Cable connection structure based on copper pipe lap joint and double-layer heat shrink tube and cable connection method
By using a copper tube overlap and double-layer heat shrink tubing connection structure, the problems of high contact resistance, insufficient mechanical strength and poor waterproof performance in three-phase low-voltage cables of different diameters are solved, achieving a highly reliable and waterproof cable connection.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-05
- Publication Date
- 2026-04-03
AI Technical Summary
In the existing technology, the connection of three-phase low-voltage cables of different diameters has problems such as high contact resistance, insufficient mechanical strength, poor waterproof performance, easy aging of conventional heat shrink tubing in low temperature or deep water environment, and difficulty in adapting ordinary copper tubing to cables of different diameters, resulting in poor contact and insulation failure.
The connection structure employs copper tube overlap and double-layer heat shrink tubing. Electrical connection is formed by crimping the copper tube to the cable conductor, and sealing is achieved using inner and outer layers of heat shrink tubing and hot melt tape. Combined with staged pressurization and heating processes, a highly reliable and waterproof connection structure is formed.
It achieves atomic-level contact in cables of different diameters, reduces resistance and temperature rise, improves mechanical strength and water resistance, extends the service life of the cables, and solves the problems of poor contact and insulation failure.
Smart Images
Figure CN121790790A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of nuclear power technology, specifically relating to a cable connection structure and method based on copper tube overlap and double-layer heat shrink tubing. Background Technology
[0002] In related technologies, the connection of cables of different diameters below three-phase low voltage often adopts methods such as welding, crimping, wrapping, or ordinary insulating tape wrapping, which have problems such as high contact resistance, insufficient mechanical strength, and poor waterproof performance. Conventional heat shrink tubing sealing process is prone to insulation aging in low temperature or deep water environments. Cables in water depths (greater than 50 meters and less than 500 meters) are prone to water ingress, resulting in decreased insulation and unusability. Ordinary copper tube crimping is difficult to adapt to cables of different diameters and is prone to loosening. Single-layer heat shrink tubing insulation cannot meet the long-term waterproof requirements. In addition, when connecting cables of different diameters (such as 10 square mm and 2.5 square mm), the difference in cross-sectional area can easily lead to poor contact, overheating, or even short circuits. In view of this, there is an urgent need for an integrated sealing and protection structure for cables of different diameters. Summary of the Invention
[0003] To overcome the problems existing in related technologies, a cable connection structure and cable connection method based on copper tube overlap and double-layer heat shrink tubing is provided.
[0004] According to one aspect of the present disclosure, a cable connection structure based on copper tube splicing and double-layer heat shrink tubing is provided. In the structure, a copper tube is used as a transition connector. One end of the copper tube is crimped to a first cable conductor, and the other end of the copper tube is crimped to a second cable conductor. The cross-sections of the first cable conductor and the second cable conductor are different, so that the copper tube forms an electrical connection with the first cable conductor and the second cable conductor.
[0005] The copper tube is wrapped with an inner heat shrink tubing and an outer heat shrink tubing from the inside out at the crimping joint with the first and second cable conductors. After the inner and outer heat shrink tubing are heated and shrunk, they form a double-sealed and insulating joint insulation layer.
[0006] Flame-retardant hot melt adhesive tape is wrapped around the outer layer of the first cable conductor, copper tube, second cable conductor and insulation layer of each connector, and acid and alkali resistant integral heat shrink tubing is added to the outer layer of the hot melt adhesive tape.
[0007] In one possible implementation, the copper tube is crimped with the first cable conductor and the second cable conductor by applying a constant pressure of 20-25 MPa using hydraulic clamps.
[0008] In one possible implementation, the low-temperature hot melt adhesive of the inner heat shrink tubing liner has a melting point of 80-100°C; the thickness of the inner heat shrink tubing is 0.8-1.2 mm; and the thickness of the outer heat shrink tubing is 1.5-2.0 mm.
[0009] In one possible implementation, the inner and outer heat shrink tubing are made of transparent material, and the outer heat shrink tubing is colored.
[0010] In one possible implementation, the thickness of the hot melt adhesive tape is 2.0-3.0 mm.
