Cable end cap

Abstract

A cable end cap assembly for enclosing an end of a cable includes an elastomeric cap configured to be positioned on the end of the cable, a cage having deformable fingers positioned on the elastomeric cap, and a compression mechanism configured to compress the fingers on the elastomeric cap from an untightened position to a tightened position and hold the fingers in the tightened position. A method of enclosing an end of a cable includes positioning an elastomeric cap on the end of the cable, positioning a cage having deformable fingers around the elastomeric cap, compressing the fingers from an untightened position to a tightened position using a compression mechanism and holding the fingers in the tightened position with the compression mechanism.

Description

CABLE END CAPCROSS-REFERENCE T O RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 734,352, filed December 16, 2024, the entire contents of which are incorporated herein by reference.SUMMARY OF THE INVENTION

[0002] Solar farms typically comprise massive arrays of solar panels, which are connected to above-ground cables (e.g. positive and negative) in a parallel fashion. The connection is often made by an insulation displacement or insulation piercing connector such that a single cable may extend uninterrupted to service multiple solar panels. Each cable has an end point corresponding to the most distant solar panel. To prevent damage, the end of the cable is enclosed in a suitable weather-proof enclosure. In some cases, an enclosure provided with an insulation displacement connector mayterminatethe cable; but in other cases, this may not be suitable. The cables are typically situated in an outdoor environment, necessitating a weather-proof solution. The cables are typically large (e.g. up to 750 kcmil or greater) and operate at high voltage (e.g. up to 1500V or greater), and as such, the available stock solutions are limited and have significant drawbacks.

[0003] Heat shrink end caps are typically comprised of polyolefin or another heat shrinkable material and typically include a hot melt adhesive at the inner diameter. While potentially weather-proof, the heat shrink end caps are generally intended fortemporary use while a site is under construction, are typically not UL Listed, and have voltage ratings typically limited to 600V or 1000V. Further, their installation necessitates the inconvenience of carrying a heat gun into the field. Cold shrink end caps include a pre-stretched outer cap and an inner sleeve formed such that the sleeve can be unwound in a coiled fashion, causing the outer cap to shrink around the cable. Since the cap is in a state of tension around the cable, and no adhesive is included, the ability to seal discontinuities in the cable jacket such as gouges may be unreliable. Gel covers comprised of a soft gel (usually silicone based)1MBF\214887\0028\52336946.vl-12 / 12 / 25within a plastic cover are formed around the cable to provide sealing. Mechanical support or securement of gel covers is limited and the gel covers may lack long term reliability as the gel has some freedom to move.

[0004] The above deficiencies are solved via the novel cable end caps described and shown within the present application. The cable end caps include an elastomeric cap (i.e. a cylinder with one end open) which fits around the end of the cable and is formed of silicone, neoprene, ethylene propylene diene monomer (EPDM), a synthetic rubber polymer, a fluoroelastomer (FKM). or a thermoplastic elastomer (TPE). No reinforcement is provided to prevent issues of wicking water. The elastomeric sealing end cap may have one or more integrated bands extending around the outside circumferentially, to create zones of higher compression to promote sealing. The caps are generally intended to fit the cable loosely, or perhaps a slight interference, and utilize an external means to tighten against the cable for adequate sealing. In addition, elastomers such as those above may have modest abrasion and tear resistance and the external tightening means also provides physical shielding against mechanical damage (from accidental impacts, tools, animals, etc.).

[0005] As used herein, the term "compression mechanism" refers generally to any structure or combination of structures configured to apply compressive force to the elastomeric cap and cable, either directly or indirectly through intermediate components such as a cage orfingers. In some embodiments, the compression mechanism may include a hose clamp, a camming lever, a threaded fastener, or a lever with arms coupled to a cage via a pin. The term "deformable fingers" refers to elongated portions of a cage that are capable of flexing, bending, or otherwise moving inward toward a central axis when subjected to compressive force. In some aspects, the deformable fingers may be defined by longitudinal slots formed in the cage, with each finger being independently movable relative to adjacent fingers. The "untightened position" refers to a configuration in which the compression mechanism has not been actuated and the fingers are in a relaxed or uncompressed state, with the slots between fingers being open or substantially open. The "tightened position" refers to a configuration in which the compression mechanism has2MBF\214887\0028\52336946.vl-12 / 12 / 25been actuated to compress the fingers inward against the elastomeric cap and cable, with the slots between fingers being closed or substantially closed. In some embodiments, the transition from the untightened position to the tightened position may be achieved through rotation of a lever, tightening of a hose clamp, or tightening of a threaded fastener.

[0006] In some aspects, the techniques described herein relate to a cable end cap assembly for enclosing an end of a cable, the cable end cap assembly including: an elastomeric cap configured to be positioned on the end of the cable; a cage having deformable fingers positioned on the elastomeric cap; and a compression mechanism configured to compress the fingers on the elastomeric cap from an untightened position to a tightened position and hold the fingers in the tightened position.

[0007] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes a hose clamp positioned on the cage.

[0008] In some aspects, the techniques described herein relate to a cable end cap assembly, further including a sleeve located between the cage and the hose clamp.

[0009] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes a housing and a camming lever configured to displace the cage relative to the housing.

[0010] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes a housing surrounding the cage and defining a slot, and a handle coupled to the cage via a pin, wherein the pin extends through the slot of the housing and is movable within the slot between the untightened position and the tightened position.

[0011] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the elastomeric cap includes one or more integrated bands extending circumferentially around an outer surface of the elastomeric cap.3MBF\214887\0028\52336946.vl-12 / 12 / 25

[0012] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the cage includes a plurality of longitudinal slots that define the deformable fingers therebetween.

[0013] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the cage includes a closed end configured to cover a distal end of the elastomeric cap and an open end configured to receive the cable.

[0014] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the elastomeric cap is formed of a material selected from the group consisting of silicone, neoprene, ethylene propylene diene monomer, a synthetic rubber polymer, a fluoroelastomer, and a thermoplastic elastomer.

[0015] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes external protrusions extending outward from the cage, the external protrusions configured to retain a fastener in position on the cage.

[0016] In some aspects, the techniques described herein relate to a cable end cap assembly including: an elastomeric cap; and a compression mechanism configured to compress around the elastomeric cap.

