High-voltage insulators are disclosed that are capable of handling diverse requirements, such as providing high standoff voltages, high temperature cycling, and the ability to withstand flexural stress. One high-voltage insulator includes a first piece formed from a first material, a second piece formed from a second material, and an interface section where the first piece contacts with and forms a seal with the second piece. The interface includes a first groove located that accommodates a first gasket, sets of matching threads on the first and second pieces. The interface section further accommodates a second gasket. In this multi-piece high-voltage insulator, the first material can have a first set of flexural, heat resistance, and electrical standoff characteristics suitable for a first environment, and the second material can have a second set of flexural, heat resistance and electrical standoff characteristics suitable for a second environment.

A feedthrough includes: a main body having at least one passage opening that extends through the main body; at least one first functional element which is disposed within the at least one passage opening and is connected to the main body in a fluid-tight manner; and an insulation material that surrounds at least some regions of the at least one first functional element and establishes the fluid-tight connection to the main body. Within the at least one first functional element, there is a pressure-guiding channel by which pressure components that have arisen as a result of pressure are guided from within the at least one first functional element outward to the surrounding insulation material such that a pressure resistance of the fluid-tight connection of the at least one first functional element to the main body is elevated.

A combination of materials and processing parameters have been developed for hermetic seals for electrical feedthroughs in high performance applications. A glass-ceramic forms a hermetic seal between a stainless steel shell and a platinum-nickel-based (Pt—Ni) pin alloy for electrical feedthroughs. The glass-ceramic is processed to develop a coefficient of thermal expansion (CTE) slightly higher than the pin alloy but lower than the stainless steel. The seal system employing the new processing conditions and Pt—Ni-based pin alloy alleviates several problems encountered in previous seal systems and improves the hermetic connector performance.

A join is provided that has an electrically insulating component and two joining partners secured to one another and electrically insulated from one another by the electrically insulating component. The electrically insulating component has a surface that extends between the two joining partners. The surface defines a structure selected from a group consisting of an elevation, a depression, and any combinations thereof. The structure elongates a direct path along the surface. The structure completely surrounds at least one of the two joining partners. The electrically insulating component and/or the structure includes a glass that is at least partially crystallized.

A metal fixing material leadthrough for igniters of airbags and/or belt tighteners includes at least one metal pin fused into a glass or glass-ceramic fixing material in a through-opening of a main body. The metal is present in a post-heated state, with an interface between the fixing material and the metal pin and an additional interface between the fixing material and an inner surface of the through-opening. The at least one metal pin, at least in its core region, consists of stainless steel, such as a chromium-containing stainless steel, the stainless steel having a thermal expansion coefficient.

High-voltage insulators are disclosed that are capable of handling diverse requirements, such as providing high standoff voltages, high temperature cycling, and the ability to withstand flexural stress. One high-voltage insulator includes a first piece formed from a first material, a second piece formed from a second material, and an interface section where the first piece contacts with and forms a seal with the second piece. The interface includes a first groove located that accommodates a first gasket, sets of matching threads on the first and second pieces. The interface section further accommodates a second gasket. In this multi-piece high-voltage insulator, the first material can have a first set of flexural, heat resistance, and electrical standoff characteristics suitable for a first environment, and the second material can have a second set of flexural, heat resistance and electrical standoff characteristics suitable for a second environment.

A glass-metal feedthrough includes: an external conductor including steel, having a coefficient of expansion .sub.external, and having an opening formed therein; an internal conductor disposed in the opening, the internal conductor including steel and having a coefficient of expansion .sub.internal. The external conductor and the internal conductor are configured to not release nickel when in contact with a human or animal body or biological cells of a cell culture. A glass material surrounds the internal conductor within the opening and has a coefficient of expansion .sub.glass. The coefficient of expansion .sub.external of the external conductor and the coefficient of expansion .sub.internal of the internal conductor both are greater than the coefficient of expansion .sub.glass of the glass material.

The disclosure relates to a glass-metal feedthrough, composed of an outer conductor or a basic body, a glass material or glass-ceramic material, and an inner conductor. The inner conductor is preferably a metal pin and the inner conductor is sealed in the outer conductor, in particular basic body, in the glass or glass-ceramic material. The metal pin comprises a material with high conductivity and/or low contact resistance, as well as a sleeve element that surrounds the metal pin at least partially.

A system for the manufacturing of high-fidelity insulated components is described. Per field requirements, components crafted via the process are hermetically sealed, and are configured to employ appropriately matched materials in accordance with their inherent properties of thermal expansion. A pin, glass insulator, and ferule are present. As opposed to conventional insulated components which employ stainless steel as an inefficient conductor, the unique matching process of the system provides for the use of copper and silver alloys to maximize efficiency while maintaining a hermetic seal. Specific glass is selected in accordance with the desired alloy in order to maintain similar degrees of expansion and contraction per temperature variations.

A system for the manufacturing of high-fidelity insulated components is described. Per field requirements, components crafted via the process are hermetically sealed, and are configured to employ appropriately matched materials in accordance with their inherent properties of thermal expansion. A pin, glass insulator, and ferule are present. As opposed to conventional insulated components which employ stainless steel as an inefficient conductor, the unique matching process of the system provides for the use of copper and silver alloys to maximize efficiency while maintaining a hermetic seal. Specific glass is selected in accordance with the desired alloy in order to maintain similar degrees of expansion and contraction per temperature variations.