High Amperage Electrical Feedthrough

BACKGROUND

A customer involved in lithium ion research approached BCE in need of a high amperage feedthrough that also met their packaging (size) requirements.

While the customer had no problem finding high amperage feedthroughs, or feedthroughs that met their size requirement, they could not find an acceptable electrical feedthrough that satisfied both.

BCE is known for designing to customer specifications, allowing engineers the freedom to build their systems according to their plans, and not having to make design sacrifices because of hardware limitations. This application is an excellent example of BCE's capability.

OUTCOME

After a comprehensive application review with the customer, BCE went to work. Designs were completed in a few days and prototypes were completed in a few weeks. After preliminary tests and designs, a final prototype High Amperage Feedthrough was delivered for customer evaluation.

After thorough testing, the customer agreed that the application requirement was precisely met and the feedthrough functioned perfectly.

With the feedthrough now in production, all customer specified tests are performed prior to shipping and completed at BCE. Production and testing are controlled by a jointly developed standard operating procedure (SOP).

While this feedthrough was designed for a single, specific use, the underlying construction is designed to easily accommodate changes. Nearly every feature is customizable, including conductor type and gauge, flange type and size, component materials, and electrical rating.

The BCE High Amperage Feedthrough needed to satisfy these customer criteria:

• 150 Amp 30 Volt
• Custom KF50 Flange 
• Vacuum rating: 10-6 ATM-cc/s 
• Feedthrough Seal Temp: -10 C to 60 C
• Able to withstand the weight of the heavy gauge wire
• ALL TESTS PERFORMED AT ROOM TEMPERATURE 

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Request More Information and Download a PDF version of the High Amperage Electrical Feedthrough Case Study Here

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Feedthroughs Used for Penetration of Vacuum and Pressure Vessels

Many types of OEM equipment, including medical, analytical, semiconductor, aerospace and laboratory test equipment, require a leak-proof penetration into a vacuum or pressure chamber. The device that accommodates this penetration is referred to as a feedthrough (sometimes spelled "feedthru"). For the most part feedthroughs allow electrical currents or voltages into the vacuum or pressurized area. There are also many other non-electrical requirements for pressure/vacuum vessel penetration. Some examples of non-electrical penetrations are fiber-optic, fluid tubing bundles, and process control sensors such as thermocouples.

Multi-pin Threaded or Flanged Feedthroughs

Multi-pin feedthroughs have circular flanged or threaded connectors for moderate pin density. They are typically offered with differing numbers of pins (often, 3, 5 or 7) and rated to 3.5 amps and 500 volts per pin. There are both single-ended and double-ended versions which offer a connector for the air side or both air and vacuum side connectors respectively.

Thermocouple Feedthroughs

A thermocouple feedthrough is an electrical vacuum feedthrough commonly used for systems involved in temperature measurement. The thermocouple feedthrough itself doesn’t measure temperature, but is used to conduct the voltage signal from the vacuum to an external device. These are suitable for use in ultra-high vacuum applications.

High Power Feedthroughs

High power electrical feedthroughs transmit high current and/or high voltage into a vacuum system. Variations of power electrical feedthroughs offer a range of current and voltage.

Epoxy Potted Feedthroughs

Epoxy vacuum feedthroughs offer the best application flexibility, they are cost competitive, and they have a high vacuum performance for today’s fast moving markets. Clear epoxy feedthroughs allow for the visual inspection of your components. They are board mountable with high vacuum performance and very competitive pricing compared to ceramic and metal seals.

Fiber Optic Feedthroughs

Fiber Optic Feedthroughs provide the interface between fiber optics and UHV technology. They allow fiber optic cables are designed for vacuum applications requiring fiber optic connections from inside a vacuum system to external equipment.

Fluid Feedthroughs

Also referred to as fluid feedthroughs, they are designed for the transmission of gases or coolants into high and ultrahigh vacuum environments.  Generally constructed from 300 series stainless steel, they are available in single or multi-tube configurations.

Many accessories are available to be used in conjunction with the wide variety of vacuum feedthroughs. These included vacuum connectors, connectors, insulated wire, cable assemblies, insulators, and spacers, just to name a few.