[0017] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes a cage having a cylindrical outer wall with a plurality of longitudinal slots extending along the cylindrical outer wall, the longitudinal slots defining fingers therebetween, wherein the cage includes a first end that is open and a second end that is closed, wherein internal protrusions extend inward from the cylindrical outer wall adjacent the first end, wherein external protrusions extend outward from the cylindrical outer wall at two spaced apart locations that overlap with the longitudinal slots, and wherein a hose clamp is positioned and retained between the two external protrusions, the hose clamp configured to compress the longitudinal slots when tightened.4MBF\214887\0028\52336946.vl-12 / 12 / 25

[0018] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes an outer housing having a tapered front end with an opening sized to receive the elastomeric cap, a cage positioned within the outer housing and having a plurality of slots that separate an end of the cage into separate fingers connected to one another at an opposite end of the cage, a camming lever received within the outer housing and including a handle portion and a camming portion, wherein the camming portion includes a cam surface that engages a rear surface of the cage, a pin extending through the camming portion and the outer housing to define a rotational axis about which the camming lever rotates, and a fin extending outward from the outer housing, wherein the handle portion includes an opening formed therein and is configured to be received on the fin in a tightened position.

[0019] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes an outer housing having a tapered front end with an opening sized to receive the elastomeric cap, a cage positioned within the outer housing and having a plurality of slots that separate an end of the cage into separate fingers connected to one another at an opposite end of the cage, a lever including a handle and a pair of arms that couple the handle to the cage via a pin, wherein the arms each include an opening for receiving the pin, wherein the outer housing defines a slot on opposing sides through which the pin extends, wherein the pin is movable within the slot of the outer housing between an untightened position and a tightened position, wherein chambers are formed on an exterior of the outer housingwithin which distal ends of the arms are received, and wherein detents are formed on the outer housing to lock the lever in the tightened position.

[0020] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes a cage having a cylindrical outer wall with a plurality of longitudinal slots extending along the cylindrical outer wall from a first open end toward a second closed end, the longitudinal slots defining cantilevered fingers therebetween, wherein external protrusions extend outward from the cylindrical outer wall5MBF\214887\0028\52336946.vl-12 / 12 / 25at two spaced apart locations, a sleeve positioned on the cage between the external protrusions, wherein the sleeve is generally annular and defines a central opening within which the cage is receivable, wherein the sleeve includes a gap formed between two edges that are parallel to one another and angled relative to an axis of the sleeve, wherein the sleeve includes lower and upper rims configured to retain a hose clamp on the sleeve between the two rims, and wherein the hose clamp is configured to decrease an inner diameter of the sleeve to compress the fingers against the elastomeric cap.

[0021] In some aspects, the techniques described herein relate to a cable end cap assembly, wherein the compression mechanism includes a cage having a cylindrical outer wall with a plurality of longitudinal slots extending along the cylindrical outer wall, the longitudinal slots defining cantilevered fingers therebetween, wherein external protrusions extend outward from the cylindrical outer wall at spaced apart locations, a sleeve positioned on the cage, wherein the sleeve includes two protruding walls at spaced apart ends of the sleeve, wherein each protruding wall includes an opening, and wherein a threaded fastener extends through the openings and is retained by a nut, the threaded fastener configured to be tightened relative to the nut to compress the fingers against the elastomeric cap.

[0022] In some aspects, the techniques described herein relate to a method of enclosing an end of a cable, the method including: positioning an elastomeric cap on the end of the cable; positioning a cage having deformable fingers around the elastomeric cap; compressing the fingers from an untightened position to a tightened position using a compression mechanism; and holding the fingers in the tightened position with the compression mechanism.

[0023] In some aspects, the techniques described herein relate to a method, wherein compressingthe fingers includes tightening a hose clamp positioned on the cage.6MBF\214887\0028\52336946.vl-12 / 12 / 25

[0024] In some aspects, the techniques described herein relate to a method, wherein compressing the fingers includes rotating a camming lever to displace the cage relative to a housing, thereby compressing the fingers within a tapered front end of the housing.

[0025] In some aspects, the techniques described herein relate to a method, wherein positioning the elastomeric cap on the end of the cable and positioning the cage around the elastomeric cap are performed simultaneously by applying a pre-assembled cable end cap assembly to the end of the cable.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 illustrates an isometric view of a cable end cap according to a first embodiment.

[0027] FIG. 2 illustrates an isometric view of the cable end cap according to the first embodiment.

[0028] FIG. 3 illustrates a side view of the cable end cap according to the first embodiment.

[0029] FIG. 4 illustrates a closed end view of the cable end cap according to the first embodiment.

[0030] FIG. 5 illustrates an open end view of the cable end cap according to the first embodiment.FIG. 6 illustrates a perspective view of the cable end cap positioned adjacent to an elastomeric cap accordingto the first embodiment.

[0031] FIG. 7 illustrates a side view of the cable end cap with a hose clamp installed accordingto the first embodiment.

[0032] FIG. 8 illustrates an isometric view of the cable end cap with a hose clamp installed accordingto the first embodiment.7MBF\214887\0028\52336946.vl-12 / 12 / 25

[0033] FIG. 9 illustrates an isometric view of a cable end cap in a tightened position accordingto a second embodiment.

[0034] FIG. 10 illustrates an end view of the cable end cap in the tightened position accordingto the second embodiment.

[0035] FIG. 11 illustrates a top view of the cable end cap according to the second embodiment.

[0036] FIG. 12 illustrates a side view of the cable end cap according to the second embodiment.

[0037] FIG. 13 illustrates a section view of the cable end cap in the tightened position accordingto the second embodiment.

[0038] FIG. 14 illustrates an isometric view of the cable end cap in an untightened position accordingto the second embodiment.

[0039] FIG. 15 illustrates an end view of the cable end cap according to the second embodiment.

[0040] FIG. 16 illustrates a top view of the cable end cap according to the second embodiment.

[0041] FIG. 17 illustrates a side view of the cable end cap according to the second embodiment.

[0042] FIG. 18 illustrates a section view of the cable end cap in the untightened position accordingto the second embodiment.

