A waterproof high-airtightness cable connector

Abstract

This invention relates to the field of cable splicing technology and discloses a waterproof and highly airtight cable connector, including a cable body. A protective component is fitted onto the outer wall of the cable body connection point. The protective component includes a first corrugated tube, which consists of a constant-diameter section in the middle and variable-diameter sections connected on both sides of the constant-diameter section. This device constructs a sealed cavity between the first and second corrugated tubes and uses a one-way constant-pressure air valve to inject gas, driving the variable-diameter sections with gradient inner diameters and gradient corrugation spacing to contract inwards. Combined with water-absorbing and expanding cotton fixed to the inclined surface of the corrugations and distributed in a volume gradient, it achieves pneumatic adaptive sealing while utilizing the volume expansion difference after water absorption to generate a toothpaste-like effect of directional discharge from the center to both ends. This achieves the dual functions of high-pressure locking at the cable body connection point and active removal of infiltrated water vapor, significantly improving the adaptive enhanced sealing and airtight reliability of the cable connection point.

Description

Technical Field

[0001] This invention relates to the field of cable splicing technology, and in particular to a waterproof and highly airtight cable connector. Background Technology

[0002] As a critical node for structural reorganization and stress concentration in the entire line, the reliability of the sealing and protection of the cable joint is the core link to ensure the stable operation of the power system. Especially at the end of the cable production and manufacturing process, two sections of cable of equal length need to be pre-connected and installed in a standardized manner. This pre-installation sealing process is the core assembly process before the cable leaves the factory, which directly determines the airtightness performance and factory qualification standards of the finished product. Currently, the main protective technologies used in the assembly of such cables include waterproof tape wrapping, heat shrink tubing, cold shrink tubing, and resin casting. Waterproof tape wrapping uses self-fusing rubber tape layers to form a seamless seal, offering flexible construction and adaptability to complex shapes. Heat shrink tubing uses heating to cause the polyolefin tubing to shrink radially, while the hot melt adhesive on the inner wall melts and fills the gaps, achieving sealing and mechanical reinforcement upon cooling. Cold shrink tubing relies on the elastic memory effect of silicone rubber or EPDM rubber, automatically shrinking after the support core is pulled out and continuously applying radial pressure, completing the assembly without open flame. Resin casting involves pouring a liquid mixture of epoxy resin or polyurethane into the joint chamber, which cures to form a fully encapsulated solid seal, achieving moisture protection. In actual assembly, these technologies are often combined, with waterproof tape initially covering and filling the gaps, followed by an outer heat shrink or cold shrink tubing to form the main seal, creating a multi-layered protective system.

[0003] However, the above-mentioned splicing technologies still have the following shortcomings: First, the above-mentioned waterproof splicing technologies mostly rely on manual operation and the experience of operators, making it difficult to achieve batch and standardized sealing, resulting in poor product consistency and large fluctuations in splicing quality; at the same time, during the cable manufacturing, assembly, and transportation process, such sealing structures are easily subjected to torsion, tension, or vibration stress, which can cause physical wrinkles and interface stretching, destroying the continuity of the sealing interface and forming tiny gaps. External high-pressure water vapor can penetrate along the gaps, causing the insulation layer to become damp, and the water inside the sealing layer cannot be actively discharged. Long-term operation can easily lead to partial discharge or even breakdown, becoming a common technical problem in the cable manufacturing and assembly process. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the existing technology has the disadvantage that the sealant is prone to wrinkles and gaps due to twisting and stretching in the dynamic environment of the cable, and the water inside cannot be actively discharged. To this end, we propose a waterproof and highly airtight cable connector.

