including coils located outside the hermetically sealed environment. The aspects of this disclosure can also be used with electrical devices of this type or any other type, as will be understood by one of ordinary skill in the art who benefits from this disclosure. As a non-limiting example, the end cap assembly 104 described herein can be used with non-sealed electrical devices.

[0032] Figure 2AAn interruption mechanism 212 is also shown, for example, near the inner surface of the cover 106 and between the contact structures 108. In an example, the interruption mechanism may include a triggering device 214 and a projectile 216, the triggering device being, for example, a pyrotechnic trigger. In operation, the triggering device 214 may detonate in response to an overcurrent, surge, arc, or some other event. Detonation applies a force that causes the projectile 216 to strike the shaft 206, driving the shaft 206 (and thus the movable contact 204) away from the contact structure 108, thereby suppressing current flow through the electrical device 100. Although Figure 2A The example shown is of interrupting mechanism 212, but this is merely an example. Many different types of electrical devices, including (or not including) any number of features, can benefit from the end cap assembly 104 detailed herein. Furthermore, various aspects of the end cap assembly 104 can be modified to work with any number of electrical devices. Without limitation, the size and / or shape of the cap 106 can be changed, the arrangement, composition, and / or style of the contact structure 108 can be changed, the type and / or inclusions of the interrupter can be changed, and so on.

[0033] although Figure 2A The electrical device 100 is shown as including various internal and external components, but Figure 2A These are merely examples. Various aspects of this disclosure can be used with any number or type of electrical installations that include end cap assemblies and housings (such as end cap assembly 104 and housing 102).

[0034] Figure 2B It is along Figure 1 The end cap assembly 104 of the electrical device 100 is cut off by section line 2-2. Figure 2B The positioning and interaction of several features of the end cap assembly, including the cap 106, contact structure 108, insulating member 112, and spacer 114, are shown in more detail.

[0035] like Figure 2B As shown, the cover 106 includes a lower surface 218 and an upper surface 220 spaced apart by the thickness of the cover 106. In one example, the lower surface 218 may be attached to the upper edge or lip of the housing 102 (not shown). In the example shown, a second portion 124 (e.g., a flange) of the spacer 114 is attached to the lower surface 218 of the cover 106 near the contact orifice 110. As shown, the radial extent of the second portion 124 of the spacer 114 is greater than the diameter of the contact orifice 110, such that the second portion 124 extends radially beyond the contact orifice 110 to contact the lower surface 218 of the cover 106. At this contact point, the second portion 124 may be secured to the cover 106, for example, via welding, brazing, and / or other conventional joining processes.

[0036] For example Figure 2BAs shown, a first portion 122 of the spacer 114 extends into the contact aperture 110. Specifically, the radial extent (e.g., diameter) of the first portion 122 of the spacer 114 is smaller than the diameter of the contact aperture 110. Therefore, the first portion 122 is surrounded by the contact aperture 110, and / or a gap is formed between the first portion 122 and the contact aperture 110. Figure 2B In one example, the axial or longitudinal extent of the first portion 122 is less than the thickness of the cover 106, such that the edge 126 of the spacer 114 is positioned within the contact opening 110. In other examples, the first portion 122 may be longer or shorter and / or wider or narrower.

[0037] The edge 126 of the first portion 122 is attached to the first side 222 of the insulating member 112. As shown, the edge 126 is attached such that the first portion 122 extends substantially perpendicularly to the first side 222 of the insulating member 112. In an example, the first side 222 of the insulating member 112 may be a metallization layer, for example, formed by deposition or other conventional processes. The first portion 122 of the spacer 114 may be brazed, welded, or otherwise fixed to the first side 222.