Specialized feedthroughs may be needed if your application includes cryogenic or very low temperatures, high temperatures, aggressive chemicals, or high pressure. Contact an experienced manufacturer who specializes in vacuum feedthroughs to discuss which feedthrough will best meet your needs. A company worth their salt should be able to discern which would be the best fit with minimal hassle.

High Temperature Vacuum Feedthroughs

Thermocouple/Feedthrough Assemblies

Thermocouple Feedthroughs are used in many vacuum applications for temperature measurement. Thermocouples create a voltage signal from inside the vacuum system to external measuring instruments. BCE offers several standard thermocouple feedthrough designs as well as custom designs to meet your exact needs.

9 Pin Vacuum Feedthroughs

Nine pin circular feedthroughs (often called instrumentation feedthroughs) are commonly used for the transmission of low power electrical signals. They are designed for applications where typical Subminiature Type-D connections will not fit, or where there is little space. The circular geometry allows the installation of this feedthrough into very small vacuum flanges. They are often used in instrumentation applications such as semiconductor processing, electron microscopy, and a variety of analyzers.

BCE designs and builds high temperature vacuum feedthroughs for OEM and R&D. Contact them by calling (510) 274-1990, or visit https://bcemfg.com/feedthroughs.

OEM Equipment Manufacturers: Look Toward the Experienced Sales Engineer for Project Success

Original Equipment Manufacturers (OEMs) who work closely with vendor sales engineers in the design of assembly components (such as electric heating elements and vacuum feedthroughs) gain a valuable competitive advantage. By understanding what these professionals have to offer, and taking advantage of their skills, OEM designers end up with better project outcomes.

Sales engineers are a readily available resource of application knowledge. Unlike information pulled from the Internet, sales engineers possess real-time product information. They are also exposed to many different product applications and are a wealth of tacit knowledge. All readily available for sharing with their customers.

OEM design engineers often find themselves sailing in uncharted waters. In the application of electric heaters or feedthroughs for instance, designers don't always have a full grasp of heater or feedthrough design constraints. When these situations occur, the heater sales person provides a real benefit in teaching and advising the designer what is possible.  Additionally, many sales engineers have access to unpublished product and application information, which can be hugely important when attempting to build a leading edge product.

Of course any solutions proposed are likely to be based upon the products sold by the representative, but the best sales people will share the virtues of their products openly and honestly. The best sales engineers will even admit when they lack the product or experience to solve the problem, but even in this situation, you can be sure their perspective will still be of value. The goal is to build a long-term, trusting relationship - one of value to both parties. Sales engineers are in the business of dealing with people and making the important connections between customers and manufacturers. They make it their business to know what’s going on with products, companies and industries.

As an engineer or purchasing professional responsible for the design and manufacture of OEM equipment, know that working closely with a vendor sales engineer will save you precious time and greatly improve the likelihood of successful project outcomes. Their success, and your success, go hand-in-hand.

Electric Heating Elements and Electrical Feedthroughs for OEM Applications

BCE offers OEM (original equipment manufacturers) custom electric heaters, feedthroughs and BCE OEM customers benefit from decades of thermal design and applications experience. With a reputation for fast prototyping, quick turnaround for pre-production runs, and an eye for cost-effective design, equipment manufacturers quickly discover that find BCE is a long-term, highly valued supplier/partner.
sensors.

OEM Equipment Markets

• Aerospace
• Semiconductor
• Analytical Instruments
• Photovoltaic
• Medical Equipment
• Plastics Processing
• Foodservice Equipment
• Packaging

OEM Electric Heaters & Feedthroughs: Price, Delivery, Performance

KF40 Flanged, 125 Volt, 15A Female-to-Female Socket Vacuum Feedthrough

BACKGROUND

A BCE customer needed to replace a bulky power system located within a chamber.  A custom KF40 three-slot single female receptacle feedthrough was the optimal solution to help reduce size and increase efficiency.

