The Lowdown on Lithium Battery Seals

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Lithium battery seals are critical components in many types of batteries. From medical equipment to weapons control systems, these batteries must serve as essential power sources. With durability, dependability and power output as important performance indicators, batteries’ seals should adequately support their functionality. In this short guide, you’ll learn about the advantages of battery seals constructed from lithium.

Benefits of Lithium Battery Seals

Battery end seals serve an important function: keeping a battery’s electrolyte and internal components inside its housing. A battery end seal ensures that its power cell stays reliable, functional and safe for ongoing use. Battery seals come in a wide range of materials:

  • Titanium alloys
  • Stainless steel
  • Aluminum
  • Steel alloys
  • Lithium

Complete Hermetics manufactures several lithium battery glass-to-metal sealed lid products. Glass-to-metal seals offer unique advantages. Their construction creates a reliable high-quality seal that withstands exposure to harsh conditions, including temperatures between -40°C and +150°C. They also resist humidity extremes, electrochemical corrosion, pressure variation and high-voltage electrical currents. Lithium seals offer excellent performance in all these areas, along with offering a longer shelf life.

Your Source for Lithium Battery Seals

Complete Hermetics custom crafts glass-to-metal and ceramic-to-metal seals, as well as hermetic seals and feedthroughs. Through engineering and manufacturing excellence, we deliver superior-grade products meeting strict quality standards. Request an online quote now or call us at (714) 265-1238.

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A Quick Overview of Battery End Seals

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Battery end seals play important roles in battery life, functionality and power delivery. They create tight seals that stop any unusual loss of electrical energy. With missing or damaged end seals, batteries lose power faster than usual and their typical lifespans decrease.

Lithium Battery Sealed Lids

Hermetic seal technology is key with lithium battery sealed lids. Glass-to-metal sealing techniques require both the glass and the metal to have similar thermal expansion properties to ensure a solid seal when the pieces cool down.

To create a hermetic seal, glass must first be heated to a molten consistency. This occurs at between 1,400 and 1,600 degrees Celsius. Once this happens, the glass can be wetted to the metal. Wetting contacts a liquid with a solid surface through intermolecular interactions. Cohesive and adhesive forces must balance adequately for wetting to succeed.

When the glass-to-metal sealing process is complete, you have a high-quality seal that can handle extreme conditions. Besides mitigating power loss, a good hermetic seal also protects against water and foreign body entry.

Dependability and Durability

Lithium batteries have a wide range of applications. Both durability and reliability are key when it comes to battery end seals. Whether on batteries powering pacemakers, weapons systems or other critical pieces of equipment, Complete Hermetics produces consistently high-quality hermetically sealed components.

A Quick Primer on Hermetic Seals and Feedthroughs

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As you may know, hermetic feedthroughs allow energy or substances to migrate from outside a hermetically-sealed area to the inside. Maintaining hermetic seals is important with a feedthrough, but providing electrical isolation is also key. Strict performance standards call for no leakage while ensuring that a powerful vacuum remains.

Constructing Hermetic Feedthroughs

A hermetic feedthrough is created using similar techniques to creating hermetic seals. Its glass-to-metal construction incorporates molten glass that can be bonded tightly to metal. To achieve this feat, the glass must be heated to between 1,400 and 1,600 degrees Celsius. Some feedthroughs incorporate ceramic-to-metal or electrical sealing. Hermetic feedthroughs can fall into one of three unique categories:

  • Low-voltage
  • Water-cooled/RF
  • High-voltage

Critical Performance Standards

A high-quality feedthrough can resist extreme temperature shifts, changes in pressure and huge swings in humidity levels. When plated, feedthroughs can also resist corrosion and handle wire bonding or soldering. Depending on product specifications, a feedthrough may need to tolerate even more extremes without so much as a tiny amount of leakages. For feedthroughs used in medical equipment, such super-strict production standards are necessary.

Complete Hermetics develops and manufactures hermetic seals and feedthroughs that deliver the dependability and durability needed in your applications. Besides our standard feedthroughs, we can also design custom versions that meet your needs. Call us at (714) 265-1238 or fill in the contact form for your needs  of hermetic seals and feedthroughs now.

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Ensure System Integrity with Quality Battery End Seals

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No matter what technology you depend upon, system integrity is crucial. Advanced battery end seals utilize custom glass-to-metal sealing solutions capable of withstanding harsh environments that encounter extreme temperatures, humidity, pressure and electrochemical corrosion.

