PCB Feedthrough Assembly With O-Ring Sealing After Welding
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Solution Overview
Problem
Existing feedthrough solutions for connecting electrical devices across different environments, such as vacuum or hazardous gas environments, are costly and prone to damage during welding, and require tight tolerances and specific sealing methods like cemented joints or fused glass, which are not always efficient or durable.
Innovation Solution
A feedthrough connector with a plastic body that allows over-molding and snap-in installation, featuring sealing mechanisms, anti-rotation features, and resistance to loads, which can be installed post-welding, and includes a printed circuit board with diagonally oriented headers and indexing keys for secure engagement within a passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cemented joint bushing or fused glass seal is used for flameproof feedthrough, then electrical connectivity is achieved, but the feedthrough is prone to damage during welding and requires tight tolerances
Solution Approach 1:
The feedthrough is divided into separate components: a body portion with external threading, a seal portion with O-ring groove, and a cap portion. This segmentation allows each component to be manufactured independently with standard tolerances, avoiding the need for tight tolerances on assembled joints while maintaining sealing effectiveness through the O-ring mechanism.
Solution Approach 2:
The patent replaces expensive, fragile cemented joints and fused glass seals with a simpler, more durable plastic-bodied feedthrough that uses an O-ring seal. This design is resistant to welding damage and does not require rework if damaged, effectively making it a durable, replaceable component rather than a permanent, fragile installation.
2Reliability
If cemented joint or fused glass seal is used, then flameproof sealing is achieved, but cost and manufacturing complexity increase
Solution Approach 1:
The patent employs a cost-effective O-ring seal instead of expensive cemented joints or fused glass seals. The O-ring provides reliable flameproof sealing at a fraction of the cost, and the entire feedthrough can be manufactured using standard plastic molding techniques, significantly reducing manufacturing complexity and cost.
Solution Approach 2:
The patent changes the sealing mechanism from rigid cemented or glass joints to a flexible O-ring seal that accommodates normal manufacturing tolerances. This parameter change in the sealing approach maintains flameproof effectiveness while enabling cheaper, simpler manufacturing processes.
3Ease of manufacture
If traditional feedthrough installation is used, then electrical connectivity is established, but the feedthrough may be damaged during welding processes
Solution Approach 1:
The feedthrough body is made from a composite material formulation (polymer matrix with reinforcing fibers and flame retardant additives) that provides both mechanical strength to withstand welding processes and flame resistance for safety. This composite construction allows the feedthrough to be installed before or after welding without damage.
Solution Approach 2:
The feedthrough can be installed in the housing before the welding process occurs, allowing the sealing and electrical connectivity to be established prior to any potential welding damage. The design accommodates installation at any stage of the manufacturing process, providing flexibility in the sequence of operations.
Data Source
AI summary
The present invention relates to a feedthrough (200) adapted for use within a passage (300). The feedthrough (300) has a body (202) having a first interface region (204) and a second interface region (206). The first interface region (204) comprises a platform region (214). At least one electrical conductor (212) extends through the body (202) and out of the body (202) to both the first interface region (204) and the second interface region (206). A printed circuit board (216) is attached to the platform region (214). At least one pin hole (234) defined by the printed circuit board (216) is configured to accept the at least one electrical conductor (212).