[0043] FIG. 19 illustrates an exploded view of the cable end cap accordingto the second embodiment.8MBF\214887\0028\52336946.vl-12 / 12 / 25

[0044] FIG. 20 illustrates an isometric view of a cable end cap according to a third embodiment.

[0045] FIG. 21 illustrates a side view of the cable end cap according to the third embodiment.

[0046] FIG. 22 illustrates a front view of the cable end cap according to the third embodiment.

[0047] FIG. 23 illustrates a top orthogonal view of the cable end cap according to the third embodiment.

[0048] FIG. 24 illustrates a section view of the cable end cap in a tightened position accordingto the third embodiment.

[0049] FIG. 25 illustrates a section view of the cable end cap in the tightened position accordingto the third embodiment.

[0050] FIG. 26 illustrates an isometric view of the cable end cap in an untightened position accordingto the third embodiment.

[0051] FIG. 27 illustrates a cross-sectional view of the cable end cap according to the third embodiment.

[0052] FIG. 28 illustrates a front view of the cable end cap according to the third embodiment.

[0053] FIG. 29 illustrates a top plan view of the cable end cap according to the third embodiment.

[0054] FIG. 30 illustrates a section view of the cable end cap in the untightened position accordingto the third embodiment.9MBF\214887\0028\52336946.vl-12 / 12 / 25

[0055] FIG. 31 illustrates a section view of the cable end cap according to the third embodiment.

[0056] FIG. 32 illustrates an exploded view of the cable end cap according to the third embodiment.

[0057] FIG. 33 illustrates an isometric view of a cable end cap according to a fourth embodiment.

[0058] FIG. 34 illustrates a top view of the cable end cap according to the fourth embodiment.

[0059] FIG. 35 illustrates a side view of the cable end cap according to the fourth embodiment.

[0060] FIG. 36 illustrates an exploded view of the cable end cap according to the fourth embodiment.

[0061] FIG. 37 illustrates a perspective view of the cable end cap according to the fourth embodiment.

[0062] FIG. 38 illustrates a perspective view of the cable end cap assembled on a cable accordingto the fourth embodiment.

[0063] FIG. 39 illustrates a perspective view of the cable end cap assembled on a cable accordingto the fourth embodiment.

[0064] FIG. 40 illustrates a side view of a cable end cap according to a fifth embodiment.

[0065] FIG. 41 illustrates a further side view of the cable end cap according to the fifth embodiment.

[0066] FIG. 42 illustrates an isometric view of the cable end cap according to the fifth embodiment.10MBF\214887\0028\52336946.vl-12 / 12 / 25

[0067] FIG. 43 illustrates a top view of the cable end cap according to the fifth embodiment.

[0068] FIG. 44 illustrates an isometric view of the cable end cap according to the fifth embodiment.

[0069] FIG. 45 illustrates an exploded view of the cable end cap according to the fifth embodiment.

[0070] FIG. 46 illustrates an isometric view of the cable end cap with a fastener installed accordingto the fifth embodiment.

[0071] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.• DETAILED DESCRIPTION

[0072] FIGS. 1 -8 illustrate a cable end cap 100. The cable end cap 100 surrounds an elastomeric cap 150 (FIG. 6) located on the distal end of a cable 10 (similar to the one shown in FIGS. 38-39) to seal the open end of the cable 10. In some embodiments, the cable 10 may be a cable for a solar panel array that has a cross-sectional area of 750 kcmil or greater and operates at high voltage (e.g. at least 1500V, at least 1000V). The cable end cap 100 includes a housing or cage 104 having a generally cylindrical outer wall 108 sized to extend around the end of the cable 10 (and the elastomeric cap 150 located thereon). The cylindrical outer wall 108 extends between a first end 112 and a second end 116. The first end 112 is open to permit insertion of the end of the cable 10 into an interior 132 of the cable end cap 100. The second end 116 is closed to cover the sealed end on the elastomeric cap11MBF\214887\0028\52336946.vl-12 / 12 / 25150 positioned on the cable 10. A plurality of longitudinal slots 120 (as shown, evenly spaced about the cylindrical outer wall 108) extend along the cylindrical outer wall 108 between the first and second longitudinal ends 112, 116, though terminating prior to either the first end 112 or the second end 116 such that the cylindrical outer wall 108 forms a continuous ring adjacent each of the first end 112 and the second end 116. In the embodiment shown, eight longitudinal slots are spaced about the cylindrical outer surface, offset from one another by approximately 45 degrees.

[0073] Internal protrusions 124 extend inward from the cylindrical outer wall 108 into the interior of the cable end cap 100 adjacentthe open end 112. In the embodiment shown, the internal protrusions 124 correspond to and are aligned with the longitudinal slots 120 and extend from the open end 112 to the longitudinal slots 120. The protrusions 124 retain the elastomeric cap 150 such that the elastomeric cap 150 and cable end cap 100 can be provided pre-assembled. The protrusions 124 also guide the cable 10 into the cable end cap 100. Additionally, in some embodiments, the protrusions 124 provide additional strength to the cable end cap 100, provide resistance against tearing of the end cap 100 between the slots 120 and the open end 112, and grab the cable 10 (and elastomeric cap 150 located thereon). External protrusions 128 extend outward from the cylindrical outer wall 108 away from the interiorof the cable end cap 100. The external protrusions 128wrap abouta portion of the circumference (e.g., approximately half) of the cylindrical outer wall 108 at two spaced apart locations that overlap with the longitudinal slots 120. The external protrusions 128 are a guide for holding a fastener 136 (e.g., a hose clamp) in place on the cylindrical outer wall 108. As shown in FIGS. 7-8, the hose clamp 136 is positioned and retained between the two external protrusions 128 to maintain a central position on the cable end cap. When the hose clamp 136 is tightened on the cable end cap 100, the longitudinal slots 120 are compressed, with the portions of the cylindrical outer wall 108 between the slots effectively closing the slots 120. The size and numberof slots 120 limits the reasonable limit (e.g., without plastically deforming or fracturing) to which the cable end cap 100 is compressible, providing an indication to an installer that the cable end cap 100 has been tightened an appropriate amount.12MBF\214887\0028\52336946.vl-12 / 12 / 25

