Implosive Cable Joint Using Tapered Explosive Charge
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Solution Overview
Problem
Existing methods for joining high-gauge wires require heavy and bulky tools, and existing implosive connectors create surface irregularities and increase manufacturing costs, while failing to provide a smooth, permanent, and stress-resistant connection.
Innovation Solution
An implosive joint apparatus using a connecting tube with an inner sleeve coated with grit particles and an outer sleeve, where the ends of cables are inserted to abut each other and an outer layer of explosive charge is detonated to compress the tube, providing a strengthened grip and a smooth surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional hydraulic compression fittings are used for high voltage transmission lines, then strong compression force is achieved, but the tools are heavy and bulky making them difficult to transport to remote sites
Solution Approach 1:
The patent replaces the conventional hydraulic compression system with an implosive connection system that uses explosive detonation to generate radial compression forces. The explosive charge creates an implosion that radially compresses the connector onto the conductor, eliminating the need for heavy hydraulic presses and enabling deployment in remote locations where such equipment cannot be transported.
Solution Approach 2:
The invention changes the method of force application from gradual hydraulic pressure to instantaneous explosive impulse. The explosive charge converts chemical energy into a rapid mechanical compression event, achieving the necessary compression force in a fraction of a second. This parameter change allows the same compression effect to be achieved with much lighter equipment.
2Stability of the object's composition
If implosive connectors with even cross-section explosive layer are used, then uniform radial compression is achieved, but surface irregularities increase and manufacturing costs rise
Solution Approach 1:
The patent introduces a tapered explosive charge where the charge density and thickness vary along the length of the connector. The charge is denser and thicker at the ends and lighter in the middle section. This local variation in charge quality compensates for the natural tendency of explosive force to be stronger at the ends, resulting in more uniform radial compression and smoother conductor surfaces after connection.
Solution Approach 2:
The invention changes the geometric parameters of the explosive charge from a uniform cross-section to a tapered configuration. By varying the charge dimensions and density along its length, the patent optimizes the distribution of compression forces to achieve both uniform radial compression and minimal surface irregularities, resolving the contradiction between compression uniformity and surface smoothness.
3Force
If steel pins are used to enlarge cable ends for implosive connection, then compaction force is increased, but surface irregularities and manufacturing costs increase
Solution Approach 1:
The patent eliminates the steel pin enlargement step entirely from the connection process. Instead of inserting pins to mechanically enlarge and strengthen cable ends, the invention uses the explosive charge directly applied to the original cable ends. The implosion from the explosive provides the necessary compression force without requiring preliminary mechanical modification of the conductor geometry, thereby avoiding surface irregularities and reducing manufacturing complexity.
4Strength
If connectors are designed for high strength connection, then permanent tight clamping is achieved, but the tools and equipment required become heavier and more complex
Solution Approach 1:
The patent replaces complex mechanical compression equipment with a simple explosive charge and detonator system. The explosive provides the necessary high-force compression event to create strong, permanent connections without requiring sophisticated hydraulic systems, power sources, or complex control mechanisms. This substitution maintains connection strength while dramatically reducing equipment complexity.
Solution Approach 2:
The invention uses a periodic impulsive action from the explosive detonation rather than continuous mechanical pressure. The explosive charge delivers a concentrated compression impulse lasting only a fraction of a second, which is sufficient to create the permanent tight clamping effect. This periodic action replaces the need for sustained mechanical force application systems, simplifying the overall equipment design.
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 lightweight, cost-effective, and efficient method for fusing cables and dead ends, ensuring a permanent, smooth connection with reduced surface irregularities and manufacturing costs, while maintaining high stress resistance and preventing corona discharge.
Implementation Method 1
providing the joint with an outer layer of explosive charge, and detonating the layer of implosive charge
Implementation Method 2
such implosive connectors comprise a conductor splice consisting of an outer aluminum sleeve equipped with a pre-mounted implosive charge
Data Source
AI summary
A method of fusing cables and a dead end assembly and a cable are provided. A joint assembly for fusing cables and a dead end fusing assembly for fusing a cable and a forge assembly are provided. The method includes cutting back strands of a cable, exposing the core; inserting the core of cables into a core grip; positioning the joint assembly over the core grip within certain marked sections of the cables; wrapping the joint assembly with one wrap of detonation cord; securing a detonator to the detonation cord explosive charge and detonating the detonator, such that the core grip fuses the cables together.