WO2009015438A1 - Procédé et appareil pour former un connecteur électrique de traversée - Google Patents

Procédé et appareil pour former un connecteur électrique de traversée Download PDF

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Publication number
WO2009015438A1
WO2009015438A1 PCT/AU2008/001123 AU2008001123W WO2009015438A1 WO 2009015438 A1 WO2009015438 A1 WO 2009015438A1 AU 2008001123 W AU2008001123 W AU 2008001123W WO 2009015438 A1 WO2009015438 A1 WO 2009015438A1
Authority
WO
WIPO (PCT)
Prior art keywords
cavity
lengths
conductive material
holes
gripping
Prior art date
Application number
PCT/AU2008/001123
Other languages
English (en)
Inventor
Desmond Mccusker
Mark Spalding
Nicholas Charles Kendall Pawsey
Jeffrey Albert Enke
Original Assignee
Cochlear Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2007904166A external-priority patent/AU2007904166A0/en
Application filed by Cochlear Limited filed Critical Cochlear Limited
Publication of WO2009015438A1 publication Critical patent/WO2009015438A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/22—Installations of cables or lines through walls, floors or ceilings, e.g. into buildings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02—Details
    • H02G3/08—Distribution boxes; Connection or junction boxes
    • H02G3/088—Dustproof, splashproof, drip-proof, waterproof, or flameproof casings or inlets