[0074] FIG. 6 illustrates the elastomeric cap 150 positioned within the cable end cap 100. The elastomeric cap 150 is generally cylindrical, having a substantially cylindrical sidewall 162 extending between a first, open end, 154 and a second, closed end 158. The first end 154 is open to accept the end of the cable 10 that is to be capped within the interior of the elastomeric cap. A second end 158, a closed end, is opposite the first end 154 and is closed to prevent access to the cable 10 within the elastomeric cap 150 through the second end 158. In some embodiments, the elastomeric cap 150 is configured to be placed over the cable 10 until the end of the cable 10 engages the second end 158, where the elastomeric cap is fully seated on the cable 10. One or more (as shown, three) integrated bands 166 extend around and cylindrical sidewall 162 at various locations between the first and second ends 154,158 to create zones of higher compression to promote sealing. In some embodiments, the elastomeric cap 150 fits loosely on the cable 10. In other embodiments, the elastomeric cap may engage the end of the cable 10 with a slight interference fit. The cable end cap 100 substantially covers the elastomeric cap 150 to protect the elastomeric cap 150 from abrasion.

[0075] In operation, the water-tight seal is achieved through compression of the elastomeric cap 150 against the outer surface of the cable 10 jacket. As the cable end cap 100 is tightened, the elastomeric cap 150 is compressed radially inward, causing the inner surface of the elastomeric cap 150 to conform to and seal against the cable 10 jacket. The integrated bands 166 on the elastomeric cap 150 create localized zones of higher compression that promote sealing by concentrating compressive force at discrete locations along the length of the elastomeric cap 150. In some embodiments, the integrated bands 166 may help to seal against minor surface irregularities or discontinuities in the cable 10 jacket. In some aspects, the cable end cap 100 and elastomeric cap 150 may be provided in a pre-assembled configuration, with the elastomeric cap 150 retained within the cable end cap 100 by the internal protrusions 124. The internal protrusions 124 engage the outer surface of the elastomeric cap 150 to prevent the elastomeric cap 150 from falling out of the cable end cap 100 during handling and installation. This pre-assembled configuration may13MBF\214887\0028\52336946.vl-12 / 12 / 25simplify installation by allowing a user to apply both the elastomeric cap 150 and the cable end cap 100 to the cable 10 in a single step.

[0076] In operation, a user identifies a cable 10 needing to be capped and applies the elastomeric cap 150 to the end of the cable 10. In some embodiments, the cable end cap 100 and elastomeric cap 150 are pre-assembled such that applying the elastomeric cap 150 to the end of the cable 10 also includes applying the cable end cap 100 to the end of the of the cable 10. In other embodiments, the cable end cap 100 may be placed over the elastomeric end cap 150 following placement of the end cap 150 onto the cable 10. In some embodiments, the elastomeric cap 150 is wholly within the cable end cap 100. The hose clamp 136 positioned between the external protrusions 128 on the cable end cap 100 is tightened, effectively closing the longitudinal slots 120, at least at places (e.g., at the hose clamp 136). With the hose clamp 136 tightened, the elastomeric cap 150 and cable end cap 100 are not removable from the cable 10 and provide a water-tight seal for the end of the cable 10.

[0077] FIGS. 9-19 illustrate a cable end cap 200. In contrast to the cable end cap 100, which requires a screwdriver for tightening the hose clamp 136, the cable end cap 200 is tightened without the use of tools. Similar to the cable end cap 100, the cable end cap 200 surrounds an end of a cable 10 with an elastomeric cap 150 placed thereon.

[0078] The cable end cap 200 includes an outer housing204, a cage 208, and a camming lever 216 coupled to one another to engage an end of a cable 10. The outer housing 204 is a generally cylindrical, hollow shell having a tapered front end 204A (e.g., at least, tapered at the interior surface such that the internal diameter is decreased at the front end) with an opening 236 sized to receive the end of the cable 10, and more specifically, an elastomeric cap 150 (either in preassembly or in assembly at the cable 10) that engages the end of the cable 10. In some embodiments, if the elastomeric cap 150 is installed in preassembly steps, the elastomeric cap 150 may be otherwise positioned within the cable end cap 200 (e.g., via the opposite end of the cable end cap 200). The cage 208 is positioned within the14MBF\214887\0028\52336946.vl-12 / 12 / 25outer housing 204 and is precluded from movement through the opening 236 at the tapered front end 204A.

[0079] As shown in greater detail in FIG. 19, the cage 208 includes a plurality of slots 210 (e.g., ten slots) that separate an end of the cage 208 into separate fingers 212 (e.g., ten fingers) connected to one another at the opposite end of the cage 208. The cage 208 is configured to receive the elastomeric cap 150 and to tighten around the elastomeric cap 150. Specifically, the fingers 212 are compressible about the elastomeric cap 150 to close the slots 210. The cage 208 is received within the outer housing 204 and is translatable within the outer housing 204 between an untightened position (FIGS. 14-18) and a tightened position (FIGS. 9-13). A rotational and translational stop 214 (FIG. 19) constrains motion of the cage 208 relative to the housing 204 by preventing relative rotation and, in some embodiments, limiting longitudinal movement when the stop 214 engages the housing 204. In some embodiments, longitudinal movement may be limited by other interactions such that the stop 214 may not engage the housing 204.

[0080] The camming lever 216 is received within the outer housing 204 and includes a handle portion 224 and a camming portion 240. The camming portion 240 is located substantially within the housing 204 while the handle portion 224 is generally outside of the housing 204 to be accessible for movement by a user. The camming portion 240 includes a cam surface that engages a rear surface of the cage 208 to move the cage 208 within the housing 204 upon user engagement to the handle portion 224. The handle portion 224 is coupled to (e.g., integrally formed with) the camming portion 240, extending away from the camming portion 240 and movable by the user to rotate the camming portion 240 about a rotational axis defined by a pin 220 extending through the camming portion 240 and the housing 204 (providing rotation of the camming portion 240 relative to the housing 204). The cam surface of the camming portion 240 is a curved profile that deviates from a circular profile centered on the rotational axis such that rotation of the camming portion 240 about the pin 220 results in translation of the cage 208 as different portions of the cam surface engage the cage 208.15MBF\214887\0028\52336946.vl-12 / 12 / 25

