Electrical feedthroughs for redistributing thermally-induced stresses that result from welding
Electrical feedthroughs are presented for redistributing thermally-induced stresses that result from welding. In some embodiments, an electrical feedthrough includes a tubular conduit having a flange at one end. The flange includes a first surface disposed opposite a second surface. The first surface includes at least one of a protrusion and a notch. The electrical feedthrough also includes an electrically-conductive terminal disposed through the tubular conduit. An electrically-insulating material is disposed between the tubular conduit and the electrically-conductive terminal and forms a seal therebetween. The protrusion and the notch are configured individually or as a combination to reduce thermally-induced stresses within the electrically-insulating material that result from welding the flange. Methods for welding such electrical feedthroughs to a wall, such as a wall of a battery housing, are also presented.
1. An electrical feedthrough, comprising:
a tubular conduit having a flange at one end, the flange comprising a first surface disposed opposite a second surface, the first surface comprising a protrusion and a notch;
an electrically-conductive terminal disposed through the tubular conduit;
an electrically-insulating material disposed between the tubular conduit and the electrically-conductive terminal and forming a seal therebetween; and
wherein the protrusion and the notch are configured individually or as a combination to reduce thermally-induced stresses within the electrically-insulating material that result from welding the flange, and wherein the protrusion is positioned between the notch and the electrically-conductive terminal.
2. The electrical feedthrough of claim 1 , wherein the protrusion comprises a continuous annular rib.
3. The electrical feedthrough of claim 1 , wherein the protrusion comprises a discontinuous annular rib having one or more gaps therein.
4. The electrical feedthrough of claim 1 , wherein the protrusion comprises a bump.
5. The electrical feedthrough of claim 1 , wherein the notch comprises a continuous annular groove in the first surface.
6. The electrical feedthrough of claim 1 , wherein the notch comprises a discontinuous annular groove in the first surface having one or more filled portions therein.
7. The electrical feedthrough of claim 1 , wherein the notch comprises an indent.
8. The electrical feedthrough of claim 1 , wherein the notch is a first notch, and the second surface comprises a second notch.
9. The electrical feedthrough of claim 1 , wherein the tubular conduit comprises a taper that narrows when traversing a direction away from the flange.
10. The electrical feedthrough of claim 1 , wherein the tubular conduit comprises a circumferential rib.
11. The electrical feedthrough of claim 1 , wherein the tubular conduit comprises a tubular bump.
12. The electrical feedthrough of claim 1 , wherein the flange comprises a circular circumference with a flat edge disposed therealong.
13. A battery, comprising:
a battery housing having a wall and an electrode assembly disposed therein, the electrode assembly comprising at least an electrode;
an electrical feedthrough disposed through the wall of the battery housing and comprising:
a tubular conduit having a flange at one end, the flange comprising a first surface disposed opposite a second surface, the first surface comprising a protrusion and a notch, the second surface disposed against the wall of the battery housing,
an electrically-conductive terminal disposed through the tubular conduit and electrically-coupled to the electrode, wherein the protrusion is disposed between the electrically-conductive terminal and the notch,
an electrically-insulating material disposed between the tubular conduit and the electrically-conductive terminal and forming a seal therebetween; and
wherein the flange is welded to the wall of the battery housing.
14. The battery of claim 13 , wherein the notch is a first notch, and the second surface comprises a second notch.
15. The battery of claim 13 , wherein the tubular conduit comprises a taper that narrows along a direction away from the flange.
16. The battery of claim 13 , wherein the flange comprises a circular circumference with a flat edge disposed therealong.
17. The battery of claim 13 , wherein the flange has an outer diameter that ranges from 0.1 mm to 10 mm.
18. The battery of claim 17 , wherein the outer diameter that ranges from 0.2 mm to 2.0 mm.
19. The battery of claim 17 , the electrically-conductive terminal has a diameter that ranges from 20% to 70% of the outer diameter of the flange.