Electrical Feedthrough Asymmetric Conductor Sealing
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Solution Overview
Problem
Electrical feedthroughs, particularly glass-to-metal seals, face challenges in achieving effective sealing properties such as electrical insulation, hermeticity, and long-term reliability when electrical conductors have relatively large diameters in relation to the feedthrough dimensions or are arranged in high density, especially in applications requiring small dimensions and specific connection standards.
Innovation Solution
The design features a base body with a through-hole containing an insulating material and an electrical conductor with varying diameters, where the conductor's diameter is larger on one side and smaller on the other, allowing for optimized conductor dimensions while enhancing sealing properties through a tapered or stepped profile, and potentially incorporating grooves for improved mechanical interlock and insulation material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrical conductors have relatively large diameters in relation to the feedthrough dimensions, then electrical connection quality is improved, but sealing properties deteriorate
Solution Approach 1:
The electrical conductor is designed with an asymmetric diameter profile, having a first diameter larger than the second diameter. This asymmetric configuration allows the conductor to provide sufficient electrical connection quality at the larger diameter end while maintaining adequate sealing properties at the smaller diameter end, thus resolving the contradiction between connection quality and sealing properties.
Solution Approach 2:
Different sections of the electrical conductor are given different diameters to fulfill different functional requirements. The first section with the larger diameter optimizes for electrical connection, while the second section with the smaller diameter optimizes for sealing, allowing each local region to have the quality needed for its specific function.
2Productivity
If electrical conductors are arranged in high density, then space utilization is improved, but sealing properties deteriorate
Solution Approach 1:
The asymmetric diameter profile of the electrical conductor allows for more efficient spatial arrangement within the feedthrough. The varying diameter enables conductors to be packed more densely while maintaining adequate clearance for sealing materials, thus improving space utilization without compromising sealing properties.
3Volume of moving object
If the feedthrough dimension is reduced, then device compactness is improved, but electrical connection quality deteriorates
Solution Approach 1:
The electrical conductor features local quality variation with different diameters at different sections. This allows the conductor to maintain adequate connection quality at the interface with the insulating material while occupying minimal space within the compact feedthrough, thus resolving the contradiction between compactness and connection quality.
Data Source
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AI summary
The invention relates to an electrical feedthrough comprising a base body having a first side and an opposed second side and at least one through-hole extending through the base body from the first side to the second side, an insulating material received in the through-hole, the insulating material having a first surface on the first side of the base body and an opposed second surface on the second side of the base body, and an electrical conductor extending through the insulating material, the electrical conductor having a first diameter at the location of the first surface of the insulating material and a second diameter at the location of the second surface of the insulating material, wherein the first diameter of the electrical conductor is larger than the second diameter of the electrical conductor.