Fluid-Tight Control Device Feedthroughs With Laser Bonding
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Solution Overview
Problem
Existing control devices face issues with electrical feedthroughs that are not reliably sealed against gases or liquids due to damage from high-temperature welding or soldering processes, leading to leaks and increased manufacturing complexity.
Innovation Solution
The use of a laser-bonded connection between the metal core and control electronics, combined with a glass or ceramic insulator, ensures a reliable electrical feedthrough that is fluid-tight and resistant to damage, using a method that minimizes thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering is used to connect the metal core to control electronics, then electrical connection is achieved, but cracks form in the glass insulator due to high temperatures causing seal failure
Solution Approach 1:
The patent replaces the thermal welding/soldering process with a laser-bonding process. The laser beam provides localized heating that is sufficient to bond the metal core to the control electronics without generating the high temperatures that cause glass insulator cracks. This substitution of the bonding mechanism eliminates the thermal damage while maintaining electrical connection reliability.
Solution Approach 2:
The patent changes the bonding parameters from high-temperature welding/soldering to lower-temperature laser bonding. By controlling the laser parameters (power, duration, focus), the process achieves sufficient bonding strength without exceeding the thermal tolerance of the glass insulator, thus preventing crack formation while maintaining seal integrity.
2Reliability
If plug connections are used to connect the metal core to control electronics, then electrical connection is achieved, but mechanical impacts occur on the insulator leading to leaks
Solution Approach 1:
The patent replaces the mechanical plug connection system with a laser-bonded connection. This eliminates the mechanical interface that is susceptible to impact forces. The laser-bonded joint creates a permanent, impact-resistant connection between the metal core and control electronics, removing the source of mechanical stress on the insulator that would otherwise lead to leaks.
3Reliability
If a corresponding plug element is located on the side of the control electronics, then electrical connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts and eliminates the separate plug element from the control electronics assembly. Instead of adding a plug element to the side of the control electronics, the invention uses the existing metal core end face as the bonding surface. This simplification removes the need for additional components and assembly steps while maintaining reliable electrical connection through the laser-bonded joint.
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 approach provides a durable, leak-resistant electrical connection suitable for high currents, simplifies manufacturing, and reduces the risk of insulator damage, maintaining the integrity of the control device's seal.
Implementation Method 1
a first bond is provided between the end face of the metal core and the control electronics, wherein the first bond is laser-bonded at the end face
Implementation Method 2
there is a connection region at the transition between the end face and the first bond, wherein the connection region consists of melted and resolidified material of the first bond as well as the metal core
Data Source
AI summary
The invention relates to a control device having a casing, control electronics located in the casing, and at least one electrical feedthrough. By means of the electrical feedthrough, a current is provided for a load which is located outside the casing of the control device. The electrical feedthrough is located on the casing. The casing is fluid-tight at least in part, and the electrical feedthrough is located in a fluid-tight region of the casing. The electrical feedthrough has a metal core and an insulator surrounding the metal core. The metal core has an end face. A first bond is provided between the end face of the metal core and the control electronics, the first bond being laser-bonded at the end face.