Cable splice
The cable splice design with a housing, dams, and encapsulant addresses the need for a robust and waterproof connection for multi-conductor cables, achieving a hermetically sealed and physically strong joint.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ACLARA TECHNOLOGIES LLC
- Filing Date
- 2025-12-16
- Publication Date
- 2026-06-25
AI Technical Summary
Existing cable splicing methods fail to provide a robust, waterproof, and compact connection that maintains the integrity of multi-conductor cables while allowing for efficient encapsulation and protection against environmental factors.
A cable splice design featuring a housing with U-shaped cutouts, dams, and longitudinal dividers, combined with an encapsulant, that securely joins and encapsulates the ends of multi-conductor cables, forming a hermetically sealed and physically strong connection.
The solution provides a hermetically sealed, waterproof, and compact cable splice with high physical strength, effectively protecting the joined cables from environmental factors and ensuring a reliable electrical connection.
Smart Images
Figure US2025059792_25062026_PF_FP_ABST
Abstract
Description
CABLE SPLICECROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 63 / 734,462, filed December 16, 2024, titled "Cable Splice," the entire contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION
[0002] Cables such as multi conductor cables may be spliced together when cut or to connect one cable to another cable.SUMMARY OF THE INVENTION
[0003] In some aspects, the techniques described herein relate to a cable splice including: a housing having a first end wall with a first cutout formed therein and a second end wall opposite the first end wall, with a second cutout formed therein, the housing defining an interior volume between the first and second end walls, a first sidewall, a second sidewall, and a base, wherein the first cutout is configured to receive a first cable and the second cutout is configured to receive a second cable joined to the first cable; a first dam received within the interior volume of the housing adjacent the first end wall, the first dam having a cutout configured to receive the first cable, the first dam configured to close a portion of the first cutout of the housing; a second dam received within the interior volume of the housing adjacent the second end wall, the second dam having a cutout configured to receive the second cable, the second dam configured to close a portion of the second cutout of the housing; an encapsulant located within the interior volume and configured to encapsulate a portion of the first cable and a portion of the second cable within the interior volume.
[0004] In some aspects, the techniques described herein relate to a cable splice, wherein the first cutout and the second cutout are each U-shaped and extend from an upper side of the housing toward a base of the housing.
[0005] In some aspects, the techniques described herein relate to a cable splice, wherein the cutout of the first dam is inverted U-shaped and the cutout of the second dam is inverted U-shaped,1MBF\214887\0030\52318875.vl-12 / 10 / 25such that the cutout of the first dam and the first cutout collectively form a substantially circular opening and the cutout of the second dam and the second cutout collectively form a substantially circular opening.
[0006] In some aspects, the techniques described herein relate to a cable splice, further including a first divider positioned within the interior volume adjacent the first end wall and a second divider positioned within the interior volume adjacent the second end wall, wherein the first divider and the first end wall define a first chamber therebetween configured to receive the first dam, and the second divider and the second end wall define a second chamber therebetween configured to receive the second dam.
[0007] In some aspects, the techniques described herein relate to a cable splice, wherein the first divider includes a divider cutout aligned with the first cutout and the second divider includes a divider cutout aligned with the second cutout.
[0008] In some aspects, the techniques described herein relate to a cable splice, wherein the first end wall includes a longitudinal protrusion extending into the first chamber and configured to apply pressure on the first dam toward the first divider, and the second end wall includes a longitudinal protrusion extending into the second chamber and configured to apply pressure on the second dam toward the second divider.
[0009] In some aspects, the techniques described herein relate to a cable splice, further including one or more longitudinal dividers extending within the interior volume in a direction parallel to the first sidewall and the second sidewall, the one or more longitudinal dividers configured to separate joined conductors of the first cable and the second cable from one another.
[0010] In some aspects, the techniques described herein relate to a cable splice, wherein the one or more longitudinal dividers extend upward from a base of the housing and are spaced apart from the first end wall and the second end wall.
