Method of making an end cap connection for a fluid-resistance electrical

Abstract

An end cap connection provides a strong mechanical bond as well as a fluid resistant seal between an electrically insulative tubular member and a conductive end piece or cap. The cap is provided with a generally U-shaped channel, and a quantity of synthetic resin adhesive disposed in the channel contacts an end portion of the tubular member as well as walls of the end cap. In one embodiment of the invention, the tubular member has a generally 90.degree. edge for engagement with outer end cap walls defining the channel, such that as the tubular member is shifted toward the bottom of the channel, curved bottom walls defining the latter maintain the tube at a position spaced from the channel bottom to enable the sealing material to fully contact the inserted end of the tubular member. In another embodiment of the invention, the outer channel defining walls of the end cap are magneformed inwardly to compress the adhesive against the tubular member and thus prestress the adhesive so that, during use, thermal expansion and contraction of the connection does not disrupt the bond between the adhesive and the tubular member. Additionally, a castable synthetic resin adhesive having improved bondability and strength after curing is utilized in order to maintain an effective seal regardless of thermal cycling and without the use of O-rings, gaskets or the like.