Hermetic Feedthrough Assembly Using Crimped Insulator Compression
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Solution Overview
Problem
There is a need for a feedthrough device that can effectively transmit electricity through a housing wall while withstanding harsh environments within the housing, preventing the transfer of matter in and out, while minimizing manufacturing time and cost.
Innovation Solution
A feedthrough device design featuring a conductor, an insulator, and a body where the insulator is compressed to create a hermetic seal, with the body and conductor made from metallic materials and the insulator from polymeric materials, using crimping to secure the components and maintain a hermetic seal across the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulator is compressed to create a hermetic seal, then the reliability of the feedthrough device is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines the insulator and conductor into a single integrated assembly that is crimped together as one unit. The insulator is compressed radially to engage with the conductor and form a hermetic seal, eliminating the need for separate sealing mechanisms and reducing assembly steps while maintaining reliability.
Solution Approach 2:
The patent utilizes radial compression of the insulator to change its dimensional parameters, creating a interference fit that establishes the hermetic seal. By controlling the compression parameters during crimping, the device achieves reliable sealing without complex assembly procedures.
2Adaptability or versatility
If the body and conductor are made from metallic materials with different thermal expansion coefficients, then the adaptability to thermal environments is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent explicitly addresses thermal expansion by selecting metallic materials for both the body and conductor with different thermal expansion coefficients. This allows the feedthrough device to accommodate thermal cycling and expansion differences without failure, improving adaptability to varying thermal environments.
Solution Approach 2:
The patent employs composite material construction with metallic body and conductor materials that have complementary properties. The combination of different metals is selected to provide both thermal adaptability and mechanical compatibility, balancing the need for thermal expansion accommodation with manufacturing feasibility.
3Object-affected harmful factors
If the insulator is highly compressed to ensure hermetic sealing, then the chemical resistance is improved, but the conductor compression increases potentially affecting electrical properties
Solution Approach 1:
The patent applies local quality by concentrating the compression effect at the interface between the insulator and the body wall, rather than uniformly compressing the entire insulator. The insulator is compressed radially at specific locations to create hermetic sealing zones, while the conductor experiences minimal compression, preserving its electrical properties.
Solution Approach 2:
The patent segments the compression function into distinct zones: the insulator is compressed at its outer surface to engage with the body for hermetic sealing, while the conductor remains relatively uncompressed. This segmentation allows the insulator to provide both sealing and chemical resistance functions without compromising conductor integrity.
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 design ensures reliable electrical transmission through a housing while preventing gas, liquid, or solid matter transfer, accommodating different thermal expansion coefficients and offering improved chemical resistance, with a cost-effective and efficient assembly process.
Implementation Method 1
the insulator is compressed to create a hermetic seal
Implementation Method 2
maintain a hermetic seal across the device
Implementation Method 3
transmit electricity through a wall
Implementation Method 4
accommodating different thermal expansion coefficients
Data Source
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AI summary
A feedthrough device includes a body having longitudinally spaced first and second end faces and an inner surface defining an opening extending longitudinally through the body, a conductor extending within the opening of the body, and an insulator extending within the opening of the body transversely intermediate the conductor and the inner surface of the body to insulate the conductor from the body, where the conductor includes an interior portion surrounded by the insulator and an exterior portion extending beyond the insulator, the exterior portion having a diameter that is greater than a diameter of the interior portion.