19 Series High-Voltage Connectors
Designed for systems operating at higher voltage levels where increased electrical spacing, insulation control, and electric field management are required. Caton's highest-voltage standard platform — rated at 60 kV DC / 20 kV RMS and specified corona free.
19 Series — additional views
Caton's highest-voltage standard platform — specified corona free
The 19 Series platform was developed for higher-voltage systems where increased electrical spacing, insulation control, and electric field management are required to maintain stable high-voltage performance. At 60 kV DC and 20 kV RMS, the 19 Series operates at voltage levels where corona inception becomes a critical design constraint — not just a performance consideration.
The 19 Series is the only standard Caton platform specified as corona free. This is not a rating applied after the fact — it is designed into the insulation architecture, connector geometry, and field grading system from the outset.
Typical capability
| Parameter | Typical Capability |
|---|---|
| Operating voltage | 60 kV DC / 20 kV RMS |
| Dielectric withstand | Configuration dependent |
| Corona / partial discharge | Corona free |
| Current rating | 20 A |
Electrical capability varies depending on conductor selection, insulation architecture, and operating environment.
Insulation architecture
| Element | Description |
|---|---|
| Primary insulation | Silicone rubber per A-A-59588 |
| Shielding | Conductive shield referenced to ground |
| Field grading | Combination of molded geometry and tapered conical interface that controls electric field stress and eliminates air gaps at the mating interface |
| Termination insulation | Overmolded silicone structure forming the termination insulation system |
| Interface control | Tapered mating geometry designed to displace air and create a continuous dielectric path between plug and receptacle |
| Receptacle insulation | Thermoset diallyl phthalate |
At 60 kV DC operating voltage, electric field management is not optional — it is the primary engineering challenge. The 19 Series manages this through molded insulation geometry, stress control materials, and a tapered conical mating interface that eliminates air gaps entirely when mated. Maintaining a corona free specification requires this level of design control at every point in the interconnect system.
Operating environment
| Parameter | Rating |
|---|---|
| Operating temperature | -55 to +125°C |
| Altitude capability | Rated values maintained to 70,000 ft |
| Chemical exposure | Application dependent — material compatibility based on insulation system |
| Humidity | Application dependent |
| IP rating | Not specified unless required by program |
Assembly arrangements
The 19 Series supports several assembly arrangements depending on system requirements, allowing integration across a range of high-voltage platforms.
How the 19 Series maintains corona free performance
At 60 kV DC, the margin between stable operation and corona inception is narrow. The engineering decisions that maintain this margin must be made at the design stage — not addressed after a failure.
At 60 kV DC, even small air gaps or field concentration points are sufficient to initiate corona — degrading insulation and introducing instability.
The corona free specification is built into the insulation architecture and field grading system from the outset. Molded geometry and tapered interface eliminate air gaps completely when mated.
Materials and geometries adequate at lower voltages may exhibit degradation or field instability at 60 kV.
Increased electrical spacing and more stringent field grading requirements are designed into the 19 Series architecture specifically for higher-voltage operation.
Corona activity, even at low levels, progressively degrades insulation — accelerating aging until failure.
The corona free design eliminates the primary mechanism of accelerated insulation aging — maintaining stable performance over the full life of the program.
Working directly with system designers
Caton engineers work directly with system designers to evaluate connector interfaces, cable insulation systems, and termination structures — ensuring the assembly performs reliably under real operating conditions. Because Caton manufactures both the cable assembly and connector interface, our team can evaluate the complete high-voltage interconnect system rather than individual components.