Hermetic Feedthrough Connector With Layered Base and Sealing Portion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional feedthrough connectors for hard disk drives are difficult to couple to the housing, especially in sealed environments, and have a large footprint, which complicates achieving a strong, reliable, and properly sealed connection, while also being expensive to manufacture due to the materials used.
Innovation Solution
A feedthrough electrical connector with an electrically insulating base having multiple layers and a sealing portion that is electroplated or adhesive-bonded to the housing, reducing the cross-sectional area and footprint, and featuring zero-insertion-force design and conductive leads for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional feedthrough connectors are used to provide electrical connections through the housing, then electrical connectivity is achieved, but the connector has a large footprint and is difficult to couple to the housing while maintaining hermetic seal
Solution Approach 1:
The connector is divided into multiple functional segments: an external portion for electrical connection, an internal portion for internal component connection, and a sealing portion that interfaces with the housing aperture. This segmentation allows each portion to be optimized independently, reducing the overall footprint while maintaining hermetic seal integrity through the specialized sealing portion.
Solution Approach 2:
The connector transitions from a conventional large-area planar design to a three-dimensional structure that extends through the housing wall in the vertical dimension. By utilizing the depth dimension rather than relying solely on horizontal footprint, the connector achieves electrical penetration through the hermetic housing with minimal cross-sectional area.
2Reliability
If conventional feedthrough connectors with large footprint are used, then electrical connections are established, but the connection strength and sealing reliability become difficult to achieve
Solution Approach 1:
The connector merges multiple functions into a single integrated component: electrical conduction, mechanical anchoring to the housing, and hermetic sealing. The sealing portion simultaneously provides structural attachment to the housing aperture and creates the hermetic barrier, eliminating the need for separate sealing elements and simplifying the overall connection system.
Solution Approach 2:
The connector utilizes composite construction with an electrically insulating base material combined with electroplated conductive surfaces. This composite approach provides both the electrical conductivity needed for signal transmission and the insulating properties required for housing integration and sealing, while the electroplating enhances both electrical performance and mechanical bonding characteristics.
3Reliability
If conventional feedthrough connectors are used, then electrical connectivity is provided, but manufacturing costs and complexity increase due to expensive materials and complex curing procedures
Solution Approach 1:
The connector employs cost-effective materials such as standard electrically insulating plastics or ceramics for the base, combined with economical electroplating processes (copper, nickel, or gold) rather than expensive conventional feedthrough materials. The design eliminates the need for complex multi-step curing procedures by using electroplating, which provides both electrical conductivity and structural integrity in a single manufacturing step.
Solution Approach 2:
The design replaces complex mechanical assembly and curing processes with electrochemical electroplating. Instead of requiring multiple curing steps to bond separate components, the electroplating process simultaneously creates the conductive pathway and bonds the connector to the housing aperture, significantly simplifying manufacturing while maintaining connection reliability.
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 solution provides a reliable, sealed, and efficient electrical connection that maintains the internal cavity's conditions, such as pressure and atmosphere, while reducing manufacturing costs and complexity.
Implementation Method 1
A feedthrough electrical connector with an electrically insulating base having multiple layers and a sealing portion that is electroplated or adhesive-bonded to the housing
Implementation Method 2
A feedthrough electrical connector with an electrically insulating base having multiple layers and a sealing portion that is electroplated or adhesive-bonded to the housing
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure relates to an apparatus that includes an electrical connector that is coupled to a housing and that extends through a feedthrough aperture in the housing. The electrical connector has an electrically insulating base that has multiple layers of electrically insulating material with electrical traces extending between the multiple layers. The electrically insulating base also has a first portion disposed in the interior cavity, a second portion disposed external to the interior cavity, and a sealing portion disposed between the inwardly positioned portion and the outwardly positioned portion. The electrical connector also includes a first plurality of electrical leads that are disposed on the outwardly positioned portion of the electrically insulating base and a second plurality of electrical leads disposed on the inwardly positioned portion of the electrically isolating base material. Each of the electrical leads is electrically coupled to a corresponding lead.