Cable assembly

Abstract

A cable assembly 4 comprising a cable 10having a longitudinal axis (X-X); a sleeve 50 extending around the circumference of the cable; a first moulding 60; and a second moulding 62; the sleeve has fir

Description

TECHNICAL FIELD The present disclosure relates to a cable assembly, an assembly including a cable assembly and a method of assembling a cable assembly. BACKGROUND In various applications including but not limited to subsea applications such as subsea energy transfer, the field of subsea oil and gas production, and the field of subsea sCO2 re-injection, there is a need to provide safe and effective electrical connections. To achieve this it is important to provide adequate sealing against ingress of fluids into any electrical components. There is therefore a need for systems with improved sealing capability which can be readily adapted to connect cables of different sizes to installations such as subsea installations for energy transfer, production and I or storage. SUMMARY From a first aspect, the disclosure provides a cable assembly comprising: a cable having a longitudinal axis; a sleeve extending around an outer circumference of the cable; a first moulding; and a second moulding, the sleeve having: a first axial side; a second axial side spaced from the first axial side; and a radially outer cylindrical surface extending from the first axial side to the second axial side, wherein the first moulding extends from the first axial side along the cable, wherein the second moulding extends from the second axial side along the cable, wherein the sleeve comprises one or more projections extending from the first and I or second axial side thereof, wherein the projections are configured to improve bonding between the sleeve and the first and / or second moulding. In any example of the disclosure, the sleeve may be resistant to deformation under pressure. In any example of the disclosure, the sleeve may be resistant to corrosion. In any example of the disclosure, the radially outer cylindrical surface may be smooth. In any example of the disclosure, the sleeve may be made of metal. In any example of the disclosure, the sleeve may be made of steel. In any example of the disclosure, the cable may comprise an electrical cable surrounded by an insulating sheath. In any example of the disclosure, the cable assembly may further include a filler material extending between the sleeve and the outer circumference of the cable. In any of these examples, the sleeve may comprise a channel extending radially inwardly from the radially outer cylindrical surface to allow the filler material to be inserted into a gap between the cable and the sleeve. In any example of the disclosure, the first moulding may extend to the radially outer cylindrical surface. In any example of the disclosure, the second moulding may extend to the radially outer cylindrical surface. From a further aspect, the disclosure provides an assembly comprising: a housing having an opening therein; and a cable assembly as described in any of the above examples, wherein the cable extends into the housing through the opening. In any example of the disclosure, a seal may be formed between the radially outer cylindrical surface and the opening. In any example of the disclosure, the opening may comprise a radially inner cylindrical surface. In any example of the disclosure, the radially inner cylindrical surface may be radially outward of the radially outer cylindrical surface. In any example of the disclosure, the radially inner cylindrical surface may be adjacent to the radially outer cylindrical surface. In any example of the disclosure, the radially inner cylindrical surface may be in contact with the radially outer cylindrical surface. In any example of the disclosure, the radially inner cylindrical surface may conform to the radially outer cylindrical surface. In any example of the disclosure, a seal may be received in a cylindrical recess extending radially outward from the radially inner cylindrical surface of the opening. In any example of the disclosure, a seal may be received in a cylindrical recess extending radially inward from the radially outer cylindrical surface of the sleeve. In any example of the disclosure, the assembly may be a subsea assembly. From a further aspect of the disclosure, a method of assembling a cable assembly as described in any of the above examples is provided, the method comprising: inserting the cable into the sleeve or installing the sleeve onto the cable; and forming the first and second mouldings. In any example of the disclosure, the method may comprise, before or after forming the first and second mouldings, injecting filler material into a channel extending radially inwardly from the radially outer cylindrical surface to allow the filler material to be inserted into a gap between the cable and the sleeve. In any example of the disclosure, the forming the first and second mouldings may comprise: assembling a mould around the cable and the sleeve; injecting a moulding material into the mould; and removing the mould once the moulding material has set. Although certain advantages are discussed below in relation to the features detailed above, other advantages of these features may become apparent to the skilled person following the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS One or more non-limiting examples will now be described, by way of example only, and with reference to the accompanying figures in which: Figure 1 is a schematic cross sectional representation of an assembly according to one example of the disclosure; Figure 2 is a schematic cross sectional representation of an assembly according to another example of the disclosure; Figure 3A is a cross sectional view through part of a cable assembly according to an example of the disclosure; Figure 3B is a perspective view of the cable assembly of Figure 3A; Figure 4A is a perspective view of a sleeve of a cable assembly according to an example of the disclosure; Figure 4B is a radial sectional view through the sleeve of Figure 4A; Figure 5 is a radial sectional view through a sleeve of a cable assembly according to another example of the disclosure; Figure 