Polymer Feedthrough Seal Assembly for Hermetic High-Voltage Insulation
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Solution Overview
Problem
Current feedthrough seal technologies for high-voltage capacitors, such as glass-to-metal seals, are complex, expensive, and time-consuming, making them inefficient for implantable medical devices that require reliable and cost-effective electrical insulation and hermetic sealing.
Innovation Solution
A feedthrough seal apparatus using a polymeric plug and ferrule assembly, where the plug is thermally joined to the lead wire and affixed within the ferrule, providing electrical insulation and hermetic sealing while reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass-to-metal seal (GTMS) is used for feedthrough sealing, then hermeticity and electrical insulation are achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention changes the material parameter from glass to polymer, and changes the joining method from thermal processing (melting/solidifying) to mechanical insertion and thermal bonding. This parameter change maintains hermetic sealing functionality while dramatically simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The invention replaces expensive glass-to-metal seal components with cheaper polymer-based alternatives. The ferrule assembly with polymer plug provides equivalent hermetic sealing at lower material and processing costs, making the overall device more cost-effective.
2Reliability
If glass-to-metal seal (GTMS) is used for feedthrough sealing, then hermeticity and electrical insulation are achieved, but manufacturing time increases
Solution Approach 1:
The polymer plug is pre-formed and ready for insertion before the actual assembly process. This preliminary preparation eliminates time-consuming on-site glass melting and solidifying operations, allowing for faster assembly while maintaining hermetic sealing quality.
Solution Approach 2:
The invention replaces the thermal-mechanical system of glass melting and solidifying with a simpler mechanical insertion system followed by thermal bonding. This substitution eliminates complex thermal processing steps and reduces manufacturing time significantly.
3Reliability
If glass-to-metal seal (GTMS) is used for feedthrough sealing, then electrical insulation and material barrier functions are achieved, but material costs increase
Solution Approach 1:
The invention changes the material parameter from expensive glass and tantalum to cheaper polymer and aluminum or aluminum alloy. This material substitution maintains electrical insulation properties while reducing material costs.
Solution Approach 2:
The invention uses cost-effective polymer materials instead of expensive glass and refractory metals. The polymer plug provides adequate electrical insulation and hermetic sealing at a fraction of the material cost of traditional GTMS components.
4Reliability
If traditional GTMS process is used, then reliable sealing is achieved, but process steps become excessive and expensive
Solution Approach 1:
The invention segments the sealing function into distinct components: the ferrule structure, the polymer plug, and the lead wire integration. This segmentation allows each component to be manufactured separately using simple processes and then assembled, greatly improving ease of manufacture while maintaining sealing reliability.
Solution Approach 2:
The invention merges multiple functions into the polymer plug: electrical insulation, hermetic sealing, and mechanical support for the lead wire. This consolidation eliminates the need for separate glass seal and metal welding operations, simplifying the manufacturing process.
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 achieves functional equivalence to traditional glass-to-metal seals with reduced manufacturing time, difficulty, and material costs, while maintaining hermeticity and electrical insulation, ensuring the seal can withstand high voltages and mechanical tests.
Implementation Method 1
the polymeric material of the plug includes a thermoplastic polymeric material configured to be thermally joined to the lead wire with heating of the thermoplastic polymeric material, thereby affixing the plug to the lead wire
Data Source
Figure 1
Figure 2A~2B
Figure 3A~4B
AI summary
A feedthrough seal apparatus (230) is configured to seal an opening in a device. The device includes a case (210) surrounding an interior space, the case including the opening (214) therein to allow access to the interior space from an exterior of the case. The feedthrough seal apparatus includes a plug (232) disposed within the opening of the case. The plug is formed from at least one of a polymeric material and an adhesive material, such as epoxy. The lead wire ()234 extends through the plug, such that a first end of the lead wire is disposed within the interior space of the case and a second end extends from the plug to the exterior of the case. The plug is configured to electrically insulate the lead wire from the case.