[0005] To achieve the above objectives, this application adopts the following technical solution: a waterproof and airtight cable connector, comprising a cable body, wherein a protective component is sleeved on the outer wall of the cable body connection; the protective component comprises a first corrugated tube, which is composed of a constant diameter section in the middle and variable diameter sections connected on both sides of the constant diameter section; a second corrugated tube is coaxially nested on the outer wall of the first corrugated tube, the ends of the second corrugated tube and the first corrugated tube are sealed together, and the first corrugated tube and the second corrugated tube together form a sealed cavity; a one-way constant pressure air valve communicating with the sealed cavity is installed at one end of the outer wall of the second corrugated tube; in the uninstalled state, the inner diameter of the variable diameter section increases in a stepwise manner from the end closer to the constant diameter section to the end farther away from the constant diameter section; the corrugation spacing of the variable diameter section increases in a stepwise manner from the end closer to the constant diameter section to the end farther away from the constant diameter section; and water-absorbing and expanding cotton is fixed to the inner wall of each corrugated protrusion of the variable diameter section.

[0006] Preferably, the first corrugated pipe is made of rubber material, and the second corrugated pipe is made of metal material.

[0007] Preferably, the radial stiffness of the second bellows is greater than that of the first bellows.

[0008] Preferably, the volume of the water-absorbing and expanding cotton exhibits a gradient distribution, with the volume of the water-absorbing and expanding cotton gradually decreasing from the end closer to the equal diameter section to the end farther away from the equal diameter section.

[0009] Preferably, the corrugation density of the variable diameter section near the constant diameter section is greater than that near the openings at both ends.

[0010] Preferably, the distance from the corrugation of the variable diameter section near the constant diameter section to the axis of the cable body is less than the distance from the corrugation of the variable diameter section near the openings at both ends to the axis.

[0011] Preferably, under the condition of being compressed and inflated in a closed cavity, the radial pressure exerted by the variable diameter section on the outer wall of the cable body decreases from the center to both ends.

[0012] Preferably, the water-absorbing and expanding cotton is fixed to the side slope of the corrugated protrusion on the inner wall of the variable diameter section facing the direction of the openings at both ends.

[0013] Preferably, the first corrugated pipe is provided with clamps at both ends of the opening, and the first corrugated pipe is fastened and sealed to the outer sheath of the cable body by the clamps.

[0014] Preferably, the end of the first corrugated pipe is provided with an outwardly folded sealing edge, and the sealing edge is fixedly connected to the inner end wall of the second corrugated pipe through a vulcanization bonding process to achieve airtightness.

[0015] The technical effects and advantages of this invention are as follows: In this invention, the device constructs a sealed cavity between the first and second corrugated pipes, and uses a one-way constant pressure air valve to inject gas to drive the variable diameter section with gradient inner diameter and gradient corrugation spacing to contract inward. Combined with water-absorbing and expanding cotton fixed on the corrugated side slope and distributed in a volume gradient, it achieves pneumatic adaptive sealing while using the volume expansion difference after water absorption to generate a toothpaste-squeezing effect that directionally discharges water from the center to both ends. This achieves the dual functions of high-pressure locking at the cable body connection and active removal of infiltrated water vapor, significantly improving the adaptive enhanced sealing and airtight reliability of the cable connection. In this invention, the device uses a second corrugated tube made of high radial stiffness metal as a rigid outer shell. The corrugated geometry of the first and second corrugated tubes absorbs the axial tensile and radial compressive stresses when the cable is bent. This ensures that the air pressure field of the sealed cavity remains constant for a long time and prevents air leakage failure. At the same time, it provides excellent mechanical strength and flexible compensation capabilities, effectively extending the service life of the connector in dynamic laying environments. It also prevents traditional wrapping sealant from easily breaking, stretching, or developing physical gaps due to wrinkles when the cable is bent. Attached Figure Description

[0016] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts: Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a cross-sectional view of the structure of the present invention; Figure 3 This is a schematic cross-sectional view of the structure of the present invention in its inflated state; Figure 4 For the present invention Figure 3 Enlarged schematic diagram of the structure at point A in the middle; Figure 5 This is a schematic diagram of the internal structure of the outer protective cover of the present invention.

