Electrical Feedthrough Contact Alignment After Compression
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Solution Overview
Problem
Existing methods for producing electrical feedthroughs face challenges in achieving precise positioning of the inner conductor within the outer conductor due to directional offsets during compression, leading to inconsistent insulating distances and potential leakage.
Innovation Solution
A method involving compression of the outer pipe, insulating material, and inner conductor to form a module, followed by determining the inner conductor's position relative to the outer pipe and positioning the contact section accurately after compression, ensuring it aligns with the outer pipe's center axis, either by machining or joining a separate section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high compression pressure is applied to assemble the feedthrough components, then mechanical strength and leakage resistance are improved, but the positioning precision of the inner conductor deteriorates due to directional offsets
Solution Approach 1:
The patent applies preliminary action by performing the positioning of the inner conductor contact section relative to the outer pipe center axis AFTER the compression process, rather than before. The method includes: (1) compressing the outer pipe, insulating material, and inner conductor to form a module, (2) determining the position of the inner conductor relative to the outer pipe, and (3) positioning the contact section of the inner conductor relative to the center axis of the outer pipe. This sequence ensures that the high compression pressure needed for mechanical strength does not compromise the positioning precision, as the positioning is established after compression when the components are already firmly assembled.
2Reliability
If larger insulating distance is designed to accommodate positioning offsets, then reliability is improved, but the device size increases
Solution Approach 1:
The patent replaces the mechanical approach of relying on large dimensional clearances with a measurement and positioning system. Instead of designing larger insulating distances to accommodate potential offsets, the method uses: (1) determination of the actual position of the inner conductor relative to the outer pipe after compression, and (2) subsequent positioning of the contact section relative to the center axis of the outer pipe. This substitution of mechanical clearance with active positioning maintains reliability while minimizing device size.
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
Ensures precise positioning of the contact section, maintaining consistent insulating distances and reducing leakage rates, particularly in high-pressure environments.
Implementation Method 1
for the compression or compaction, very high pressures must be processed to achieve the desired mechanical strength and low leakage rates
Implementation Method 2
the electrical insulating material itself, if it is used optionally as a molded body, is a porous starting material, whose porosity must be significantly reduced
Data Source
AI summary
A method for producing an electrical feedthrough with an inner conductor arranged in some sections in a metallic outer pipe and electrically insulated from this outer pipe by an electrically insulating material. The inner conductor of the feedthrough has a contact section projecting out of the metallic outer pipe. The metallic outer pipe, the electrically insulating material, and the sections of the inner conductor, which are already arranged in the metallic outer pipe, are compressed with each other to form a module, in which the contact section projecting out of the metallic outer pipe is joined to the inner conductor only after completion of the compression of the metallic outer pipe, the electrically insulating material, and the sections of the inner conductor, which are already arranged in the metallic outer pipe. The contact section is positioned such that it is oriented along the center axis of the metallic outer pipe.