Cold Shrink Splice System for High-Voltage Heating Cables
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Solution Overview
Problem
Existing splice solutions for high-voltage, skin-effect heating cables lack ease of installation and high-temperature resistance, particularly in applications where cables need to be joined efficiently while maintaining electrical integrity and resistance to environmental factors.
Innovation Solution
A cold shrink splice system comprising primary and secondary cold shrink shims, a connector, and an outer cold shrink tube with a metallic pull box, which allows for easy installation and high-temperature resistance by ensuring electrical contact and protection against moisture and electrical discharges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat shrink splices are used to join cables, then electrical connectivity and insulation are achieved, but installation complexity and time increase due to soldering or crimping requirements
Solution Approach 1:
The invention extracts and eliminates the soldering and crimping steps from the traditional heat shrink splice process. By using a pre-assembled connector with integrated electrical connections that simply needs to be inserted and secured, the complex soldering/crimping operations are removed while maintaining reliable electrical connectivity.
Solution Approach 2:
The connector is pre-assembled with all electrical connections, insulation, and sealing components configured before installation. This preliminary preparation allows the installer to simply insert and secure the connector without performing complex assembly steps during installation, thereby improving ease of operation while ensuring reliable electrical connectivity.
2Ease of operation
If cold shrink splices with pre-expanded tubing are used, then installation is simplified, but the tubing cannot shrink past a predetermined shape limiting adaptability
Solution Approach 1:
The invention uses memory foam material that can be compressed to different densities and shapes during installation, then returns to its original shape. By controlling the compression parameters during installation, the foam can adapt to various cable configurations and sizes, providing both ease of installation and shape adaptability.
Solution Approach 2:
The connector combines memory foam with other materials having different mechanical properties. The memory foam provides shape adaptability and sealing, while the composite structure maintains structural integrity and electrical insulation, allowing the connector to adapt to predetermined shapes while remaining installable.
3Ease of operation
If push-on splices with rubber materials are used, then installation is simplified, but high-temperature resistance is reduced
Solution Approach 1:
The connector uses a composite construction combining rubber materials for the flexible sealing components with high-temperature resistant materials such as silicone or fluoropolymer for the structural and electrical insulation components. This allows the connector to maintain ease of installation through the rubber's flexibility while achieving high-temperature resistance through the thermally stable materials.
Solution Approach 2:
Different portions of the connector are made from materials with different temperature resistance characteristics. The sealing surfaces use rubber for ease of installation, while the structural components and areas exposed to high temperatures use heat-resistant materials, providing localized optimization of both installation ease and temperature resistance.
4Loss of substance
If self-fusing tapes are used for cable splices, then material usage is minimized, but installation time and labor intensity increase
Solution Approach 1:
The connector is pre-assembled with all necessary sealing, insulation, and electrical connection components configured during manufacturing. This preliminary preparation eliminates the need for time-consuming field assembly and material layering, reducing installation time while the integrated design ensures minimal material usage.
Solution Approach 2:
The invention merges multiple functions (sealing, insulation, electrical connection, and structural support) into a single integrated connector component. This consolidation eliminates the need for multiple separate materials and application steps required by self-fusing tapes, reducing both installation time and total material usage.
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 enables easy, cost-effective installation of high-voltage heating cables while providing reliable electrical connectivity and high-temperature resistance, addressing the limitations of existing splice technologies.
Implementation Method 1
a primary cold shrink shim shrunk over a first length of the insulation layer of the first portion of the heating cable and a secondary cold shrink shim shrunk over a second length of the insulation layer of the second portion of the heating cable
Implementation Method 2
the metallic pull box is welded to and in electrical communication with the first heating tube and the second heating tube, the metallic pull box housing the splice, and in electrical communication with the outer semiconductive layer of the outer cold shrink tube
Implementation Method 3
the metallic pull box is welded to and in electrical communication with the first heating tube and the second heating tube
Data Source
AI summary
A splice for a skin-effect effect heating cable. The splice includes a primary shim configured to be shrunk over part of an insulation layer of a first portion of the heating cable, a secondary shim configured to be shrunk part of the insulation layer of a second portion of the heating cable, a connector configured to electrically couple the first portion of the heating cable and the second portion of the heating cable, and an outer cold shrink tube configured to be shrunk over the primary shim, the secondary shim, and the connector.