SCOPE

The KF40 Socket Feedthrough needed to satisfy the following criteria:

• 80°C continuous operating temperature 
• 125V and 15A
• Female to female connection
• Vacuum rating: 10-5
• ALL TESTS PERFORMED AT ROOM TEMPERATURE 

OUTCOME

BCE designed a simple yet effective unit using a custom elongated KF40 flange with two three-slot single female receptacles. The customer was able to relocate the power system to the outside chamber increasing the available space within the vacuum chamber while maintaining the desired vacuum rating.

BCE’s Epoxy chemical adhesion, the strongest mechanism of any adhesive bond, made the seal possible.  The viscoelastic nature of the epoxy absorbs vibrations and allows for a better performance by reducing fatigue.

Download the BCE Application Note here.

Understanding Vacuum

At sea level, the earth's atmosphere exerts a standard pressure upon us of 14.7 pounds per square inch absolute (PSIA), or 29.92" of mercury (Hg), or 760 mm of mercury (Torr). All of these values refer to "standard atmosphere" which is measured at sea level.

Vacuum is a term used to describe an area, zone, or compartment containing less pressure than atmospheric pressure.

Vacuum is measured in inches of mercury (Hg) in the United States. There are two different scales to measure vacuum.

One scale is referred to as "inches of mercury gauge vacuum" ("HgV), where the measuring range starts at 0 inches of mercury (atmospheric pressure) and goes up to 29.92 inches of mercury, known as perfect vacuum (not achievable on Earth).

The alternative scale is "inches of mercury absolute vacuum" ("HgA), which reverses the "HgV scale, having it instead read 29.92 inches of mercury at atmospheric pressure and 0 inches of mercury at perfect vacuum.

Here's an example of the relationship between inches of mercury gauge and inches of mercury absolute:

24 inches of Hg gauge = 5.92 inches of mercury absolute.
Calculation: 29.92 - 24 = 5.92

It is very important to  determine what scale you are using, meaning gauge or absolute. A misunderstanding can result in large errors.

The unit "Torr" is used when working in higher vacuum ranges (low absolute pressure). 1 Torr equals 1 millimeter (mm) of mercury in absolute pressure.

Considering one linear inch equals 25.4 mm, and atmospheric pressure (at sea level) is 29.92 inches of mercury, then using the equation 29.92 inches x 25.4 mm = 760 Torr. 760 Torr is 0 vacuum, while 0 Torr is perfect vacuum.

BCE is a leading manufacturer of electrical, fiber optic, and tubing feedthroughs for use in vacuum applications. Visit https://bcemfg.com or call (510) 274-1990 to learn more.

Vacuum Feedthroughs the Way You Want Them

Equipment manufacturers and scientific researchers are continually challenged with supplying power, fiber-optic, control, and monitoring cables into sealed vacuum vessels. Whether due to space restrictions, special geometries, or number and type of conductors, standard glass-to-metal or ceramic feedthroughs never quite fit the bill. Unfortunately, because of limited options, many designers are forced to compromise and go for an off-the-shelf solution.

Until now. 

BCE designs, engineers, and manufacturers feedthroughs that can handle custom shapes, tight angles, curves, shielded wire and still provide a tight seal.

Why You Need to Consider BCE:

• Feedthroughs Designed to Your Specifications
• 24 Hour Turnaround on Custom Drawings & Quotations
• Custom Feedthroughs Ship in 2 Weeks

Call today. 510-274-1990

What is a Vacuum Feedthrough?

Electrical Vacuum Feedthrough
(Epoxy)

A vacuum feedthrough is designed to pass matter or energy, without leakage, from the outside of a vacuum chamber to the inside. The term vacuum feedthrough is often used interchangeably with electrical feedthrough, glass feedthrough, ceramic feedthrough, epoxy feedthrough and hermetic feedthrough. There are of course differences, but they all provide the same function - provide a leak-tight seal between the inside and outside of a vacuum chamber.

Epoxy, glass or ceramic feedthroughs refer to the materials used to seal the conductor, tube, or fiber optic cable from the vacuum/process connection. Hermetic feedthrough refers to the device's nature of being airtight or vacuum tight, such as "hermetically sealed".

