High Voltage Connectors

High voltage connectors are used in applications that require the transfer of high voltage signals. Like other electrical connectors, they are available in a single-pin and multi-pin models and male and female designs. Most high voltage connectors are used in aerospace, marine, medical and military applications because they have high dielectric strength and are usable over a wide range of temperatures and environmental conditions. Some high voltage connectors are preassembled, hermetically sealed, oil and chemical resistant, or color-coded for easy identification. Other are designed to resist radiation, ultraviolet light, or radio frequency interference (RFI). High voltage connectors that meet U.S. military specifications (MIL-SPEC) comply with specific standard and can operate at high altitudes without voltage de-ratings. Lightweight high voltage connectors and products with non-toxic insulation are also available.

Suppliers of high voltage connectors categorize their products in different ways. Types include single-end lead assemblies, single-end lead assemblies with positive-stop ferrules, shielded lead assemblies, and RFI shielded lead assemblies. Some lead assemblies have a silicone rubber end and a specified mating length that is molded onto color-coded silicone rubber wire. High voltage connectors that use insulation materials such as polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE) are also available. Often, the electrical conductors are silver-plated and comply with specifications such as MIL-W-16878/8 and ASTM B298-58T. The pigtail may be solder-dipped while the socket may be made of bronze and crimped to the lead wire. Common plating materials include gold and silver. There are two main choices for cap materials: polycarbonate glass-filled polyester and glass-filled epoxy. High voltage connectors with a positive-stop ferrule often use glass-filled polyester.

Ruggedized high voltage connectors are designed for harsh environments with relatively high levels of shock and vibration, and are used in a variety of civilian and military applications. These high voltage connectors may feature an integrally-molded end to provide positive mating and a superior seal. When mated with the appropriate receptacle, they provide complete RFI shielding. Receptacles made of molded glass epoxy have a protective metal shroud that is sealed hermetically between plastic and metal. High voltage connectors with removable caps and dirt-protective caps are also available. The latter protect receptacles against damage to threads and prevent the ingress of contaminants on the insulator barrel and male contact.

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Part Numbers for High Voltage Connectors