Studseal™ Hermetic Terminal Seals
Hermetic terminal seals handle operational loads of up to 1,000 amps and 15kV.
StudSeal™ hermetic terminal seals provide a secure barrier for high current or high voltage transfers in sealed environments. Our products are designed for high vacuum and pressure applications, including air conditioning and refrigeration compressors, semiconductor processing equipment, vacuum furnaces, and power distribution equipment.
Standard Designs
Our standard hermetic terminal seals feature solid copper, heavy-current conductors sealed in NPT and face seal packages housing styles and stainless steel materials, with a hermetic, moisture-tight epoxy to seal between the conductor and housing. They are compatible with a wide range of liquids and gases, including refrigerants, oils, heat transfer fluids, and jet fuel, and comply with various certifications and standards.
Customize your terminal seal
We also offer completely customized terminal seals with individual terminal ends or built as a multi-terminal plate assembly. The mechanical interface, number of terminals, and each terminal feedthrough end can be customized to meet the requirements of your specific application. While threaded terminals are most popular, other variations of threaded terminals as well as wires and connectors can be designed into a StudSeal feedthrough.
We manufacture custom designs for a range of production volumes to meet your fit, form, and functional requirements. Our products offer a moisture-tight seal for transferring power in and out of a sealed environment, and can handle operational loads of up to 1,000 amps and 15kV. Choose from standard or customized designs to meet your specific application needs.
Contact us today to discuss your hermetic terminal seal and power feedthrough requirements.
Features
PERFORMANCE CAPABILITIES
- Suitable for high-current/amperage applications
- Transfers power in and out of sealed environments
- Up to 1,000 A and 15,000VAC
- Easy connection points with simple ring terminals
- Custom stud electrical connections available
- Operating pressures of 10,000 psi
- Operating temperatures range from -160°C through high temperatures of 200°C
- Epoxy insulation
- Brass or Copper Conductors
- Custom housing materials available on request
ELECTRICAL CONNECTION TYPES
- Threaded stud terminals (male and female)
- Right-angle studs
- Stud-to-wire
- Busbar
- Tubes
- Pins
- and more
MARKET CAPABILITIES
- ISO 9001:2015
- ISO 14001:2015
- UL984 Standard for Hermetic Refrigerant Motor Compressors
- ITAR DDTC Registration
STANDARD SAE DESIGNS
| Stud Thread | Housing Thread | Housing Material | LA | LP | L | Hex | Maximum Current | Catalog Number |
| 1/4”-20 | 3/4”-16 | Stainless Steel | 1.95” | 3.14” | 1.19” | 1.0” | 105 amps | 27404 |
| 3/8”-16 | 3/4”-16 | Stainless Steel | 1.95” | 3.14” | 1.19” | 1.0” | 275 amps | 27405 |
| ½”-13 | 7/8”-14 | Stainless Steel | 2.0” | 3.36” | 1.34” | 113/16” | 500 amps | 27406* |
| 5/8”-11 | 1 1/16”-12 | Stainless Steel | 4.36” | 3.31” | 1.27” | 13/8” | 750 amps | 27407*+ |
| O-ring is Nitril rubber. Four Brass nuts per StudSeal. Custom power feedthroughs are common. Complete our contact form for any design modifications you require.
Pressure: To 1000 psi (higher pressure designs available) Temperature: -40°F to 225°F Vacuum: 1×10-10 Torr *Voltage for 27406 and 27407 is limited to 1000V + Convoluted Standoff |
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STANDARD NPT DESIGNS
| Stud Thread | Housing Thread | Housing Material | LA | LP | L | Hex | Maximum Current | Catalog Number |
| 1/4”-20 | ½” NPT | Brass | 2” | 3.09” | 1.09” | 7/8” | 105 amps | 27408 |
| 1/4”-20 | ½” NPT | Stainless Steel | 2” | 3.31” | 1.09” | 7/8” | 105 amps | 27408-SS |
| 3/8”-16 | ¾” NPT | Brass | 2” | 3.17” | 1.17” | 11/8” | 275 amps | 27409 |
| 3/8”-16 | ¾” NPT | Stainless Steel | 2” | 3.57” | 1.17” | 11/8” | 275 amps | 27409-SS |
| ½”-13 | 1” NPT | Brass | 2” | 3.36” | 1.36” | 13/8” | 500 amps | 27410 |
| ½”-13 | 1” NPT | Stainless Steel | 2” | 3.36” | 1.75” | 13/8” | 500 amps | 27410-SS |
| 5/8”-11 | 1” NPT | Brass | 3.38” | 4.29” | 1.36” | 13/8” | 750 amps | 26212 |
| 5/8”-11 | 1” NPT | Stainless Steel | 3.38” | 4.29” | 1.36” | 13/8” | 750 amps | 26212-SS |
| Douglas Electrical offers a wide range of sealed conductors for high pressure and vacuum applications. Multi-pin plates from 1.5″ to 9″ square have been manufactured in volume, with current capacities from 10 to 1200 amps. Our flexible technology affords far greater design latitude than our competitors and provides customers with custom solutions at off-the-shelf prices.
