Double-Layer Shield Sock for Flexible Cable Splices
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Solution Overview
Problem
Existing electrical cable splices face challenges with unfinished, ragged ends of conductive shield socks that can interfere with connections and limit flexibility, while also requiring thicker gauge wires to carry sufficient current.
Innovation Solution
A double-layer conductive shield sock assembly with folded ends covered by a cold shrink jacket, allowing for thinner gauge wire usage and improved flexibility, along with a method of forming electrical connections using clamps and a cold shrink short jacket for environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single layer shield sock is used with thicker gauge wire, then current carrying capacity is sufficient, but flexibility is reduced and the structure is less efficient
Solution Approach 1:
The shield sock is divided into multiple layers (typically two layers) of thinner gauge wire instead of using a single layer of thicker wire. This segmentation allows each layer to be more flexible while the combined structure provides sufficient current carrying capacity, resolving the contradiction between flexibility and current capacity.
2Device complexity
If a single layer shield sock is used, then the structure is simpler, but unfinished ragged ends are exposed which interfere with making splices
Solution Approach 1:
The shield sock is constructed with multiple layers where the ends of one layer are positioned to be covered by the overlapping layer. This layered segmentation ensures that all cut ends are contained within the multi-layer structure, preventing exposed ragged edges from interfering with splice formation, while adding only minimal complexity to the overall structure.
3Ease of operation
If a double layer shield sock is used with thinner gauge wire, then flexibility is improved and current carrying capacity is maintained or exceeded, but the structure is more complex
Solution Approach 1:
The shield sock is segmented into multiple layers of thinner gauge wire, where each layer contributes to both flexibility and current carrying capacity. The segmented layered structure naturally contains the wire ends within the layers themselves, reducing the need for additional end-covering components and thus limiting the increase in overall structural complexity.
Solution Approach 2:
The multi-layer shield sock structure nests the wire ends within the layered configuration, where inner layer ends are contained by outer layers. This nesting approach eliminates the need for separate end-covering structures, thereby reducing the complexity increase that would otherwise result from adding multiple layers.
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 the use of thinner gauge wires to carry more current, enhances flexibility, and ensures complete coverage of unfinished ends, facilitating secure and efficient electrical connections without exposed ragged edges, while maintaining or exceeding the current-carrying capacity of traditional splices.
Implementation Method 1
a cold shrinkable jacket configured to circumferentially surround the conductive shield sock and the splice body
Data Source
AI summary
An assembly is provided that includes a tubular support core, a splice body configured to circumferentially surround the support core, a conductive shield sock comprising at least two overlapping layers and configured to circumferentially surround the splice body and a cold shrink jacket circumferentially surrounding the shield sock. The ends of the shield sock are located beneath the cold shrink jacket and the shield sock extends beyond both ends of the splice body. In some embodiments the shield sock includes folded portions that extend beyond the ends of the splice body.