Segmented Cold Shrink Core for Easier Cable Splice Sealing
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Solution Overview
Problem
Existing support core designs for deploying cold shrink rubber over cable splice connections in electrical distribution systems are inefficient, requiring significant force to remove the core and often leading to repetitive motion injuries, and may fail to form a moisture seal without additional mastic, which can be misplaced or forgotten.
Innovation Solution
A support core system utilizing two solid cores with a polyethylene terephthalate (PET) film, where one core is shorter and easier to remove, assisted by the shrinking rubber, and the other longer core is removed with less force, aided by the rubber's grip, along with a PET film providing a low friction surface and mastic for forming a waterproof seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional solid core is used to hold cold shrink rubber in an expanded state, then the rubber can be properly positioned over the cable splice, but significant force is required to remove the core which can cause repetitive motion injuries
Solution Approach 1:
The support core is divided into two separate cores: an inner core and an outer core. The inner core is removed first with minimal force, and the outer core is removed second with the assistance of the already-shrunk rubber. This segmentation eliminates the need to remove a single long core with significant force, thereby preventing repetitive motion injuries while maintaining sealing reliability.
Solution Approach 2:
The first portion of the cold shrink rubber shrinks onto the cable before the second portion is removed. This preliminary shrinking action creates a grip that assists in removing the outer core with less force. The system is designed so that the first core removal and initial shrinking occurs before the second core removal, making the overall process safer and easier.
2Reliability
If mastic is added to form a moisture seal, then waterproof sealing is achieved, but the mastic can be misplaced or forgotten during deployment
Solution Approach 1:
The mastic is pre-applied to the cable surface before the cold shrink rubber is deployed. The PET film is also pre-positioned between the rubber and the core. This preliminary preparation ensures that the mastic is already in place and cannot be misplaced or forgotten during the deployment process, maintaining both sealing reliability and operational simplicity.
Solution Approach 2:
The PET film serves as an intermediary layer between the cold shrink rubber and the support core. This film ensures proper positioning and facilitates smooth removal of the core while the pre-applied mastic forms the moisture seal. The combination of these pre-positioned elements eliminates deployment errors.
3Length of stationary object
If a single long core is used to hold the entire cold shrink rubber, then the full length of rubber can be supported, but the removal process requires significant force and repetitive motion
Solution Approach 1:
The single long core is segmented into two separate cores of different lengths: an inner core and an outer core. The inner core is shorter and is removed first with minimal force. The outer core, while longer, is removed second with the assistance of the already-shrunk rubber. This segmentation reduces the removal force required compared to removing a single long core.
Solution Approach 2:
The first portion of the cold shrink rubber shrinks onto the cable before the outer core is removed. This preliminary shrinking creates a mechanical advantage that reduces the force needed to remove the outer core, even though it is longer. The system leverages the shrinking action itself to assist in the removal process.
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 system simplifies the deployment process by reducing the force required to remove the core and ensures a reliable moisture seal by using the PET film and mastic, minimizing the risk of repetitive motion injuries and ensuring effective sealing.
Implementation Method 1
a first solid core is positioned over a cable in the electrical distribution system and holds a first portion of the cold shrink rubber in an expanded state. The first solid core is removed from between the first portion of the cold shrink rubber and the cable, thereby allowing the first portion of the cold shrink rubber to shrink against the cable.
Implementation Method 2
The PET film is positioned between the cold shrink rubber and each of the first solid core and the second solid core.
Data Source
AI summary
The present disclosure provides a support core system for deploying a cold shrink rubber over a cable splice connection in an electrical distribution system. The support core system includes a first solid core, a second solid core, and a polyethylene terephthalate (PET) film. The first solid core is configured to fit over a cable in the electrical distribution system and hold a first portion of the cold shrink rubber in an expanded state. The cable includes the cable splice connection. The second solid core is configured to fit over the cable and hold a second portion of the cold shrink rubber in an expanded state. The PET film is positioned between the cold shrink rubber and each of the first solid core and the second solid core.