Unitary Cover Assembly for Cable Splices with Collapsible Duct
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Solution Overview
Problem
Existing cold shrinkable covers for electrical cables and connections do not effectively integrate neutral conductors, often requiring separate re-jacketing and may not provide adequate electrical continuity due to insufficient conductivity in the conductive mesh.
Innovation Solution
A unitary cover assembly comprising an inner elastomeric sleeve, an outer elastomeric sleeve, and a collapsible duct that accommodates neutral conductors, allowing for a single, integrated solution that ensures proper gauge continuity and ease of installation by collapsing to securely encase the neutral conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate re-jacketing cover is used for neutral conductors, then coverage and protection is provided, but device complexity and installation time increase
Solution Approach 1:
The patent combines the cover for primary conductors and the cover for neutral conductors into a single integrated cover assembly. The first cover portion covers the primary conductors while the second cover portion covers the neutral conductors, eliminating the need for separate re-jacketing covers and reducing overall device complexity.
Solution Approach 2:
The single cover assembly serves multiple functions: it protects both primary conductors and neutral conductors, provides electrical continuity through the conductive mesh, and eliminates the need for separate protective components. This multi-functional design reduces the total number of parts required.
2Reliability
If separate re-jacketing cover is used for neutral conductors, then coverage is provided, but installation time increases
Solution Approach 1:
By merging the coverage function for both primary and neutral conductors into a single pre-assembled cover unit, the installation process is streamlined. The integrated cover is installed as one component rather than requiring sequential installation of separate covers, significantly reducing installation time.
Solution Approach 2:
The cover assembly is pre-assembled with both cover portions and the conductive mesh integrated before installation. This preliminary preparation eliminates the need for field assembly of multiple components, allowing for faster on-site installation while maintaining complete coverage.
3Ease of operation
If integrated cover assembly is used, then installation ease is improved, but manufacturing complexity increases
Solution Approach 1:
The integrated cover assembly is manufactured by dividing the molding process into segments: the first cover portion, the second cover portion, and the conductive mesh are formed separately or in staged operations. This segmentation allows each component to be optimized for its specific function while still achieving integration in the final assembly.
Solution Approach 2:
The conductive mesh is nested within or between the cover portions during manufacturing. The mesh is positioned and secured within the cover structure, allowing the smaller conductive element to be integrated into the larger cover assembly through a nested configuration that simplifies the overall manufacturing process.
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, easy-to-install, and integrated protection for both primary and neutral conductors, ensuring adequate electrical continuity and protection against environmental moisture, eliminating the need for separate re-jacketing and improving the conductivity across the splice connection.
Implementation Method 1
The duct is selectively collapsible from an initial open configuration to a collapsed configuration about the at least one neutral conductor
Implementation Method 2
Cold shrinkable covers are commonly employed to protect or shield electrical power cables and connections
Data Source
AI summary
An integral, unitary cover assembly for covering an electrical connection between first and second electrical cables each having a primary conductor and a neutral conductor includes an inner elastomeric sleeve, an outer elastomeric sleeve, and a collapsible duct. The inner elastomeric sleeve defines a cable passage to receive the electrical connection and the primary conductors of the first and second cables. The outer elastomeric sleeve surrounds the inner sleeve. The collapsible duct is interposed radially between the inner and outer sleeves. The duct defines a neutral conductor passage configured to receive at least one of the neutral conductors therethrough. The duct is selectively collapsible from an initial open configuration to a collapsed configuration about the at least one neutral conductor.