[0017] Legend: 1. Cable body; 2. Protective components; 21. First corrugated pipe; 211. Equal diameter section; 212. Variable diameter section; 22. Second corrugated pipe; 23. Water-absorbing expansion cotton; 24. One-way constant pressure air valve. Detailed Implementation

[0018] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0019] Reference Figure 1-5As shown, the present invention provides a technical solution: a waterproof and airtight cable connector, including a cable body 1, with a protective component 2 sleeved on the outer wall of the connection of the cable body 1; during the cable manufacturing and assembly process, the protective component 2 is sleeved on the pre-assembled connection of the two cable body sections 1, providing a high-strength multi-level sealing environment for the connection of the two cable body sections 1 through the dual action of physical barrier and pneumatic compression. The modular structure replaces the traditional manufacturing process of potting or wrapping, improving assembly efficiency and reducing the risk of failure caused by human factors. It can make the assembly process more standardized, reduce the dependence on the skill level of assembly personnel, and only requires simple sleeve and air inflation to complete the sealing. It is suitable for rapid pre-assembly in cable manufacturing workshops and automated assembly lines, while reducing the types and quantities of manufacturing tooling and reducing the complexity of assembly line operations; the protective component 2 includes a first corrugated pipe 21, which is composed of a constant diameter section 211 in the middle and variable diameter sections 212 connected on both sides of the constant diameter section 211.

[0020] The equal diameter section 211 corresponds to the core area at the connection of the two cable body sections 1, while the variable diameter sections 212 on both sides extend outward to the outer sheath of the cable body 1, smoothly transitioning the sealing stress from the connection to both sides. This segmented structure is beneficial for absorbing the shear force generated by the cable body 1 during bending or vibration during factory pre-connection, subsequent transportation, and actual field use, ensuring that the core sealing area is always in a static and stable state. This not only protects the cable connection point but also extends the service life of the protective component 2 itself, avoiding fatigue cracking caused by stress concentration. At the same time, the flexible characteristics of the corrugated pipe allow the cable to flex to a certain extent during connection, subsequent transportation, and actual field use, adapting to deformation caused by foundation settlement or thermal displacement during subsequent use.

[0021] The outer wall of the first bellows 21 is coaxially nested with the second bellows 22. The end of the second bellows 22 is sealed to the end of the first bellows 21, and the first bellows 21 and the second bellows 22 together form a sealed cavity. One end of the outer wall of the second bellows 22 is equipped with a one-way constant pressure valve 24 that communicates with the sealed cavity.

[0022] A fixed amount of compressed gas is injected into the sealed cavity through the one-way constant pressure air valve 24 via the air supply device. The pressure is uniformly transmitted to the flexible first bellows 21 by utilizing the fluid characteristics of the gas. Adaptive sealing is achieved by using pneumatic pressure. Regardless of whether there are grooves, scratches or eccentricity on the outer wall of the cable body 1, the first bellows 21 can fill the gaps through radial deformation, achieving an airtight effect far exceeding that of mechanical compression. The one-way constant pressure air valve 24 can ensure that the pressure in the sealed cavity is maintained at a preset value. Even if the gas volume fluctuates due to temperature changes, the valve can maintain constant pressure through automatic adjustment, thereby ensuring the durability of the sealing effect. In the uninstalled state, the inner diameter of the variable diameter section 212 increases in a stepwise manner from the end closer to the equal diameter section 211 to the end farther away from the equal diameter section 211.

[0023] As can be seen from the above structure, when the sealed cavity is inflated, the part with the smaller inner diameter in the variable diameter section 212 will contact and press the cable body 1 first, generating the maximum initial sealing pre-tightening force. This forms a stepped barrier from the inside out, ensuring the highest tightness. The stepped barrier makes the sealing pressure naturally decrease from the inside out, which conforms to the physical principle of waterproof sealing. At the same time, the stepped structure guides the first corrugated pipe 21 to deform in an orderly manner during the inflation process, avoiding local excessive stretching that could cause material damage.

