UV Curing System for Electrical Fitting Sealing
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Solution Overview
Problem
Existing electrical cable connectors require lengthy curing times at high temperatures for sealing compounds, which is problematic in cold temperature environments, such as outdoor installations, and may not effectively prevent arcing or flashover in high voltage settings.
Innovation Solution
A system using an ultra-violet (UV) curable sealing compound and a transparent sealing sleeve and cartridge with radial notches to maintain conductors in a spaced relationship, cured by an array of UV light sources within a curing chamber, allowing for rapid curing independent of temperature and preventing arcing between conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing compounds are used, then the sealing function is achieved, but the curing time becomes excessively long and temperature requirements cannot be met in cold environments
Solution Approach 1:
The patent replaces the traditional thermal curing mechanism with a UV light-based curing mechanism. The UV-curable sealing compound is cured by exposing it to UV light sources, eliminating the need for high temperature thermal processing. This substitution enables rapid curing independent of ambient temperature, solving the problem of excessively long curing times and inability to cure in cold environments while maintaining reliable sealing effectiveness.
Solution Approach 2:
The patent changes the curing activation parameter from temperature-dependent thermal energy to wavelength-specific UV light energy. By formulating the sealing compound with UV-curable properties and providing corresponding UV light sources, the system achieves rapid curing (reducing curing time significantly) while being independent of ambient temperature conditions, thus resolving both the time loss and reliability concerns.
2Reliability
If traditional sealing compounds are used, then sealing is provided, but the curing process requires high temperatures which are problematic in outdoor installations
Solution Approach 1:
The patent substitutes the thermal curing system with a UV photopolymerization system. Instead of requiring high temperature environments for curing, the sealing compound is cured by UV light exposure. This replacement eliminates the temperature constraint, enabling outdoor installations in cold environments while maintaining the same sealing effectiveness as traditional high-temperature curing processes.
Solution Approach 2:
The patent fundamentally changes the curing activation parameter from temperature to UV light wavelength. The sealing compound is formulated to cure upon exposure to specific UV wavelengths rather than requiring elevated temperatures. This parameter change allows the curing process to proceed independently of ambient temperature, making outdoor and cold-weather installations feasible while preserving reliable sealing performance.
3Productivity
If UV-curable sealing compound is used, then rapid curing is achieved independent of temperature, but additional curing equipment is required
Solution Approach 1:
The patent replaces the complex thermal curing infrastructure (heating equipment, temperature control systems, long curing cycles) with a UV light-based curing system. The UV curing apparatus, while requiring specific light sources, eliminates the need for sustained high-temperature environments and extended curing times, achieving rapid curing independent of ambient temperature. The trade-off of added equipment is offset by the elimination of temperature control infrastructure and significantly reduced processing time.
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 UV-curable sealing compound effectively seals electrical cable connectors in cold temperatures, preventing arcing and flashover, and achieves a rapid curing process, ensuring reliable electrical connections in high voltage environments.
Implementation Method 1
an ultra-violet (UV) curable sealing compound and a transparent sealing sleeve and cartridge with radial notches to maintain conductors in a spaced relationship, cured by an array of UV light sources within a curing chamber
Data Source
AI summary
A system for curing a sealing compound provided in an electrical fitting, includes a curing chamber for receiving at least a portion of the electrical fitting therein, wherein the electrical fitting received within the curing chamber comprises a body and a sealing sleeve configured to engage the forward end of the body during assembly of the fitting to receive the two or more conductors of an electrical cable passing through the body. The sealing sleeve is configured to receive an ultra-violet (UV)-curable sealing compound therein, such that the sealing compound flows between the two or more conductors during filling of the sealing sleeve. The system further includes a plurality of UV light sources configured to provide UV light into the curing chamber to cure the UV-curable sealing compound and to initiate curing of the UV-curable sealing compound in the sealing sleeve.