The v2 PEEK/PTFE hybrid insulator is currently in testing. This design is based on the results of the v1 torture testing discussed in previous posts. Overall the v1 hybrid held up quite well to the abuse. And even though the PTFE insert in v1 was partially threaded and held in place by - M6 barrel threads, friction and the acyrlic pieces securely fastened across top of the insulator - I found a scenario where it was still possible for the PTFE insert to expand out of the top of the insulator. I'll get into the details of that scenario in a follow-up post. More importantly, the v2 hybrid addresses the issue by inserting a 3/8" by 10mm PEEK plug into the top of the insulator and secures it with two M3 set screws. The PEEK plug seals the insulator and allows no room for the PTFE to expand.
v2 Hybrid dimensions
Overall length - 40mm (same as v1)
PEEK is drilled 3/8" to 30mm
20mm 3/8" PTFE insert (threaded M6 for 10mm)
10mm 3/8" PEEK plug (secured with set screws)
Filament opening 3.35mm with beveled entry
Jeff – The set screws are screwed into the PEEK shell as well as the PEEK plug to prevent the plug from being pushed out. I added a photo to help. The reason for using set screws is that they are located at the same place as the mounting groove and normal capped screws would interfere with the mount. Does that make sense?
I don’t quite understand how the set screws work here.. Are there trapped nuts in there? What orientation do the set screws go in?
I’m used to set screws preventing rotation.. here it seems you want to keep the top bolted down onto the bottom part to apply pressure to the PTFE.. So I don’t see it yet. ?
Keep at it!