Electrical Feedthrough Assembly With Adhesive Cavity Sealing
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Solution Overview
Problem
Existing electrical feedthrough assemblies for housings, such as those in electronic compressors, face challenges in achieving a secure and reliable connection between insulation elements and base bodies, often resulting in low yield due to damage from molding tools and difficulties in applying adhesive correctly, leading to potential short circuits and hermetic seal failures.
Innovation Solution
The proposed electrical feedthrough assembly features a base body with embedded conductors sealed in fixation material and an insulation element with a cavity for adhesive confinement, allowing precise adhesive introduction and compensation for manufacturing tolerances, ensuring a secure and hermetic seal without adhesive overflow or air bubbles, using materials like glass, ceramic, and resilient rubbers for insulation and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If injection molding is used to connect the insulation element to the base body, then a tight connection is achieved, but specialized molding tools are required and the molding process may damage the feedthrough
Solution Approach 1:
An adhesive is introduced as an intermediary substance between the insulation element and the base body. The adhesive is injected into a cavity formed between these components, creating a reliable chemical bond without requiring complex molding tools. This mediator approach resolves the contradiction by achieving strong connection through a simpler process.
2Reliability
If adhesive is applied to connect the insulation element to the base body, then the connection is secure, but it is difficult to apply the correct amount of adhesive without overflow or gaps
Solution Approach 1:
A cavity is pre-formed between the insulation element and the base body before adhesive application. This preliminary structural preparation creates a defined space that guides and confines the adhesive, ensuring it is distributed evenly without overflow or gaps. The cavity acts as a built-in dosing chamber that eliminates the need for precise manual adhesive application.
3Strength
If the insulation element is directly molded onto the base body, then a tight connection is achieved, but casting burr must be removed and the process has low yield
Solution Approach 1:
The manufacturing process is segmented into distinct steps: first forming the cavity between components, then injecting adhesive separately, and finally curing. This segmentation allows each step to be optimized independently, avoiding the need for complex integrated molding tools and eliminating burr formation issues that plague single-step molding processes.
4Reliability
If epoxy-glue is used to attach the insulation element to the feedthrough, then the insulating element is securely attached, but overflowing glue may block parts of the feedthrough assembly or cover conductor contact parts
Solution Approach 1:
The cavity is designed with specific local geometry that confines the adhesive to the exact region where bonding is needed. The cavity walls and opening dimensions are carefully controlled to ensure adhesive remains within boundaries, preventing overflow onto conductors or mounting surfaces while maintaining secure attachment in the critical bonding zone.
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
This solution provides a reliable, easy-to-manufacture feedthrough assembly with enhanced insulation and hermetic sealing, reducing the risk of short circuits and improving the yield of good feedthrough elements by ensuring a secure connection and precise adhesive application, suitable for use in electronic compressors.
Implementation Method 1
The adhesive is introduced into the cavity through the at least one further opening. The cavity is at least partially filled with the adhesive for forming a connection between the base body and the insulation section of the insulation element.
Implementation Method 2
A fixation material, for example a glass material, is used to seal the opening and to hold the conductor within the opening. The fixation material also provides an electrical insulation between the conductor and the housing.
Data Source
Figure 1~2
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Figure 5~6
AI summary
An electrical feedthrough assembly (1) comprising a base body (10), preferably configured as e-compressor terminal is provided, the base body having at least one opening (14) for at least one conductor (12) embedded in a fixation material (16) that is fed into each of the respective openings (14) and sealing the respective opening (14), wherein said electrical feedthrough assembly (1) further comprises at least one insulation element (20) affixed to the base body (10), the insulation element (20) having at least an insulation section (22) for a conductor (12), the insulation section (22) having an conductor opening (24) through which the respective conductor (12) is fed, the insulation element (20) being configured and arranged such that a cavity (30) is formed between the base body (10) and the insulation section (22), the insulation section (22) further comprising at least one further opening (26) allowing access to the cavity (30), the cavity (30) being at least partially filled with an adhesive (40) for forming a connection between the base body (10) and the insulation section (22) of the insulation element (20). Further aspects of the invention relate to a method for manufacturing of such an electrical feedthrough assembly (1) and to an electric compressor comprising such an electrical feedthrough assembly (1).