Electrical Feedthrough Assembly With Thermal Collar for High Power RF

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Solution Overview

Problem

Existing electrical feedthrough assemblies face challenges in efficiently transferring high levels of electrical or radio frequency (RF) power at high frequencies without significant loss and damage, while also requiring compact dimensions and hermetic sealing for harsh environments.

Innovation Solution

The electrical feedthrough assembly comprises an elongate conductor and a thermally conductive collar with a high thermal conductivity material, such as beryllium oxide, brazed together with a copper silver alloy filler, and mounted within a Kovar shell to provide a hermetic seal and efficient heat dissipation, enabling high power and frequency transmission with minimal loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional electrical feedthrough assemblies are used to transfer high power at high frequencies, then electrical communication between sides is achieved, but significant power loss and damage occur

Engineering Contradiction:

Improvepower lossVSAvoiddamage to feedthrough assembly

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent changes the thermal conductivity parameter of the collar material to at least 170 W/(m-K) and optimizes the length parameters to provide quarter-wave transforms at operating frequencies, enabling efficient high-power RF transmission with minimal loss and damage

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining a nonferrous elongate conductor with a thermally conductive dielectric collar, and joins them through brazing with copper-silver alloy filler material, creating a composite assembly that achieves both electrical conductivity and thermal management

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If the feedthrough assembly is made compact, then the profile is reduced, but fabricating dimensions sufficient to transfer electrical power at high frequencies becomes challenging

Engineering Contradiction:

Improveprofile sizeVSAvoiddimensions for high frequency power transfer

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent optimizes the length parameters of the conductor and collar to provide quarter-wave transforms at the operating frequency, enabling compact dimensions while maintaining sufficient electrical performance for high-frequency power transfer

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses the radial dimension by surrounding the conductor with a thermally conductive collar, achieving thermal management and electrical performance in a compact axial profile

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If high thermal conductivity material is used in the collar, then heat dissipation is improved, but the complexity of joining and assembly increases

Engineering Contradiction:

Improveheat dissipationVSAvoidjoining and assembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent uses copper-silver alloy filler material as an intermediary in the brazing process, enabling reliable thermal and mechanical joining between the nonferrous conductor and the thermally conductive collar, and between the collar and the Kovar shell

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If hermetic sealing is implemented for harsh environments, then environmental protection is improved, but the manufacturing and assembly difficulty increases

Engineering Contradiction:

Improvehermetic sealingVSAvoidassembly difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses the thermally conductive collar and brazing filler materials as intermediaries to achieve hermetic sealing between the conductor, collar, and Kovar shell, creating an integrated sealed assembly that protects against harsh environments

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration allows for the efficient transfer of electrical signals with input powers up to 300 W and frequencies from 30 GHz to 300 GHz, while maintaining a compact profile and ensuring hermetic sealing, thus preventing damage from heat and environmental stress.

Implementation Method 1

a thermally conductive collar with a high thermal conductivity material, such as beryllium oxide

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

brazed together with a copper silver alloy filler

Methodology Applied

Scientific EffectBrazing: Brazing

Implementation Method 3

transfer high levels of electrical or radio frequency (RF) power at high frequencies

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Data Source

PatentUS11350537B2Electrical feedthrough assembly

Publication Date: 2022.05.31 ANALOG DEVICES INC

AI summary

Various embodiments relate to an electrical feedthrough assembly an elongate conductor and a collar at least partially surrounding the elongate conductor along a portion of a length of the elongate conductor. The collar can be composed of a material having a thermal conductivity of at least 170 W/(m-K). A shell can be disposed around the collar. At one or more operating frequencies, at least a portion of a length of the electrical feedthrough assembly can be selected to provide at least one quarter wave transform.