[0024] The corrugation spacing of the variable diameter section 212 increases gradually from the end closer to the constant diameter section 211 to the end farther away from the constant diameter section 211; the corrugations are more densely distributed near the middle. By increasing the density of the contact corrugations, the permeation resistance between the connection and the external environment is significantly improved, effectively blocking the permeation of trace amounts of water vapor. The inner wall of each corrugated protrusion of the variable diameter section 212 is fixed with water-absorbing and expanding cotton 23.

[0025] The water-absorbing and expanding cotton 23 serves as an auxiliary protective structure and does not function under normal circumstances. Once external moisture penetrates the mechanical seal and enters the corrugated gap, the water-absorbing and expanding cotton 23 immediately absorbs water and undergoes physical volume expansion. This transforms leakage into a force that strengthens the seal, preventing moisture from penetrating further. The water-absorbing and expanding cotton 23 is made of highly absorbent polymer material, and its expansion ratio can reach tens of times. Even after expansion, it remains soft and will not damage the cable sheath. At the same time, its chemical stability ensures that its performance does not degrade within the cable's operating temperature range. The material also contains antibacterial agents to prevent the growth of microorganisms that could affect the sealing performance.

[0026] Reference Figure 1-5 As shown in this embodiment: the first corrugated pipe 21 is made of rubber, and the second corrugated pipe 22 is made of metal. Utilizing the complementary properties of the high elasticity of rubber and the rigidity of metal, the metal second corrugated pipe 22 acts as a rigid frame, not only supporting the entire component but also effectively preventing damage to the internal sealing layer from sharp objects or animal bites. This improves the service life of the device in underground or extreme environments. The radial stiffness of the second corrugated pipe 22 is greater than that of the first corrugated pipe 21. Since the second corrugated pipe 22 undergoes almost no radial deformation, pressure is forcibly directed to the first corrugated pipe 21, causing it to collapse inward and compress the cable. This eliminates, to some extent, the waste of outward pressure dissipation, maximizing pressure conversion efficiency.

[0027] Reference Figure 2-5As shown in this embodiment, the volume of the water-absorbing and expanding cotton 23 exhibits a gradient distribution, with the volume of the water-absorbing and expanding cotton 23 gradually decreasing from the end closer to the constant diameter section 211 to the end farther away from the constant diameter section 211. This volume gradient difference establishes a gradient of expansion energy, and the expansion pressure generated by the water-absorbing and expanding cotton 23 near the center is the highest. The expansion force will diffuse towards both ends along the pressure difference, generating a driving force from the inside out.

[0028] Reference Figure 2-5 As shown in this embodiment, the corrugation density of the variable diameter section 212 near the constant diameter section 211 is greater than that near the openings at both ends. This further strengthens the pressure gradient, and the densely corrugated area not only has a larger number of sealing rings but also a more concentrated stress area, thus constructing a high-strength water-blocking layer in the core area.

[0029] Reference Figure 2-5 As shown in this embodiment, the distance from the corrugation of the variable diameter section 212 near the constant diameter section 211 to the axis of the cable body 1 is less than the distance from the corrugation of the variable diameter section 212 near the openings at both ends to the axis. By shortening the physical distance from the corrugation to the axis, the rubber corrugations can impact and squeeze the cable with a shorter displacement and stronger potential energy when driven by air pressure, directly increasing the positive pressure at the core dividing point. Under the air-filled compression state of the sealed cavity, the radial pressure of the variable diameter section 212 acting on the outer wall of the cable body 1 decreases from the center to both ends.

[0030] The combined effect of all the above geometric features is as follows: the pressure is higher at the end of the variable diameter section 212 with a smaller inner diameter, which is used to lock in water vapor, while the pressure is moderate at the two ends with a larger inner diameter, which is used for initial isolation and provides displacement space. This distribution makes water vapor only diffuse towards the periphery with lower pressure, and cannot penetrate into the center with high pressure.

