1) Field of the Invention
The present invention relates to a cold-shrinkable type rubber insulation sleeve that is used for a joint of power cables such as high-voltage CV (cross-linked polyethylene insulated vinyl sheath) cables.
2) Description of the Related Art
There are various kinds of structures for insulation joints for high-voltage CV cables. Such structures include an extrusion molded type, a pre-fabricated type, a tape wrapping molded type, and a tape wrapping type. In addition, a one-piece joint that has an excellent assembility and uses a cold-shrinkable type rubber sleeve has become available and been spreading recently with remarkable improvements in rubber molding technology.
As shown in
The cold-shrinkable type rubber insulation sleeve is manufactured, for example, as follows. The internal semiconductive layer 5 is molded in advance by injecting a semiconductive rubber material in a special mold (not shown). The internal semiconductive layer 5 is then arranged at a predetermined position around a core 9 (see
Then, a mold (not shown) for the reinforced insulation sleeve 1 is set around the core 9 and the internal semiconductive layer 5. The reinforced insulation sleeve 1, with a slope 1a at each end (see
Then the mold for the reinforced insulation sleeve 1 is replaced with a mold (not shown) for the external semiconductive layer 7. The external semiconductive layer 7 is molded by injecting a semiconductive rubber material into this mold (see
The cold-shrinkable type rubber insulation sleeve can be manufactured even as follows. The internal semiconductive layer 5 and the semiconductive stress-relief cone 3 are molded in advance with the molds specially prepared for each with the semiconductive rubber material. The internal semiconductive layer 5 is arranged at a predetermined position around the core 9 (see
Then, a mold (not shown) for the reinforced insulation sleeve 1 is set in such a manner that the mold covers both the semiconductive stress-relief cones 3. The reinforced insulation sleeve 1 with a slope 1a at each end (see
Then, the mold for the reinforced insulation sleeve 1 is replaced with a mold (not shown) for the external semiconductive layer 7. The mold for the external semiconductive layer 7 is set around the core 9 so as to cover both the reinforced insulation sleeve 1 and the semiconductive stress-relief cones 3. The external semiconductive layer 7 is molded by injecting a semiconductive rubber material into this mold (see
As described above, the conventional cold-shrinkable type rubber insulation sleeve includes the reinforced insulation sleeve 1, the semiconductive stress-relief cone 3, the internal semiconductive layer 5, and the external semiconductive layer 7 that are molded. The method explained with
In the method explained with
Moreover, in both the methods, there is a problem that the thickness of the external semiconductive layer 7 may vary. This is because both the methods employ molding to form the external semiconductive layer 7. Molding sometimes causes an unbalance in the flow of the injected semiconductive rubber material inside the mold because of presence of the parts in which the rubber material does not flow well. To solve this problem, the external semiconductive layer 7 is generally formed of thickness of 3 millimeters (mm) or more, i.e., thicker than that is required. This causes inefficiency in manufacturing because more time is required for molding and curing. This also causes increased manufacturing cost because the mold for the external semiconductive layer 7 becomes larger than the mold for the reinforced insulation sleeve 1, and because, if the thickness of the external semiconductive layer 7 is to be made thick, a mold and a press even larger and more expensive are required.
It is an object of the present invention to provide a cheaper and more effective method for forming a cold-shrinkable type rubber insulation sleeve.
A cold-shrinkable type rubber insulation sleeve according to an aspect of the present invention includes a reinforced insulation sleeve made mainly with an elastic material that is elastic at room temperature; a semiconductive stress-relief cone that is arranged at each end of the reinforced insulation sleeve; an internal semiconductive layer that is arranged on an inner surface of the reinforced insulation sleeve; and an external semiconductive layer that is arranged around the reinforced insulation sleeve and covers the outer surface of the reinforced insulation sleeve. The reinforced insulation sleeve, the semiconductive stress-relief cone, and the internal semiconductive layer are formed by molding. The external semiconductive layer is formed by coating.
