How Hermetic Feedthroughs Enhance System Safety

In various industries such as aerospace, medical, military, and semiconductor manufacturing, system safety is a top priority. These industries require components that can maintain the integrity of their systems, especially when dealing with extreme conditions like high pressure, vacuum, or hazardous environments. One such critical component is the hermetic feedthrough. This small yet powerful device plays a key role in ensuring that sensitive systems remain safe and reliable.

What are Hermetic Feedthroughs?

Hermetic feedthroughs are sealed connectors that allow electrical or optical signals, power, or fluids to pass through a barrier while maintaining a perfect seal against gases, liquids, dust, and contaminants. They are widely used in high-performance systems that require a secure connection between components while preserving the system’s integrity in challenging environments.

The seal is achieved using materials like glass or epoxy, which form a hermetic seal between the feedthrough and the system. This ensures that no external elements can infiltrate the system, which is crucial for the safety and performance of the equipment.

1. Prevention of Contamination

One of the primary ways hermetic feedthroughs enhance system safety is by preventing contamination. In sensitive systems such as medical devices or semiconductors, contamination from air, moisture, dust, or other particles can cause malfunctions, reduce the lifespan of components, or even lead to system failure. Hermetic feedthroughs maintain a tight seal, preventing these contaminants from entering critical areas and ensuring the system operates efficiently without the risk of degradation.

In vacuum or pressurized systems, contamination can also interfere with delicate chemical or physical processes. Hermetic feedthroughs help maintain the purity of the environment by providing a sealed pathway for wiring, cables, or optical fibers to pass through.

2. Maintaining Pressure and Vacuum Integrity

Many systems, such as those used in space exploration, medical equipment (e.g., MRI machines), and high-energy physics, rely on maintaining pressure or vacuum integrity. The failure of a feedthrough in these systems could lead to dangerous pressure imbalances or loss of a vacuum, both of which could jeopardize system safety and performance.

Hermetic feedthroughs are designed to withstand extreme pressure differentials, making them ideal for maintaining the integrity of these systems. They prevent leaks and ensure that the pressure or vacuum is maintained, thus preventing hazardous conditions that could arise from loss of containment.

3. Electrical and Signal Safety

In environments where electrical or optical signals need to pass through a barrier, such as a vacuum chamber or a pressurized vessel, hermetic feedthroughs are essential for ensuring safety. These components prevent electrical shorts, arcs, or signal interference, which could otherwise lead to system failures, fires, or even explosions in certain hazardous settings.

The sealed environment of hermetic feedthroughs ensures that electrical components remain insulated, reducing the risk of electrical hazards. In environments with flammable or explosive gases, the safety of the system is enhanced by ensuring that electrical signals or power are transmitted safely without sparking or causing ignition.

4. Protecting Against Extreme Temperatures

Many hermetic feedthroughs are designed to operate in extreme temperature ranges. Whether in space, under the sea, or in industrial applications, systems often experience temperature fluctuations that can cause mechanical stress or failure if not managed properly. Hermetic feedthroughs are built to withstand these temperature extremes, providing a reliable and secure connection regardless of the external environment.

The robust sealing properties of hermetic feedthroughs ensure that the internal components of a system are protected from temperature-induced damage, contributing to the overall safety and longevity of the system.

5. Durability and Reliability

One of the most significant factors in ensuring system safety is the long-term reliability of the components in use. Hermetic feedthroughs are known for their durability and ability to perform consistently under harsh conditions. Their design prevents wear and tear, ensuring that the system remains secure and safe throughout its operational lifespan.

By using high-quality materials like metal, ceramics, or glass, hermetic feedthroughs resist corrosion, fatigue, and other forms of degradation, ensuring that they continue to provide a secure, sealed pathway for electrical or optical connections even in the most demanding environments.

6. Compliance with Safety Standards

Hermetic feedthroughs are often designed to meet stringent safety and quality standards. Many industries, especially those dealing with critical or hazardous materials, require compliance with regulations such as MIL-SPEC, ISO, or IEC standards. These standards ensure that feedthroughs meet safety requirements related to sealing, electrical performance, and mechanical strength.

By choosing hermetic feedthroughs that comply with these standards, companies can ensure that their systems meet the highest safety requirements, reducing the likelihood of accidents, system failures, or regulatory violations.

Conclusion

Hermetic feedthroughs play a critical role in enhancing the safety of systems across many industries. By preventing contamination, maintaining pressure and vacuum integrity, ensuring electrical and signal safety, protecting against extreme temperatures, and providing durability and reliability, hermetic feedthroughs are indispensable in maintaining the integrity and performance of sensitive systems.

For industries where system safety is non-negotiable, choosing hermetic feedthroughs is an essential step in safeguarding both equipment and people. Whether you’re designing equipment for space exploration, medical applications, or industrial machinery, hermetic feedthroughs provide the security, reliability, and performance necessary to ensure safe operations.

Chris Rempel, with over two decades of experience, serves as the Director of Sales and New Product Development at Douglas Electrical Components.