To ensure quality engineering, Complete Hermetics inspects and conducts rigorous testing for leakage rates, high energy isolation and break down voltage. Advanced material specifications make our battery end covers and capacitor lids ideal for many industries:

  • Communication systems
  • Medical and health equipment
  • Automotive applications
  • Sensor and monitor systems
  • Weapons systems

Lithium battery sealed lids are especially reliable. We offer a complete line of titanium connectors and terminals for equipment that requires excellent lithium battery performance.

Material Specifications for Battery End Seals

With a choice of materials, your company can select battery components tailored for specific applications. Body makeup includes a variety of high-quality metals: titanium, stainless steel, aluminum and more. Available pin materials include molybdenum, alloy 52, titanium and stainless steels, while glass materials include Corning 9010, Corning 9013, Cabal 12 and options for custom materials.

Lithium battery sealed lids provide the best technology for longevity and safety, ensuring steady performance in many crucial functions. At Complete Hermetics, we understand the need to keep systems going at all times. Talk to our experts today for help in selecting the optimal product for your critical applications.

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What Are Lithium Battery Seals?

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Lithium battery seals preserve battery life by preventing the loss of electrolytes. A lithium battery glass-to-metal sealed lid is extremely effective in making a good seal.

Why Lithium Battery Seals Are Important

During normal use, a battery generates gas. This won’t be a problem unless the pressure inside the battery gets too high. Without a way to release the gas, the cell could rupture and damage the battery.

Specially-made battery end seals solve this problem by providing a low-pressure venting system. The battery end has a gasket that seals onto the cell. That gasket has a vent mechanism to release pressure, protecting the battery from damage.

Caring for a Lithium Battery

Lithium battery seals prolong the life of your battery but you can also protect it by making sure it doesn’t get too hot. Keep these things in mind:

  • Provide space between the battery and any heat source.
  • Keep your battery away from transistors and transformers.
  • Try to keep your battery between 20-25 degrees Celcius.
  • Place your battery near an air inlet rather than an exhaust vent.

We offer a wide range of sealing technologies, including glass-to-metal lids that are highly reliable and can handle high electrical currents as well as electrochemical corrosion. If you are looking for a custom-made product, contact us.

Vacuum Viewports

How Can High Vacuum Viewports Prevent Outgassing Risks?

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Monitor your equipment or transmit energy into a sealed system using vacuum viewports by Complete Hermetics. Review the common uses of viewports and compare window materials today to find a product that fits your laser or infrared needs.

Typical Uses

The most basic use of a vacuum viewport is a window to view the interior of a sealed system. This application can assist you in monitoring the performance components in a vacuum. A more common application of hermetic viewports is to allow a wide spectrum of light to pass through in one or both directions.

Infrared and laser lights require a hermetic viewport to be transmitted through an otherwise sealed environment. A viewport plays a unique role in allowing a single type of light or wide spectrum light to send energy in and out of the hermetically sealed system. Here are a few industries where these components are commonly used:

  • Defense industry
  • Medical endoscopic fields
  • Space industry
  • Laser designation systems

Common Viewport Materials

Vacuum windows need to use specific materials to allow energy to pass through without compromising the structure of the chamber. These are the most common materials used by Complete Hermetics to create viewport windows:

  • Zinc selenide
  • Fused silica
  • Sapphire
  • Magnesium fluoride
  • Glass

Explore our line of vacuum viewports today if you need a customized solution for your infrared, laser or optical application. Work with Complete Hermetics to achieve industry-leading quality control using standard or customized viewport solutions.

Vacuum Viewports

How Are Vacuum Viewports Used?

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Monitor your equipment or transmit energy into a sealed system using vacuum viewports by Complete Hermetics. Review the common uses of viewports and compare window materials today to find a product that fits your laser or infrared needs.

Typical Uses

The most basic use of a vacuum viewport is a window to view the interior of a sealed system. This application can assist you in monitoring the performance components in a vacuum. A more common application of hermetic viewports is to allow a wide spectrum of light to pass through in one or both directions.

Infrared and laser lights require a hermetic viewport to be transmitted through an otherwise sealed environment. A viewport plays a unique role in allowing a single type of light or wide spectrum light to send energy in and out of the hermetically sealed system. Here are a few industries where these components are commonly used:

  • Defense industry
  • Medical endoscopic fields
  • Space industry
  • Laser designation systems

Common Viewport Materials

Vacuum windows need to use specific materials to allow energy to pass through without compromising the structure of the chamber. These are the most common materials used by Complete Hermetics to create viewport windows:

  • Zinc selenide
  • Fused silica
  • Sapphire
  • Magnesium fluoride
  • Glass

Explore our line of vacuum viewports today if you need a customized solution for your infrared, laser or optical application. Work with Complete Hermetics to achieve industry-leading quality control using standard or customized viewport solutions.