6A is a perspective view of a mould tool for forming a cable assembly according to an example of the disclosure; and Figure 6B is a perspective view of the mould tool of Figure 6A, when assembled around a cable. DETAILED DESCRIPTION According to various examples of the disclosure, a cable assembly is provided. The cable assembly may be an electrical cable assembly. The cable assembly may be used to form an electrical connection with an installation such as, for example, a power transfer device such as a power hub, a transformer, a switchgear, a variable speed drive or a motor load. In any example, the installation may be for use in a subsea environment, for example for use with offshore power generation installations such as wind or wave energy converters. The installation could also be used in a variety of other subsea applications including but not limited to subsea oil and gas production and subsea sCO2 re-injection. Referring to Figure 1, a schematic representation of an assembly 2 according to one example of the disclosure is shown. The assembly 2 includes a cable assembly 4 as will be described in further detail below. The assembly 2 further includes a housing 6 having an opening 8 therein. The cable assembly 4 includes a cable 10 which extends along a longitudinal axis X-X. The cable 10 passes through the opening 8 in the housing 6 such that a first axial portion 12 of the cable 10 is located within the housing 6 and a second axial portion 14 of the cable 10 is located outside the housing 6. In any example of the disclosure, the housing 6 may be the housing or exterior casing of an installation of any of the types described above. The housing may be formed from any suitable material including but not limited to metals such as steel. The housing 6 may taken any required form. In any example of the disclosure, the housing 6 can form a hollow cuboid shape made up of a base wall 16 joined to an upper wall 18 by first and second end walls 20, 22 and first and second side walls (not shown) which extend between the first and second end walls 20, 22. The opening 8 may be formed in any suitable location on the housing 6, for example extending through the upper wall 18 thereof. In any example of the disclosure, the opening 8 may be formed in one of the first and second end walls 20, 22. In the example shown in Figure 1, the opening 8 is formed in the second end wall 22. Figure 2 is a schematic cross sectional representation of an assembly 2 according to one example of the disclosure in which those parts corresponding to the parts shown in the example of Figure 1 are given the same reference number. In any example of the disclosure and as seen in Figure 2, the cable 10 may be an electrical cable. In any example of the disclosure, the cable 10 may comprise an electrical cable 30 surrounded by an insulating sheath 32. The insulating sheath 32 may for example be formed from one or more layers of polymer material. It will be understood that the electrical cable may be sized to carry any desired electrical voltage and current. Accordingly, the diameter d of the electrical cable 30 may be chosen for a required power. The thickness t of the insulating sheath 32 may be varied but where standard materials are used, the thickness of the insulating sheath 32 may remain approximately constant or change by a relatively small amount such that the outer diameter D of the cable 10 (in other words the diameter to the outer circumference 34 of the cable 10, in this example defined by the outer circumference of the insulating sheath 32) may vary depending on the chosen size of the electrical cable 30. In any example of the disclosure, the opening 8 (which could be at any location on the housing but in this example is in the end wall 22 of the housing 6) provides an aperture large enough for the cable assembly 4 to pass through. The opening 8 may have any desired shape, for example being square in cross section. In some examples, the opening 8 may be circular in cross section, such that the opening 8 forms a radially inner cylindrical surface 36 around the opening 8 extending through the end wall 22 of the housing 6. In any example of the disclosure, a seal can be formed between the radially outer cylindrical surface 56 and the opening 8. The seal could take any suitable form, some possible examples of which are described below. It will be understood that the seal may reduce or stop substances such as fluid (more specifically oil or water for example) from entering or exiting the housing 6 via the opening 8. In any example of the disclosure, a recess 38 may be provided which may extend radially outwardly from the opening 8, for example extending into the wall of the housing from the opening 8. In the example of Figure 2, the recess 38 is a cylindrical recess 38 which extends radially outward from the radially inner cylindrical surface 36 of the opening 8 into the end wall 22. In any example of the disclosure, the recess 38 may be a groove. In any example of the disclosure, a seal 40 may be provided in the recess 38. In any example of the disclosure, the seal 40 may be an O-ring seal but it will be understood that any other suitable type of seal could also be used such as for example a feather seal or a concertina shape seal. In any example of the disclosure, either additionally or alternatively, a recess (not shown) may be provided which may extend radially inwardly from the opening 8, for example extending into the sleeve 50 from the radially outer cylindrical surface 56. The recess may for example be a cylindrical recess which extends radially inward from the radially outer cylindrical surface 56 into the sleeve 50. In any example of the disclosure, the recess may be a groove. In any example of the disclosure, a seal (not shown) may be provided in the recess. In any example of the disclosure, the seal may be an O-ring seal but it will be understood that any other suitable type of seal could also be used such as for example a feather seal or a concertina shape seal. Figure 3A is a cross sectional view of a cable assembly 4 according to one example of the disclosure in which those parts corresponding to the parts shown in the examples of Figures 1 and 2 are given