Direct Bury Splice Kit Waterproof Encapsulation

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Solution Overview

Problem

Existing direct bury splice kits for irrigation systems require multiple connections and can be prone to electrical failures due to the need to force twist-on wire connectors into grease tubes, which can exert separating forces on the wires, leading to potential system failures, especially in wet locations.

Innovation Solution

The use of mateable pods with integrated sealants that encapsulate electrical wire connectors without exerting separating forces on the joined wires, providing in situ waterproof encapsulation and minimizing the risk of electrical failures by folding the pods around the connectors rather than pushing the connectors into a sealant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If twist-on wire connectors are forced into grease tubes by grasping the twisted wire leads, then the wire connector can be encapsulated in the insulating sealant, but separating forces are exerted on the wires which can disrupt the electrical connection

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidencapsulation operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The encapsulation system is divided into two separate functional components: the wire connector (for making electrical connections) and the grease tube (for providing insulation and waterproofing). This segmentation allows the wire connector to be installed and secured independently before encapsulation, so that subsequent encapsulation operations do not exert separating forces on the electrical connection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wire connector is installed and the electrical connection is established before the encapsulation process begins. The wire connector is first forced into the grease tube to secure it in position, and only then is the encapsulation performed. This preliminary action ensures that the electrical connection is already established and secured before any forces are applied during encapsulation.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If multiple direct bury splice kits are used for decoder systems, then wire splices can be made in wet locations, but the number of potential failure points increases

Engineering Contradiction:

Improveability to splice in wet locationsVSAvoidsystem failure risk

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The wire connector is designed to perform multiple functions: it makes the electrical connection between wires and simultaneously provides a secure anchoring point within the grease tube. This multi-functionality eliminates the need for separate connection and encapsulation devices, reducing the number of components and potential failure points while maintaining the ability to splice in wet locations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the wire connector is forced into the grease tube, then encapsulation can be achieved, but the insulating sealant must be separated and allowed to flow back which may leave connections uncovered

Engineering Contradiction:

Improveencapsulation completenessVSAvoidencapsulation process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wire connector is first forced into the grease tube to secure it in position and displace the sealant, creating a cavity that will be completely filled during encapsulation. This preliminary positioning action ensures that when encapsulation follows, the sealant will flow into all available spaces and completely cover the connection without leaving gaps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The grease tube is designed with sufficient length and volume to accommodate the wire connector and provide adequate space for complete encapsulation. The tube acts as a cushioning container that allows the sealant to flow back and completely surround the connection, ensuring no exposed portions remain after encapsulation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

This solution reduces the likelihood of electrical failures by ensuring complete encapsulation of wire connectors and leads in a waterproof condition, maintaining the integrity of the connections and reducing the stress on wire junctions, thus enhancing the reliability of underground electrical connections.

Implementation Method 1

each of a pair of partial pods that are mateable to each other about an electrical connector are capable of carrying a sealant to provide insitu waterproof encapsulation of the electrical leads and the wire connector

Methodology Applied

Scientific EffectWaterproof encapsulation:

Data Source

PatentUS7763801B2Direct bury splice kit

Publication Date: 2010.07.27 THE PATENT STORE LLC

AI summary

A decoder system and a direct bury splice kit for in situ encapsulation of an electrical wire and wire connector wherein the encapsulation minimizes separating forces between the joined wires in the wire connector.