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| Design History of High Voltage Connector Interfaces |
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| High voltage connectors consist of some of the same components as general purpose connectors. There are, however, fundamental differences that set them apart. The Advanced interface connector series is the latest in the evolution of high voltage connectors developed at Reynolds Industries. Figure 1 illustrates this evolution. A discussion follows: |
| Figure A |
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| These connectors, designed for sea level use, were the industry standard prior to 1960. Whenever the connectors were required to operate at reduced atmospheric pressure, the recommended procedure was to apply generous amounts of silicone grease to the interface of the receptacle.
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| Figure B |
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| Reynolds added molded annular seals to the nose of the plug shown in Figure A to provide an altitude seal. This worked well except that reliability became marginal at extremely cold temperatures. Reynolds later introduced a special compound of silicone rubber which improved performance under these conditions.
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| Figure C |
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In 1963, Reynolds introduced a sub-miniature high voltage connector in which a hard plastic nose was used to compress an ‘O’ ring at the base of the male receptacle pin to provide an altitude seal. This same interface concept is used by other high voltage connector manufacturers. This design can lead to compression set of the ‘O’ ring.
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| Figure D |
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The conical interface works well even though compression set of the elastomer plug insulator member can create the same compression set problems described in Figure C. This was improved by Reynolds with the addition of the molded-in-place annular ‘O’ rings in the plug. This interface is widely used by Reynolds in multi-pin connectors but usually with a spring loaded coupling ring to compensate for the compression set of the silicone rubber plug insulator.
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| Figure E |
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The Advanced interface sealing system was invented, developed and placed into production by Reynolds in the 1980’s. The advent of this unique system of high voltage interface sealing solved nearly every known disadvantage of all the connector designs that preceded it in the field of aerospace high voltage connectors. The capability of this interface sealing system to be scaled up or down in size, depending on the operating voltage, provides the components and systems designers flexibility never before afforded in the selection of high voltage connectors and cable.
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