Definitions

  • the present invention generally relates to methods and apparatus for forming electrically conducting feedthrough devices.
  • the term 'feedthrough' as used herein refers to the provision of an electrically conducting path extending through an insulative member, from one side of the insulative member to another.
  • the electrically conducting path may extend from the interior of a hermetically sealed container or housing on one side of the insulative member, to an external location outside the container or housing on the other side of the insulative member.
  • a conductive path is provided by an electrically conductive pin, which is electrically insulated from the container or housing by an electrically insulating body surrounding the pin.
  • a feedthrough device can therefore allow one or more electrical connections to be made with electronic circuitry or components within an hermetically sealed container or housing, whilst protecting the circuitry or components from any damage or malfunction that may result from exposure to the surrounding environment.
  • feedthroughs used in medical implant applications typically consist of a ceramic or glass bead that is bonded chemically at its perimeter through brazing or the use of oxides, and/or mechanically bonded through compression, to the walls of the sealed package.
  • a suitable wire or other conductor passes through the centre of the bead, and this wire or conductor must also be sealed to the bead through chemical bonds and/or mechanical compression.
  • Such feedthroughs are typically cylindrical and the wire(s) or conductors) mounted within the bead are centred or mounted in a uniform pattern, centrally within the bead.
  • feedthroughs which rely, for example, on use of aluminium oxide ceramic and binders. These types of feedthroughs are widely used for cardiac implants and cochlear implants.
  • One of the processes for making such a feedthrough consists of pre-drilling holes in a sintered ceramic plate and then forcing electrical conductive pins through the holes. Examples of such processes are disclosed in US patent no. 5046242. While useful, this method is tedious and slow and does not necessarily guarantee a hermetic seal and generally results in unsatisfactory leakage rates on testing and low yields. It has been found that drill bits wear out quickly when used on ceramics, due to their abrasive nature, hence to meet required tolerances the drill bits tend to be required to be constantly replaced. Furthermore, the build-up of stress around punched or drilled holes can result in cracking after in the sintered ceramic.
  • a second method involves inserting the conductive pins into an unsintered (or 'green') ceramic plate and then curing the assembly by firing to achieve a hermetic seal.
  • a major disadvantage of this last method is that, historically the manufacturing process has been performed by hand. Such a method of manufacture can lead to inaccuracies and be time consuming, expensive and labour intensive.
  • the feedthrough devices resulting from such a process do not necessarily have precisely positioned electrical conductors, with the position of the conductors being greatly dependent upon the process itself.
  • the conductors are typically wires being of a general cylindrical shape and configuration, the size and shape of the conductor extending from the insulative material of the feedthrough is generally the same as the conductor embedded in the insulative material of the feedthrough.
  • an electrically insulating structure having holes for feedthroughs is formed by powder injection moulding (PIM).
  • PIM powder injection moulding
  • the mould includes a pair of opposed mould plates. One of the plates carries a number of pins, and the other plate has recesses which operatively receive the pins.
  • the plates are slowly moved apart to expose a partial cavity, into which hot feedstock is injected.
  • the moulded structure is ejected, the moulded structure having holes formed therethrough where the pins were located.
  • the holes then allow feedthrough conductors to be arranged through the moulded structure.
  • an electrically conductive structure is provided with feedthrough conductors and sacrificial portions. Electrically insulating material is moulded directly on and around the feedthrough conductors. Following the moulding, the sacrificial portions are removed to leave the moulded feedthrough device.
  • the process While conceptually efficient in respect of time saving, the process has found to have practical limitations. Firstly, the process has proven difficult to efficiently automate. The process requires an operator to manually load the conductive structure before the moulding cycle. The time taken to load varies between every cycle and varies between operators, consequently causing variations in each cycle time. Another issue relates to flashing around the feedthrough conductors in the conductive structure. Each feedthrough has a minor variation in the amount of flash which also causes variations in the injection pressure. Removing the flash is a labour intensive exercise.
  • an apparatus for use in the formation of an electrically conducting feedthrough device including: first and second portions, wherein at least one of the first and second portions is movable with respect to the other portion between an open and closed position; the first portion including an open-ended mould cavity; a moveable cavity member is arranged within the mould cavity, the cavity member extending across and biased towards a position substantially at the open end; the cavity member having a plurality of holes extending therethrough; the second portion including an electrical conductor feed mechanism for feeding lengths of solid electrically conductive material from the second portion into and through the holes in the cavity member; a retaining mechanism for receiving and retaining the ends of the lengths of electrically conductive material fed through the holes in the cavity member; an injection nozzle arranged on the second portion and directed towards the open end of the cavity, when the first and second portions are in the closed position
