Spliced Cable Water-Tight Seal Using Cross-Linked Polyethylene
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Solution Overview
Problem
Cables with Teflon-based insulating layers face challenges in forming a strong bond with sealants, leading to water infiltration under high pressure in underwater environments, as Teflon has poor bonding qualities and polyethylene melts during the application of the outer jacket, preventing effective splicing and sealing.
Innovation Solution
A cable design featuring an outer jacket of polyethylene surrounding conductive wires with cross-linked polyethylene insulating layers, which allows for a nylon sheath or spray-on slip agent as an intermediate substance, and a fusion bonding process using polyethylene to create a homogenous, water-tight seal by intertwining free-end components at specific temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Teflon-based insulating layer is used, then electrical insulation is achieved, but bonding quality with sealants deteriorates
Solution Approach 1:
The patent introduces an intermediate bonding layer between the Teflon insulating layer and the outer polyethylene jacket. This intermediate layer serves as a mediator that provides both electrical insulation properties and good bonding affinity with sealants, resolving the contradiction between insulation reliability and bonding strength.
Solution Approach 2:
The patent employs a composite structure consisting of multiple material layers: Teflon insulating layer, intermediate bonding layer, and polyethylene outer jacket. This composite material approach allows each layer to contribute its specific properties - electrical insulation from Teflon, bonding capability from the intermediate layer, and water resistance from polyethylene.
2Object-affected harmful factors
If polyethylene is used for outer jacket, then water resistance is improved, but material integrity under high pressure deteriorates
Solution Approach 1:
The patent uses a composite structure where the polyethylene outer jacket is bonded to the Teflon insulating layer through an intermediate bonding layer. This composite construction allows the polyethylene to provide water resistance while the bonded structure maintains overall material integrity under high pressure conditions.
Solution Approach 2:
The patent employs a multi-layer curved/rounded structure where the outer polyethylene jacket envelops the inner Teflon insulating layer. This layered curvature design distributes stress more evenly under pressure, preventing material failure while maintaining water resistance.
3Ease of operation
If insulating layer is removed for splicing, then electrical connection is enabled, but water tightness deteriorates
Solution Approach 1:
The intermediate bonding layer acts as a mediator that extends over the spliced connection area, sealing the exposed conductor ends. This allows electrical splicing to be performed while the intermediate layer prevents water from penetrating into the splice area, maintaining water tightness.
Solution Approach 2:
The intermediate bonding layer is applied in advance over the areas where splicing will occur, creating a pre-sealed environment. This preliminary action ensures that when conductors are exposed for splicing, the surrounding area is already protected against water ingress.
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 effectively prevents water from reaching the underlying wires by forming a solid, homogenous polyethylene mass that maintains integrity under pressure, ensuring reliable electrical connections and preventing water ingress even under extreme conditions.
Implementation Method 1
a fusion bonding process using polyethylene to create a homogenous, water-tight seal by intertwining free-end components at specific temperatures
Data Source
AI summary
A cable includes an outer jacket of polyethylene surrounding a plurality of conductive wires. Each one of the plurality of insulated conductive wires comprises a conductive core and an insulating layer surrounding the conductive core, the insulating layer being made of cross-linked polyethylene.