Fiber Optic Vacuum Feedthrough

Vacuum feedthroughs are used for 2 primary functions: delivering energy (usually in the form of electricity or light pulse); and for delivering matter in the form of liquids and gases.

Electrical feedthroughs use electrical conductors such as wires to deliver electricity inside the vacuum chamber.

Liquid and gas feedthroughs use metal tubes or fiber optic cables to introduce fluids or light beams.

Liquid & Gas Vacuum Feedthrough

There is debate over what sealing material provides the best over-all performance-to-cost benefit.  Glass to metal seals and ceramic seals are ubiquitous and provide very good sealing properties, but they are expensive and difficult to customize, making prototyping and small production runs challenging. Early epoxy seals were limited in temperature range and were known to outgas, but new, modern epoxy compounds have been developed to perform as well as glass to metal and ceramic.

Modern epoxy feedthroughs can now achieve vacuum up to 10^-8 Torr, temperatures up to 200°C continuous (300°C intermittent), and meet NASA's outgassing requirement of <1.0% Total Mass Loss (TML).

For more information, contact BCE by visiting http://bcemfg.com or call (510) 274-1990.

High-Temperature Vacuum Feedthrough Assembly with Multi-Thermocouples and Electric Heater with Thermowell

Multi-Thermocouple and Heater Feedthrough

Introducing the latest in temperature sensing and heating technology. BCE’s High-Temp Vacuum thermowell assembly is a robust, laser-welded design integrating the sensing capabilities of type K thermocouples. These thermocouples can be easily mounted to any part in a vacuum chamber by the means of shims with mounting holes. Furthermore, they can be positioned with ease due to integrated compression fittings, which also allow for easy replacement of the thermocouples should the need arise. A 304 Stainless Steel flange achieves a vacuum tight seal into any vacuum or degassing chamber port and there is virtually no outgassing, enhancing performance in high-vacuum environments. Moreover, a cartridge heater embedded inside an Aluminum 6061 thermowell allows for uniform and efficient heating of the chamber. BCE’s Hi-Temp Vacuum Thermowell Assembly: breaking barriers in high vacuum applications.

Specifications

• CAD modeling and Engineering Design Consultation 
• High-Vacuum compatible up to 10-7 Torr 
• Max Operating Temperature can be up to 400°C (dependent on lead insulation material) 
• 10X thermocouples, Type K, Grounded, with shims and mounting holes (multiple options available) 
• 450W, 240V embedded cartridge heater (multiple options available) 
• 10X SS316 compression fittings (multiple options available) 
• AL6061 thermowell 
• SS304 Isolating Flange with dovetail O-ring groove 

Simply-designed, Versatile and Robust Vacuum Feedthrough

BCE’s plug feedthrough is an ideal product for any vacuum application. Not only is it easy to install and withdraw due to its stainless steel, threaded plug body, it can be embedded with leads, thermocouples and RTDs. Thus, it can be designed and customized to meet all requirements at a low production cost.

As it is sealed with BCE’s proprietary epoxy meeting NASA ASTM E595, outgassing is excessively low. Furthermore, all leads come with standard KAPTON insulation to limit contamination in vacuum applications. It should be noted that the 316 SS construction allows it greater resistance to corrosion increasing product life. This means fewer replacements.

Specifications

• CAD modeling and engineering design consultation. 
• Vacuum compatible to 10-9 ATM.CC/Sec. 
• Max. operating temperature: 200°C. 
• BCE proprietary epoxy meets NASA ASTM E595 low outgassing spec. 
• Corrosion resistant. 
• Embedded thermocouple(s), lead wire(s) and rtd(s) with kapton insulation (multiple options available). 
• All dimensions, materials and features can be customized.

Custom Electrical, Pneumatic, and Optical Feedthroughs

Equipment manufacturers and scientific researchers are continually challenged with supplying power, fiber-optic, control, and monitoring cables into (and out of) sealed vacuum vessels. Whether due to space restrictions, special geometries, or number and type of conductors, standard glass-to-metal or ceramic feedthroughs never quite fit the bill. Unfortunately, because of limited options, many designers are forced to compromise and go for an off-the-shelf solution.