  • the retaining mechanism includes a retaining member having recesses, aligned with the holes in the cavity member, for receiving the ends of the lengths of electrically conductive material, wherein the member is movable with respect to the cavity member to misalign the recesses with respect to the holes in order to retain the received ends.
  • the retaining member may be rotatable with respect to the cavity member.
  • the feed mechanism includes a plurality of rotatable reels for holding the solid electrically conductive material, whereby rotating the reels causes the lengths of conductive material to advance through the second portion.
  • Channels may be provided via which the lengths of electrically conductive material advance through the second portion from the reels.
  • the feed mechanism may further include a gripping mechanism for receiving and gripping the lengths of conductive material from the reels, wherein the gripping mechanism is movable with respect to the second portion to feed the gripped lengths of conductive material into and through the holes in the cavity member.
  • the gripping mechanism includes a first and second gripping member, each gripping member having holes aligned with the holes on the cavity member and arranged to receive the lengths of conductive material from the reels, wherein at least one of the first and second gripping members is movable with respect to the other in order to misalign the respective holes and grip the received lengths of conductive material.
  • the second gripping member may be rotatable with respect to the first gripping member.
  • the gripping mechanism is adapted to sever the lengths of conductive material.
  • the present invention further provides a method for forming an electrically conductive feedthrough device employing the above apparatus and feedthrough devices formed by such methods.
  • the present invention advantageously provides an apparatus and method for forming an electrically conductive feedthrough device which allows for efficient use of automation for large scale fabrication with reduced labour requirements.
  • FIG. 1 is a cross-sectional view of an apparatus according to a preferred embodiment with the upper and lower portions in a closed position;
  • Fig. 2 is an enlarged sectional view of the apparatus of Fig. 1 with the gripping mechanism in an upper position;
  • Fig. 3 is an enlarged sectional view of the apparatus of Fig. 1 with the gripping mechanism in a lower position;
  • Fig. 4 is an exploded view of the gripping mechanism, cavity member and retaining mechanism of the apparatus of Fig. 1 ;
  • Fig. 5 is an exploded view of the gripping mechanism and cavity member of the apparatus of Fig. 1 ;
  • Fig. 6 is an exploded view of the gripping mechanism of Fig. 5 with the upper and lower gripping members shown as separated for illustrative purposes;
  • Fig. 7 is a cross-sectional view of the apparatus of Fig. 1 with the gripping mechanism, cavity member and retaining mechanism removed for illustrative purposes;
  • Fig. 8 is a perspective cross-sectional view of the apparatus of Fig. 1 prior to feedstock injection;
  • Fig. 9 is a perspective cross-sectional view of the apparatus of Fig. 1 during feedstock injection;
  • Fig. 10 is a plan cross-sectional view of the apparatus of Fig. 9;
  • Fig. 11 is a perspective cross-sectional view of the apparatus of Fig. 1 illustrating the severing of the lengths of conductive material;
  • Fig. 12 is a cross-sectional view of the apparatus of Fig. 1 with the upper and lower portions in an open position;
  • Fig. 13 is a perspective view of a moulded device
  • Fig. 14 is a cross-sectional view of the moulded device of Fig. 13. DESCRIPTION OF PREFERRED EMBODIMENT
  • FIGs. 1 and 2 there is shown an apparatus 10 having an upper portion 12 and a lower portion 14 meeting at a parting line 16.
  • the two portions 12, 14 are arranged to be separable.
  • the upper portion 12 is fixed while the lower portion 14 is movable.
  • the upper portion 12 carries an injection nozzle 18 via which mouldable electrically insulating material, such as ceramic feedstock, can be injected.
  • the injection nozzle 18 is directed towards an open top end of a mould cavity 20 arranged in the lower portion 14.
  • an o-ring (not shown) provides a vacuum seal which allows a negative pressure to be provided in the cavity 20.
  • the upper portion 12 is provided with a number of reels 22 carrying lengths of solid electrically conductive material 24, for example platinum wire.
  • a number of channels 26 or tubes extend through the upper portion 12 from the reels 22, providing guides via which the lengths of conductive material 24 can advance through the upper portion 12 from the reels 22 when rotated.
  • the channels 26 guide the lengths of conductive material 24 to a gripping mechanism 28.
  • the gripping mechanism 28 has an upper and lower gripping member 30, 32, shown in the form of disc-like members arranged around an end of a feed tube 34 for the ceramic feedstock. Referring to Figs. 4-6, the upper and lower members 30, 32 have through-holes 36, 38 aligned with the channels 26, which allow the lengths of conductive material 24 to pass through the gripping mechanism 28.