[0011] In some aspects, the techniques described herein relate to a cable splice, wherein the one or more longitudinal dividers include three longitudinal dividers that separate a central portion of the interior volume into four channels.2MBF\214887\0030\52318875.vl-12 / 10 / 25
[0012] Tn some aspects, the techniques described herein relate to a cable splice, wherein the encapsulant includes an epoxy or a urethane.
[0013] In some aspects, the techniques described herein relate to a cable splice, wherein the encapsulant cures to a rigid consistency.
[0014] In some aspects, the techniques described herein relate to a cable splice, wherein the housing and the first and second dams are fabricated via additive manufacturing.
[0015] In some aspects, the techniques described herein relate to a cable splice, wherein the first cable and the second cable are multiconductor cables each having a jacket surrounding multiple wires.
[0016] In some aspects, the techniques described herein relate to a method of forming a cable splice, the method including: joining together an end of a first cable and an end of a second cable; positioning the end of the first cable and the end of the second cable within an interior volume of a housing, such that the first cable extends through a cutout in a first end wall of the housing and the second cable extends through a cutout in a second end wall of the housing; inserting a first dam adjacent the first end wall to surround the first cable and close up a portion of the cutout in the first end wall; inserting a second dam adjacent the second end wall to surround the second cable and close up a portion of the cutout of the second end wall; and filling the interior volume with an encapsulant to surround the end of the first cable and the end of the second cable.
[0017] In some aspects, the techniques described herein relate to a method, wherein joining together the end of the first cable and the end of the second cable includes soldering conductors of the first cable to conductors of the second cable.
[0018] In some aspects, the techniques described herein relate to a method, wherein joining together the end of the first cable and the end of the second cable includes at least one of crimping, sonic welding, or using screw terminals.
[0019] In some aspects, the techniques described herein relate to a method, further including cutting and stripping the first cable and the second cable to expose individual conductors prior to joining together the end of the first cable and the end of the second cable.3MBF\214887\0030\52318875.vl-12 / 10 / 25
[0020] Tn some aspects, the techniques described herein relate to a method, wherein the cutout in the first end wall and the cutout in the second end wall are each U-shaped, and wherein the first dam and the second dam each include an inverted U-shaped cutout that closes an upper portion of the respective U-shaped cutout.
[0021] In some aspects, the techniques described herein relate to a method, further including positioning joined conductors of the first cable and the second cable within channels defined by one or more longitudinal dividers extending within the interior volume.
[0022] In some aspects, the techniques described herein relate to a method, wherein filling the interior volume with the encapsulant includes introducing an epoxy or a urethane into the interior volume and allowing the encapsulant to cure to a rigid consistency.• BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. l is a perspective view of a housing of a cable splice.
[0024] FIG. 2 is a top view of the housing of the cable splice of FIG. 1.
[0025] FIG. 3 is an end view of the housing of the cable splice of FIG. 1.
[0026] FIG. 4 is a side view of the housing of the cable splice of FIG. 1.
[0027] FIG. 5 is a cross-section through the housing of the cable splice of FIG. 1.
[0028] FIG. 6 is a perspective view of a dam of the cable splice.
[0029] FIG. 7 is an end view of the dam of the cable splice of FIG. 6.
[0030] FIG. 8 is a side view of the dam of the cable splice of FIG. 6.
[0031] FIG. 9 is a perspective view of two cable splices with two spliced cables received therein.
[0032] 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. The4MBF\214887\0030\52318875.vl-12 / 10 / 25invention 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
[0033] A cable splice includes a housing 100 (FIGS. 1-5) and a pair of dams 200 (FIGS. 6-8) that collectively surround distal, joined ends of a pair of cables 300, 400 (FIG. 9). Each cable 300, 400 may be, in some embodiments, a multi conductor cable having a jacket surrounding multiple wires (such as insulated and / or non-insulated wires). An encapsulant 500 (FIG. 9) fdls the housing 100, encapsulating the distal ends of the cables 300, 400 in a watertight manner.
