High voltage hermetic feedthrough assembly with integral wire and connectors
Douglas Electrical Components manufactures hermetic feedthroughs for high voltage wire, cable, terminal, and connector applications. Utilizing a proprietary hermetic epoxy material and process, Douglas can seal wires , cables and connectors to 30kV and stud terminals over 20kV in a variety of applications and industries.
Transmitting high voltages can be its own challenge but is compounded when a hermetic seal is required. Utilizing a hermetic epoxy design permits engineers to utilize the same components such as wires, terminals, or connectors as the existing design, but hermetically seal it.
Other technologies can face challenges to utilize the same components within the design due to the elevated temperatures the seal is exposed to during the manufacturing process versus the component ratings. This often requires an extra installation step for engineers to integrate the preferred electrical connection.
Douglas is prepared to design a specific high voltage feedthrough for your application regardless of the quantity you need. Our engineering team will work through the design process with you to specify the components to meet the voltage and current ratings as well as the mechanical interface that is preferred.
Types of High Voltage Feedthroughs
High Voltage Wire / Cable Solutions
Voltage ratings: > 30kV
High voltage vacuum feedthrough designs are available with integral wires and connectors.
High voltage wires and cables are used across a wide span of applications and industries including aerospace, oil and gas, power generation and distribution, and semiconductor. The intent of a hermetic high voltage wire or cable is to transmit power between two environments. Douglas hermetically seals the conductor or cable to ensure its encapsulation within the feedthrough. Specify the exact wire or cable already designed into the system and make it hermetic with a Douglas high voltage feedthrough. Douglas can incorporate shielding, termination, and interconnect capabilities to create a plug and play solution.
Douglas high voltage wire feedthroughs can operate in a wide range of temperatures and pressures. Cryogenic feedthrough designs commonly incorporate higher voltages for pumps and motors.
High voltage wire feedthroughs are available for hazardous locations including Class I Division 1 explosion proof and ATEX and IECEx Exd flame proof. Our hermetic epoxy is field-proven in harsh environments with excellent chemical compatibility.
High Voltage Connectors
High voltage hermetically sealed connector assembly
Voltage ratings: Up to 5 kV
High voltage connectors are an excellent way to transmit power when the ratings permit. Douglas can hermetically seal commercial off the shelf (COTS) high voltage connectors with integral wires or terminals. Create high density connections that meet the ratings required. Hermetic bulkhead high voltage connectors are available with both plug and receptacle configurations.
Connectors can include common MIL-spec rated connectors in a non-hermetic package. Douglas can either utilize our backpotting process integrating wires or terminations such as solder cups, or a more complete assembly with integral flange and housing for feedthrough mounting.
Douglas will test and verify operating voltages of high voltage connector assemblies with hipot testing as well as helium leak testing.
High Voltage Terminal Seals
Voltage ratings: > 20kV
Terminal to wire hermetic seal design with CF Flange.
Douglas offers StudSeal and Portplate terminal seals for applications requiring a stud or threaded terminal interface to transmit power in a hermetic environment. Standard and custom configurations are available. This includes motor terminal seals and hermetic battery seals. Specialty terminal designs are manufactured for harsh environments, vacuum and positive pressure conditions, and various liquids and gases. Combine terminal seals with other feedthrough connection types including high voltage cables, copper rods, and custom electrodes.
Summary
- Integrate the exact electrical components you need into your next high voltage feedthrough design.
- Partner with the expert in epoxy hermetic sealing, increasing design flexibility.
- Design high voltage feedthroughs with a variety of electrical interfaces including high voltage wire connector, high voltage cable, terminals, studs, or some combination thereof for virtually any industry.