  • the upper gripping member 30 is rotatably movable with respect to the lower gripping member 32 which causes the corresponding through-holes 36, 38 in the gripping members 30, 32 to offset or misalign.
  • the lower gripping member 32 is arranged to be movable in a direction towards and away from the injection nozzle 18.
  • the reels 22 are rotated to cause the lengths of electrically conductive material 24 to advance through the channels 26 and through the aligned through-holes 36, 38 of the gripping members 30, 32, when arranged at an upper position as shown in Fig. 2.
  • the ends of the lengths of conductive material 24 are advanced until reaching guiding holes 40 formed around the injection nozzle 18.
  • the upper gripping member 30 is moved to cause the lengths of conductive material 24 to be gripped by the gripping members 30, 32.
  • the lower gripping member 32 is moved towards the injection nozzle 18, as shown in Fig. 3. At this lower position, the end of the feed tube 34 is flush with the injection nozzle 18.
  • the ends of the lengths of conductive material 24 have passed through the guiding holes 40 and past the parting line 16, where they have been received in aligned through-holes 42 arranged in a movable cavity member 44 arranged within the mould cavity 20.
  • the cavity member 44 extends across the cavity 20.
  • the cavity member 44 is engaged with a spring-loaded carrier (not shown) which biases the cavity member 44 towards the parting line 16. In this biased position, the cavity 20 is substantially closed to the injection nozzle 18.
  • the through-holes 42 in the cavity member 44 allow the lengths of electrically conductive material 24 to pass from the upper portion 12 and through the cavity member 44 towards a retaining mechanism 46 arranged on the opposite side of the cavity member 44.
  • the retaining mechanism 46 is shown in the form of a disc-shaped retaining member 48 having recesses 50 for receiving the ends of the lengths of conductive material 24 fed through the cavity member 44.
  • the retaining member 48 is arranged to be rotatably movable with respect to the cavity member 44 in order to align and misalign the recesses 50 with the through-holes 42 in the cavity member 44.
  • This arrangement acts like the gripping members 30, 32 in allowing the received ends of the lengths of conductive material 24 to be gripped between the cavity member 44 and the retaining member 48 by rotating the retaining member 48 to slightly offset or misalign the respective holes 42 and recesses 50.
  • the upper gripping member 30 Prior to injecting the feedstock via the injection nozzle 18, the upper gripping member 30 is rotated in order to relax the grip on the lengths of conductive material 24.
  • the injected feedstock contacts the upper surface of the cavity member 44.
  • the pressure of the injected feedstock causes the cavity member 44 to slide against the spring bias within the cavity 20, thus exposing the cavity 20 to the injected feedstock and allowing the exposed cavity to fill, see Figs 9 and 10.
  • the movement of the cavity member 44 causes the retaining mechanism 46 to similarly move.
  • the movement of the retaining mechanism 46 and the cavity member 44 pulls on the lengths of conductive material 24 under tension to draw further lengths of the conductive material 24 through the upper portion 12.
  • the feedstock gradually fills the cavity 20 and moulds around the exposed lengths of conductive material 24. The gradual exposure of the lengths of conductive material 24 prevents the material deforming or becoming damaged due to the high injection pressures.
  • an actuator member (not shown) is arranged with respect to the cavity member 44 and is associated with a pressure sensor
  • the pressure in the cavity 20 can be monitored.
  • the pressure sensor is linked in a closed loop arrangement with a controller for the injection process; thereby allowing control of injection pressure and holding pressures within the cavity 20.
  • the upper surface of the lower portion 14 is provided with a trench arrangement (not shown) extending from the cavity 20. This trench arrangement allows air to be evacuated from the cavity 20 as the cavity 20 is being filled by the injected feedstock.
  • the lengths of conductive material 24 can be cut to required length. This cutting step is conducted by the gripping mechanism 28.
  • the upper and lower portions 12, 14 are separated to allow the moulded device 52 to be ejected from the mould cavity 20, see Fig. 12.
  • the ejected device 52 has an insulted body 56 with feedthrough connectors 58 extending therethrough, see
  • a suitable de-binding process would include a water de-binding step, in which the device 52 is washed over several hours at 40°C, followed by a thermal de-binding step at approximately 300°C over a period of approximately 24 hours.
  • the device 52 is sintered at high temperatures of around 1600 0 C, for example.
  • the ceramic 56 shrinks and clamps around the connectors 58, thereby creating a hermetic seal.
  • a second preferred characteristic is the production of a glass phase during sintering which can allow a glaze to form around the connectors 58.
  • Two preferred materials which provide these characteristics are Alumina and Zirconia. These two materials have a high shrinkage rate, in the range of 16-25 percent.
  • a preferred composition of the feedstock would include 94-96 percent Alumina (AI 2 O 3 ) or Zirconia (ZrO 2 ) with a particle size between 0.5 microns to 3 microns.
  • the composition can preferably include polyethylene which acts as a binder for the composition. Providing trace amounts of Magnesium oxide, Silicon oxide, Zinc oxide or other oxides can stabilize the ceramic and assist in the formation of the glaze.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Insulating Bodies (AREA)

