Multi-Tap Enclosure Frangible Walls Sealant Corrosion
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Solution Overview
Problem
Existing environmentally protective enclosures for cable connections are inadequate for large connections and cables, requiring excessive force to close and offering limited corrosion protection, leading to potential corrosion and installation issues with overhead multi-tap connectors.
Innovation Solution
A multi-tap enclosure with a housing featuring frangible walls and covers that allow horizontal movement of cables, combined with a sealant for environmental protection, and a method for inserting uncut electrical cables through frangible walls and covers to secure them within the enclosure, providing improved corrosion protection and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional gel-filled enclosures are used for large connections and cables, then the enclosure can provide environmental protection, but the force required to close the enclosure becomes unduly large
Solution Approach 1:
The enclosure is divided into two separate components: a connector portion that remains on the cable and a housing portion that provides environmental protection. This segmentation eliminates the need to apply excessive closing force to seal large cables, as the sealant is contained within the housing portion and applies sealing pressure locally at the interface rather than requiring the entire enclosure to be compressed shut.
2Device complexity
If overhead multi-tap connectors are provided with only empty plastic housing and separate caps, then the connector structure is simple, but corrosion protection of the connector and tap screws is very limited
Solution Approach 1:
The connector and housing are merged into a single integrated unit where the connector portion is permanently attached to the housing portion. The sealant is applied at the interface between these portions, creating a unified corrosion-resistant assembly. This merging eliminates the need for separate caps while providing comprehensive corrosion protection for both the connector and tap screws through the sealant barrier.
3Strength
If tap screws corrode to the point of being no longer removable, then the connector provides structural integrity, but the cable cannot be removed or replaced
Solution Approach 1:
The sealant is applied in advance at the interface between the connector and housing portions, creating a protective barrier before corrosion can occur. This preliminary protective action prevents the tap screws from corroding in the first place, maintaining both structural integrity and ease of operation over time by preventing the corrosion that would make cable removal impossible.
4Ease of operation
If frangible walls and covers are used to allow horizontal cable movement, then ease of installation is improved, but the enclosure structure becomes more complex
Solution Approach 1:
The frangible features are segmented into specific locations: frangible walls in the housing portion and frangible covers on the connector portion. This segmentation allows cable installation personnel to access and break only the specific frangible elements needed for cable insertion, rather than dealing with a completely complex enclosure structure. The frangible features are integrated locally rather than throughout the entire enclosure.
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 provides a reliable, moisture-tight seal for cables of varying sizes, enhances corrosion protection, and facilitates easy installation and removal of cables, reducing the risk of corrosion and improving the reliability of connections.
Implementation Method 1
A sealant is disposed in the housing and contacts the multi-tap connector to provide environmental protection to the multi-tap connector and connections thereto
Implementation Method 2
The main cable access opening has a frangible wall therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis. The first opening and the second opening have frangible covers therein configured to allow movement of the electrical cable horizontally therethrough
Data Source
AI summary
A multi-tap enclosure for an electrical cable includes a housing including a first wall and an opposite second wall and a third wall extending between the first and second wall. A first opening is in the first wall of the housing. The first opening defines a main cable axis for the multi-tap enclosure. A second opening is in the second wall of the housing. The second opening is located on the main cable axis. A main cable access opening is in the third wall of the housing. The main cable access opening has a frangible wall therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis. The first opening and the second opening have frangible covers therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis to allow the electrical cable to extend along the main cable axis through the first and second openings when installed in the multi-tap enclosure.