A method of manufacturing a cold-shrinkable type rubber insulation sleeve according to another aspect of the present invention includes forming a tube-shaped internal semiconductive layer by injecting a semiconductive rubber material into a first mold; forming two substantially tube-shaped semiconductive stress-relief cones by injecting a semiconductive rubber material into a second mold; arranging the internal semiconductive layer at a predetermined position around a substantially cylindrical core; arranging the semiconductive stress-relief cone at each side of the internal semiconductive layer in such a manner that there is a predetermined gap between the semiconductive stress-relief cone and the internal semiconductive layer; forming a reinforced insulation sleeve, in such a manner that the reinforced insulation sleeve covers the internal semiconductive layer and both the semiconductive stress-relief cones, by injecting an elastic material into a third mold; removing the third mold; forming a coating that covers an outer surface of the reinforced insulation sleeve mounting over the semiconductive stress-relief cone by spray coating a liquid semiconductive rubber material; drying and vulcanizing the coating to form an external semiconductive layer; and removing the core.
The other objects, features, and advantages of the present invention are specifically set forth in or will become apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings.
Exemplary embodiments of the present invention are explained with reference to the accompanying drawings.
The cold-shrinkable type rubber insulation sleeve is formed into one piece mainly with rubber materials such as Ethylene-Propylene Rubber (EPR) and Silicone Rubber (SR) that are elastic at room temperature. The cold-shrinkable type rubber insulation sleeve includes a reinforced insulation sleeve 11, a semiconductive stress-relief cone 13 at each end of the reinforced insulation sleeve 11, an internal semiconductive layer 15 that is arranged on the inner surface of the reinforced insulation sleeve 11, and an external semiconductive layer 17 that is arranged around the reinforced insulation sleeve 11 to cover the outer surface.
The reinforced insulation sleeve 11 is molded with the rubber material such as Ethylene-Propylene into a tube shape that has a slope 11a at each end. The thickness of the reinforced insulation sleeve 11 gradually becomes thin at each of the slopes 11a.
The semiconductive stress-relief cone 13 is molded with a semiconductive rubber material, which includes the above rubber material and carbon, into a tube shape. The semiconductive stress-relief cone 13 is arranged at each side of the internal semiconductive layer 15 in such a manner that there is a predetermined gap between the semiconductive stress-relief cone 13 and the internal semiconductive layer 15. The semiconductive stress-relief cone 13 is set in such a manner that a slope-shaped concave section 13a faces toward the internal semiconductive layer 15.
The internal semiconductive layer 15 is molded with the semiconductive rubber material. The internal semiconductive layer 15 is embedded inside the tube shaped structure of the reinforced insulation sleeve 11 at the center in such a manner that the inner surface fo the internal semiconductive layer 15 is exposed.
The external semiconductive layer 17 is formed around and on entire outer surface of the reinforced insulation sleeve 11 mounting over the semiconductive stress-relief cone 13. The external semiconductive layer 17 that has the elasticity of 50% or higher is formed by spray coating a liquid semiconductive rubber material with a nozzle jet sprayer, or by applying the semiconductive rubber material with a roller. The external semiconductive layer 17 includes a coating 17a and a contact coating 17b. The coating 17a is tube shaped and of thickness of 1 mm or less. The contact coating 17b is arranged at each end of the coating 17a so as to contact each of the semiconductive stress-relief cone 13. Thus, two of the semiconductive stress-relief cones 13 become conductive with each other through the contact coating 17b and the coating 17a.
In the cold-shrinkable type rubber insulation sleeve according to the present invention, since the reinforced insulation sleeve 11, the semiconductive stress-relief cone 13, and the internal semiconductive layer 15 are formed by molding but the external semiconductive layer 17 is formed by coating, a large mold and a large press to mold the external semiconductive layer 17 are not required. Thus, the manufacturing cost for the cold-shrinkable type rubber insulation sleeve can be lowered.
In addition, it is possible to form the external semiconductive layer 17 easily without considering stagnation or uneven flow of the semiconductive rubber material inside the mold, and without trouble to control the molding pressure. The yield is also improved. Furthermore, it is possible to form the external semiconductive layer 17 thinner in thickness than the conventional molded type without causing nonuniformity in the thickness. This also leads to improved manufacturing efficiency of the cold-shrinkable type rubber insulation sleeve because less time is required for formation, including processes of coating and curing, of the external semiconductive layer 17.
