Lead-Free Cable Joint Transition Sleeve Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for joining high voltage cables, particularly deep-sea cables, rely on lead-based solders for water-tight and electrical connections, which may be prohibited by future regulations, necessitating an alternative solution that avoids lead-based materials.
Innovation Solution
A joint, termination, or cross-connection arrangement using a transition sleeve welded to both the metallic sheath of the cable and the protective casing, providing a water-tight connection without lead, allowing for the selection of materials based on weldability rather than compatibility, and minimizing the risk of material deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead-based solder is used for connecting metallic sheath and protective casing, then water-tight connection is achieved, but environmental regulations may prohibit this method
Solution Approach 1:
The patent introduces a transition sleeve as an intermediary component between the metallic sheath and protective casing. This transition sleeve is made of a material that is weldable to both components, enabling welding-based connection without direct contact between incompatible materials. The transition sleeve acts as a mediator that facilitates the connection while avoiding the need for lead-based solder, thus resolving the contradiction between achieving reliable water-tight connection and complying with environmental regulations.
2Strength
If welding is performed directly between metallic sheath and protective casing, then connection strength is improved, but material properties may deteriorate due to diffusion
Solution Approach 1:
The transition sleeve serves as a protective intermediary layer between the metallic sheath and protective casing during welding. By welding to the transition sleeve instead of directly to the protective casing, the harmful diffusion of elements is prevented, maintaining the corrosion resistance and mechanical properties of both the metallic sheath and protective casing. This intermediary approach enables strong welding connections without compromising material stability.
Solution Approach 2:
The patent applies local quality by making the transition sleeve from a specific material (such as nickel or nickel-based alloy) that has good weldability with both the metallic sheath and protective casing, while the protective casing and metallic sheath can maintain their original material properties optimized for their specific functions. Each component has locally optimized material properties suitable for its role in the assembly.
3Adaptability or versatility
If lead-free connection methods are used, then environmental compliance is improved, but connection reliability may be compromised
Solution Approach 1:
The patent replaces the chemical-based soldering process with a mechanical/thermal welding process. Instead of using lead-based solder that relies on metallurgical bonding, the invention uses welding (such as TIG or MIG welding) to create strong, reliable, and permanent joints between the transition sleeve and the metallic sheath and protective casing. This substitution maintains connection reliability while eliminating lead-based materials, achieving both environmental compliance and connection reliability.
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
This solution ensures a reliable, lead-free water-tight connection that maintains mechanical and chemical properties, enabling the use of diverse materials for the cable and protective casing while adhering to environmental regulations.
Implementation Method 1
The transition sleeve is, at the first longitudinal end surface welded to the metallic sheath of the first cable around the whole circumference of the metallic sheath
Implementation Method 2
The transition sleeve is further welded to the first tubular end portion of the protective casing around the whole circumference of the transition sleeve
Data Source
AI summary
A joint, termination or cross-connection arrangement for a cable includes a first cable and a protective casing. The arrangement further includes a transition sleeve. The transition sleeve, at a first longitudinal end surface thereof, is welded to the metallic sheath of the first cable around the whole circumference of the metallic sheath. The transition sleeve is furthermore welded to the protective casing around the whole circumference of the transition sleeve. A method of providing such an arrangement includes: welding the transition sleeve, at the first longitudinal end surface, to the metallic sheath of the first cable around the whole circumference of the metallic sheath; and welding the transition sleeve to a first tubular end portion of the protective casing around the whole circumference of the transition sleeve.