[0038] As described herein, insulating member 112 is also connected to contact structure 108. Figure 2B As shown, the insulating member 112 includes a second side 224 opposite (e.g., axially spaced apart) to the first side 222 to which the spacer 114 is attached. Also as shown, the contact structure 108 may include a flange 226 extending radially outward from the elongated body 116. The flange 226 is shown as including a protrusion 228 formed by an undercut at the junction of the flange 226 and the body 116. In some instances, the protrusion 228 may not be included; for example, the flange 226 may directly contact the second side 224 of the insulating member. In some instances, the flange 226 (e.g., at the protrusion 228) is attached to the second side 224 by brazing, welding, and / or some other conventional joining process.

[0039] like Figure 2B As shown, the contact structure 108 and the insulating member 112 are dimensionally designed to provide a space or gap between the inner surface 118 of the insulating member 112 and the outer surface of the contact structure. However, in other embodiments, the inner surface 118 of the insulating member 112 may contact the contact structure 108, for example, as long as the insulating member 112 still insulates the contact structure 108 from the spacer 114 and the cover 106. Also... Figure 2B As shown, the contact structure 108 may include a threaded hole 230. The threaded hole 230 can be used in some conventional devices to facilitate threaded connections of power supplies and / or electrical loads.

[0040] As mentioned above, due to Figure 2BThe arrangement of the contact structure 108, with the contact structure 108 insulated from the cover 106 (and spacer 114) by an insulating member 112. Figure 2B In one example, the insulating member 112 is partially disposed in the contact aperture 110, but extends over or protrudes from the upper surface 220 (e.g., the outer surface) of the cover 106. Additionally, as described above, the axial extent of the first portion 122 of the spacer 114 can be varied so that the insulating member 112 and the contact structure 108 (e.g., relative to the cover 106) have different axial orientations. As will be understood, by securing the second portion 124 of the spacer 114 to the lower surface 218 and extending the spacer into the contact aperture 110, the extent to which the contact structure 108 extends over the cover 106 can be reduced, for example, relative to an arrangement where the second portion 124 of the spacer 114 is disposed on top of the upper surface 220.

[0041] Figure 3 An alternative arrangement of the end cap assembly 300 according to an additional embodiment of this disclosure is shown. Figure 3 In this context, the previously used reference numerals are used to refer to the same parts.

[0042] Figure 3 Generally shown, the end cap assembly 300 includes a cap 106 with contact orifices 110 and alternative contact structures 108'. Each of the alternative contact structures 108' is coupled to an insulating member 112, and the insulating member 112 is further coupled to the cap 106 via spacers 114. However, several aspects of the end cap assembly 300 are "flipped" relative to the end cap assembly 104 discussed above.

[0043] like Figure 3 As shown, the second portion 124 of the spacer 114 is attached to the upper surface 220 of the cover 106, for example, rather than to the lower surface 218. The first portion 122 of the spacer 114 still extends into the contact orifice 110, but faces towards the lower surface 218 of the cover 106. Therefore, when the end cap assembly 300 is attached to the base ( Figure 3 When (not shown in the image), the insulating member 112, which is connected to the edge 126 of the spacer 114, extends below the cover 106, for example, into the interior 202. Figure 2B As in the example, the alternative contact structure 108' is shown as including a flange 226 and a protrusion 228, wherein the protrusion 228 is coupled to the insulating member 112. Therefore, with Figure 2B Unlike other examples, the flange 226 of the alternative contact structure 108' is disposed below the cover 106. The alternative contact structure 108' also includes a threaded hole 230 formed in the end of the structure 108' extending from the upper surface 220 of the cover 106. As will be understood, the distance by which the alternative contact structure 108' extends from the cover 106 can be shorter than... Figure 2A and Figure 2B The distance by which the contact structure 108 extends from the cover can further reduce the overall height of the electrical components of the combined end cover assembly 300.

[0044] Figure 4 This is a flowchart illustrating multiple aspects of process 400, which may be a manufacturing process for forming an hermetically sealed electrical device (such as electrical device 100).

[0045] At operation 402, process 400 includes providing a cover having contact orifices. For example, the cover may be cover 106 discussed above. For example, cover 106 has multiple orifices, including contact orifice 110. In an example, cover 106 may be made of a metal (such as steel, stainless steel, or some other robust metallic material). In an example, cover 106 does not need to be made of a dielectric material, for example, because several aspects of this disclosure include insulating cover 106 from contacts configured to carry electrical current.

