Composite Protective Casing for High Voltage Cable Joints
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Solution Overview
Problem
Establishing a strong and tight connection between a protective casing of metal material and the sheath of high voltage cables in deep-sea environments is challenging due to the poor soft soldering properties of stainless steel and the risk of heat damage during hard soldering processes.
Innovation Solution
A protective casing comprising a first metal portion, such as stainless steel, and a second metal portion with good soft soldering properties, like copper or brass, allows for a strong and tight connection via a soft soldering process, ensuring the connection is not damaged by low temperatures and can withstand high pressures and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stainless steel protective casing is used, then the casing has the required strength to withstand high pressure and is resistant to corrosion, but it is difficult to create a strong and tight connection between the stainless steel casing and the lead or copper sheath of the cable parts
Solution Approach 1:
The protective casing is constructed as a composite structure with a first material portion of stainless steel providing pressure resistance and corrosion resistance, and a second material portion with good soft soldering properties (such as copper or brass) providing solderability. This composite material approach allows the casing to simultaneously achieve mechanical strength, corrosion resistance, and ease of connection to the cable sheath.
2Ease of manufacture
If a hard soldering process is used to connect the stainless steel casing to the sheath, then a connection can be established, but the high temperature during the process damages the sheath of the cable or other sensitive components in the vicinity
Solution Approach 1:
The invention changes the temperature parameter of the soldering process by using soft soldering instead of hard soldering. The second material portion of the casing is designed to be compatible with soft soldering processes, which operate at significantly lower temperatures, thereby preventing thermal damage to the cable sheath and surrounding sensitive components while still achieving a strong connection.
3Object-affected harmful factors
If soft soldering is used to connect the casing to the sheath, then the low temperature guarantees no damage to the sheath or sensitive components, but stainless steel materials have relatively bad soft soldering properties making it difficult to make a strong and tight connection
Solution Approach 1:
The protective casing combines two different materials: stainless steel for structural integrity and a second material with excellent soft soldering properties (such as copper or brass) for reliable low-temperature connection. This composite construction enables the casing to be connected to the cable sheath using soft soldering at low temperatures, preventing heat damage while achieving a strong and tight connection through the solderable second material portion.
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 a reliable, corrosion-resistant, and pressure-resistant connection between the casing and the cable sheath, preventing damage to the cable sheath and other components during the soldering process, while maintaining the strength and integrity of the joint.
Implementation Method 1
the second metal material has good soft soldering properties such that it is possible to provide a strong and tight connection between the second material portion of the protective casing and a sheath of at least one of the cable parts by means of a soft soldering process
Data Source
AI summary
A protective casing for a joint, termination or cross-connection of at least one high voltage cable. The protective casing includes a first material portion of a first metal material having good strength properties. The protective casing includes a second material portion of a second metal material which is fixedly attached to the first material portion. The second metal material has good soft soldering properties such that it is possible to provide a strong and tight connection between the second material portion of the protective casing and a sheath of at least one of the cable parts by a soft soldering process.