the same reference number. Figure 3B is a perspective view of the cable assembly of Figure 3A. As seen in Figures 2, 3A and 3B, as well as the cable 10, the cable assembly 4 comprises a sleeve 50 extending around the outer circumference 34 of the cable 10. The sleeve 50 has a first axial side 52 and a second axial side 54 spaced from the first axial side. In any example of the disclosure therefore, the second axial side 54 may be axially spaced or separated from the first axial side 52. The sleeve 50 may take the form of a hollow cylinder. The sleeve 50 may further comprise a radially outer cylindrical surface 56 extending from the first axial side 52 to the second axial side 54 thereof. The first axial side 52 and the second axial side 54 may form respective side walls of the sleeve 50 which extend in a radial direction between the radially outer cylindrical surface 56 and a radially inner surface 58 of the sleeve 50. In any example of the disclosure, the sleeve 50 may be configured to receive the cable 10 therein. In other words, a diameter Ds of the opening formed by the sleeve 50 (in other words, formed by the radially inner surface 58) is greater than or equal to the outer diameter D of the cable 10. As seen in Figures 2 and 3, the cable assembly 4 also includes a first moulding 60 extending from the first axial side 52 of the sleeve along the cable 10. The cable assembly 4 also includes a second moulding 62 extending from the second axial side 54 of the sleeve 50 along the cable 10. It will be understood that in any example of the disclosure, and as described in further detail below, the first and second mouldings 62, 64 may be formed from a single moulding process using a single mould. In other examples, however, the first and second mouldings 62, 64 could be formed from two separate moulds or moulding processes. In any example of the disclosure, one or both of the first and second mouldings 62, 64 may be formed from an epoxy or from a polymer. In any example of the disclosure, one or both of the first and second mouldings 62, 64 may extend to the radially outer cylindrical surface 56 of the sleeve 50. In any example of the disclosure one or both the first and second mouldings 62, 64 may be tapered from the radially outer cylindrical surface 56 towards the cable 10 and may extend axially outwardly away from the sleeve 50. In any example of the disclosure, one or both the first and second mouldings 62, 64 may bond to the outer circumference of the cable and I or may bond to the sleeve 50. In any example of the disclosure, the first and second mouldings 62, 64 may bond to the first and second axial sides 52, 54 of the sleeve 50. However as described further below, the sleeve 50 includes one or more projections extending from the first and I or second axial sides 52, 54 thereof. The projections are configured to improve bonding between the sleeve 50 and the first and / or second mouldings 60, 62. In any example of the disclosure, there may be no gap that remains between the sleeve 50 and the outer circumference 34 of the cable 10. In any example of the disclosure, this may either be because the sleeve 50 is in contact with the outer circumference 34 of the cable 10 when the cable assembly 4 is assembled or because the polymer material of the first and / or second mouldings 60, 62 flows into any space which does remain between the sleeve 50 and the outer circumference 34 of the cable 10. However, at least in some examples of the disclosure, a gap may remain between the sleeve 50 and the outer circumference 34 of the cable 10 even after the first and second mouldings 62, 64 have been formed (for example by the method described below). In any example of the disclosure therefore, the cable assembly may also include a filler material 66 extending between the sleeve and the outer circumference of the cable. It will be understood that any gap left between the sleeve 50 and the outer circumference 34 of the cable 10 may therefore be filled by the filler material 66 which may for example be a potting material such as but not limited to urethane, silicone or an acrylic compound. As seen for example in Figure 3, the sleeve 50 may include a channel 68 extending radially inwardly from the radially outer cylindrical surface 56 to allow the filler material 66 to be inserted into any gap which may exist between the cable 10 and the sleeve 50. In any example of the disclosure, the radially inner cylindrical surface 36 formed by the opening 8 is radially outward of and / or adjacent to the radially outer cylindrical surface 56 of the sleeve 50. In any example of the disclosure, the radially inner cylindrical surface 36 may be in contact with the radially outer cylindrical surface 56. In any example of the disclosure, the radially inner cylindrical surface 36 may conform to the radially outer cylindrical surface 56. In any example of the disclosure, the radially inner cylindrical surface 36 may extend substantially parallel to the radially outer cylindrical surface 56. In any example of the disclosure, the cable 10 may be mounted in the sleeve 50 to extend coaxially therewith. The cable assembly 4 may be mounted in the assembly 2 such that the cable 10 extends coaxially with the opening 8 in the housing 6. The sleeve 50 will now be described in greater detail with reference to Figures 4A, 4B and 5, where Figures 4A and 4B show a perspective and a sectional view respectively of a sleeve 50 according to a first example and Figure 5 shows a sectional view respectively of a sleeve 50 according to a second example. As described above, the sleeve 50 may comprise a radially outer cylindrical surface 56 extending from the first axial side 52 to the second axial side 54 thereof. The first axial side 52 and the second axial side 54 may form respective side walls of the sleeve 50 which extend in a radial direction between the radially outer cylindrical surface 56 and a radially inner surface 58 of the sleeve 50. The channel 68 for injection of filler material may be provided at any desired location on the circumference of the sleeve 50 as seen in Figure 4A. The sleeve can be formed of any suitable material. At least in some examples, for instance when the assembly 