[0011] According to another aspect of the present disclosure, a cable connection method is provided, the method being used to prepare the above-described cable connection structure, the method comprising the following steps:
[0012] Step 101: Stripping: Strip the insulation layer from the ends of the first and second cable conductors at a 10mm offset to expose the conductors;
[0013] Step 102: Cleaning: Clean the exposed conductors of the first and second cable conductors and the rubber sheath surfaces that need to be wrapped with alcohol;
[0014] Step 103: Pre-threading: Thread the inner heat shrink tubing, outer heat shrink tubing, and overall heat shrink tubing onto the cable in advance;
[0015] Step 104: Crimping: Crim one end of the copper tube to the first cable conductor and the other end of the copper tube to the second cable conductor;
[0016] Step 105: Hot melt: For the crimping joint between the copper tube and the first and second cable conductors, move the inner hot melt adhesive tube and the outer heat shrink tube to the crimping joint in sequence, use a hot air gun to heat it, so that the inner hot melt adhesive tube melts and fills the joint and is squeezed out from both ends, and the inner and outer heat shrink tubes shrink tightly.
[0017] Step 106: Overall wrapping: Wrap flame-retardant hot melt adhesive tape around the overall exterior formed by the first cable conductor, copper tube, second cable conductor, and insulation layers of each connector, as well as the adjacent cable rubber sheath;
[0018] Step 107: Overall Encapsulation: Move the pre-pierced heat shrink tubing to the wrapped hot melt tape, use a hot air gun to heat it, causing the heat shrink tubing to shrink and form an integrated protective layer with the hot melt tape.
[0019] In one possible implementation, in step 104, the copper tube and the first and second cable conductors are pressurized in stages: first, a pressure of 10 MPa is applied for pre-pressurization, and then a pressure of 25 MPa is applied for final pressurization. In each stage, the copper tube and the cable conductors are compacted from a first angle and a second angle, respectively.
[0020] In one possible implementation, when using a hot air gun for heating in steps 105 and 107, the temperature is controlled at 120-150°C, and the heating is uniform from the middle to both ends.
[0021] The beneficial effects of this disclosure are as follows: The cable connection structure based on copper tube overlap and double-layer heat shrink tubing provided by this disclosure adopts copper tube overlap pressing technology. Through the use of copper tubes of different diameters and a staged pressing process, atomic-level contact is achieved, reducing resistance and temperature rise. The double-layer heat shrink tubing design, with hot melt adhesive filling the micro-gaps, avoids the aging and peeling of traditional tape. The structure of this disclosure adopts an overall encapsulation method, with an inner adhesive layer to block water and an outer acid and alkali resistant heat shrink tubing to extend outdoor service life. This forms a highly reliable, waterproof, and adaptable connection structure for cables of different diameters. Through copper tube overlap pressing and double-layer heat shrink tubing sealing technology, problems such as poor contact, insulation failure, and poor waterproofing in the connection of cables of different diameters are solved. Attached Figure Description
[0022] Figure 1 This is a schematic diagram illustrating a cable connection structure based on copper tube overlap and double-layer heat shrink tubing, as shown in an embodiment of this disclosure.
[0023] Figure 2 This is a flowchart illustrating a cable connection method according to an embodiment of this disclosure.
[0024] In the picture:
[0025] 1-Integral heat shrink tubing, 2-Hot melt tape, 3-Cable outer sheath, 4-Outer heat shrink tubing, 5-Inner heat shrink tubing, 6-Cable single-core inner sheath, 7-First cable conductor, 8-Second cable conductor, 9-Copper tube. Detailed Implementation
[0026] The present disclosure will now be described in further detail with reference to the accompanying drawings and specific embodiments.
[0027] Unless otherwise defined, the technical and scientific terms used in this disclosure have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains; the terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure; the term "comprising" and any variations thereof in this disclosure are intended to cover non-exclusive inclusion. Clearly, the embodiments described in this disclosure are only a part of the embodiments of this disclosure, and not all of them. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of this disclosure without inventive effort are within the scope of protection of this disclosure.
