Epoxy Hermetic Seal Structure for Thermal-Cycling Contactors
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Solution Overview
Problem
Conventional contactor devices experience seal failure due to mismatched coefficients of thermal expansion (CTE) between internal components and sealing materials, leading to degradation of hermetic seals during thermal cycling, which affects reliability and longevity.
Innovation Solution
Incorporating an internal housing with a CTE closely matching the sealing material, combined with flexibility and surface texturing, to ensure the internal components expand and contract in sync with the sealing material, maintaining adhesion and the hermetic seal during thermal cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional internal components with mismatched CTE are used, then device complexity is reduced, but hermetic seal reliability deteriorates during thermal cycling
Solution Approach 1:
An internal housing is introduced as an intermediary component between the sealing material and internal operational components. This internal housing has a CTE substantially matching the sealing material, acting as a mediator that accommodates thermal expansion differences and maintains seal integrity during thermal cycling.
Solution Approach 2:
The device is segmented into distinct functional components: an outer housing, an internal housing with matched CTE, and internal operational components. This segmentation allows each component to be optimized for its specific function, particularly the internal housing's role in maintaining the hermetic seal.
2Ease of manufacture
If internal components with different CTE than sealing material are used, then ease of manufacture is improved, but seal adhesion deteriorates during thermal cycles
Solution Approach 1:
The CTE parameter of the internal housing is specifically selected to substantially match the sealing material's CTE. This parameter change ensures that both components expand and contract at similar rates during thermal cycling, maintaining adhesion and preventing seal failure.
3Strength
If rigid internal housing is used, then structural strength is improved, but adaptability to thermal expansion deteriorates
Solution Approach 1:
The internal housing is designed with flexible characteristics that allow it to expand and contract with the sealing material during thermal cycling. This flexibility enables the internal housing to adapt to thermal expansion while maintaining structural integrity and seal adhesion.
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 enhances the reliability of contactor devices by maintaining a consistent hermetic seal through repeated thermal cycles, preventing seal failure and ensuring the device's operational integrity.
Implementation Method 1
the internal housing has a coefficient of thermal expansion (CTE) that substantially matches the CTE of the sealing material, allowing for the internal housing to flex/move with the sealing material during thermal cycles
Data Source
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AI summary
Electrical switching devices, such contactor and fuse devices, are disclosed that have improved reliability particularly through thermal cycling. One electrical switching device according to the present invention comprises an outer housing and internal operational components within the outer housing. An internal housing in included in that outer housing that surrounds at least some of the internal operational components. A sealing material is also included within the outer housing that is capable of forming a hermetic seal within the outer housing, wherein the sealing material contacts the internal housing. The internal housing has a CTE that substantially matches the CTE of the sealing material. Electrical system according to the present invention comprises an electrical circuit and an improved electrical switching device electrically connected to the electrical circuit to reliably open or close the circuit.