[0046] At operation 404, process 400 includes, for example, providing angled spacers, contact structures, and insulating members for each of the contact orifices. As described herein, the angled spacers may be spacer 114, the contact structures may be contact structures 108, 108', and / or the insulating members may be insulating members 112. The spacers may be formed of a metal such as low-carbon steel and may be a curved structure including a first portion and a second portion bent relative to the first portion. The contact structures may be made of a highly conductive material such as copper. The insulating members 112 may be made of a dielectric material such as ceramic.

[0047] At operation 406, process 400 includes securing a first portion of the angled spacer to a first position on the insulating member. For example, and as described above, spacer 114 may include a generally cylindrical first portion 122 terminating at edge 126. Edge 126 may be secured to one side of the insulating member 112 (e.g., such as in...). Figure 2B (Second side 224 in the example). In the example, operation 406 may include brazing insulating member 112 and spacer 114.

[0048] At operation 408, process 400 includes securing the contact structure to a second position on the insulating member. For example, and as described above, the contact structure 108 may include a flange 226, and the flange 226 may be secured to a first side 222 of the insulating member 112. The first side 222 and the second side 224 are spaced apart from each other sufficiently such that the contact structure and the angled spacer are insulated from each other. In an example, operation 408 may include brazing the insulating member 112 and the contact structure 108.

[0049] At operation 410, process 400 includes forming an end cap assembly by securing a second portion of an angled spacer to the cap such that a first portion of the angled spacer extends into a contact orifice. As described herein, spacer 114 may include a flanged second portion 124 substantially perpendicular to the first portion 122. At operation 410, the second portion 124 of spacer 114 may be coupled to a surface, for example, to the bottom surface 218 of cap 106 (e.g., Figures 1 to 2B (middle) or the top surface 220 of the cover 106 (e.g.) Figure 3 (in the middle). In an example, operation 410 may include brazing spacer 114 to cover 106.

[0050] Although operations 406, 408, and 410 are shown and described as separate and sequential steps, as will be understood, operations 406, 408, and 410 may be performed in different orders and / or in a single step (such as a single brazing step). For example, since brazing involves the application of heat, different brazing operations may be performed simultaneously (e.g., via the same heat application, such as in a furnace).

[0051] At operation 412, process 400 includes securing the component to the housing to form a sealed housing. For example, known methods, including welding, epoxy resin, and / or other processes, can be used to secure component 104 to the housing.

[0052] At operation 414, process 400 may include venting the sealed housing. For example, ambient air in the housing after sealing may be removed and / or replaced with an electronegative gas (such as hydrogen) to provide a hermetically sealed electrical device, such as electrical device 100.

[0053] As described above, aspects of this disclosure relate to providing an electrical device incorporating an improved end cap assembly that insulates the contact terminals from the cap. The end cap assembly described herein can provide numerous advantages over conventional end cap assemblies.

[0054] In some aspects of this disclosure, components for hermetic sealing and electrical insulation used in high-voltage DC contactors, fuses, and pyrotechnic fuses can utilize unique arrangements of parts and geometries joined using conventional brazing techniques to reduce costs and improve performance compared to conventional sealing assemblies. For example, aspects of this disclosure can reduce copper waste associated with contact terminals, for example, because contact terminals can be narrower than conventional terminals. Furthermore, brazed joints can be more robust than those used in conventional end cap assemblies. Moreover, and as detailed above, the arrangements and techniques described herein can facilitate shorter overall electrical installations, for example, because the contacts do not need to extend excessively above the housing.

[0055] The hermetic glass-metal assembly described herein can further reduce costs compared to existing ceramic-metal and epoxy sealing applications by utilizing manufacturing methods with lower raw material costs. For example, but not limited to, the techniques described herein can facilitate the use of metals such as stainless steel instead of more expensive and / or less robust materials for the cap.

