Electromagnetic Coupling of Polymeric Housings for Watertight Cable Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The traditional polyethylene (PE) overmold method for protecting undersea cable junctions is time-consuming and expensive, and alternative methods like metal pressure vessels with O-ring seals face reliability issues.
Innovation Solution
A method utilizing electromagnetic energy to couple polymeric components through susceptors that convert electromagnetic energy into heat, melting and solidifying the components to form a reliable and watertight joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional PE overmold method is used to protect undersea cable junctions, then reliable watertight protection is achieved, but the process is time-consuming and expensive
Solution Approach 1:
The patent replaces the traditional mechanical injection molding process with an electromagnetic induction heating system. The susceptor embedded in the PE housing converts electromagnetic energy to heat, melting and fusing the PE material to seal the cable junction. This substitution of mechanical molding with electromagnetic-thermal processing significantly reduces processing time while maintaining the reliability of watertight protection.
Solution Approach 2:
The invention utilizes the phase transition of polyethylene from solid to molten state through electromagnetic-induced heating. The susceptor generates heat that melts the PE material in the housing, allowing it to flow and seal around the cable junction, then solidifies upon cooling to form a permanent watertight bond. This phase transition mechanism enables rapid sealing without traditional molding equipment.
2Strength
If traditional PE overmold method is used, then durable cable joint is achieved, but expensive molds and time-consuming processes are required
Solution Approach 1:
The patent eliminates the need for expensive injection molding molds by using electromagnetic induction heating with a susceptor. The susceptor, when exposed to electromagnetic fields, generates heat that fuses the PE housing material directly onto the cable junction. This approach removes the requirement for costly mold fabrication and maintenance while simplifying the manufacturing process into a more accessible technology.
Solution Approach 2:
The susceptor acts as an intermediary element between the electromagnetic energy source and the PE housing material. It converts electromagnetic energy into localized heat at the cable junction area, enabling controlled melting and fusing of the PE material. This intermediary mechanism allows precise thermal processing without requiring complex molding equipment, reducing manufacturing costs and complexity.
3Adaptability or versatility
If field splicing is performed, then on-site cable connection is enabled, but significant investment in time and money is required
Solution Approach 1:
The patent employs electromagnetic induction heating with a susceptor to rapidly heat and fuse the PE housing material in the field. This eliminates the need for time-consuming traditional molding processes or complex field splicing procedures. The electromagnetic-thermal method provides quick heating and sealing capability that can be performed on-site without extensive equipment or preparation time.
Solution Approach 2:
The PE housing is pre-equipped with an embedded susceptor during manufacturing, preparing it in advance for rapid electromagnetic-induced sealing in the field. This preliminary inclusion of the heat-generating element allows the housing to be quickly activated and sealed on-site using electromagnetic energy, significantly reducing the time required for field splicing operations.
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 method enables quick, reliable, and cost-effective formation of polymeric protective housings for undersea cable junctions, providing a high-strength, watertight seal in less time than traditional injection molding processes.
Implementation Method 1
a susceptor proximate the first and second coupling portions, the susceptor being operable to convert electromagnetic energy to heat sufficient to melt the first and second coupling portions
Implementation Method 2
melt portions of the first and second coupling portions about the susceptor to couple the first and second components to one another upon solidification
Data Source
AI summary
A method of coupling polymeric components utilizing electromagnetic energy is disclosed. The method can include obtaining a first component having a first coupling portion, a second component having a second coupling portion, and a susceptor. The method can also include mating the first and second components such that the susceptor is proximate the first and second coupling portions. In addition, the method can include applying electromagnetic energy to the susceptor. The susceptor can convert the electromagnetic energy to heat, which can melt portions of the first and second coupling portions about the susceptor to couple the first and second components to one another upon solidification.