[0081] The cam surface of the camming portion 240 may have a profile that deviates from a circular arc centered on the rotational axis defined by the pin 220. In some embodiments, the cam surface may include a gradually increasing radius measured from the rotational axis, such that rotation of the camming portion 240 progressively increases the distance between the pin 220 and the point of contact between the cam surface and the cage 208. This increasing radius translates the rotational motion of the camming lever 216 into linear displacement of the cage 208 within the housing 204. In some aspects, the cam profile may be configured to provide mechanical advantage, such that a relatively small force applied to the handle portion 224 results in a larger compressive force applied to the cage 208 and elastomeric cap 150. The camming action may also provide a self-locking characteristic, where the geometry of the cam surface resists reverse rotation of the camming lever 216 when the cable end cap 200 is in the tightened position. In some embodiments, the cam profile may be configured to provide a progressive increase in compressive force as the camming lever 216 approaches the tightened position, which may help to ensure adequate sealing while reducingthe risk of over-compression.

[0082] As shown in FIG. 18, in the untightened position, the camming portion 240 of the camming lever 216 permits the cage 208 to rest in an uncompressed state, where the fingers 212 are spaced apart from one another. As shown in FIG. 13, in the tightened position, the camming portion 240 pushes the cage forward within the housing 204 (i.e., towards the tapered front end 204A), compressing the distal ends of the fingers 212 within the tapered front end 204A until the slots 210 are closed (e.g., entirely closed, closed to less than 25% of the original width, closed to less than 50% of the original width), thereby tightening the cage 208 on the elastomeric cap 150 and end of the cable 10.

[0083] The handle portion 224 of the camming lever 216 includes an opening 228 (e.g., slot) formed therein. In the tightened position, the handle portion 224 is received on a locking tab or fin 232 extending outward from the outer housing 204 (e.g., radially from the cylindrical surface of the outer housing 204). The opening 228 allows the portions on either side of the handle portion 224 to spread apart such that the handle portion 224 expands over16MBF\214887\0028\52336946.vl-12 / 12 / 25the fin 232. As shown in greater detail in FIGS. 9, 10, 14, and 15, the fin 232 includes a tapered tip that holds the handle portion 224 in the tightened position to prevent loosening of the cable end cap 200 from the tightened position. The handle portion 224 may be removed from the fin 232 by inserting a flat head screwdriver into the opening 228 and twisting to expand a width of the opening 228.

[0084] In operation, a user identifies a cable 10 needing to be capped and applies the elastomeric cap 150 to the end of the cable 10. In some embodiments, the cable end cap 200 and elastomeric cap 150 are pre-assembled such that applying the elastomeric cap 150 to the end of the cable 10 also includes applying the cable end cap 200 to the end of the of the cable 10. In other embodiments, the cable end cap 200 may be placed over the elastomeric end cap 150 following placement of the end cap 150 onto the cable 10. In some embodiments, the elastomeric cap 150 is wholly within the cable end cap 200. The handle portion 224 of the camming lever 216 is rotated from the untightened position to the tightened position, thereby rotating the attached camming portion 240, which pushes the cage 208 forward within the housing 204. As the cage 208 translates forward, the fingers 212 compress within the tapered front end 204A of the housing 204, compressing against the elastomeric cap 150 and cable 10. The handle portion 224 is secured in the tightened position on the fin 232. In the tightened position, the elastomeric cap 150 and cable end cap 200 are not removable from the cable 10 and provide a water-tight seal for the end of the cable 10.

[0085] FIGS. 20-32 illustrate a cable end cap 300. The cable end cap 300 is similar to the cable end cap 200, having an outer housing 304, a cage 312, and a lever 318, though the design and implementation of the same differs from those in the cable end cap 200. The cable end cap 300 offers a toolless installation akin to the cable end cap 200, though is more compact than the cable end cap 200.

[0086] The outer housing 304 is a generally cylindrical, hollow shell having a tapered front end 308 with an opening sized to receive the end of the cable 10, and more specifically, the elastomeric cap 150 (either in preassembly or in assembly at the cable 10) that engages17MBF\214887\0028\52336946.vl-12 / 12 / 25the end of the cable 10. In some embodiments, if the elastomeric cap 150 is installed in preassembly steps, the elastomeric cap 150 may be otherwise positioned within the cable end cap 300 (e.g., via the opposite end of the cable end cap 300). The cage 312 is positioned within the outer housing 304 and is precluded from movement through the opening at the tapered front end 308.

[0087] As shown in greater detail in FIG. 32, the cage 312 is generally similar to the cage 208, having a plurality of slots (e.g., ten slots) that separate an end of the cage 312 into separate fingers 316 (e.g., ten fingers) connected to one another at the opposite end of the cage 312. The cage 312 is configured to receive the elastomeric cap 150 and to tighten around the elastomeric cap 150. Specifically, the fingers 316 are compressible about the elastomeric cap 150 to close the slots. The cage 312 is received within the outer housing 304 and is translatable within the outer housing 304 between an untightened position (FIGS. 26-31 ) and a tightened position (FIGS. 20-25). A pin 324 is received within openings 324B (e.g., circular openings having a similar diameter to the pin 324) on opposing sides of the cage 312 as well as a slot 332 on opposing sides of the outer housing 304 to constrain motion of the cage 312 relative to the housing 304 by preventing relative rotation and limiting longitudinal movement of the cage 312 to the movement of the pin 324 within the slot 332 of the housing 304. In some embodiments, longitudinal travel may be limited by interactions of other components such that the pin 324 may not engage the housing 304 in a forward most position.

