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Dielectric Sciences Inc. manufactures high quality castings for use as either high voltage insulation or encapsulation. Typically, the mating receptacle or female side of the high voltage connection system is a cast product, often epoxy, although various materials are utilized depending on the complexity of the interface and the environmental requirements.
Using our expertise in high voltage applications combined with our working knowledge of mold design and molding techniques, we developed the technologies required to provide castings suitable for high voltage cabling systems. We are often called upon to provide non cable-related products as illustrated herein.
Applications
Tube Shields
DSI cast shields are used on vacuum tubes, magnetrons, cyclotrons, gyrotrons and klystrons to improve their performance and reduce leakage and noise.
Insulators
We use our castings as the plug or socket body on most of our high voltage interconnects and cables to provide electrical insulation and protection from weathering.
Transformers
Large coils of high voltage transformers are cast to impart mechanical strength, protection from dust, dirt, moisture and corrosion.
Potting
Circuit elements, PCBs and transformers can be encapsulated and potted to reduce vibration, shield emissions and protect from moisture, dirt, corrosion and damage. /Asset/CAST-PRODUCTS_edit.JPG
Design Examples
It is increasingly common for rotating anode x-ray tubes to be constructed with the motor stator at high voltage so as to provide closer coupling to the rotor. Usually these three phase motors are PWM controlled using a conventional three conductor x-ray cable to bring 440 volts to the motor but floating at 75 KV or higher. Typically the cable used is a standard cathode cable and the three wires which normally carry the cathode heater current rarely see more than 25 volts between them. These cables have performed well at 440 volts until recently.
DSI research has demonstrated that an unintended consequence of replacing older SCR drive systems with those using new, faster switches with much faster pulse risetimes can transform the cable into a transmission line with the effect of doubling the 440 volts at the stator end of the cable. This tends to occur on cables over about 50 feet long. Breakdown of the insulation between the conductors can occur over an extended period of time (months) due to corona damage.
DSI has designed a cable with superior insulation integrity and higher corona inception voltage to be used in cases where the anode stator drive is at high voltage. This cable is of the same size and flexibility as a standard cathode cable. It has been in service for three years without incident. /Asset/Custom-Designs.JPG
Depending on the requirements, DSI may suggest an insulation system comprised of one or more of the following:
Wire & Cable
(85) The high voltage wire and cable options listed below can be customized (e.g. shielded and/or jacketed with the materials of your choice) to your specifications. Contact our engineering department for more information. /Asset/WIRE--CABLE_edit.JPG Cast Products
GeneralDielectric Sciences Inc. manufactures high quality castings for use as either high voltage insulation or encapsulation. Typically, the mating receptacle or female side of the high voltage connection system is a cast product, often epoxy, although various materials are utilized depending on the complexity of the interface and the environmental requirements.
Using our expertise in high voltage applications combined with our working knowledge of mold design and molding techniques, we developed the technologies required to provide castings suitable for high voltage cabling systems. We are often called upon to provide non cable-related products as illustrated herein.
Applications
Tube Shields
DSI cast shields are used on vacuum tubes, magnetrons, cyclotrons, gyrotrons and klystrons to improve their performance and reduce leakage and noise.
Insulators
We use our castings as the plug or socket body on most of our high voltage interconnects and cables to provide electrical insulation and protection from weathering.
Transformers
Large coils of high voltage transformers are cast to impart mechanical strength, protection from dust, dirt, moisture and corrosion.
Potting
Circuit elements, PCBs and transformers can be encapsulated and potted to reduce vibration, shield emissions and protect from moisture, dirt, corrosion and damage. /Asset/CAST-PRODUCTS_edit.JPG
Custom Products & Designs
Although many of our products have become industry standards and are available to all, often with slight modifications to suit, they nearly all began as custom solutions. We are reluctant to present a catalog of our nearly 1000 designs as we have found the best and most efficient approach is to deal with each requirement presented us on an individual basis. Based on the variety of parts and building blocks available to us we can customize a solution based, often, on existing, proven and available components yielding a solution more closely suited to the application.Design Examples
It is increasingly common for rotating anode x-ray tubes to be constructed with the motor stator at high voltage so as to provide closer coupling to the rotor. Usually these three phase motors are PWM controlled using a conventional three conductor x-ray cable to bring 440 volts to the motor but floating at 75 KV or higher. Typically the cable used is a standard cathode cable and the three wires which normally carry the cathode heater current rarely see more than 25 volts between them. These cables have performed well at 440 volts until recently.
DSI research has demonstrated that an unintended consequence of replacing older SCR drive systems with those using new, faster switches with much faster pulse risetimes can transform the cable into a transmission line with the effect of doubling the 440 volts at the stator end of the cable. This tends to occur on cables over about 50 feet long. Breakdown of the insulation between the conductors can occur over an extended period of time (months) due to corona damage.
DSI has designed a cable with superior insulation integrity and higher corona inception voltage to be used in cases where the anode stator drive is at high voltage. This cable is of the same size and flexibility as a standard cathode cable. It has been in service for three years without incident. /Asset/Custom-Designs.JPG
Test Facilities
DSI maintains an extensive test facility enabling complete investigation and characterization of materials and product for both developmental and production testing. A partial listing of our testing capabilities includes:- DC testing to 400KV
- AC testing to 100KV
- Impulse testing to 1.3MV
- AC and DC corona testing
- Insulation resistance
- Mass spec leak detection
- Environmental chamber
- Hydrostatic test vessel
- Vacuum test chambers
Materials & Environments
The wide variety of environmental requirements requires a working knowledge of materials under high voltage conditions as modified by temperature, pressure, radiation flux and a host of other factors.Depending on the requirements, DSI may suggest an insulation system comprised of one or more of the following:
- Ethylene Propylene Rubber
- Silicone Rubber
- Polyethylene
- Polyester
- Polyimide
- Polyamide
- Polyamine
- PTFE (Teflon ™)
- Epoxy
- Urethane
- Ultem
- Acrylic
- PVC
- Polycarbonate
- Oil
- Gas
- Vacuum
- Alumina
- Impregnated Paper
