Application Notes

Termination Design in High-Voltage Cable Assemblies

Caton Connector Corporation — Fri, 29 May 2026 17:42:20 GMT

The termination region — where the cable transitions into the connector — concentrates more sources of electrical risk in less space than almost any other location in a high-voltage assembly. Many partial-discharge and dielectric failures originate here when field stress, material interfaces, trapped air, or mechanical strain are not explicitly controlled. The mechanisms are understood, and with the right engineering approach they are preventable.

Production Consistency in High-Voltage Cable Assembly Programs

Caton Connector Corporation — Fri, 29 May 2026 17:41:05 GMT

Qualification establishes that a specific design, built from specific materials through specific processes, meets the program's performance requirements. It does not guarantee that the assembly shipped two years later is identical. In high-voltage programs — where performance is determined by controlled geometry, material properties, surface condition, void content, and process stability — production drift is a credible and preventable path to reduced dielectric margin and field failure. The mechanisms are understood, and a controlled production system reduces the risk before it reaches the customer.

Insulation System Selection for High-Voltage Cable Assembly Applications

Caton Connector Corporation — Fri, 29 May 2026 17:39:18 GMT

Insulation system selection is an architecture decision — not a materials lookup. The wrong choice, or the right material improperly applied, produces assemblies that pass incoming inspection and fail in service. The mechanisms that drive these failures are well understood, and they can usually be prevented or detected when the design process accounts for the full operating environment from the start.

Electric Field Management in High-Voltage Cable Assemblies

Caton Connector Corporation — Fri, 29 May 2026 17:37:44 GMT

Electric field management is the foundational engineering discipline in high-voltage cable assembly design. Every other decision — material selection, connector geometry, termination architecture — is either a response to a field management requirement or a consequence of one. Many high-voltage cable assembly failures trace back to localized field stress that was not identified, controlled, or verified under the relevant service conditions. Field concentration is not the only failure mechanism, but it is one of the most predictable — and one of the most preventable. The tools to find and reduce these risks exist; the question is whether a supplier uses them before hardware is built.

Corona & Partial Discharge in High-Voltage Cable Assemblies

Caton Connector Corporation — Fri, 29 May 2026 17:35:40 GMT

Partial discharge and corona are among the most consequential — and most misunderstood — long-term failure mechanisms in high-voltage interconnects. They often develop without external symptoms, can accelerate as insulation damage accumulates, and are usually preventable or detectable when the assembly is engineered and tested correctly from the start.

High-Voltage Cable Assembly Performance at Altitude

Caton Connector Corporation — Fri, 29 May 2026 17:02:17 GMT

A high-voltage cable assembly that passes sea-level testing cannot be assumed to perform safely at altitude. As air pressure falls, gas breakdown voltage changes nonlinearly with the pressure-gap product — and the worst-case altitude for corona inception is often not the highest altitude. The physics is well established, the failure modes are predictable, and they can usually be prevented or detected with the correct design and qualification approach.