[0028] In this disclosure, the reference to "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this disclosure. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0029] Figure 1 This is a schematic diagram illustrating an embodiment of the present disclosure of a cable connection structure based on a copper tube (the material of the copper tube can be, for example, pure copper) overlap and a double-layer heat shrink tubing, as shown in the diagram. Figure 1 As shown, in the structure, a copper tube 9 is used as a transition connector. One end of the copper tube 9 is crimped to the first cable conductor 7, and the other end is crimped to the second cable conductor 8, thus forming an electrical connection between the copper tube 9, the first cable conductor 7, and the second cable conductor 8. The cross-sections of the first cable conductor 7 and the second cable conductor 8 are different. Generally speaking, see [link to relevant documentation]. Figure 1 The cable conductor (including the first cable conductor 7 and the second cable conductor 8) is provided with a single-core inner sheath 6 and an outer sheath 3 from the inside to the outside. When making the cable connection structure disclosed herein, it is necessary to strip the single-core inner sheath 6 and the outer sheath 3 to expose the cable conductor.
[0030] At the crimping joint between the copper tube 9 and the first cable conductor 7 and the second cable conductor 8, an inner heat-shrink tubing 5 and an outer heat-shrink tubing 4 are sequentially wrapped from the inside out. After being heated and shrunk, the inner heat-shrink tubing 5 and the outer heat-shrink tubing 4 form a double-sealed and insulated joint insulation layer. Generally speaking, see... Figure 1 The cable conductor (including the first cable conductor 7 and the second cable conductor 8) is provided with a single-core inner sheath 6. The inner heat shrink tubing 5 and the outer heat shrink tubing 4 need to cover the single-core inner sheath 6 close to the conductor at a predetermined distance.
[0031] Flame-retardant hot melt adhesive tape 2 is wrapped around the outer surface of the integral structure formed by the first cable conductor 7, copper tube 9, second cable conductor 8, and insulation layers of each connector. An acid- and alkali-resistant integral heat-shrink tubing 1 is then applied over the outer layer of the flame-retardant hot melt adhesive tape 2. An outer cable sheath 3 is also provided outside the inner sheath 6 of the single cable core, and the hot melt adhesive tape 2 needs to cover the outer cable sheath 3 at a predetermined distance from the conductor.
[0032] In one possible implementation, the copper tube is crimped with the first cable conductor and the second cable conductor by applying a constant pressure of 20-25 MPa using hydraulic clamps.
[0033] In one possible implementation, the low-temperature hot melt adhesive of the inner heat shrink tubing liner has a melting point of 80-100°C; the thickness of the inner heat shrink tubing is 0.8-1.2 mm; and the thickness of the outer heat shrink tubing is 1.5-2.0 mm.
[0034] In one possible implementation, both the inner and outer heat shrink tubing layers are made of transparent material, while the outer heat shrink tubing is colored. The inner heat shrink tubing facilitates observation of the crimping quality, while the colored outer tubing provides identification and secondary protection.
[0035] In one possible implementation, the thickness of the flame-retardant hot melt adhesive tape is 2.0-3.0 mm.
[0036] Figure 2 This is a flowchart illustrating a cable connection method according to an embodiment of this disclosure. The method is used to prepare the aforementioned cable connection structure. See also... Figure 2 The method includes the following steps:
[0037] Step 101: Stripping: Strip the insulation layer from the ends of the first cable conductor and the second cable conductor respectively, offset by 10mm, to expose the first cable conductor and the second cable conductor.
[0038] Step 102: Cleaning: Clean the exposed conductors of the first and second cable conductors and the rubber sheath surfaces that need to be wrapped with alcohol;
[0039] Step 103: Pre-threading: Thread the inner heat shrink tubing, outer heat shrink tubing, and overall heat shrink tubing onto the cable in advance;
[0040] Step 104: Crimping: Crim one end of the copper tube to the first cable conductor and the other end of the copper tube to the second cable conductor;
[0041] Step 105: Hot melt: For the crimping joint between the copper tube and the first and second cable conductors, move the inner hot melt adhesive tube and the outer heat shrink tube to the crimping joint in sequence, use a hot air gun to heat it, so that the inner hot melt adhesive tube melts and fills the joint and is squeezed out from both ends, and the inner and outer heat shrink tubes shrink tightly.
[0042] Step 106: Overall wrapping: Wrap flame-retardant hot melt adhesive tape around the overall exterior formed by the first cable conductor, copper tube, second cable conductor, and insulation layers of each connector, as well as the adjacent cable rubber sheath;
[0043] Step 107: Overall Encapsulation: Move the pre-pierced heat shrink tubing to the wrapped hot melt tape, use a hot air gun to heat it, causing the heat shrink tubing to shrink and form an integrated protective layer with the hot melt tape.