2 or the cable assembly 4 is for use in a harsh environment such as a subsea environment, the sleeve 50 may be formed of a material that is resistant to corrosion and resistant to deformation under pressure. This may improve the quality of the seal formed between the sleeve 50 and the housing 6 by improving the sealing surface provided. In any example of the disclosure, the radially outer cylindrical surface 56 of the sleeve 50 may be smooth. This may again improve the quality of the seal formed between the sleeve 50 and the housing 6 by improving the sealing surface provided. In any example of the disclosure, the sleeve can be made of a metal, such as for example a stainless steel, or from a ceramic. In any example of the disclosure, the sleeve 50 may be provided with projections as described above for improving bonding between the sleeve 50 and the moulding material. In some examples, such as that shown in Figures 4A and 4B, the sleeve 50 includes a first axial projection 70 extending axially away from the first axial side 52 and forming a continuation of the radially inner surface 58 of the sleeve 50 extending in a first axial direction. The sleeve 50 in some examples may also include a second axial projection 72 extending axially away from the second axial side 54 and forming a continuation of the radially inner surface 58 of the sleeve 50 extending in a second axial direction, opposite to the first axial direction. In any example of the disclosure and as seen in Figures 4A and 4B, each of the first and second axial projections 70, 72 may also include at least one radial protrusion 74, 76 extending radially outwardly therefrom. In any example of the disclosure, the at least one radial protrusion 74, 76 may form an annular component extending around the full circumference of the sleeve 50. In other examples which are not shown, radial protrusions may instead be provided as circumferentially discreet protrusions distributed evenly or unevenly about the circumference of the sleeve 50. In some alternative examples, such as that shown in Figure 5, the sleeve 50 includes a first projection 80 extending axially away from the first axial side 52 and forming a continuation of the radially inner surface 58 of the sleeve 50 extending in a first axial direction. The sleeve 50 in some examples may also include a second projection 82 extending axially away from the second axial side 54 and forming a continuation of the radially inner surface 58 of the sleeve 50 extending in a second axial direction, opposite to the first axial direction. In any example of the disclosure and as seen in Figure 5, each of the first and second projections 80, 82 may be tapered radially inwardly from the radially outer cylindrical surface 56. Each of the first and second projections 80, 82 may also include at least one, for example, two three, four or more, radial crenulation 84, 86. In any example of the disclosure, the at least one radial crenulation 84, 86 may form an annular component extending around the full circumference of the sleeve 50. In other examples which are not shown, radial crenulation 84, 86 may instead be provided as circumferentially discreet protrusions distributed evenly or unevenly about the circumference of the sleeve 50. A method of assembling a cable assembly according to any example of the disclosure includes: inserting the cable 10 into the sleeve 50 or installing the sleeve 50 onto the cable 10; and forming the first and second mouldings 60, 62. Before or after forming the first and second mouldings 60, 62, the method may further include injecting filler material, for example filler material as described above, into the channel 68 extending radially inwardly from the radially outer cylindrical surface 56 of the sleeve 50 to allow the filler material to be inserted into a gap between the cable 10 and the sleeve 50. It will be understood that the first and second mouldings 60, 62 could be formed by various methods. In any example of the disclosure however, the forming the first and second mouldings may comprise assembling a mould around the cable and the sleeve, injecting a moulding material such as a polymer or epoxy into the mould, and removing the mould once the moulding material has set. In any example of the disclosure, the mould may be a mould tool as shown in Figures 6A and 6B. As seen in Figure 6A, the mould may be formed in two mould halves 88, 90. The two mould halves 88, 90 together form an internal cavity 92, which is shaped to conform to the radially outer cylindrical surface 56 of the sleeve 50 when assembled thereon. The internal cavity 92 is further shaped to form tapered cavities extending radially inwardly from the radially outer cylindrical surface 56 of the sleeve 50 to the cable 10 at a point axially removed from the radially outer cylindrical surface 56 of the sleeve 50. It will be understood that the cable 10 and the sleeve 50 in which the cable 10 is inserted may be mounted in the mould such that they are concentric therewith and the two mould halves 88, 90 may then be held together, for example by screws 94. Moulding material is then injected into the mould via openings 96. Once the moulding material has set, the screws 94 may be removed, thus releasing the two mould halves 88, 90 such that the mould may be removed from the completed cable assembly 4. It will be understood that in any example of the disclosure, the sleeve 50 may be made to a chosen specification to allow a seal to be formed between the opening 8 in the housing 6 and the radially outer cylindrical surface 56 of the sleeve 50. Thus, for example, the diameter Ds of the opening formed by the sleeve 50 and the diameter of the sleeve from the radially outer cylindrical surface 56 thereof may be chosen or varied as needed. While the disclosure has been described in detail in connection with only a limited number of examples, it should be readily understood that the disclosure is not limited to such disclosed examples. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the scope of disclosure. Additionally, while various examples of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described examples. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims

