High Voltage Connectors & Cable Assemblies
Teledyne Reynolds UK supplies
high voltage connectors and cable assemblies engineered for dependable performance in harsh electrical environments where insulation integrity, creepage/clearance and mechanical robustness are critical. Designed for aerospace, defence and high-reliability industrial systems, these interconnect solutions support safe, repeatable high-voltage power delivery and signal transfer with attention to long service life, secure terminations and controlled assembly processes.
Our connector and cable assembly solutions are specified where high voltage must be routed through confined envelopes without compromising safety margins. Programmes commonly prioritise controlled insulation systems, stable contact performance and robust strain relief—especially in equipment exposed to vibration, shock, temperature cycling or contamination risk.
Typical applications
- High-voltage power distribution and conditioning units
- Pulsed-power and capacitor discharge equipment
- Test and measurement high-voltage instrumentation
- Defence and aerospace power systems and payloads
- Scientific and industrial high-voltage platforms
Selection considerations
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Voltage and transients: maximum working voltage plus expected surge events
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Insulation coordination: creepage/clearance, altitude and contamination class
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Cable construction: dielectric system, screening, flex requirements and bend radius
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Mechanical needs: coupling method, keying, strain relief and mounting
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Environment: temperature range, vibration/shock and sealing requirements
Single Pin Connectors
Single pin high voltage connectors are chosen for straightforward, rugged high-voltage interconnect where one conductor must be routed with strong dielectric separation and secure mating. They are commonly used for point-to-point HV power connections, charging circuits and pulsed-power interfaces where reliability, safety margins and ease of assembly are key drivers.
Typical applications
- High-voltage power inputs and outputs
- Capacitor charging and discharge interfaces
- Ignition, trigger and pulsed-power connections
- High-voltage test equipment connections
Selection considerations
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Voltage rating: working voltage plus margin for transients
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Shielding: unshielded vs shielded requirements for EMI and safety
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Mechanical interface: locking/coupling, keying and mounting constraints
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Creepage/clearance: required distances for your environment and standards
Multi Pin Connectors
Teledyne Reynolds UK
multi pin connectors support compact interconnect solutions where multiple conductors—power and/or signal—must be routed through a single robust interface. Multi pin architectures can reduce harness complexity and improve maintainability in systems where space, weight and service access matter, while still preserving insulation coordination and mechanical integrity.
Typical applications
- Multi-circuit high-voltage distribution assemblies
- Subsystem interconnect for aerospace and defence electronics
- Combined power and signal interfaces
- High-reliability harnessing and backplane-style connections
Selection considerations
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Pin configuration: number of ways, mixed signal/power and spacing constraints
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Voltage per contact: insulation requirements across adjacent pins
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Keying and polarisation: mis-mate prevention and serviceability
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EMI needs: screening, grounding and shielding strategy
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Environment: vibration/shock, sealing and temperature cycling
Hermetic Connectors
Hermetic connectors are specified when an electrical feedthrough must maintain a sealed barrier between environments—such as pressure vessels, enclosures requiring moisture exclusion, or systems needing controlled atmosphere integrity. Hermetic interconnects support high-reliability operation by reducing ingress risk and helping maintain consistent electrical performance in challenging conditions.
Typical applications
- Sealed aerospace and defence enclosures
- High-reliability power supplies and high-voltage equipment housings
- Moisture-sensitive electronics and controlled-atmosphere systems
- Feedthroughs for ruggedised instrumentation
Selection considerations
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Seal requirement: leak rate expectations and system pressure differentials
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Materials and compatibility: housing alloys, plating and corrosion environment
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Electrical stress: working voltage, creepage/clearance and pin spacing
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Mounting: flange, bulkhead, weld/braze interface and mechanical loads
Frequently Asked Questions
1) What’s the difference between “high voltage connectors” and “high voltage cable assemblies”?
High voltage connectors are the mating interfaces (plug/receptacle) designed to safely carry high voltage. High voltage cable assemblies are complete,
built-to-spec harnesses that combine cable, terminations, strain relief and (where required) screening, tested as a finished assembly for reliable installation.
2) What information do you need to recommend the right connector or cable assembly?
The quickest shortlist comes from: maximum working voltage (and any transient/surge levels), current, environment (temperature, vibration/shock, contamination,
altitude), number of circuits/pins, shielding requirements, mounting constraints, and any compliance or programme documentation needs.
3) Why are creepage and clearance so important in high voltage interconnect?
Creepage (surface distance) and clearance (air gap) help prevent arcing and tracking, especially in humid or contaminated environments. They’re fundamental
to insulation coordination, and often drive connector geometry, pin spacing, and housing design.
4) How do I decide between shielded and unshielded single pin connectors?
Unshielded options are often used where EMI is not a primary concern and physical routing provides adequate separation. Shielded options can reduce radiated
emissions and improve noise immunity, and may also support a defined grounding strategy for safety or system performance.
5) When should I use a single pin connector instead of a multi pin connector?
Single pin connectors are ideal for a straightforward, rugged high-voltage feed with strong dielectric separation for one conductor. Multi pin connectors are
preferred when you need multiple circuits in a single interface to reduce harness complexity, improve maintainability, or combine power and signal connections.
6) What is meant by “mixed signal” in multi pin connectors?
Mixed signal typically refers to combining different circuit types within the same connector—such as high-voltage power contacts alongside lower-voltage control
or monitoring signals. This can reduce connector count, but it requires careful attention to pin assignment, spacing, shielding and insulation coordination.
7) What makes a connector “hermetic”?
A hermetic connector is designed as a sealed electrical feedthrough that maintains a barrier between environments (for example, keeping moisture out of a sealed
enclosure or maintaining a controlled internal atmosphere). Hermeticity is achieved through specific materials and sealing processes and is typically defined by
a leak-rate requirement at the system level.
8) Do hermetic connectors also support high voltage?
Many hermetic interconnects are designed to carry elevated voltages, but the maximum working voltage depends on the specific design, pin spacing, dielectric
system and required creepage/clearance. The safest approach is to define your voltage and environment first, then select a hermetic design that meets both the
seal and insulation requirements.
9) What installation details most affect high voltage connector performance?
Maintain the specified creepage/clearance in the final assembly, keep terminations clean and contamination-free, follow recommended torque/coupling guidance,
and use appropriate strain relief and bend radius for cables. Lead length, routing and grounding (for shielded solutions) can also materially affect performance.
10) How should I think about altitude, humidity and contamination?
Altitude can reduce dielectric strength of air, while humidity and contamination increase the risk of surface tracking. If your equipment operates in these
conditions, it’s important to account for insulation coordination early—often influencing connector choice, sealing approach and spacing requirements.
11) Can you provide custom cable assemblies or special terminations?
Yes. Many programmes require build-to-print assemblies or tailored configurations. If you share your electrical envelope, mechanical constraints, connector
preference (if known) and any test/inspection requirements, we can help define a manufacturable assembly and documentation package.
12) What should I provide for quoting and lead time accuracy?
A part number or target configuration (if available), required quantities, delivery schedule, drawing or interface details, and any specific test, inspection,
traceability or certification requirements. If you’re early in the design, even a simple block diagram and voltage/current requirements can be enough to start.
