Double-Acting Compression Joint for Compact HVDC Cable Splicing

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Solution Overview

Problem

Existing conductor joints for high voltage direct current (HVDC) cables compromise bending properties and tensile strength, increase cross-sectional diameter, and are cumbersome to install, failing to match the properties of the connected cables.

Innovation Solution

A double-acting conductor joint comprising a tubular sleeve and an elongated element, where the sleeve and elongated element work together under hydraulic pressure to compress the stranded wires, maintaining the same diameter and enhancing mechanical strength and flexibility, with a method involving removal of protective layers and precise insertion of the core rod into the conductor ends.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional conductor joints are used to connect HVDC cable conductors, then the conductors can be joined together, but the joint has a larger cross-sectional diameter than the original cables, impairing bending properties

Engineering Contradiction:
Improvetensile strengthVSAvoidcross-sectional diameter
Core Design Contradiction:
StrengthVSShape

Solution Approach 1:

The invention uses a nested structure where an inner compression sleeve is placed inside an outer compression sleeve. The inner sleeve compresses the conductor strands first, then the outer sleeve provides additional compression. This nested arrangement allows the joint to maintain a compact cross-sectional diameter comparable to the original cables while achieving sufficient compression force for strong electrical and mechanical connection.

Inventive Principle:
Principle #7Nested doll (Nesting)

Solution Approach 2:

The invention transitions from single-direction compression to multi-directional compression by using both inner and outer sleeves that can apply compressive forces from different directions. The inner sleeve provides radial compression, while the outer sleeve adds circumferential compression, creating a three-dimensional compression field that reduces the joint diameter while maintaining connection strength.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Shape

If conventional conductor joints are used to connect HVDC cable conductors, then the conductors can be joined together, but the joint cannot withstand the same tensile forces as the original cables

Engineering Contradiction:
Improvecross-sectional diameterVSAvoidtensile strength
Core Design Contradiction:
ShapeVSStrength

Solution Approach 1:

The nested dual-sleeve structure enables progressive compression where the inner sleeve first compresses the conductor strands to a reduced diameter, then the outer sleeve applies additional compression force. This multi-stage compression process ensures that the conductor strands are tightly bound with sufficient compressive stress to withstand tensile forces equal to or greater than the original cables, while maintaining a compact joint diameter.

Inventive Principle:
Principle #7Nested doll (Nesting)

Solution Approach 2:

The invention combines the functions of multiple compression elements (inner sleeve and outer sleeve) into a single integrated joint structure. By merging these compression functions, the joint achieves both compact dimensions and high tensile strength simultaneously, as the combined compressive action of both sleeves creates a mechanically robust connection that matches the original cable properties.

Inventive Principle:
Principle #5Merging (Combining)

3Ease of manufacture

If conventional conductor joints are used to connect HVDC cable conductors, then the conductors can be joined together, but the installation process is cumbersome and time-consuming

Engineering Contradiction:
Improveinstallation simplicityVSAvoidinstallation time
Core Design Contradiction:
Ease of manufactureVSLoss of time

Solution Approach 1:

The joint is segmented into distinct functional components: an inner compression sleeve, an outer compression sleeve, and optional positioning elements. This segmentation allows each component to be prepared and positioned independently before final assembly, simplifying the installation process. The modular structure enables workers to insert conductors into the inner sleeve first, then add the outer sleeve, making the process more systematic and less cumbersome than conventional single-piece joints.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The inner compression sleeve can be pre-positioned on the conductor strands before the outer sleeve is added. This preliminary action allows for proper alignment and initial compression to be established before the final assembly step, reducing installation time and complexity. The pre-positioned inner sleeve serves as a guide and initial compression element, making the subsequent addition of the outer sleeve a simpler operation.

Inventive Principle:
Principle #10Preliminary action

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 joint maintains the same bending diameter and tensile strength as the connected cables, ensuring efficient and simple installation with improved mechanical properties and conductive performance.

Implementation Method 1

compressing the sleeve radially towards the elongated element by means of a hydraulic press

Methodology Applied
Scientific EffectHydraulic press: Hydraulic Press

Implementation Method 2

compression of the sleeve causes the layers of stranded wires to be squeezed between the outer sleeve and the inner elongated element

Methodology Applied
Scientific EffectCompression: Compression

Data Source

PatentEP3694052B1Double-acting high tension compression joint
Publication Date: 2025.07.02 NEXANS SA
  • EP3694052B1 patent drawingFigure 1
  • EP3694052B1 patent drawingFigure 2A~2B
  • EP3694052B1 patent drawingFigure 3A~3B

AI summary

The invention discloses a conductor joint ant a method for connecting a conductor end of a first cable with a conductor end of a second cable with the conductor joint. The conductor joint comprises a tubular longitudinal sleeve (1) and an elongated element (10). The sleeve has a sleeve length Ls and sleeve openings at each longitudinal end with an inner diameter allowing insertion of the conductor ends to be connected, the sleeve (1) comprising an inner surface shaped as two tubular stairs mirrored around a radial cross-sectional area at a longitudinal center of the sleeve (1), wherein each stair comprises a lower step surface at the nearest sleeve opening oriented along a longitudinal axis of the sleeve (1), a higher step surface at the longitudinal center and a step wall (3a,3b, 3a', 3b') arranged between the lower step surface and the higher step surface oriented along the radial cross-sectional direction of the sleeve (1). The elongated element (10) arranged concentrically within said sleeve (1), wherein the elongated element (10) comprises a core rod (12) having a core rod length Lr and a terminal rod wall (13, 13') at each longitudinal end.