Pressure: To 1000 psi (higher pressure designs available) Temperature: -40°F to 225°F Vacuum: 1×10-10 Torr
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Products
FAQ
Is it possible to customize a StudSeal terminal seal?
Yes, it’s our specialty. Customize any terminal seal feature including the connection points, stand-off and conductor materials, and mechanical interface to ensure the best fit, form, and function for your application. Terminal seals are used in a variety of industries to reliably transmit power through a sealed environment. Douglas has the ability to customize the terminal seal or integrate it directly into a customer furnished housing.
Are there alternate standard design options?
- Yes. We also offer some lower current rated options with 1/8”, ¼”, 3/8”, and ¾” NPT housings. Contact us below with your needs and we can share drawings, pricing, and availability.
Our NPT series in brass and stainless steel are most common in the HVAC industry. Standard catalog items are available as well as customized solutions.
- Our Faceseal designs are more common in UHV applications such as space simulation. Typically, these feedthroughs are customized to integrate multiple feedthroughs into a single seal or faceplate.
Are StudSeals available as terminal plate feedthroughs?
Yes. Terminal plate feedthroughs provide hermetic sealing capability for medium to heavy current requirements. Douglas will partner with you to create the right terminal plate for your sealing, electrical, and environmental needs. Multi-stud designs are common for our customers.
Are StudSeals available for vacuum applications?
Yes, standard configurations are available with both knife edge style flanges as well as O-ring seal designs. StudSeals are also commonly integrated into our Portplate assemblies where multiple electrical connections can share the same bulkhead connection point. Download the catalog for more information or contact us with your exact specifications.
Are there installation guidelines?
Installation is typically specific to the thread and connection type for a specific design. Contact us via form, email, or phone for details specific to your new needs or an existing design.
Are StudSeal products used in hazardous locations?
In a variety of applications, our StudSeal power feedthroughs are designed into equipment such as compressors that operate in hazardous locations. The feedthrough can be independently certified or as part of the system. Contact us to discuss your application and certification requirements. We have various product types including line bushings that have explosion-proof ratings. Further certification of our power feedthroughs is possible.
Image Library
StudSeal Family
StudSeal hermetic terminal seals are available in a variety of configurations.
Hermetic Terminal Seal with stud to wire assembly
Terminal to wire hermetic seal design with CF Flange.
Hermetic Terminal to Wire side view
Customized hermetic motor terminal seal showing complete assembly
Radial O-ring Compressor Terminal Seal
Radial O-ring compressor feedthroughs reduce customer install time while utilizing a low cost molded housing.
Motor High Power Terminal Seal
Motor high power terminal feedthroughs with NPT and copper studs work in compressors ranging in size from fractional horsepower to high-tonnage.
Hermetic Terminal Plate Assembly
Customized hermetic terminal plate assembly
StudSeal rectangular flange power feedthrough
Custom flange with integral hermetic terminals for power transmission.
Right-angle power feedthrough
StudSeal power feedthrough with right angle connections are available as well as threaded studs.
Threaded and Tabbed Hermetic Terminal Seal
Threaded studs in custom housing.
Hermetic Busbar Assembly
Busbar power feedthrough assembly in flanged housing.
Power and Signal Hermetic Flange
Combine power and signal feedthroughs into a single PortPlate design.
Right-angle StudSeal Power Feedthru
StudSeal power feedthrough with right angle connections are available as well as threaded studs. High current studs of our hermetically sealed electrical connectors handle up to 1,000 amps to meet most of process power needs.
Documents & Downloads
Downloads
StudSeal Hermetic Terminal Seals Datasheet
PDF Catalog
New Cryogenic Feedthrough Improves Ease-Of-Use
PDF Catalog
ISO 9001:2015 Certificate
PDF CatalogISO 14001:2015 Certificate
PDF CatalogUL984 Standard for Hermetic Refrigerant Motor Compressors
PDF Catalog