Need a watertight electrical bulkhead connection 1

[Mike79]

I'm designing a waterproof electrical housing and am trying to figuring out how to get a sensor wire and possibly a antenna wire out of the housing with out it leaking while under a possible pressure of 500 psi. I have found some aerospace applications but the price is far to high.

I've looked into glands, but ideally I would like to be able to quickly disconnect the connection. I was thinking about a simple spade type connection on the bulkhead.

Any recommendations would be appreciated. I'm liking not using the correct key words in my searches.

Mike

 

[MintJulep]

500 psi is going to cost you.

Google for "hermetic electrical connector" for plenty of options.

 

[mfalk99]

You might want to look at Burton connectors. We used them extensivly when I worked in the sub-sea business.... never had any problems down to 4000 meters. If you choose to use a gland Pepper Glands work well.

http://www.burtonee.com/products.html

http://www.cableglands.com

Mike.

 

[Mike79]

I haven't looked in to burton yet, looks like I'll have to give them a call. Unfortunately, the customer for the project requires the 500 psi. I'm hoping to change his mind if I can find a lower priced alternative with acceptable results. Thanks for the help.

 

[Mike79]

I've been tossing around the idea of an feeding the wires through a 3/8" hole and then filling the cavity with epoxy or similar resin and allowing it to harden. I'm hoping this would provide a leak-proof and cost effective solution. Has anyone ever tried something like this or do you see any potential problems.

I really appreciate any input.


Mike

 

[MintJulep]

Epoxy does not bond well to most common wire insulation material.

 

[Mike79]

That was a concern I had. A possible solution was to use non insulated solid copper wire.

 

[MintJulep]

Home made "cheap" solutions are invariably more costly in the long run that using an "expensive" proven commercially available system.

How much will it cost you in warranty repair or replacements and bad will when your seal fails?

 

[TheBlacksmith]

1) Find a proven solution for 500 psi, regardless of cost. Dcument that cost.

2) You seem to think 500 psi is excessive; find other solutions for what you think is an appropriate pressure (hopefully with lower costs).

Make a simple report/presentation from the data above for your customer and let him decide. If he sticks by the 500 psi, it's his money. You will have performed due diligance.

 

[ScottyUK]

http://www.jowosy.de/englisch/

http://www.douglaselectrical.com/pdf/deco_catalog.pdf

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If we learn from our mistakes I'm getting a great education!

 

[Cockroach]

Try the Kemlon connectors. I've used them past 15k psi.

Other than that, you wuld need the Conax Buffalo type sockets, potted wires inside a steel jacket, threaded into the bulkhead on an NPT pin.

Kenneth J Hueston, PEng
Principal
Sturni-Hueston Engineering Inc
Edmonton, Alberta Canada