[0031] Reference Figure 2-5 As shown in this embodiment, the water-absorbing and expanding cotton 23 is fixed to the side slope of the corrugated protrusion on the inner wall of the variable diameter section 212 facing the openings at both ends. When the water-absorbing and expanding cotton 23 expands in volume, the stress component generated will extend along the slope towards the openings, actively pushing the water vapor that has entered the corrugated pipe to the outside, thereby achieving dehumidification.

[0032] Reference Figure 1-5As shown in this embodiment: The first corrugated pipe 21 has clamps at both ends of its openings, and the first corrugated pipe 21 is securely sealed to the outer sheath of the cable body 1 through the clamps. The clamps provide a rigid mechanical seal at both ends of the device, preventing large amounts of mud, sand, or water from entering, and providing physical support points at both ends of the sealed cavity, ensuring the mechanical strength of the connection between the component and the cable body 1. The end of the first corrugated pipe 21 has an outwardly folded sealing edge, which is fixedly connected to the inner end wall of the second corrugated pipe 22 through a vulcanization bonding process to achieve airtightness. The vulcanization process bonds the rubber sealing edge to the metal wall at the molecular level, creating an absolutely airtight space, ensuring constant pressure in the sealed cavity over a long operating period of several years, and preventing pneumatic pressure compensation failure due to air leakage.

[0033] Working principle: First, the protective component 2 pre-covers the connection between the two cable bodies 1. The equal diameter section 211 of the first corrugated pipe 21 covers the core connection area, and the clamps at both ends are used to mechanically fasten and lock the opening of the first corrugated pipe 21. Thus, the first physical protective barrier is built around the joint of the two cable bodies 1. This modular structure replaces the traditional potting process at the manufacturing end, improving the assembly efficiency of the manufacturing assembly line.

[0034] Secondly, a metered amount of compressed gas is injected into the sealed cavity formed between the first corrugated pipe 21 and the second corrugated pipe 22 via a one-way constant pressure air valve 24 installed on the outer wall of the second corrugated pipe 22 using an air supply device. Since the radial stiffness of the second corrugated pipe 22 is much greater than that of the rubber material of the first corrugated pipe 21, the air pressure in the sealed cavity is forcibly guided to the first corrugated pipe 21 and drives it to collapse inward. The isotropic fluid characteristics of the gas are used to achieve adaptive pneumatic compensation sealing of the irregular outer wall of the cable body 1, ensuring that the first corrugated pipe 21 can tightly fill the fine scratches or grooves on the surface of the cable body 1, achieving an airtight protection strength far exceeding that of ordinary mechanical compression.

[0035] Furthermore, during the pneumatic extrusion process, the structure of the variable diameter section 212, which has a smaller inner diameter and denser corrugation spacing at the end near the constant diameter section 211 when it is not installed, ensures that when the first bellows 21 is inflated and subjected to force, the part near the constant diameter section 211 will impact and press the cable body 1 with a shorter displacement distance, thereby generating the maximum initial sealing pre-tightening force. This pressure distribution state, which decreases in stages from the center to both ends, creates a high-pressure locking center, forming a stepped pressure barrier from the inside out, ensuring that the sealing tightness reaches the highest state.

[0036] Next, the focus is on leveraging the gradient active defense and drainage self-healing function of the water-absorbing and expanding cotton 23 for minor water seepage. When a small amount of water vapor in the external environment breaks through the front-end mechanical defense line and seeps into the corrugated gap inside the variable diameter section 212, the water-absorbing and expanding cotton 23 fixed on the inner wall of the corrugated protrusion will immediately absorb water and generate significant physical volume expansion. Through this water-absorbing and expanding cotton 23, the negative leakage phenomenon is transformed into a positive force to enhance the seal. Utilizing the volume gradient distribution characteristic of the water-absorbing and expanding cotton 23 that gradually decreases from the center to both ends, the water-absorbing and expanding cotton 23 near the area of ​​the constant diameter section 211 generates the highest level of expansion pressure, thereby establishing an expansion energy gradient inside the protective component 2 that points towards the external opening.