Moreover, because the reinforced insulation sleeve 11, the semiconductive stress-relief cone 13, and the internal semiconductive layer 15 are formed not by coating but by molding, it is possible to obtain the cold-shrinkable type rubber insulation sleeve enough rugged and durable not to be deformed even while the cold-shrinkable type rubber insulation sleeve is kept expanded, or when the cold-shrinkable type rubber insulation sleeve is let shrink at assembly. It is also possible to stably maintain a desirable performance for a long time, and to enhance reliability.
A manufacturing method of the cold-shrinkable type rubber insulation sleeve according to the present invention is explained next with reference to
Then, the internal semiconductive layer 15 is arranged at a predetermined position, for example at the center, around a cylindrical core 19. Further, the semiconductive stress-relief cone 13, which has been molded, is arranged on each outward side of the internal semiconductive layer 15 in such a manner that there is a predetermined gap between the semiconductive stress-relief cone 13 and the internal semiconductive layer 15, and that the slope-shaped concave section 13a faces toward the internal semiconductive layer 15.
Then, the reinforced insulation sleeve 11 is molded. A mold (not shown) for the reinforced insulation sleeve 11 is set around the core 19 and the internal semiconductive layer 15, so as to mount to cover the semiconductive stress-relief cones to the edges. The reinforced insulation sleeve 11 with a slope 11a at each end (see
Then, the external semiconductive layer 17 is formed as shown in
During application of the semiconductive rubber material over the reinforced insulation sleeve 11 to form the coating 17a and the contact coating 17b, the nozzle 21, instead of the core 19, may be rotated around the core 19 making reciprocating movement in the direction of the length of the core 19, while the core 19 is fixed. Moreover, the core 19 may be rotated and make reciprocating movement in the direction of the length, while the nozzle is fixed. Furthermore, the nozzle 21 may be rotated around the core 19, and the core 19 may make reciprocating movement in the direction of the length. Moreover, the coating 17a and the contact coating 17b may be formed by dropping the liquid semiconductive rubber material on the outer surface of the reinforced insulation sleeve 11, and then by spreading with a roller while rotating the core 19. The contact coating 17b may be arranged at only one of the semiconductive stress-relief cones 13 so that the coating 17a becomes conductive only with one of the semiconductive stress-relief cones 13. Furthermore, the coating 17a may be conductive with neither of the semiconductive stress-relief cones 13 without preparing the contact coating 17b.
As described above, according to the cold-shrinkable type rubber insulation sleeve of the present invention, since the reinforced insulation sleeve, the semiconductive stress-relief cone, and the internal semiconductive layer are formed by molding but the external semiconductive layer is formed by coating, a large mold and a large press to mold the external semiconductive layer are not required. Thus, the manufacturing cost for the cold-shrinkable type rubber insulation sleeve can be lowered.
In addition, it is possible to form the external semiconductive layer easily without considering stagnation or uneven flowing of the semiconductive rubber material inside the mold, and without trouble to control the molding pressure. The yield is also improved. Furthermore, it is possible to form the external semiconductive layer thinner in thickness than the conventional molded type without causing nonuniformity in the thickness. This also leads to improved manufacturing efficiency of the cold-shrinkable type rubber insulation sleeve because less time is required for formation, including processes of coating and curing, of the external semiconductive layer.
Moreover, because the reinforced insulation sleeve, the semiconductive stress-relief cone, and the internal semiconductive layer are formed not by coating but by molding, it is possible to obtain the cold-shrinkable type rubber insulation sleeve enough rugged and durable not to be deformed even while the cold-shrinkable type rubber insulation sleeve is kept expanded, or when the cold-shrinkable type rubber insulation sleeve is let shrink at assembly. It is also possible to stably maintain a desirable performance for a long time, and to enhance reliability.
Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth.
Number | Date | Country | Kind |
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2003-174,964 | Jun 2003 | JP | national |
Number | Date | Country | |
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Parent | 10868843 | Jun 2004 | US |
Child | 11589108 | Oct 2006 | US |