[0056] Although the subject matter has been described with respect to preferred embodiments, those skilled in the art will readily understand that various changes and / or modifications can be made to the subject matter without departing from its spirit or scope. For example, each claim may be dependent on any or all claims in a plurality of dependent manner, even if such manner was not originally claimed.

Claims

1. An electrical device comprising: case; as well as End cap assembly, sealing to the housing, the end cap assembly comprising: build, Contact opening, formed through the cover, A contact terminal is disposed in the contact orifice, such that a first end of the contact terminal is disposed within a volume defined by the housing and the end cap assembly, and a second end of the contact terminal is disposed outside the volume. An insulating member includes a first surface and a second surface opposite to the first surface, wherein the first surface is coupled to the contact terminal; and A spacer that connects the insulating member to the cover, the spacer comprising a first portion and a second portion angled relative to the first portion, wherein the first portion is connected to a second surface of the insulating member and the second portion is connected to the cover such that the first portion extends into the contact orifice.

2. The electrical device according to claim 1, wherein, The insulating member is at least partially disposed in the contact orifice.

3. The electrical device according to claim 1, wherein: The insulating component includes an opening; and The body of the contact terminal extends through the orifice.

4. The electrical device according to claim 1, wherein, The insulating component includes a ceramic component or a metallized ceramic component.

5. The electrical device according to claim 1, wherein, The first portion of the spacer is coupled to the second surface of the insulating member such that the first portion extends substantially perpendicular to the second surface.

6. The electrical device according to claim 1, wherein, The first part and the second part are substantially perpendicular.

7. The electrical device according to claim 1, wherein, The first portion of the spacer is brazed to the second surface of the insulating member, wherein the second surface of the insulating member includes a metal layer.

8. The electrical device according to claim 1, wherein, The second portion of the spacer is brazed to the cover.

9. The electrical device according to claim 1, wherein: The second portion is attached to the inner surface of the cover, the inner surface of the cover facing the volume portion; and The insulating member extends outward from the end cap assembly relative to the inner surface of the cover.

10. The electrical device according to claim 1, wherein: The second part is attached to the outer surface of the cover that is opposite to the volume portion; and The insulating member extends at least partially relative to the cover into the volume defined by the housing and the end cap assembly.

11. An end cap assembly for an electrical device, the end cap assembly comprising: build, Contact opening, formed through the cover, The contact terminal is disposed in the contact orifice. Insulating components are connected to the contact terminals; as well as A spacer connects the insulating member to the cover, the spacer comprising a first portion and a second portion bent relative to the first portion, wherein the first portion is connected to the insulating member and the second portion is connected to the cover such that the first portion extends into the contact orifice.

12. The end cap assembly according to claim 11, wherein: The second part is attached to the first surface of the cover; and The insulating member protrudes from a second surface of the cover that is opposite to the first surface of the cover.

13. The end cap assembly according to claim 11, wherein, The insulating member is at least partially disposed in the contact orifice.

14. The end cap assembly of claim 11, wherein: The insulating component includes an opening; and The body of the contact terminal extends through the orifice.

15. The end cap assembly according to claim 11, wherein, The insulating component includes a ceramic component.

16. The end cap assembly of claim 11, wherein, The first portion of the spacer is coupled to a surface of the insulating member such that the first portion extends substantially perpendicular to the surface.

17. The end cap assembly of claim 11, wherein, The first part and the second part are substantially perpendicular.

18. The end cap assembly of claim 11, wherein: The insulating component includes a metal layer; and The first portion of the spacer is brazed to the metal layer.

19. The end cap assembly according to claim 11, wherein, The second portion of the spacer is brazed to the cover.

20. The end cap assembly of claim 11, wherein: The insulating component is ring-shaped; The inner diameter of the insulating member allows for a clearance fit between the insulating member and the body of the contact terminal; and The outer diameter of the insulating member allows the insulating member to form a clearance fit with the contact orifice.

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