Underground Composite Cable Enclosure Reducing Installation Weight
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Solution Overview
Problem
Existing underground cement troughs for cable enclosures are extremely heavy, requiring heavy equipment for installation, which increases costs, time, and risks of injury, while also being inefficient for accessing or adding cables.
Innovation Solution
The development of underground cable enclosures and troughs made partially from lightweight composite materials, featuring a body and cover assembly with polymer concrete cover rails and struts, allowing for immediate access and reduced weight, enabling easier installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cement troughs are used for underground cable enclosures, then structural integrity and protection are provided, but the weight becomes extremely heavy requiring heavy equipment for installation
Solution Approach 1:
The patent applies composite materials by combining polymer concrete for the body with fiberglass reinforcement embedded within the cover rails and sidewalls. This composite construction provides the necessary structural integrity and load-bearing capacity while significantly reducing the overall weight compared to traditional solid cement troughs, eliminating the need for heavy installation equipment.
2Reliability
If cement troughs are used, then cable protection is achieved, but installation cost and time increase due to heavy equipment requirements
Solution Approach 1:
The polymer concrete composite material provides adequate protection for cables while being lightweight enough to be installed without heavy equipment, thereby reducing both installation costs and time while maintaining cable protection reliability.
Solution Approach 2:
The enclosure is segmented into modular components including the body, cover rails, struts, and covers that can be manufactured separately and assembled on-site. This segmentation allows for easier handling and installation of individual components, improving installation productivity without compromising overall cable protection.
3Reliability
If cement troughs are used, then cable enclosure is provided, but access to cables requires cover removal which is time-consuming
Solution Approach 1:
The cover assembly is segmented into removable covers that can be independently taken off to provide immediate access to cables. This segmentation allows maintenance personnel to access specific cable sections without removing entire covers, significantly reducing access time while the remaining covers continue to provide protection to other cable sections.
4Ease of operation
If lightweight composite materials are used, then installation becomes easier and quicker, but structural strength may be compromised
Solution Approach 1:
The patent uses polymer concrete as the base material and embeds fiberglass reinforcement within the cover rails and sidewalls. This composite structure maintains structural strength comparable to traditional cement troughs while keeping the overall weight low enough for easy installation without heavy equipment.
Solution Approach 2:
The fiberglass reinforcement is strategically placed in specific locations where additional strength is needed, such as within the cover rails and along the sidewalls, rather than uniformly throughout the entire structure. This local reinforcement approach optimizes strength-to-weight ratio while maintaining ease of installation.
Data Source
AI summary
The present disclosure provides an underground cable enclosure having a body made of a composite material, and a cover assembly having at least one cover rail that is made of polymer cement and molded to at least a portion of the body, and at least one cover that is made of polymer cement and can rest on the at least one cover rail.