Power Cable Intermediate Joint Structure for Stress-Resistant Sealing
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Solution Overview
Problem
Existing intermediate connection structures for power cables face issues with stress concentration on soldered parts, leading to deformation or breakage, especially when bent or curved, and struggle with maintaining airtight or watertight sealing due to internal pressure and mechanical stress.
Innovation Solution
The intermediate connection structure features a metal sheath and metal sheath restoration layer with ends spaced apart to form a soldered part, using a metal taping layer as insulation and heat dissipation, and inclined surfaces to distribute stress, ensuring airtight sealing and minimizing thermal history during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the metal sheath and metal sheath restoration layer are joined using a soldered part, then airtight or watertight sealing is ensured, but stress concentration occurs on the soldered part leading to deformation or breakage
Solution Approach 1:
The patent applies different surface treatments to different regions of the metal sheath and restoration layer. The inclined surfaces are provided with a roughened surface or coating layer in the stress concentration region, while other regions maintain their original smooth surface. This local differentiation enhances stress distribution and prevents deformation at critical joints without compromising overall sealing integrity.
Solution Approach 2:
The patent pre-provides inclined surfaces and roughened surface treatments or coating layers on the metal sheath and restoration layer before the soldering process. These preliminary structural preparations ensure that when stress is applied during operation, the force is already distributed along the inclined surfaces rather than concentrating at sharp edges, preventing deformation before it occurs.
2Ease of manufacture
If the soldered part is pressed or bent, then connection is formed, but stress concentration causes deformation or breakage of the soldered part
Solution Approach 1:
The patent replaces sharp edges and flat surfaces with curved inclined surfaces at the junction between the metal sheath and restoration layer. This curvature design allows stress to be distributed along the gradual slope rather than concentrated at abrupt transitions. The rounded geometry maintains ease of manufacturing through standard forming processes while significantly improving resistance to deformation under pressing or bending loads.
3Volume of moving object
If the ends of metal sheath and metal sheath restoration layer are close to each other, then the intermediate connection structure is compact, but stress concentration occurs on the soldered part
Solution Approach 1:
The patent transitions from a conventional end-to-end linear connection to an inclined surface configuration that utilizes angular geometry. By forming the metal sheath and restoration layer surfaces at angles relative to each other, the connection achieves both compactness in the longitudinal direction and effective stress distribution across the inclined interface. This dimensional reconfiguration reduces the projected length while maintaining structural integrity.
4Reliability
If soldering is performed to join the metal sheath and restoration layer, then sealing is achieved, but thermal history is generated in the power cable
Solution Approach 1:
The patent applies localized roughened surfaces or coating layers only at the inclined surfaces where soldering occurs, rather than treating the entire metal sheath or restoration layer. This localized treatment concentrates the thermal effect only where needed for sealing, minimizing the volume of material exposed to high temperatures and reducing overall thermal history in the power cable while maintaining effective sealing at the joint.
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 design reduces stress concentration and deformation, enhances sealing integrity, and improves the flexural and tensile characteristics of the connection, allowing for more reliable and durable power cable connections.
Implementation Method 1
using a metal taping layer as insulation and heat dissipation
Implementation Method 2
inclined surfaces to distribute stress
Implementation Method 3
a soldered part, which is configured to join a metal sheath of the power cable and a metal sheath restoration layer
Data Source
AI summary
The present disclosure relates to a power cable and an intermediate connection structure, for connection thereof, which is capable of preventing the concentration of stress on a soldered part, which is configured to join a metal sheath of the power cable and a metal sheath restoration layer of the intermediate connection structure while ensuring airtight or watertight sealing therebetween, preventing deformation of or damage to the soldered part due to stress applied thereto, and minimizing thermal history in the power cable during the formation of the soldered part.