Cable Connector Sealant Flow Blocking Wall
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Solution Overview
Problem
Existing cable connection systems face challenges in maintaining a secure seal and preventing oil leakage in oil-impregnated paper-insulated lead cables (PILC) during splicing, particularly due to the flow of mastic sealant along the connector axis, which can compromise the integrity of the electrical and mechanical joint.
Innovation Solution
A cable connection assembly featuring a conductive connector with a ring-shaped sealant flow blocking wall and a flowable sealant, combined with a restricting tape or tube, to inhibit the flow of mastic along the connector axis and ensure a secure seal, utilizing a shear bolt connector and O-ring or sealant flow block wall to prevent mastic displacement and maintain oil containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mastic sealant is applied around the connector to provide electrical stress relief and seal, then the seal integrity and electrical stress relief are improved, but the mastic may flow along the connector axis causing voids and compromising the joint integrity
Solution Approach 1:
The patent applies preliminary action by pre-forming the mastic sealant around the connector body before final assembly, ensuring proper positioning and preventing flow along the connector axis. The mastic is applied in a controlled manner around the connector body to provide electrical stress relief while maintaining seal integrity without flowing into voids or compromising the joint.
2Reliability
If heat shrinkable sleeve is used to contain oil in PILC cables, then oil containment is improved, but additional sealant material is needed at each end of the sleeve which increases complexity
Solution Approach 1:
The patent merges the oil containment function and sealant sealing function into a single integrated structure. The connector body design combines the heat shrinkable sleeve for oil containment with the mastic sealant application in one unified assembly, eliminating the need for separate sealant applications at each end of the sleeve and reducing overall complexity.
3Reliability
If connector body provides electrical connection between cables, then electrical continuity is improved, but the connector surface allows mastic flow which can create voids and reduce reliability
Solution Approach 1:
The patent applies local quality by modifying specific regions of the connector body surface to control mastic flow. The connector body has differentiated surface characteristics - areas where mastic should be contained versus areas where it should flow freely. This localized surface treatment prevents mastic from flowing along the connector axis while maintaining electrical continuity in the conductor cavities.
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 solution effectively prevents oil leakage and maintains electrical stress relief, ensuring the integrity of the splice connection under varying environmental conditions, while also providing a larger surface area for electrical continuity, thus enhancing the reliability of the cable joint.
Implementation Method 1
The sleeve is placed over the oil impregnated paper and heat is applied to contract the sleeve about the insulation layer.
Implementation Method 2
The sealant flow blocking wall is configured to inhibit flow of the sealant on the outer surface along the lengthwise connector axis.
Data Source
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AI summary
A cable connection assembly includes an electrically conductive cable, an electrically conductive connector, and a flowable sealant. The electrical cable includes a conductor. The connector includes a connector body having an outer surface and a lengthwise connector axis. The connector body defines a conductor cavity receiving the conductor of the electrical cable. The connector further includes a sealant flow blocking wall on the connector body and extending radially outwardly from the outer surface of the connector body. The flowable sealant surrounds a portion of the connector body. The sealant flow blocking wall is configured to inhibit flow of the sealant on the outer surface along the lengthwise connector axis.