[0037] Next, through the special orientation design of fixing the water-absorbing expansion cotton 23 to the corrugated side slope of the inner wall of the variable diameter section 212, when the water-absorbing volume of the water-absorbing expansion cotton 23 increases, the expansion stress component generated by it will be physically guided by the corrugated slope and will extend in a directional direction towards the openings at both ends along the geometric slope of the variable diameter section 212. Using this expansion force that radiates from the inside out, a physical driving force similar to the toothpaste squeezing effect is generated, which actively forces the water vapor that has seeped into the first corrugated pipe 21 to be discharged outward along the corrugated channel, thereby achieving the dynamic self-adaptation and automatic dehumidification effect inside the protective component 2 without damaging the overall sealing structure.

[0038] Finally, the rigid metal shell of the second corrugated pipe 22 is used to defend against mechanical impacts or biological bites from sharp objects. At the same time, the vulcanization bonding process between the end sealing edge and the inner wall of the second corrugated pipe 22 ensures that the sealed cavity maintains a constant air pressure compensation capability during long-term operation. Through the logical coupling between the above structures, a dynamic pneumatic sealing system with active defense function is finally built in the connection area of ​​the two cable bodies 1.

[0039] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. A waterproof and airtight cable connector, characterized in that, The cable body includes a protective assembly fitted on the outer wall of the cable body connection. The protective assembly includes a first corrugated tube, which consists of a constant-diameter section in the middle and variable-diameter sections connected on both sides of the constant-diameter section. A second corrugated tube is coaxially nested on the outer wall of the first corrugated tube, and the ends of the second corrugated tube and the first corrugated tube are sealed together, forming a sealed cavity. A one-way constant-pressure air valve communicating with the sealed cavity is installed at one end of the outer wall of the second corrugated tube. In the uninstalled state, the inner diameter of the variable-diameter section increases in a stepwise manner from the end closer to the constant-diameter section to the end farther away from the constant-diameter section. The corrugation spacing of the variable-diameter section also increases in a stepwise manner from the end closer to the constant-diameter section to the end farther away from the constant-diameter section. Water-absorbing and expanding cotton is fixed to the inner wall of each corrugated protrusion of the variable-diameter section.

2. The waterproof and airtight cable connector according to claim 1, characterized in that: The first corrugated pipe is made of rubber material, and the second corrugated pipe is made of metal material.

3. A waterproof and airtight cable connector according to claim 1, characterized in that: The radial stiffness of the second bellows is greater than that of the first bellows.

4. A waterproof and airtight cable connector according to claim 1, characterized in that: The volume of the water-absorbing and expanding cotton exhibits a gradient distribution, with the volume gradually decreasing from the end closer to the constant diameter section to the end farther away from the constant diameter section.

5. A waterproof and airtight cable connector according to claim 1, characterized in that: The corrugation density of the variable-diameter section near the constant-diameter section is greater than that near the openings at both ends.

6. A waterproof and airtight cable connector according to claim 1, characterized in that: The distance from the corrugation on the side of the variable diameter section closest to the constant diameter section to the axis of the cable body is less than the distance from the corrugation on the side of the variable diameter section closest to the openings at both ends to the axis.

7. A waterproof and airtight cable connector according to claim 1, characterized in that: Under the condition of being compressed by air in a closed cavity, the radial pressure exerted on the outer wall of the cable body by the variable diameter section decreases from the center to both ends.

8. A waterproof and airtight cable connector according to claim 1, characterized in that: The water-absorbing and expanding cotton is fixed to the side slope of the corrugated protrusion on the inner wall of the variable diameter section, facing the direction of the openings at both ends.

9. A waterproof and airtight cable connector according to claim 1, characterized in that: The first corrugated pipe has clamps at both ends of its openings, and the first corrugated pipe is fastened and sealed to the outer sheath of the cable body through the clamps.

10. A waterproof and airtight cable connector according to claim 1, characterized in that: The end of the first bellows is provided with an outwardly folded sealing edge, and the sealing edge is fixedly connected to the inner end wall of the second bellows through a vulcanization bonding process to achieve airtightness.

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