Sealed Feedthrough Connector Plate and Conductor Seals
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Solution Overview
Problem
Current solutions for hermetically sealing high-power electronics do not effectively manage high currents and temperatures, and fail to provide a reliable insulation from metal chassis while allowing for rotational strain and heat tolerance.
Innovation Solution
A high-power sealed feedthrough connector assembly featuring a non-conductive clamp plate and terminal panel with conductor apertures, sealed with a plate seal and conductor seal, which insulates and secures conductors from the chassis while preventing gas or liquid ingress and accommodating high currents and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetic seal is implemented for high-power electronics, then environmental protection is improved, but the ability to conduct high currents and withstand high temperatures deteriorates
Solution Approach 1:
The seal system is divided into two distinct components: a plate seal for sealing the chassis opening and a conductor seal for sealing the conductor passage. Each seal is optimized independently for its specific function, allowing the plate seal to provide hermetic protection while the conductor seal accommodates thermal expansion and current conduction requirements.
Solution Approach 2:
A non-conductive clamp plate is introduced as an intermediary component between the metal chassis and the conductor assembly. This clamp plate provides thermal isolation, electrical insulation, and mechanical clamping force, mediating between the hermetic sealing requirement and the high-temperature, high-current environment.
2Reliability
If a hermetic seal is implemented for high-power electronics, then environmental protection is improved, but the ability to conduct high currents deteriorates
Solution Approach 1:
The sealing function is segmented from the current conduction function. The plate seal handles the hermetic sealing of the chassis opening, while the conductor seal specifically addresses the sealing of the conductor passage. This segmentation allows each component to be optimized for its primary function without compromising the other.
Solution Approach 2:
Different sealing qualities are applied to different locations: the plate seal provides a rigid, hermetic seal for the main chassis opening, while the conductor seal provides a flexible, conforming seal around the conductor. This local differentiation allows the system to maintain hermetic protection while accommodating high current conduction through the conductor seal's design.
3Stability of the object's composition
If conductors are secured to the chassis, then mechanical stability is improved, but rotational strain resistance deteriorates
Solution Approach 1:
The non-conductive clamp plate serves as a mediator between the chassis and the conductor assembly. It provides a stable mounting surface for securing conductors while its non-conductive nature and flexible clamping mechanism allow for some rotational movement without compromising the electrical connection or the hermetic seal.
Solution Approach 2:
The conductor seal acts as a flexible element that accommodates rotational strain. Its flexible nature allows it to deform and return to its original position, absorbing rotational stresses that would otherwise damage rigidly secured conductors while maintaining the hermetic seal.
Data Source
AI summary
A sealed feedthrough connector can include a non-conductive clamp plate having at least one first conductor aperture and further including at least one conductor having a first end connecting to electronics in a high-power electronics chassis. The conductor can include a second end connecting to a circuit external to the electronics chassis, with a shoulder between the first and second ends. The connector can include a non-conductive terminal panel, a plate seal, and a conductor seal, the terminal panel having at least one second conductor aperture. The non-conductive clamp plate can be secured to the non-conductive terminal panel with a wall of the electronics chassis and the plate seal between them. At least one conductor can extend the first end through the first conductor aperture and the second end through the second conductor aperture, the conductor seal being positioned between the shoulder and the clamp plate or the terminal panel.