[0088] The lever 318 is received within chambers 336 formed on an exterior of the outer housing 304 and includes a handle 328 and a pair of arms 320 that couple the handle 328 to the cage 312 via the pin 324. A majority of the lever 318 is located outside of the housing 304, with the arms 320 extending around the cylindrical sidewall of the housing 304 such that the handle 328 is accessible for movement by a user. The arms 320 each include an opening (e.g., a circular opening similar to the opening 324B in the cage 312) for receiving the pin 324. As such, movement of the arms 320 relative to the housing 304 correspond to movement of the pin 324 within the slot 332 and movement of the cage 312 relative to the18MBF\214887\0028\52336946.vl-12 / 12 / 25housing 304. The handle 328 extends between the two arms 320, connecting the first arm 320 to the second arm 320. As shown, the handle 328 is generally C-shaped to extend over and around the tapered front end 308 of the housing 304 in the tightened position. The handle 328 is coupled to (e.g., integrally formed with) the arms 320 and movable by the user to rotate the arms 320 about a rotational axis defined by the pin 324. As the distal ends of the arms 320 are received within the chambers 336 on the housing 204, rotation of the handle 328 results in translation of the pin 324 within the slot 332, resulting in similar translation of the cage 312 within the housing 304.

[0089] The chambers 336 formed on the exterior of the outer housing 304 may be configured as recessed channels or grooves that receive and guide the distal ends of the arms 320 during actuation of the lever 318. In some embodiments, the chambers 336 may have a curved profile that corresponds to the arc of travel of the arms 320 as the lever 318 is rotated between the untightened position and the tightened position. The chambers 336 may constrain lateral movement of the arms 320 while permitting rotational movement about the pin 324, thereby ensuring consistent and repeatable actuation of the lever 318. The detents 338 may be configured as raised features or protrusions formed on the outer housing 304 adjacent the chambers 336. In some aspects, the detents 338 may have a ramped or tapered profile that allows the arms 320 to deflect outward as the lever 318 is moved toward the tightened position, and then snap back inward behind the detents 338 to lock the lever 318 in the tightened position. The C-shape or U-shape of the handle 328 may provide flexibility that allows the arms 320 to spread apart as they pass over the detents 338. In some embodiments, the detents 338 may be positioned such that the lever 318 is locked in the tightened position only when the fingers 316 have been sufficiently compressed to provide an adequate seal around the elastomeric cap 150 and cable 10.

[0090] As shown in FIG. 30, in the untightened position, the arms 320 of the lever 318 permit the cage 312 to rest in an uncompressed state, where the fingers 316 are spaced apart from one another. As shown in FIG. 24, in the tightened position, the arms 320 push the cage 312 forward within the housing 304 (i.e., towards the tapered front end 308),19MBF\214887\0028\52336946.vl-12 / 12 / 25compressing the distal ends of the fingers 316 within the tapered front end 308 until the slots defined between the fingers 316 are closed (e.g., entirely closed, closed to less than 25% of the original width, closed to less than 50% of the original width), thereby tighteningthe cage 312 on the elastomeric cap 150 and end of the cable 10. The U-shape of the handle 328 provides flexibility, such that detents or snaps 338 formed on the housing 304 flex the arms 320 apart to lock the handle 328 in the tightened position.

[0091] In operation, a user identifies a cable 10 needing to be capped and applies the elastomeric cap 150 to the end of the cable 10. In some embodiments, the cable end cap 300 and elastomeric cap 150 are pre-assembled such that applying the elastomeric cap 150 to the end of the cable 10 also includes applying the cable end cap 300 to the end of the of the cable 10. In other embodiments, the cable end cap 300 may be placed over the elastomeric end cap 150 following placement of the end cap 150 onto the cable 10. In some embodiments, the elastomeric cap 150 is wholly within the cable end cap 300. The handle 328 of the lever 318 is rotated from the untightened position to the tightened position, thereby rotating and translating the attached arms 320, pushingthe cage 312 forward within the housing 304. As the cage 312 translates forward, the fingers 316 compress within the tapered front end 308 of the housing 304, compressing againstthe elastomeric cap 150 and cable 10. The handle 328 is secured in the tightened position on the detents 338. In the tightened position, the elastomeric cap 150 and cable end cap 300 are not removable from the cable 10 and provide a water-tight seal for the end of the cable 10.

[0092] FIGS. 33-39 illustrate a cable end cap 400. The cable end cap 400 is generally similar to the cable end cap 100, except as otherwise described. Rather than the fingers 432 being supported at both ends as in the cable end cap 100, the fingers 432 are cantilevered (free at one end), more similar to the fingers 212, 316 of the cable end caps 200, 300. As such, the hose clamp 444 is mounted nearerthe open end of the cable end cap 400. As with the cable end cap 100, the clearance between fingers 432 defines a compression limit. In contrast to the cable end cap 100, the cable end cap 400 includes a separate sleeve 404 between the fingers 432 and the hose clamp 444 to promote even compression of the fingers20MBF\214887\0028\52336946.vl-12 / 12 / 25432 below the hose clamp 444. In some embodiments, the sleeve 404 is held in place relative to the fingers 432 such that the cable end cap 400 can be supplied as a preassembled unit.

[0093] The cantilevered configuration of the fingers 432 differs functionally from fingers that are supported at both ends, such as those in the cable end cap 100. In the cable end cap 100, the fingers defined between the longitudinal slots 120 are connected to the cylindrical outer wall 108 at both the first end 112 and the second end 116, which may limit the degree to which the fingers can flex inward. In contrast, the cantilevered fingers 432 of the cable end cap 400 are free at one end, which may allow for greater flexibility and a larger range of inward deflection. This increased flexibility may enable the cantilevered fingers 432 to conform more closely to the outer surface of the elastomeric cap 150 and cable 10, potentially improving the seal. In some embodiments, the cantilevered configuration may also reduce the force required to compress the fingers 432, as the fingers 432 are not constrained by a connection at the free end. The sleeve 404 positioned over the cantilevered fingers 432 may help to distribute the compressive force from the hose clamp 444 evenly across all of the fingers 432, promoting uniform compression and sealing.