Custom Hermetic Feedthroughs

What Are Electrical Feedthroughs For?

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You might not think that there are many components that can be found in X-ray machines, transformers and furnaces. But electrical feedthroughs are commonly used in a wide variety of technologies to help make sure that electricity doesn’t escape and cause malfunctions. It is important to know what these feedthroughs are used for and to appreciate this important piece of technology that keeps so many different technologies running.

The Importance of Vacuums 

Creating a vacuum guarantees that the electricity being transported from one part of a machine to another does not get out. Vacuum feedthroughs effectively make sure that the electricity is distributed safely.

Using Seals

The key to creating a vacuum is the type of seal that is used. Hermetic feedthroughs use glass-to-metal seals and ceramic seals to create this vacuum. When building a new seal, it is extremely important that the materials used are able to withstand intensive use and not break down over time.

This is why many seals are made with glass and ceramics; these materials are designed to withstand extreme temperatures, as well as other wear and tear. Many of these seals are used in technology like furnaces that operate at extreme temperatures. Making sure the seals do not break down easily will make sure the machine runs smoothly.

Custom Hermetic Connectors

How to Choose the Right Hermetically Sealed Connectors

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Extremely harsh environments call for extra protection to ensure the integrity of a system. Hermetically sealed connectors provide such protection by keeping all air, moisture and contaminants out. If you’re looking for the right connectors for your application, consider these tips to begin your search.

  1. Select the Shell

There are two major types of connector shell shapes: circular and rectangular. Sizes typically range from 0.25 inches to 3.0 inches in diameter. Connectors can be made from a variety of materials such as:

  • 300 Series Stainless Steel
  • Cold Rolled Steels
  • Kovar
  • Inconel
  • Titanium
  • Aluminum

Kovar is a nickel- and cobalt-based alloy that contains iron, and Inconel is a nickel-based alloy that contains iron and chromium. Titanium and aluminum hermetically sealed connectors are lightweight but still provide the same quality of seal as heavier materials.

  1. Select the Pins

To select the correct pin configuration, determine how many pins you need and how they need to be oriented. Pin end shapes usually include rounded, eyelet and hook types and range from 4 AWG to 16 AWG in size. Typical pin materials are:

  • Kovar and Copper Cored Kovar
  • Alloy 52
  • Inconel
  • Molybdenum
  • Stainless Steel

Alloy 52 is composed of nickel and iron and works well for sealing glass to metal, while molybdenum is known for reducing wear and friction.

  1. Select the Finish

The finish is important because it protects hermetically sealed connectors from the environment. Standard finishes include:

  • Bright Tin Plating
  • Electroless/Electrolytic Nickel Plating
  • Copper Plating
  • Gold Plating
  • Silver Plating

Though the finish primarily protects the connector against corrosion, it is also a considered design element that makes your system look sharp. For instance, bright tin plating creates a shiny exterior, while gold plating can make the connectors stand out.

Ask the Pros

If you’re having trouble deciding which hermetically sealed connectors are right for your application, call your dealer for help. The experts can help you select the right size, shape and finish to ensure the integrity of your system.

Hermetically Sealed Connectors

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What Are Hermetically Sealed Connectors?

Hermetically sealed connectors are commonly used when machines or equipment will be exposed to harsh environments. Some items, such as photographic and surveillance equipment mounted on unmanned vehicles, are exposed to severe weather, fluctuating atmospheric conditions, and high altitudes. Hermetically sealed connectors are chosen to connect vacuum-sealed boxes and equipment because they can maintain the airtight condition even under severe flight conditions. It’s also common to find a hermetically sealed connector in use on submarines and satellites in orbit. Although the connectors are exposed to very different environments, their ability to withstand pressure differences and prevent moisture seepage into machinery is consistent.

A Vital Component of Protection From Moisture

In these, and other conditions, packaging technology is used to prevent gases from moving through barriers because of the connector. When a high-pressure differential barrier is built to allow for the passage of electric currents, there’s a potential for gases or moisture to also penetrate the barrier. Appropriately-constructed, hermetically sealed connectors will be effective against those environmental exposures and should be unaffected by moisture as well as resistant to corrosion. Ultimately, the purpose of the hermetically sealed connectors isn’t just to prevent gas and moisture to get beyond the barrier, but to protect sensitive electronic systems from malfunctions related to moisture.