Adhesive Cable Splice Seal for Thermal Cycling Reliability
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Solution Overview
Problem
Existing cable connection assemblies fail to maintain a reliable seal during heat cycling, leading to leakage of dielectric enhancement fluid and water ingress, which compromises the insulation layer and reduces the lifespan of cables.
Innovation Solution
A cable splice connection assembly with a main body and collar assemblies that utilize adhesive seals, selected from materials like acrylic, epoxy, and thermosetting adhesives, to create a fluid-tight seal between the cables and the main body, maintaining mechanical strength even during thermal changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing devices like O-ring seals are used in cable connection assemblies, then the assembly structure is simple and easy to manufacture, but the seal fails during heat cycling allowing fluid leakage
Solution Approach 1:
The patent changes the sealing mechanism from mechanical (O-rings relying on compression) to chemical (adhesive bonds). The adhesive sealant is applied to the interface between the cable insulation and collar, creating a chemical bond that maintains sealing integrity during thermal expansion and contraction, eliminating the reliability issues of traditional mechanical seals.
Solution Approach 2:
The patent replaces the mechanical O-ring seal system with an adhesive-based sealing system. Instead of using elastic deformation of O-rings to maintain seal pressure, the invention uses adhesive chemistry to create a permanent bond that seals the interface, substituting mechanical sealing with chemical bonding.
2Reliability
If dielectric enhancement fluid is injected into the cable insulation layer, then water tree growth is eliminated or retarded, but the fluid leaks from the cable during heat cycling
Solution Approach 1:
The adhesive seal acts as an intermediary barrier between the dielectric enhancement fluid inside the cable insulation and the external environment. This adhesive layer prevents the fluid from migrating out of the cable during thermal cycling, while still allowing the fluid to perform its function of preventing water tree growth within the insulation layer.
Solution Approach 2:
The adhesive seal is applied in advance to prevent fluid leakage before heat cycling occurs. By establishing the seal during assembly, the system proactively prevents the harmful effect of fluid leakage that would otherwise occur during subsequent thermal expansion and contraction cycles.
3Reliability
If O-ring seals are used to seal cable connections, then the sealing mechanism is simple, but the seals fail when insulation layer tension is released during heat cycling
Solution Approach 1:
The patent replaces the mechanical O-ring seal system with an adhesive-based sealing system. Instead of using elastic deformation of O-rings to maintain seal pressure, the invention uses adhesive chemistry to create a permanent bond that seals the interface, substituting mechanical sealing with chemical bonding.
Solution Approach 2:
The sealing solution uses composite material properties by combining the adhesive sealant with the cable insulation and collar materials. The adhesive forms a composite bonded structure that integrates these different materials into a unified sealing system that maintains integrity under thermal stress.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adhesive seals effectively prevent fluid leakage and water entry, enhancing the mechanical strength and reliability of the cable connections, thereby extending the lifespan of the cables by maintaining a consistent seal during dynamic thermal conditions.
Implementation Method 1
the cable seal includes an adhesive seal
Data Source
AI summary
A cable splice connection assembly for coupling a first cable to a second cable generally includes a main body having first and second ends and defining an inner cavity, the first end configured to receive at least a portion of a first cable therein, and the second end configured to receive at least a portion of a second cable therein, and a first engagement mechanism configured to couple the main body to a first cable wherein the first engagement mechanism includes a cable seal, wherein the cable seal includes an adhesive seal.