Abstract

L'invention concerne un appareil (10) destiné à être utilisé dans la formation d'un dispositif de traversée électriquement conducteur (52). L'appareil (10) comprend des première et seconde parties (12, 14). Au moins une des première et seconde parties (12, 14) est déplaçable par rapport à l'autre partie entre une position ouverte et une position fermée. La première partie (14) comprend une cavité de moule à extrémité ouverte (20). Un élément de cavité mobile (44) est agencé à l'intérieur de la cavité de moule (20). L'élément de cavité (44) s'étend à travers, et est orienté vers une position sensiblement au niveau de l'extrémité ouverte. L'élément de cavité (44) présente une pluralité de trous (42) s'étendant à travers lui. La seconde partie (12) comprend un mécanisme d'avance de conducteur électrique destiné à faire avancer des longueurs de matériau électriquement conducteur solide (24) depuis la seconde partie (12) dans et à travers les trous (42) de l'élément de cavité (44). Un mécanisme de retenue (46) reçoit et retient les extrémités des longueurs de matériau électriquement conducteur (24) introduites à travers les trous (42) dans l'élément de cavité (44). Une buse d'injection (18) est agencée sur la seconde partie (12) et est dirigée vers l'extrémité ouverte de la cavité (20), lorsque les première et seconde parties (12, 14) sont dans la position fermée, pour injecter du matériau électriquement isolant dans la cavité (20). L'élément de cavité (44) et le mécanisme de retenue (46) se déplacent contre la force de rappel sous la pression du matériau injecté pour exposer la cavité (20) et les longueurs de matériau conducteur (24), et permettent au matériau électriquement isolant de se mouler dans la cavité exposée (20) et autour des longueurs exposées de matériau conducteur (24).
PCT/AU2008/001123 2007-08-02 2008-08-01 Procédé et appareil pour former un connecteur électrique de traversée WO2009015438A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2007904166A AU2007904166A0 (en) 2007-08-02 Method and Apparatus for Forming a Feedthrough Electrical Connector Device
AU2007904166 2007-08-02

Publications (1)

Publication Number Publication Date
WO2009015438A1 true WO2009015438A1 (fr) 2009-02-05

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2504500A1 (fr) * 2009-11-26 2012-10-03 National Ict Australia Limited (NICTA) Formation de trous d'interconnexion d'interfaces pour des boîtiers fermés hermétiquement à l'aide de deux moulages par injection de poudre de matériau
EP2527000A2 (fr) 2011-04-15 2012-11-28 LITRONIK Entwicklungs GmbH Passage de conduite et unité de fonctionnement électrique

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3880453A (en) * 1973-09-06 1975-04-29 Gen Signal Corp Process for sealing cable at fittings
US4301325A (en) * 1978-12-21 1981-11-17 Bicc Limited Sealing conduits
US5831217A (en) * 1995-11-16 1998-11-03 The Boeing Company Wire bundle sealing system having individual tubular segments gathered around the wire bundles and containing sealant
WO2007023006A1 (fr) * 2005-08-24 2007-03-01 Endress+Hauser Flowtec Ag Dispositif pour determiner et/ou surveiller une grandeur de processus

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3880453A (en) * 1973-09-06 1975-04-29 Gen Signal Corp Process for sealing cable at fittings
US4301325A (en) * 1978-12-21 1981-11-17 Bicc Limited Sealing conduits
US5831217A (en) * 1995-11-16 1998-11-03 The Boeing Company Wire bundle sealing system having individual tubular segments gathered around the wire bundles and containing sealant
WO2007023006A1 (fr) * 2005-08-24 2007-03-01 Endress+Hauser Flowtec Ag Dispositif pour determiner et/ou surveiller une grandeur de processus

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2504500A1 (fr) * 2009-11-26 2012-10-03 National Ict Australia Limited (NICTA) Formation de trous d'interconnexion d'interfaces pour des boîtiers fermés hermétiquement à l'aide de deux moulages par injection de poudre de matériau
EP2504500A4 (fr) * 2009-11-26 2013-05-15 Nat Ict Australia Ltd Nicta Formation de trous d'interconnexion d'interfaces pour des boîtiers fermés hermétiquement à l'aide de deux moulages par injection de poudre de matériau
US9089715B2 (en) 2009-11-26 2015-07-28 Saluda Medical Pty Limited Forming feedthroughs for hermetically sealed housings using two-material powder injection molding
EP2527000A2 (fr) 2011-04-15 2012-11-28 LITRONIK Entwicklungs GmbH Passage de conduite et unité de fonctionnement électrique
US8941020B2 (en) 2011-04-15 2015-01-27 Litronik Entwicklungs Gmbh Lead feedthrough and electrical functional unit
EP2954928A1 (fr) 2011-04-15 2015-12-16 LITRONIK Entwicklungs GmbH Passage de conduite et unité de fonctionnement électrique

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