Feedthrough Ceramic Coating for Creepage Breakdown Prevention
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Solution Overview
Problem
Feedthrus used in connecting electrical devices face issues with creepage breakdown, particularly at high temperatures, due to moisture condensation and contamination, leading to short circuits, which existing insulating materials like Lektro-Tech fail to prevent effectively above 205°C.
Innovation Solution
A ceramic-based coating is applied to the feedthru, specifically on the exposed ends of conductive pins and the header, to create an elongated creepage pathway, preventing moisture-induced short circuits by using high-temperature stable ceramic coatings such as CP 4050 Corr-Paint, Ceramabond 512, or similar materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating material coating (e.g., Lektro-Tech) is applied to increase creepage distance, then creepage breakdown is prevented at lower temperatures, but the coating becomes ineffective at temperatures exceeding 205°C due to moisture condensation
Solution Approach 1:
The patent changes the material parameter of the coating from organic insulating material (Lektro-Tech) to inorganic ceramic-based coating. This parameter change enables the coating to maintain its insulating properties at temperatures exceeding 205°C where the original material failed, directly resolving the temperature limitation contradiction.
Solution Approach 2:
The patent uses ceramic-based coatings that can be applied over existing insulating material coatings, creating a composite structure. The ceramic outer layer provides high-temperature stability while the underlying insulating material provides base creepage protection, together resolving both the low-temperature and high-temperature reliability requirements.
2Reliability
If exposed conductive portions are left uncoated to maintain electrical connectivity, then electrical connection is ensured, but creepage breakdown occurs due to moisture condensation and contamination
Solution Approach 1:
The patent applies ceramic-based coating specifically to the exposed conductive portions of pins and headers where electrical connection is needed. This localized application provides creepage protection at the critical interfaces without interfering with the electrical connectivity function, resolving the contradiction between connection integrity and harmful factor resistance.
Solution Approach 2:
The ceramic-based coating acts as an intermediary layer between the exposed conductive surfaces and the harmful environment (moisture and contamination). It provides a protective barrier that prevents moisture condensation and contamination from directly contacting the conductive surfaces, thereby eliminating creepage breakdown while maintaining electrical connection.
3Reliability
If insulation material is used to coat exposed conductive material to eliminate creepage, then creepage breakdown is prevented, but the material fails above 205°C due to condensation
Solution Approach 1:
The patent changes the material composition parameter from organic insulating material to inorganic ceramic-based coating. This fundamental material parameter change provides both creepage elimination and high-temperature stability, as ceramic materials maintain their structural and insulating properties at temperatures where organic materials decompose or become ineffective.
Solution Approach 2:
The patent employs ceramic-based coatings that can be applied over existing insulating material coatings, creating a composite protective system. The ceramic outer layer provides high-temperature stability and creepage protection, while the underlying insulating material provides additional barrier properties, together resolving both the creepage elimination and high-temperature stability requirements.
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 ceramic-based coating effectively eliminates creepage breakdown and maintains electrical insulation integrity at temperatures exceeding 205°C, preventing short circuits and ensuring reliable electrical connections.
Implementation Method 1
The ceramic based coating is located on at least one of the following at least a portion of the first end of the at least one conductive pin that abuts the insulated portion of the at least one conductive pin, at least a portion of the second end of the at least one conductive pin that abuts the insulated portion of the pin, at least a portion of a first side of the header that abuts the insulated portion of the pin, and at least a portion of a second side of the header that abuts the insulated portion of the pin.
Implementation Method 2
A ceramic-based coating is applied to the feedthru, specifically on the exposed ends of conductive pins and the header, to create an elongated creepage pathway, preventing moisture-induced short circuits by using high-temperature stable ceramic coatings
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present invention relates to a feedthru (210, 210′) provided with a ceramic based coating (260) and a method of providing a feedthru (210, 210′) with a ceramic based coating (260). The feedthru (210, 210′) includes at least one conductive pin (220) that extends through a header (217) and includes an exposed first end (221) and an exposed second end (222) spaced by an insulated portion (224). The at least one conductive pin (220) connects a first conductive element (121) connected with a first electrical device (300, 300a, 300b, 104, 105, 105′) and a second conductive element (121′) connected with another electrical device (20, 301), whereby the exposed first end (221) connects to the first conductive element (121) and the exposed second end (221) connects to the second conductive element (121′). The ceramic based coating (260) located on at least one of the following at least a portion of the first end (221) of the at least one conductive pin (220) that abuts the insulated portion (224) of the at least one conductive pin (220), at least a portion of the second end (222) of the at least one conductive pin (220) that abuts the insulated portion (224) of the pin (220), at least a portion of a first side (217a) of the header (217) that abuts the insulated portion (224) of the pin (220), and at least a portion of a second side (217b) of the header (217) that abuts the insulated portion (224) of the pin (220).