[0034] FIGS. 1-5 illustrate the housing 100. The housing 100 includes first and second sidewalls 104, 108 that extend substantially parallel to one another along a longitudinal direction of the housing 100. First and second end walls 112, 116 extend between the first and second sidewalls 104, 108, (e.g., perpendicular to the sidewalls 104, 108) and connect the first sidewall 104 to the second sidewall 108 at the lengthwise extents of each. Collectively, the sidewalls 104, 108 and end walls 112, 116 define an overall height, width, and length of the housing 100. A base 120 extends between all four walls 104, 108, 112, 116 at a lower end of each. The base 120 defines a bottom side of the housing 100. An upper side 124 of the housing 100 is defined by an upper edge of the four walls 104, 108, 112, 116 and is opposite the lower side and base 120. The four walls 104, 108, 112, 116 and base 120 collectively define an internal volume 128 within which the distal ends of the cables 300, 400 may be positioned. While shown as rectangular, the walls 104, 108, 112, 116 may form other shapes such as a racetrack (having curved ends), an oval, a circle, or other shapes to accommodate the preferred insertion direction of the cables 300, 400.
[0035] A divider 136 is positioned within the internal volume 128 of the housing 100 adjacent to each of the first end wall 112 and the second end wall 116 and extends substantially parallel to the respective end walls 112, 116. In some embodiments, the dividers 136 are formed integrally with the remainder of the housing 100. The dividers 136 partition off a small internal volume or chamber 132 adjacent each of the two end walls 112, 116, each sized to receive one of the dams 200 (FIGS. 6-8).5MBF\214887\0030\52318875.vl-12 / 10 / 25
[0036] Each of the end walls 112, 116 includes a notch or cutout 140 extending from the upper side 124 of the housing 100 downwards toward the base 120 of the housing 100. As shown, the cutout is generally U-shaped and is sized to accept a cable 300, 400 (e.g., a multiconductor cable). The lower, curved portion of the cutout 140 may have a diameter approximately the same diameter (e.g., the same diameter, 0-5% greater than the diameter) of the cable 300, 400. The lower-curved portion of the cutout is spaced apart from the base 120 and the upper side 124 such that when a cable 300, 400 is positioned therein, the interior volume 128 (to be fdled with an encapsulant) extends above, below, and to both sides of the cable 300, 400.
[0037] Each of the dividers 136 includes a cutout 144 sized and shaped similar to the cutout 140 on the adjacent end wall 112, 116. As shown in, for example, FIGS. 2, 3, and 5, the cutouts 140, 144 are aligned with one another along the length of the housing 100 such that a cable 300, 400 extends in the longitudinal direction when simultaneously extending through the two cutouts 140, 144. The cutouts 144 provide access for the cables 300, 400 to be inserted into the central portion of the internal volume 128.
[0038] Longitudinal dividers 148 extend in the longitudinal direction (e.g., parallel to the side walls 104, 108 and parallel to the length of the cables 300, 400 positioned within the housing 100) within the interior volume 128 of the housing 100. The longitudinal dividers 148 extend upward from the base 120, spaced apart from each of the walls 104, 108, 112, 116. As shown, three longitudinal dividers 148 (along with the interior surfaces of the two sidewalls 104, 108) separate a central portion of the interior volume 128 into four channels. One or more of the four channels are configured to simultaneously receive the soldered (or otherwise joined) connection of two conductors (e.g., wires) of the two cables 300, 400, as shown in FIG. 9. As such, the longitudinal dividers 148 separate the joined ends of the spliced cables 300, 400 from adjacent joined ends of the cables 300, 400.
[0039] FIGS. 6-8 illustrate a dam 200. A dam 200 is received within each one of the chambers 132 to seal off the cutouts 140, 144 when the cables 300, 400 extend therethrough. The dam 200 has a front side 204 and a rear side 208 and an inverted U-shaped cutout 212 extending through the dam 200 from the front side 204 to the rear side 208. When positioned within the chamber 132, the front side 204 of the dam 200 is positioned adjacent the end wall 112, 116 of the housing6MBF\214887\0030\52318875.vl-12 / 10 / 25100 and the rear side 208 of the dam 200 is positioned adjacent the divider 136 of the housing 100. In some embodiments, the dam 200 is reversible such that the front side 204 of the dam 200 is also positionable adjacent the divider 136 of the housing 100 and the rear side 208 of the dam 200 is positionable adjacent the end wall 112, 116 of the housing 100. The end walls 112, 116 include longitudinal protrusions 152 extending into the chamber 132 that apply pressure on the dam 200 to push the dam 200 against divider 136, providing a stronger seal against the encapsulant 500 placed within the interior volume 128.
