Cold Shrinkable Splice Housing for Electrical Distribution
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Solution Overview
Problem
Current electrical power distribution splice housing systems face issues such as increased installation errors, high skill requirements, and safety hazards due to complex component configurations, material compromises, and the lack of flexibility in core sizes and testing capabilities.
Innovation Solution
A splice housing design featuring a center section with a constant internal diameter and end sections that expand for secure fitting, using different rubber materials for elasticity and conductivity, and incorporating a capacitive test point for energized circuit detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heat shrinkable splice housing is used, then the housing can be stored and installed easily, but the necessity of using a torch or heat-applying device creates safety hazards and requires high skill level
Solution Approach 1:
The patent changes the activation parameter from thermal (heat) to mechanical (vacuum pressure). The elastomeric material is activated by applying vacuum pressure during installation, causing it to expand and conform to the connector and cable assembly, eliminating the need for heat application devices and associated safety hazards while maintaining ease of storage and installation
Solution Approach 2:
The patent replaces the thermal field (heat shrinkable material activated by torch) with a mechanical field (vacuum expandable material activated by vacuum pressure). This substitution eliminates the harmful thermal effects while achieving the same functional result of secure fitting and sealing
2Adaptability or versatility
If multiple types of splice housings are used to cover different cable sizes, then adaptability is improved, but the number of components increases leading to installation errors and decreased reliability
Solution Approach 1:
The patent employs a dynamic expansion mechanism where a single elastomeric housing expands under vacuum pressure to accommodate different cable and connector size combinations. The material's elastic properties allow it to conform to various dimensions, providing adaptability across multiple cable sizes without requiring multiple pre-sized housing types
Solution Approach 2:
The single elastomeric splice housing performs multiple functions: it secures connectors of various sizes, provides environmental sealing, and adapts to different cable configurations. This universal design eliminates the need for multiple specialized housing types, reducing component complexity and installation errors
3Manufacturing precision
If heat is applied to activate heat shrinkable housing, then the housing shrinks completely in place, but too much heat damages materials and cable insulation
Solution Approach 1:
The patent changes the activation parameter from thermal to mechanical (vacuum pressure). The elastomeric material expands uniformly under controlled vacuum pressure, eliminating the risk of overheating and damage to surrounding materials and cable insulation while achieving complete activation and sealing
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 design reduces installation errors, simplifies the splicing process, enhances safety by eliminating the need for high heat application, and allows for smaller core centers and flexible material selection, while enabling effective environmental sealing and circuit testing.
Implementation Method 1
The splice housing of the present invention is made from a vacuum expandable elastomeric material and is initially in an expanded state. After the connector is installed, the splice housing is slid back over the connector and cable ends. A support core is removed from one end (or removed from each end in the case of a two-piece support core) allowing the insulating housing to constrict over the connector and cable ends.
Implementation Method 2
The splice housing of the present invention is made from a vacuum expandable elastomeric material. The cold shrinkable housing can be sealed with a seal material in order to provide the proper environmental sealing.
Implementation Method 3
end seals can be provided to prevent water migration under the cable jacket. The cold shrinkable housing can also be sealed with a seal material in order to provide the proper environmental sealing.
Data Source
AI summary
A splice housing is configured to slide over and engage with a metallic connector that couples together cable conductors in an electrical distribution system. The splice housing has a first end arranged to engage a first cable, a second end arranged to engage a second cable and a central portion set between the first and second ends that engages the metallic connector. A first support core holds the first end in an expanded state, while a second support core holds the second end in an expanded state. The first and the second ends are molded so that they have relaxed internal diameters that are smaller than a relaxed internal diameter of the central portion.