Undersea Cable Plug With Electrofusion PE Splice Joining
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Solution Overview
Problem
Current methods for forming polyethylene (PE) encapsulations for undersea cables are time-consuming and expensive, requiring significant investment in equipment and time to achieve durable cable splices, while existing solutions like electrofusion are not readily applicable for PE jacketed cables.
Innovation Solution
The use of pre-formed fittings with embedded heating wires that allow for rapid fusion of PE jacketed cables to PE tubes, eliminating the need for pre-heating and reducing processing time to minutes, thereby facilitating efficient and cost-effective joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional PE encapsulation processes are used for undersea cables, then long term durability in seawater is achieved, but the process takes relatively long time and requires expensive molds
Solution Approach 1:
The patent replaces the traditional mechanical molding process with electrofusion technology. Instead of using expensive molds and mechanical encapsulation equipment, the invention uses electrical heating elements embedded in the PE fitting to melt and fuse the polyethylene material directly onto the cable, achieving the same protective encapsulation effect through thermal-electrical means rather than mechanical molding.
Solution Approach 2:
The invention changes the processing parameters by using controllable electrical heating to achieve precise temperature control during the fusion process. By adjusting electrical parameters (voltage, current, time), the process can be optimized to complete encapsulation in minutes rather than hours, while maintaining the required durability through proper fusion temperature and pressure control.
2Strength
If traditional PE encapsulation processes are used for undersea cables, then high-strength durable cable with PE housing overmold is achieved, but significant investment in equipment and time is required
Solution Approach 1:
The patent replaces expensive mechanical molding equipment with relatively simple electrofusion equipment. The system uses embedded heating elements and basic compression fixtures instead of costly injection molding machines and custom molds, significantly reducing equipment investment while achieving equivalent or superior bond strength through direct thermal fusion of the PE materials.
Solution Approach 2:
The invention uses pre-manufactured PE fittings with embedded heating elements that can be applied in the field without requiring expensive, specialized molding equipment. Each fitting is a self-contained unit that performs the encapsulation function through electrofusion, eliminating the need for costly reusable molds and complex manufacturing infrastructure.
3Ease of manufacture
If electrofusion is used for pipeline welding, then high quality inexpensive welding is achieved, but it is not readily applicable for PE jacketed cables
Solution Approach 1:
The patent adapts electrofusion technology originally developed for pipeline welding to work with PE-jacketed cables by designing specialized fittings with embedded heating elements that match cable dimensions. The same basic electrofusion principle is applied, but the equipment and procedures are modified to accommodate the different geometry and requirements of cable splicing, making the inexpensive electrofusion method universally applicable to both pipelines and cables.
Solution Approach 2:
The invention applies electrofusion locally at the cable splice point using pre-formed PE fittings that contain heating elements positioned precisely where needed. This localized application allows the cable to remain flexible and unaffected in other sections, while the splice area receives the beneficial inexpensive electrofusion treatment. The local heating and fusion process adapts the pipeline welding technique to cable-specific requirements.
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 method significantly reduces the time required for cable splicing, achieving a strong and durable bond in a fraction of the time of conventional processes, while maintaining the integrity of internal components and allowing for underwater use.
Implementation Method 1
a plug (101) for joining a polyethylene (PE) jacketed cable (102) to a PE tube (103)... first heating wires (110) embedded in an outermost surface (142) of a first surface (141)... second heating wires (120) embedded in an innermost surface (152) of a second surface (151)... applying current to the first heating wires (110) to heat proximal PE portions of the PE tube (103) and the first section (140) and to the second heating wires (120) to heat proximal PE portions of the PE jacketed cable (102) and the second section (150)
Implementation Method 2
applying current to the first heating wires (110) to heat proximal PE portions of the PE tube (103) and the first section (140) and to the second heating wires (120) to heat proximal PE portions of the PE jacketed cable (102) and the second section (150) thereby to melt and bond the PE body (130) to the PE tube (103) and to the PE jacketed cable (102)
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
A plug (101) for joining a polyethylene (PE) jacketed cable (102) to a PE tube (103) is provided. The plug (101) includes first (110) and second (120) heating wires and a PE body (130). The PE body (130) includes a first section (140) and a second section (150). The first section (140) is insertible into the PE tube (103) and includes a first surface (141) to engage with the PE tube (103). The first heating wires (110) are embeddable in the first surface (141). The second section (150) is within the first section (140) and the PE jacketed cable (102) is insertible into the second section (150). The second section (150) includes a second surface (151) to engage with the PE jacketed cable (102). The second heating wires (120) are embeddable in the second section (150).