You don't have to fit a square peg in a round hole anymore. Choose BCE custom feedthroughs for your next design.

http://www.belilove.com/feedthrough

(510) 274-1990

9 Pin Vacuum Feedthrough: UHV Compatible Technology Serving the Semiconductor Industry

Some of the most stringent tolerances and vacuum requirements exist in the ever-expanding semiconductor industry. Tight restrictions in vacuum ports, high temperature applications and exposure to high stress environments further add to the challenge of designing an electrical feedthrough that can be manufactured quickly and installed with ease. An American multinational manufacturer of chips and microprocessors approached BCE with these exact requirements in order to replace their existing vacuum feedthroughs incapable of providing an adequate performance in ultra-high vacuum environments. Furthermore, their existing supplier had long lead times and the procured feedthroughs needed to be replaced often as their contacts would fail due to oxidation formation on the conductive layer.

SCOPE

• The feedthrough needed to satisfy the following requirements: 
• Ultra-High Vacuum (UHV) compatibility up to 1 X 10-10 atm.cc/sec 
• Remain operable at temperatures exceeding 250°C 
• Pins preventing oxidation of conductive layer for longevity 
• 9 pin feedthrough configuration 
• Voltage requirement: 750 AC RMS 
• Current requirement: 7 AMPS 
• Quick-turnaround on feedthrough manufacturing 
• Robust seal withstanding high stress environments 
• Ease in installation, simple design 
• Low cost for application 

OUTCOME

All customer requirements were exceeded by BCE’s 9 pin vacuum feedthrough. Not only did it meet all electrical and configuration specifications, it provided a vacuum compatibility twice as much as that required by the customer allowing them to expand their capabilities to higher vacuum thresholds. It also remained operable at higher temperatures, nearing maximums of 300°C. Furthermore, the gold plated pins proved to be ideal in the prevention of oxidative layers inhibiting current flow. Moreover, BCE’s proprietary ceramic seal achieved the desired robustness and allowed the feedthrough to remain operable under high stress conditions. Finally, the client was equally impressed by BCE’s quick-turnaround time and competitive pricing.

Download the PDF for this application note from the Belilove site here.

Video: Flanged, Replaceable, Multi-Thermocouple Electrical Feedthrough

With most vacuum feedthroughs, troubleshooting can be difficult as well when multiple fixed elements are involved. If one element fails, generally the entire vacuum feedthrough is rendered useless. With BCE’s Multi-TC, Flanged Feedthrough, arduous troubleshooting procedures are a thing of the past. In fact, this feedthrough’s thermocouples are replaceable as they can be extracted from the compression fittings with great ease. This means that if thermocouples fail, they can be removed, tested and replaced within minutes. Thus, this no-hassle design allows for faster, more accurate and more cost-effective thermal data collection. Trust BCE’s Multi-TC, Flanged Feedthrough for your most complicated thermal detection needs. Contact BCE for more information.

Welcome to BCE

BCE (Belilove Company-Engineers) has over 60 years experience as a California based manufacturer, value added component integrator, and distributor serving the analytical instrumentation, semiconductor, photovoltaic, medical equipment, plastics processing, foodservice equipment, packaging, and aerospace industries. 

BCE offers custom electrical heaters, sensors, controls and custom vacuum feedthroughs for sale. Supported by their wealth of knowledge and experience, BCE will assist you with your electric heating, vacuum feedthrough, and ceramic substrate needs.

http://www.belilove.com | (510) 274-1990

Vacuum Technology and Vacuum Design Handbook for Accelerator Technicians

A handbook titled "Vacuum Technology and Vacuum Design Handbook for Accelerator Technicians" published in 2011 and downloaded from the Lawrence Berkeley National Laboratory website, is a compilation of information gathered from over 50 years of direct hands-on experience to applicable information widely available from the vacuum technology industry.

It seeks to address common and specific vacuum technology problems while clarifying the design standards and philosophies adopted for use in the ANSTO accelerator facilities.

The link to the Vacuum Technology and Vacuum Design Handbook for Accelerator Technicians PDF can be found here.