1. A cable assembly comprising:a cable having a longitudinal axis;a sleeve extending around an outer circumference of the cable;a first moulding; anda second moulding,the sleeve having:a first axial side;a second axial side spaced from the first axial side; anda radially outer cylindrical surface extending from the first axial side to the second axial side,wherein the first moulding extends from the first axial side along the cable, wherein the second moulding extends from the second axial side along the cable,wherein the sleeve comprises one or more projections extending from the first and I or second axial side thereof, wherein the projections are configured to improve bonding between the sleeve and the first and / or the second moulding.

2. A cable assembly as claimed in claim 1, wherein the sleeve is resistant to deformation under pressure, and / or wherein the sleeve is resistant to corrosion.

3. A cable assembly as claimed in claim 1 or 2, wherein the radially outer cylindrical surface is smooth.

4. A cable assembly as claimed in claim 1,2 or 3, wherein the sleeve is made of metal, optionally steel.

5. A cable assembly as claimed in any preceding claim, wherein the cable comprises an electrical cable surrounded by an insulating sheath.

6. A cable assembly as claimed in any preceding claim, further including a filler material extending between the sleeve and the outer circumference of the cable.

7. A cable assembly as claimed in claim 6, wherein the sleeve comprises a channel extending radially inwardly from the radially outer cylindrical surface to allow the filler material to be inserted into a gap between the cable and the sleeve.

8. A cable assembly as claimed in any preceding claim, wherein the first moulding extends to the radially outer cylindrical surface, and I orwherein the second moulding extends to the radially outer cylindrical surface.

9. An assembly comprising:a housing having an opening therein; anda cable assembly as claimed in any preceding claim, wherein the cable extends into the housing through the opening.

10. An assembly as claimed in claim 9, wherein a seal is formed between the radially outer cylindrical surface and the opening.

11. An assembly as claimed in claim 9 or 10, wherein the opening comprises a radially inner cylindrical surface.

12. An assembly as claimed in claim 11, wherein the radially inner cylindrical surface is radially outward of and / or adjacent to the radially outer cylindrical surface.

13. An assembly as claimed in claim 11 or 12, wherein the radially inner cylindrical surface is in contact with and / or conforms to the radially outer cylindrical surface.

14. An assembly as claimed in claim 11, 12 or 13, wherein a seal is received in a cylindrical recess extending radially outward from the radially inner cylindrical surface of the opening, orwherein a seal is received in a cylindrical recess extending radially inward from the radially outer cylindrical surface of the sleeve.

15. An assembly as claimed in any of claims 9 to 14, wherein the assembly is a subsea assembly.

16. A method of assembling a cable assembly as claimed in any of claims 1 to8, the method comprising:inserting the cable into the sleeve or installing the sleeve onto the cable; and forming the first and second mouldings.

17. An assembly method as claimed in claim 16, comprising, before or after forming the first and second mouldings, injecting filler material into a channel extending radially inwardly from the radially outer cylindrical surface to allow the filler material to be inserted into a gap between the cable and the sleeve.

518. An assembly method as claimed in claim 16 or 17, the forming the first and second mouldings comprising:assembling a mould around the cable and the sleeve;10 injecting a moulding material into the mould; and removing the mould once the moulding material has set.

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