[0044] In one possible implementation, in step 104, the copper tube and the first and second cable conductors are pressurized in stages: first, a pressure of 10 MPa is applied for pre-pressurization, and then a pressure of 25 MPa is applied for final pressurization.
[0045] In one possible implementation, when using a hot air gun for heating in steps 105 and 107, the temperature is controlled at 120-150°C, and the heating is uniform from the middle to both ends.
[0046] The various embodiments of this disclosure have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.
Claims
1. A cable connection structure based on copper tube overlap and double-layer heat shrink tubing, characterized in that, In the structure, a copper tube is used as a transition connector. One end of the copper tube is crimped to the first cable conductor, and the other end of the copper tube is crimped to the second cable conductor, so that the copper tube forms an electrical connection with the first cable conductor and the second cable conductor. The cross-sections of the first cable conductor and the second cable conductor are different. The copper tube is wrapped with an inner heat shrink tubing and an outer heat shrink tubing from the inside out at the crimping joint with the first and second cable conductors. After the inner and outer heat shrink tubing are heated and shrunk, they form a double-sealed and insulating joint insulation layer. Flame-retardant hot melt adhesive tape is wrapped around the outer layer of the first cable conductor, copper tube, second cable conductor and insulation layer of each connector, and acid and alkali resistant integral heat shrink tubing is added to the outer layer of the hot melt adhesive tape.
2. The cable connection structure according to claim 1, characterized in that, The copper tube is formed by pressing the first cable conductor and the second cable conductor together with a constant pressure of 20-25 MPa using hydraulic clamps.
3. The cable connection structure according to claim 1, characterized in that, The inner heat shrink tubing has a lining with a low-temperature hot melt adhesive with a melting point of 80-100℃; the inner heat shrink tubing has a thickness of 0.8-1.2mm; and the outer heat shrink tubing has a thickness of 1.5-2.0mm.
4. The cable connection structure according to claim 1, characterized in that, The thickness of the hot melt adhesive tape is 2.0-3.0 mm.
5. The cable connection structure according to claim 1, characterized in that, The inner and outer heat shrink tubing are made of transparent material, while the outer heat shrink tubing is colored.
6. A cable connection method, characterized in that, The method is used to prepare the cable connection structure as described in any one of claims 1-4, characterized in that the method includes the following steps: Step 101: Stripping: Strip the insulation layer from the ends of the first and second cable conductors respectively, offset by 10mm, to expose the conductors; Step 102: Cleaning: Clean the exposed conductors of the first and second cable conductors and the rubber sheath surfaces that need to be wrapped with alcohol; Step 103: Pre-threading: Thread the inner heat shrink tubing, outer heat shrink tubing, and overall heat shrink tubing onto the cable in advance; Step 104: Crimping: Crim one end of the copper tube to the first cable conductor and the other end of the copper tube to the second cable conductor. Step 105: Hot melt: For the crimping joint between the copper tube and the first and second cable conductors, move the inner hot melt adhesive tube and the outer heat shrink tube to the crimping joint in sequence, use a hot air gun to heat it, so that the inner hot melt adhesive tube melts and fills the joint and is squeezed out from both ends, and the inner and outer heat shrink tubes shrink tightly. Step 106: Overall wrapping: Wrap flame-retardant hot melt adhesive tape around the overall exterior of the first cable conductor, copper tube, second cable conductor, and insulation layers of each connector, as well as the adjacent cable rubber sheath; Step 107: Overall Encapsulation: Move the pre-pierced heat shrink tubing to the wrapped hot melt tape, use a hot air gun to heat it, causing the heat shrink tubing to shrink and form an integrated protective layer with the hot melt tape.
7. The cable connection method according to claim 6, characterized in that, In step 104, the copper tube and the first and second cable conductors are pressurized in stages: first, a pressure of 10 MPa is applied for pre-pressurization, and then a pressure of 25 MPa is applied for final pressurization.
8. The cable connection method according to claim 6, characterized in that, When using a hot air gun to heat in steps 105 and 107, the temperature should be controlled at 120-150℃, and the heat should be applied evenly from the middle to both ends.