[0040] The cutout 212 of the dam 200 is aligned with the cutouts 140, 144 of the housing 100, though rather than extending in a U-shape, the cutout 212 has an inverted U-shape, such that the dam 200 closes off the upper portion of the U-shaped cutout 140, 144 to prevent leakage of the encapsulant 500, and also holds the cable 300, 400 within the inverted U-shaped cutout 212 against the bottom of the U-shaped cutouts 140, 144. Collectively, the cutouts 140, 144, 212 provide a roughly circular opening through which one of the cables 300, 400 extends, with the remainder of the sidewall 208, 212, divider 136, and dam 200 closing the end of the housing 100 to hold the encapsulant 500 within the interior volume 128.
[0041] In other embodiments, the dam may have a different shape or material. In some embodiments, the dam is formed as a rubber grommet positioned within the chambers 132. In some embodiments, the dams include a central opening (rather than a slotted opening in the dam 200) that is closed on all sides through which the cable 300, 400 is linearly insertable prior to soldering to the other of the cables 300, 400.
[0042] FIG. 9 illustrates two housings 100 having spliced cables 300, 400 positioned therein, and encapsulant 500 covering the cables 300, 400. In operation, the cable splice is formed by cutting and stripping the first cable 300 and the second cable 400 to expose the individual conductors of the two cables 300, 400 that are to be joined. The mating conductors of the two cables 300, 400 are soldered together or otherwise joined together via other methods such as crimping, sonic welding, or using screw terminals. The joined ends of the spliced cables 300, 400 are positioned within the housing 100, such that the cables 300, 400 extend through the opposing housing end slots. The joined conductors are separated from one another by the longitudinal dividers 148, with the joints disposed within the interior volume 128 between the dividers7MBF\214887\0030\52318875.vl-12 / 10 / 25148. The dams 200 are then inserted into place within the chambers 132. The encapsulant 500 (e g., adhesive or potting compound) is introduced into the interior volume 128 of the housing 100, flowing below, above, and around the cables 300, 400 on all sides within the interior volume 128, and cures to a hard (rigid) consistency. In some embodiments, the encapsulant 500 is (or includes) an epoxy or urethane, providing physical strength to the joint. As the encapsulant cures, the dams 200 substantially prevent leakage. Once cured, the cable splice is a hermetically sealed and a waterproof joint, in-line with the cables 300, 400, with high physical strength and a compact form factor.
[0043] In some embodiments, the components of the cable splice, such as the housing 100 and the dams 200, may be fabricated via additive manufacturing. As such, the size of the cutouts 140, 144, 212 may be selected to correspond to the outer diameter of the cables 300, 400 to substantially prevent leakage of the encapsulant therethrough. The size of the interior volume 128 and the number of longitudinal dividers 148 may likewise be chosen depending on the number of spliced conductors to be encapsulated. In other embodiments, the housing 100 and dams 200 may be formed of other manufacturing methods such as injection molding.
[0044] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.8MBF\214887\0030\52318875.vl-12 / 10 / 25
Claims
CLAIMS1. A cab 1 e spl i ce compri sin : a housing having a first end wall with a first cutout formed therein and a second end wall opposite the first end wall, with a second cutout formed therein, the housing defining an interior volume between the first and second end walls, a first sidewall, a second sidewall, and a base, wherein the first cutout is configured to receive a first cable and the second cutout is configured to receive a second cable joined to the first cable; a first dam received within the interior volume of the housing adjacent the first end wall, the first dam having a cutout configured to receive the first cable, the first dam configured to close a portion of the first cutout of the housing; a second dam received within the interior volume of the housing adjacent the second end wall, the second dam having a cutout configured to receive the second cable, the second dam configured to close a portion of the second cutout of the housing; an encapsulant located within the interior volume and configured to encapsulate a portion of the first cable and a portion of the second cable within the interior volume.
