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Registered Member #1083
Joined: Mon Oct 29 2007, 06:16PM
Location: Upland, California
Posts: 256
We had do build some underwater through-chassis connections for a submarine project and you might be able to do something similar. What I did was take a pvc pipe union and epoxied a receptacle on one side of the union, and a plug on the other side. We turned down the O.D. on a lathe a bored a hole in the sub body so one side of the union is a press fit into the submarine. Since there's so much plastic surrounding the connection along with a rubber gasket, it might be something to consider.
Registered Member #480
Joined: Thu Jul 06 2006, 07:08PM
Location: North America
Posts: 644
jpsmith123 -
Caution on the commercial "HV banana cables" you found. It's only the cable that's rated for 20kV, not the banana plugs. I think all these "shrouded" banana plugs are rated only to IEC CAT-II (300V) or CAT-III (1,000V).
For connecting your banana plugs to coax, there are a number of options. One is to use the "self-encapsulating" heat-shrink tubing that has an inner lining of heat-activated adhesive/sealant. The sealent softens first, then once it's "flowable" the outer shrink-tubing shrinks, forcing the sealant into any airspaces in the assembly. Another way is to machine a "potting sleeve" that fits around your cable and the body of the banana plug, with a small hole in the side. After assembling everything, inject the potting sleeve with electronic-grade RTV sealant to mechanically bond everything together and eliminate any voids in the insulation system.
Registered Member #2431
Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
I was pondering what Herr Zap suggested with the RTV, i have porcilain im about to fire to cone 6, if you need parts for this thread, post a DXF, maybe a can make some prototypes and mail them to you.
Is there such a thing as soft silicone epoxy, maybe we could cast our own flexible wire sections with the connector already embbeded .
Registered Member #480
Joined: Thu Jul 06 2006, 07:08PM
Location: North America
Posts: 644
Patrick -
No real benefit to porcelain in this application, and numerous drawbacks. Just machine a sleeve out of ABS rod stock, slide it onto the cable, install the banana plug, slide the sleeve up over the banana plug, and inject your potting compound.
No such thing as a "soft silicone epoxy", epoxies and silicones are completely different chemical families. Although there are epoxies that are slightly flexible after curing, they are nowhere near as elastomeric as typical silicone compounds.
Registered Member #2431
Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
Herr Zapp wrote ...
Patrick -
No real benefit to porcelain in this application....
Just thought id throw it out there.
Herr Zapp wrote ...
No such thing as a "soft silicone epoxy"....
I realize that epoxy and silicone are different in families, but are there no flexible two part silicones? not the evaporating tub and tile hardware store stuff.
Registered Member #480
Joined: Thu Jul 06 2006, 07:08PM
Location: North America
Posts: 644
Patrick -
Yes, there are MANY different two-part silicone potting and sealing compounds of various viscosities and Shore hardnesses.
Stay clear of the "household" RTV silicone sealants that release acetic acid as a byproduct of the cure cycle. If you want a single-component RTV, use the GE or Dow Corning non-corrosive "electronic grade" sealants that release alcohol instead of acetic acid during curing.
Registered Member #1321
Joined: Sat Feb 16 2008, 03:22AM
Location:
Posts: 843
I don't like politicians; spiders, snakes, scorpions, centipedes, etc. (or do I repeat myself?); liver; dental work; or potting compounds of any kind. Thus I've been trying to avoid the use of any more potting compound...but as Herr Zapp suggests, it may be called for here.
It wouldn't be too bad if I could find an inexpensive, single-component, primerless, non-corrosive RTV sealant, but apparently most if not all of these single-component type products will not cure properly in any thickness greater than a few mm. So I need to see if there are any two-part RTV products available anywhere in a small quantity at a reasonable price.
I was thinking about trying to duplicate the method used in the Beru spark plug connectors I have (whereby a brass wood-screw threads into the center conductor of the silicone HV wire, making electrical contact with it, while at the same time expanding the wire radially outward against the wall of the connector, thus holding the wire), but the potting method would be much more reliable I think.
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Making HV Plugs And Receptacles From Banana Plugs & Jacks