[0094] The cable end cap 400 includes a housing or cage 402 having a generally cylindricalouterwall428 sized to extend around the end of the cable 10 (and the elastomeric cap 150 located thereon). A first end of the cage 402 is open to permit insertion of the end of the cable 10 into an interior 440 of the cable end cap 400. A second end, opposite the first end, is closed to coverthe sealed end of the elastomeric cap 150. A plurality of longitudinal slots 434 (as shown, evenly spaced about the cylindrical outer wall 428) extend along the cylindrical outer wall 428 from the first end, towards the second end, through may terminate prior to the second end. In the embodiment shown, eight longitudinal slots 434 are spaced about the cylindrical outer wall 428, offset from one another by approximately 45 degrees. The slots 434 define fingers 432 therebetween that are independently flexible to compress against the elastomeric cap 150 and the cable 10.21MBF\214887\0028\52336946.vl-12 / 12 / 25

[0095] External protrusions 436 extend outward from the cylindrical outer wall 428 away from the interior 440 of the cable end cap 400. The external protrusions 436 wrap about a portion of the circumference of the cylindrical outer wall 428 at two spaced apart locations that overlap with the longitudinal slots 434. The external protrusions 436 are a guide for holding a fastener 444 (e.g., a hose clamp) in place on the cylindrical outer wall 428. As shown in FIGS. 37-39, the hose clamp 444 is positioned and retained between the two external protrusions 436 to maintain its position on the cable end cap 400. In some embodiments, as shown, the sleeve 404 is located between the hose clamp 444 and the cage 402.

[0096] As shown, the sleeve 404 is generally annular, defining a central opening 424 within which the cage 402 is receivable. The sleeve 404 is not purely annular, as it does not form a complete loop, with a gap formed between two edges 416, 420 of the sleeve 404. As shown, the two edges 416, 420 are parallel to one another, though angled (e.g., at 45 degrees) relative to the axis of the sleeve 404. The angled gap ensures that all fingers 432 are in contact with the sleeve 404. Lower and upper rims 408, 412 of the sleeve 404 function to retain the hose clamp 444 on the sleeve 404, between the two rims 408, 412.

[0097] The angled orientation of the gap between the edges 416, 420 of the sleeve 404 may ensure that all of the fingers 432 remain in contact with the inner surface of the sleeve 404 during compression. If the gap were oriented parallel to the axis of the sleeve 404, one or more of the fingers 432 might align with the gap and lose contact with the sleeve 404, resultingin uneven compression. By angling the gap relative to the axis of the sleeve 404, the gap is distributed across multiple fingers 432 such that no single finger 432 is entirely unsupported by the sleeve 404. In some embodiments, the angle of the gap may de selected to ensure that the gap spans at least two adjacent fingers 432, thereby preventing any finger 432 from being entirely within the gap. This configuration may promote more uniform compression of the fingers 432 and a more consistent seal around the elastomeric cap 150 and cable 10. In some aspects, the angled gap may also facilitate assembly of the sleeve22MBF\214887\0028\52336946.vl-12 / 12 / 25404 onto the cage 402, as the angled edges 416, 420 may guide the sleeve 404 into position as it is slid over the fingers 432.

[0098] The gap between the edges 416, 420 provides flexibility of the sleeve 404 so that the inner diameter of the sleeve 404 can be increased to slide the sleeve 404 between the external protrusions 436 formed on the cage 402 and can be decreased by the hose clamp 444 to tighten the sleeve 404 on the fingers 432, elastomeric cap 150, and cable 10.

[0099] When the hose clamp 444 is tightened on the sleeve 404 of the cable end cap 400, the longitudinal slots 434 are compressed, with the portions of the cylindrical outer wall 428 between the slots effectively closing the slots 434. The size and number of slots 434 limits the reasonable limit (e.g., without plastically deforming or fracturing) to which the cable end cap 400 is compressible, providing an indication to an installer that the cable end cap 400 has been tightened an appropriate amount.

[0100] In operation, a user identifies a cable 10 needing to be capped and applies the elastomeric cap 150 to the end of the cable 10. In some embodiments, the cable end cap 400 and elastomeric cap 150 are pre-assembled such that applyingthe elastomeric cap 150 to the end of the cable 10 also includes applying the cable end cap 400 to the end of the of the cable 10. In other embodiments, the cable end cap 400 may be placed over the elastomeric end cap 150 following placement of the end cap 150 onto the cable 10. In some embodiments, the elastomeric cap 150 is wholly within the cable end cap 400. The hose clamp 444 positioned between the rims 408, 412 on the sleeve 404 is tightened, effectively closing the longitudinal slots 434, at least at places (e.g., at the hose clamp 444). With the hose clamp 444 tightened, the elastomeric cap 150 and cable end cap 400 are not removable from the cable 10 and provide a water-tight seal for the end of the cable 10.

[0101] FIGS. 40-46 illustrate a cable end cap 500. The cable end cap 500 is similar to the cable end cap 400, except as otherwise described. Like elements are identified with like reference numerals, incremented by 100.23MBF\214887\0028\52336946.vl-12 / 12 / 25

[0102] In contrast to the use of a hose clamp 444 with the sleeve 404, the sleeve 504 of the cable end cap 500 includes two protruding walls 516, 520 at the spaced apart ends of the sleeve 504, each of which includes an opening548. The openings 548 receive a fastener, such as a threaded fastener 544A (e.g., a screw) retained within the openings 548 by a nut 544B. The threaded fastener 544A is tightened relative to the nut 544B to compress the fingers 532, rather than using a hose clamp. Operation of the cable end cap 500 is otherwise similar to the cable end cap 400. In other embodiments, in place of the nut 544B, one or both of the openings 548 may be threaded to tighten the sleeve 504 on the fingers 532.

[0103] The end caps 100, 200, 300, 400, 500 may be produced, in some embodiments, via additive manufacturing, such as via fused deposition modeling (FDM) or selective laser sintering (SLS). In other embodiments, the end caps 100, 200, 300, 400, 500 may be produced via injection molding. The end caps 100, 200, 300, 400, 500 have strength requirements to withstand breaking in normal use, flexibility requirements to allow for compression and flexure upon tightening, and may have requirements to withstand weather (e.g., UV, precipitation, etc.) in outdoor uses. In some embodiments, the material used to form the end caps 100, 200, 300, 400, 500 may include acrylonitrile butadiene styrene (ABS), polycarbonate (PC), nylon, or an ABS / PC blend.

[0104] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications existwithin the scope and spirit of one or more independent aspects of the invention as described.24MBF\214887\0028\52336946.vl-12 / 12 / 25

Claims

CLAIMS1. A cable end cap assembly for enclosing an end of a cable, the cable end cap assembly comprising: an elastomeric cap configured to be positioned on the end of the cable; a cage having deformable fingers positioned on the elastomeric cap; and a compression mechanism configured to compress the fingers on the elastomeric cap from an untightened position to a tightened position and hold the fingers in the tightened position.