2. The cable splice of claim 1, wherein the first cutout and the second cutout are each U- shaped and extend from an upper side of the housing toward a base of the housing.
3. The cable splice of claim 1, wherein the cutout of the first dam is inverted U-shaped and the cutout of the second dam is inverted U-shaped, such that the cutout of the first dam and the first cutout collectively form a substantially circular opening and the cutout of the second dam and the second cutout collectively form a substantially circular opening.
4. The cable splice of claim 1, further comprising a first divider positioned within the interior volume adjacent the first end wall and a second divider positioned within the interior volume adjacent the second end wall, wherein the first divider and the first end wall define a first chamber therebetween configured to receive the first dam, and the second divider and the second end wall define a second chamber therebetween configured to receive the second dam.9MBF\214887\0030\52318875.vl-12 / 10 / 255. The cable splice of claim 4, wherein the first divider includes a divider cutout aligned with the first cutout and the second divider includes a divider cutout aligned with the second cutout.
6. The cable splice of claim 4, wherein the first end wall includes a longitudinal protrusion extending into the first chamber and configured to apply pressure on the first dam toward the first divider, and the second end wall includes a longitudinal protrusion extending into the second chamber and configured to apply pressure on the second dam toward the second divider.
7. The cable splice of claim 1, further comprising one or more longitudinal dividers extending within the interior volume in a direction parallel to the first sidewall and the second sidewall, the one or more longitudinal dividers configured to separate j oined conductors of the first cable and the second cable from one another.
8. The cable splice of claim 7, wherein the one or more longitudinal dividers extend upward from a base of the housing and are spaced apart from the first end wall and the second end wall.
9. The cable splice of claim 7, wherein the one or more longitudinal dividers comprise three longitudinal dividers that separate a central portion of the interior volume into four channels.
10. The cable splice of claim 1, wherein the encapsulant comprises an epoxy or a urethane.
11. The cable splice of claim 1, wherein the encapsulant cures to a rigid consistency.
12. The cable splice of claim 1, wherein the housing and the first and second dams are fabricated via additive manufacturing.
13. The cable splice of claim 1 , wherein the first cable and the second cable are multi conductor cables each having a jacket surrounding multiple wires.10MBF\214887\0030\52318875.vl-12 / 10 / 2514. A method of forming a cable splice, the method comprising: joining together an end of a first cable and an end of a second cable; positioning the end of the first cable and the end of the second cable within an interior volume of a housing, such that the first cable extends through a cutout in a first end wall of the housing and the second cable extends through a cutout in a second end wall of the housing; inserting a first dam adjacent the first end wall to surround the first cable and close up a portion of the cutout in the first end wall; inserting a second dam adjacent the second end wall to surround the second cable and close up a portion of the cutout of the second end wall; and filling the interior volume with an encapsulant to surround the end of the first cable and the end of the second cable.
15. The method of claim 14, wherein joining together the end of the first cable and the end of the second cable comprises soldering conductors of the first cable to conductors of the second cable.
16. The method of claim 14, wherein joining together the end of the first cable and the end of the second cable comprises at least one of crimping, sonic welding, or using screw terminals.
17. The method of claim 14, further comprising cutting and stripping the first cable and the second cable to expose individual conductors prior to joining together the end of the first cable and the end of the second cable.
18. The method of claim 14, wherein the cutout in the first end wall and the cutout in the second end wall are each U-shaped, and wherein the first dam and the second dam each include an inverted U-shaped cutout that closes an upper portion of the respective U-shaped cutout.
19. The method of claim 14, further comprising positioning joined conductors of the first cable and the second cable within channels defined by one or more longitudinal dividers extending within the interior volume.11MBF\214887\0030\52318875.vl-12 / 10 / 2520. The method of claim 14, wherein filling the interior volume with the encapsulant comprises introducing an epoxy or a urethane into the interior volume and allowing the encapsulant to cure to a rigid consistency.12MBF\214887\0030\52318875.vl-12 / 10 / 25