Sealing between an electrical cable and a flexible metal conduit to be used in a high temperature, high vibration environment

1. A cable assembly including:

a housing, wherein the housing defines an internal volume and the housing includes a first cable end portion and a second cable end portion;

at least two cable fittings, wherein the first cable end portion and the second cable end portion are connected to a respective cable fitting through a first seal, each of the cable fittings defining a cable fitting opening;

an electrical cable, wherein the electrical cable is inserted through the cable fitting opening in each cable fitting and through the internal volume of the housing;

a second seal located in the annular space between the electrical cable and the cable fitting opening at the first cable end portion, the second seal being configured to prevent moisture and contaminants from passing through the cable fitting opening; and

a third seal and at least deformable sealing component located at the second cable end portion, the third seal and the at least deformable sealing component being configured to prevent moisture, gas, and contaminants from passing through the cable fitting opening.

2. The cable assembly according to claim 1 , wherein the second seal and/or third seal include an epoxy material.

3. The cable assembly according to claim 2 , wherein the epoxy material is a high-temperature epoxy for use up to about 250° C. or greater.

4. The cable assembly according to claim 1 , wherein the internal volume is sealed and filled with an inert gas.

5. The cable assembly according to claim 1 , wherein the first seal includes silver brazing alloy and silver brazing flux.

6. A flame sensor apparatus including:

a sensor assembly for sensing characteristics of a flame within a combustion chamber;

an electrical assembly that is remote from the sensor assembly; and

a cable assembly extending between the sensor assembly and the electrical assembly, the cable assembly including:

a housing, wherein the housing defines an internal volume and the housing includes a first cable end portion and a second cable end portion;

at least two cable fittings, wherein the first cable end portion and the second cable end portion are connected to a cable fitting through a first seal, each of the cable fittings defining a cable fitting opening;

an electrical cable, wherein the electrical cable is inserted through the cable fitting opening in each cable fitting and through the internal volume of the housing;

a second seal located in annular space between the cable and the cable fitting opening located at the first cable end portion, the second seal being configured to prevent moisture, gas, and contaminants from passing through the cable fitting opening;

a third seal and at least one deformable sealing component located at the second cable end portion, the third seal and the at least one deformable sealing component being configured to prevent moisture, gas, and contaminants from passing through the cable fitting opening.

7. The flame sensor apparatus according to claim 6 , wherein the second seal and/or the third seal include an epoxy material.

8. The flame sensor apparatus according to claim 7 , wherein the epoxy material is a high-temperature epoxy for use up to about 250° C. or greater.

9. The flame sensor apparatus according to claim 6 , wherein the internal volume is sealed and filled with an inert gas.

10. The flame sensor apparatus according to claim 6 , wherein the first seal includes silver brazing alloy and silver brazing flux.

11. The flame sensor apparatus according to claim 6 , wherein the characteristics of the flame include the presence and absence of the flame within the combustion chamber.

12. The flame sensor apparatus of claim 6 , wherein the cable assembly is attached at one end to the sensor assembly and attached at an opposing second end to the electrical assembly.

13. A method of sealing an electrical cable and a flexible conduit including:

providing a housing, wherein the housing defines an internal volume and the housing includes a first cable end portion and a second cable end portion;

connecting a cable fitting to each of the first cable end portion and the second cable end portion using a first seal, each of the cable fittings defining a cable fitting opening;

providing an electrical cable, wherein the electrical cable is inserted through the cable fitting opening in each cable fitting and through the internal volume of the housing;

sealing the annular space between the electrical cable and a cable fitting opening with a second seal at the first cable end portion, the second seal preventing moisture, gas, and contaminants from passing through the cable fitting opening; and

sealing the annular space between the electrical cable and a cable fitting with a third seal and at least one deformable sealing component at the second cable end portion.

14. The method according to claim 13 , further including the steps of:

evacuating an ambient atmosphere from the internal volume; and

filling the internal volume with an inert gas,

each of the steps occurring prior to the step of sealing the annular space, and wherein the steps of evacuating the ambient atmosphere and filling the internal volume are the only steps requiring a controlled atmosphere.

15. The method according to claim 14 , wherein the controlled atmosphere includes an atmosphere within an oven.

16. The method according to claim 13 , wherein the second seal and the third seal includes an epoxy material.

17. The method according to claim 15 , wherein the epoxy material is a high-temperature epoxy for use up to about 250° C. or greater.

18. The method according to claim 15 , wherein the inert gas is selected from the group consisting of nitrogen and argon.