Compacted Coupling Joint for High Voltage Insulated Conductors
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Solution Overview
Problem
Conventional mineral insulated (MI) cable splice designs are not suitable for high voltages above 1000 volts, 1500 volts, or 2000 volts and fail at elevated temperatures, requiring improved compaction of mineral insulation to match the level in MI cables, and need higher bending and tensile strengths to withstand subsurface conditions.
Innovation Solution
A fitting system with tapered splice housings and a sleeve for compacting electrically insulating material, reducing electric field intensities and enhancing mechanical strength, allowing for splicing of insulated conductors at high voltages and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional MI cable splice designs are used, then assembly is simpler, but reliability fails at high voltages above 1000 volts and elevated temperatures
Solution Approach 1:
The splice assembly is divided into distinct functional segments: a body portion containing the insulating material, a first sleeve for the first conductor, and a second sleeve for the second conductor. This segmentation allows each component to be optimized independently for its specific function while maintaining overall reliability at high voltages and temperatures.
Solution Approach 2:
An electrically insulating material is introduced as an intermediary substance within the body portion of the splice assembly. This insulating material mediates between the conductors and the metallic components, providing electrical isolation and thermal management that enables reliable operation at elevated temperatures and high voltages where conventional splices fail.
2Reliability
If mineral insulation compaction is increased to match MI cable levels, then reliability at high voltages improves, but manufacturing complexity increases
Solution Approach 1:
The electrically insulating material is pre-placed within the body portion of the splice assembly before final assembly. This preliminary positioning allows the material to be compacted to the required density for high voltage reliability while simplifying the overall manufacturing process, as the compaction can be performed in a controlled manner during assembly rather than requiring complex post-assembly processing.
3Strength
If bending and tensile strength are increased to withstand subsurface conditions, then durability improves, but device complexity increases
Solution Approach 1:
The splice assembly utilizes composite construction with a body portion made of electrically insulating material and metallic sleeves for mechanical strength. This composite structure provides both the required bending and tensile strength to withstand subsurface conditions while maintaining electrical insulation properties, avoiding the need for overly complex single-material structures.
4Object-generated harmful factors
If electric field intensities are reduced, then leakage currents decrease, but manufacturing precision requirements increase
Solution Approach 1:
The electric field distribution is optimized by changing the geometric parameters of the insulating material and its positioning within the body portion. By adjusting the shape, size, and location of the insulating material, the electric field intensity is reduced throughout the splice assembly, minimizing leakage currents while maintaining manufacturability through standard precision tolerances.
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 enables reliable splicing of insulated conductors at high voltages and temperatures, reducing leakage currents and increasing the operating range of splices, ensuring durability and efficiency in subsurface applications.
Implementation Method 1
the interior volume of the fitting is configured to be reduced such that the electrically insulating material substantially filling the interior volume is compacted
Implementation Method 2
reducing electric field intensities and enhancing mechanical strength, allowing for splicing of insulated conductors at high voltages and temperatures
Data Source
AI summary
A fitting for coupling an end of a first insulated conductor to an end of a second insulated conductor is described. The fitting includes a first splice housing placed over the end of the first insulated conductor and coupled to the first insulated conductor. The fitting also includes a second splice housing placed over the end of the second insulated conductor and coupled to the second insulated conductor. A sleeve is located over the end of the second insulated conductor and adjacent to the second splice housing. An interior volume of the fitting is substantially filled with electrically insulating material. The interior volume of the fitting is reduced such that the electrically insulating material substantially filling the interior volume is compacted.