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Connector Selection Criteria
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| Introduction |
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Today’s aerospace operational requirements for electrical connectors dictate simultaneous solutions of mechanics, electronics, materials and processes. Nowhere else in the connector industry do these multi-engineering disciplines require more diligence than the solution to high voltage aerospace connector applications, which is the principal product of Reynolds Industries’ Electrical Connector Products Division.
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| High Altitude Operation |
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| Reynolds Industries pioneered the development of miniature high voltage connectors used within non-pressurized areas of high altitude flying aircraft over twenty five years ago. To help understand the problem, one must look at what happens as a high performance aircraft climbs to and operates at altitudes typically 30,000 to 70,000 feet. At these altitudes air pressure is less than 1/4 that of sea level. As air pressure reduces with altitude, accompanying dielectric strength, or the resistance to arcing, decreases. |
| Arcing Due to Reduced Atmospheric Pressure |
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| In low voltage electrical connector applications (less than 500 volts D.C.), reduced air pressure presents little concern or special design considerations. But taking, for example, a high voltage connector operating requirement of 10,000 volts D.C., the creep path (arc distance) between two conductors at sea level would be 1/2 inch, and at 70,000 feet it would be 5 inches minimum. If no solution were possible other than the lengthening of creep path, then aerospace high voltage connectors would occupy unreasonable volume and be extremely heavy. |
| The Solution |
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To eliminate the need for lengthened creep path, precision silastic seals are incorporated within the connector, effectively blocking high voltage creep at reduced air pressure. Another problem, that of temperature swings between -55° to +125° C typical of aircraft operations, must be considered. Elastomeric materials at these temperatures exhibit compression set, or loss of memory between hot and cold cycles, which can result in voltage creep or breakdown through the elastomeric dielectric. Through proper selection of elastomeric materials and designing the optimum shape, Reynolds connectors can effectively meet the simultaneous exposure of reduced pressure and hot and cold cycling. Reynolds Advanced series of connectors provide the designer with a wide selection of connectors and cable assemblies which will operate with high reliability at 70,000 feet and over a temperature range of -55° to +125° C.
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