Pre-assembled Cable Joint with Collapsed Channel for Torchless Installation
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Solution Overview
Problem
Conventional cable joints require hazardous and skill-sensitive heatshrinking processes, which can be hazardous to installers and may lead to improper installations, and existing cold shrink cover assemblies suffer from performance issues and higher production costs.
Innovation Solution
A cable joint design with a pre-installed conductive element and a re-jacketing sleeve that forms a channel, allowing for torchless heatshrinking in a single installation sequence, ensuring continuity of the outer shield and reducing installation errors and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heatshrinking process is used, then the cable joint can be assembled, but the process is hazardous and skill-sensitive leading to installation errors
Solution Approach 1:
The conductive element is pre-installed on the joint body before the heatshrinking process. This preliminary action ensures that the shielding continuity is established before the heatshrinking step, eliminating the risk of installation errors during the heatshrinking process while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces a pre-installed conductive element as an intermediary component that facilitates the electrical connection and shielding continuity. This intermediary element simplifies the installation process by providing a ready-made solution that does not require complex heatshrinking operations, thereby improving both reliability and ease of operation.
2Reliability
If conventional heatshrinking process is used, then the cable joint can be assembled, but the process is hazardous to installers
Solution Approach 1:
The patent extracts the hazardous heatshrinking step from the assembly process by providing a pre-assembled joint body with the conductive element already installed. This eliminates the need for installers to perform dangerous heatshrinking operations while maintaining the functional integrity of the cable joint.
Solution Approach 2:
The pre-assembled joint body can be treated as a disposable or single-use component that is simply installed and discarded after use. This approach eliminates the need for complex installation procedures and hazardous materials handling, improving safety while maintaining ease of operation.
3Ease of operation
If cold shrink cover assemblies are used, then heatshrinking process is avoided, but performance issues and higher production costs occur
Solution Approach 1:
The patent changes the physical state or properties of the joint body by providing a pre-assembled structure with specific dimensional parameters that allow direct installation without heatshrinking or cold shrinking. This parameter optimization maintains installation safety while ensuring product performance through precise manufacturing tolerances and material selection.
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 quick, safe, and cost-effective installation of cable joints with improved shielding continuity and reduced risk of errors, while allowing for automation of heatshrinking steps, thus enhancing the reliability and efficiency of the cable jointing process.
Implementation Method 1
allowing for automation of heatshrinking steps
Data Source
AI summary
A cable joint includes a cable joint body, a conductive connector disposed within the cable joint body and electrically connecting a first cable to a second cable, and a first conductive element electrically connecting a first shielding layer of the first cable to a second shielding layer of the second cable. The cable joint body includes a first insulating sleeve and a re-jacketing sleeve at least partly encompassing the first insulating sleeve. The re-jacketing sleeve forms a channel along a longitudinal axis of the first insulating sleeve. The first conductive element is disposed within the channel. The channel is collapsed after heat shrinking the first insulating sleeve and the re-jacketing sleeve.