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Making HV Plugs And Receptacles From Banana Plugs & Jacks

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Herr Zapp

Tue Nov 22 2011, 05:58AM

Registered Member #480 Joined: Thu Jul 06 2006, 07:08PM
Location: North America
Posts: 644

jpsmith123 -

Don't let a single bad experience with potting compound prevent you from utilizing them in your designs.

Careful attention to proper metering and mixing, use of clinically clean containers and stirring rods, and use of fresh materials will generally guarantee good results (all very dependent on proper process control). Two-part silicones are usually pretty forgiving IF metered and mixed properly (don't use a waxed paper cup!).

I've had good luck with the GE one-part electronic grade RTV silicones curing in sections up to 3/8" thick. For your HV cable/banana plug setup, I can't imagine that anything thicker than 1/8" to 3/16" would be needed (or desired).

Herr Zapp

Patrick

Tue Nov 22 2011, 06:57PM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

How do you guarantee with our materials, that the screw would thread itself through the center of the wire ? And not go off to one side.

Herr Zapp

Tue Nov 22 2011, 11:23PM

Registered Member #480 Joined: Thu Jul 06 2006, 07:08PM
Location: North America
Posts: 644

Patrick -

In these old "replacable wire" German spark-plug connectors, the connector housing has an outer sleeve and a fixed "screw". The sleeve centers the wire over the "screw" so everything stays concentric as the connector is "screwed" onto the wire.

Common on old Volkswagen and Mercedes ignition systems (mostly Bosch or Beru ignition system components).

Herr Zapp

Ash Small

Wed Nov 23 2011, 12:05PM

Registered Member #3414 Joined: Sun Nov 14 2010, 05:05PM
Location: UK
Posts: 4245

Here is a link to the Sikaflex 221 datasheet.

I've no idea how suitable polyurathane sealants are for HV, but it gives curing times for thicknesses up to 1/2 inch or so at various humidities/temperatures.

(I'd suggest trying the white one)

Patrick

Wed Nov 23 2011, 07:10PM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

Ash Small wrote ...

Here is a link to the Sikaflex 221 datasheet.

I've no idea how suitable polyurathane sealants are for HV, but it gives curing times for thicknesses up to 1/2 inch or so at various humidities/temperatures.

(I'd suggest trying the white one)

Is any polyurethane suitable for HV work? i use the two-part cast type for making hybrid rocket propellant grains.

Ash Small

Wed Nov 23 2011, 07:36PM

Registered Member #3414 Joined: Sun Nov 14 2010, 05:05PM
Location: UK
Posts: 4245

Patrick wrote ...

Is any polyurethane suitable for HV work? i use the two-part cast type for making hybrid rocket propellant grains.

I don't know. I know it's used on boats for electrical insulation, I guess the black one could contain carbon black and the silver one probably contains powdered aluminium, but the white one probably contains titanium dioxide, if anything.

I'll have to run some tests.

Patrick

Wed Nov 23 2011, 09:44PM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

Ash Small wrote ...

Patrick wrote ...

Is any polyurethane suitable for HV work? i use the two-part cast type for making hybrid rocket propellant grains.

I was referring more to flame and combuston issues.

jpsmith123

Wed Nov 23 2011, 10:28PM

Registered Member #1321 Joined: Sat Feb 16 2008, 03:22AM
Location:
Posts: 843

AFAIK, only silicone based sealants/adhesives will stick to silicone wire, so I think other compounds can be immediately ruled out for that reason alone.

Ash Small

Thu Nov 24 2011, 09:07AM

Registered Member #3414 Joined: Sun Nov 14 2010, 05:05PM
Location: UK
Posts: 4245

jpsmith123 wrote ...

AFAIK, only silicone based sealants/adhesives will stick to silicone wire, so I think other compounds can be immediately ruled out for that reason alone.

"Do not
apply over silicones or in the
presence of curing silicones.
Contact with alcohol or alcoholcontaining
solvents will prevent
cure."

Yep, not suitable for use with silicon.

EDIT: I'm sure I've stuck silicone to it before, once it's cured. I'll get a tube and run some tests.

I'll look at the flammability as well.

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