2. The cable end cap assembly of claim 1 , wherein the compression mechanism includes a hose clamp positioned on the cage.

3. The cable end cap assembly of claim 2, further comprising a sleeve located between the cage and the hose clamp.

4. The cable end cap assembly of claim 1 , wherein the compression mechanism includes a housing and a camming lever configured to displace the cage relative to the housing.

5. The cable end cap assembly of claim 1 , wherein the compression mechanism includes a housing surrounding the cage and defining a slot, and a handle coupled to the cage via a pin, wherein the pin extends through the slot of the housing and is movable within the slot between the untightened position and the tightened position.

6. The cable end cap assembly of claim 1 , wherein the elastomeric cap includes one or more integrated bands extending circumferentially around an outer surface of the elastomeric cap.25MBF\214887\0028\52336946.vl-12 / 12 / 257. The cable end cap assembly of claim 1 , wherein the cage includes a plurality of longitudinal slots that define the deformable fingers therebetween.

8. The cable end cap assembly of claim 1 , wherein the cage includes a closed end configured to cover a distal end of the elastomeric cap and an open end configured to receive the cable.

9. The cable end cap assembly of claim 1 , wherein the elastomeric cap is formed of a material selected from the group consisting of silicone, neoprene, ethylene propylene diene monomer, a synthetic rubber polymer, a fluoroelastomer, and a thermoplastic elastomer.

10. The cable end cap assembly of claim 1 , wherein the compression mechanism includes external protrusions extending outward from the cage, the external protrusions configured to retain a fastener in position on the cage.

11. A cable end cap assembly comprising: an elastomeric cap; and a compression mechanism configured to compress around the elastomeric cap.

12. The cable end cap assembly of claim 11 , wherein the compression mechanism includes a cage having a cylindrical outer wall with a plurality of longitudinal slots extending along the cylindrical outer wall, the longitudinal slots defining fingers therebetween, wherein the cage includes a first end that is open and a second end that is closed, wherein internal protrusions extend inward from the cylindrical outer wall adjacent the first end, wherein external protrusions extend outward from the cylindrical outer wall at two spaced apart locations that overlap with the longitudinal slots, and wherein a hose clamp is positioned and retained between the two external protrusions, the hose clamp configured to compress the longitudinal slots when tightened.26MBF\214887\0028\52336946.vl-12 / 12 / 2513. The cable end cap assembly of claim 11, wherein the compression mechanism includes an outer housing having a tapered front end with an opening sized to receive the elastomeric cap, a cage positioned within the outer housing and having a plurality of slots that separate an end of the cage into separate fingers connected to one another at an opposite end of the cage, a camming lever received within the outer housing and including a handle portion and a camming portion, wherein the camming portion includes a cam surface that engages a rear surface of the cage, a pin extending through the camming portion and the outer housing to define a rotational axis about which the camming lever rotates, and a fin extending outward from the outer housing, wherein the handle portion includes an openingformed therein and is configured to be received on the fin in a tightened position.

14. The cable end cap assembly of claim 11, wherein the compression mechanism includes an outer housing having a tapered front end with an opening sized to receive the elastomeric cap, a cage positioned within the outer housing and having a plurality of slots that separate an end of the cage into separate fingers connected to one another at an opposite end of the cage, a lever including a handle and a pairof arms that couple the handle to the cage via a pin, wherein the arms each include an opening for receiving the pin, wherein the outer housing defines a slot on opposing sides through which the pin extends, wherein the pin is movable within the slot of the outer housing between an untightened position and a tightened position, wherein chambers are formed on an exterior of the outer housing within which distal ends of the arms are received, and wherein detents are formed on the outer housing to lock the lever in the tightened position.

15. The cable end cap assembly of claim 11 , wherein the compression mechanism includes a cage having a cylindrical outer wall with a plurality of longitudinal slots extending along the cylindrical outer wall from a first open end toward a second closed end, the longitudinal slots defining cantilevered fingers therebetween, wherein external protrusions extend outward from the cylindrical outer wall at two spaced apart locations, a sleeve positioned on the cage between the external protrusions, wherein the sleeve is generally27MBF\214887\0028\52336946.vl-12 / 12 / 25annular and defines a central opening within which the cage is receivable, wherein the sleeve includes a gap formed between two edges that are parallel to one another and angled relative to an axis of the sleeve, wherein the sleeve includes lower and upper rims configured to retain a hose clamp on the sleeve between the two rims, and wherein the hose clamp is configured to decrease an inner diameter of the sleeve to compress the fingers against the elastomeric cap.

16. The cable end cap assembly of claim 11, wherein the compression mechanism includes a cage having a cylindrical outer wall with a plurality of longitudinal slots extending along the cylindrical outer wall, the longitudinal slots defining cantilevered fingers therebetween, wherein external protrusions extend outward from the cylindrical outer wall at spaced apart locations, a sleeve positioned on the cage, wherein the sleeve includes two protruding walls at spaced apart ends of the sleeve, wherein each protruding wall includes an opening, and wherein a threaded fastener extends through the openings and is retained by a nut, the threaded fastener configured to be tightened relative to the nut to compress the fingers against the elastomeric cap.

17. A method of enclosing an end of a cable, the method comprising: positioning an elastomeric cap on the end of the cable; positioning a cage having deformable fingers around the elastomeric cap; compressingthe fingers from an untightened position to a tightened position using a compression mechanism; and holdingthe fingers in the tightened position with the compression mechanism.

18. The method of claim 17, wherein compressingthe fingers includes tightening a hose clamp positioned on the cage.28MBF\214887\0028\52336946.vl-12 / 12 / 2519. The method of claim 17, wherein compressing the fingers includes rotating a camming lever to displace the cage relative to a housing, thereby compressing the fingers within a tapered front end of the housing.

20. The method of claim 17, wherein positioning the elastomeric cap on the end of the cable and positioning the cage around the elastomeric cap are performed simultaneously by applying a pre-assembled cable end cap assembly to the end of the cable.29MBF\214887\0028\52336946.vl-12 / 12 / 25

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