The disclosed apparatus relates generally to connectors between electrical cables. Specifically, this application relates to technology that allows cables to be spliced together with a splice of minimal length while maintaining the proper positioning between components.
A routine task faced by utility linepersons is the need to connect two cables that do not possess some form of mutually compatible connector device. Typically, the utility lineperson removes sections of the outer semi-conductive layer and the inner insulating layer of the cable to expose the electrical conductor of both cables. The electrical conductors of both cables are then electrically coupled. Once the electrical conductors are electrically coupled, the utility lineperson now has to protect the exposed electrical conductors in a manner that is consistent with the remaining sections of the outer semi-conductive layer and inner insulating layer. The covering used to replicate the semi-conductive layer and the insulating layer is referred to as a splice.
Conventional pre-molded splices have operated by inserting the first cable through the splice, causing the exposed end of the cable to project out of the opposite end of the splice. The two cables are then electrically coupled. The splice is then slid over the electrical coupling to protect the electrical coupling from the external environment. Additionally, as the splice is slid over the electrical coupling, a semiconductive insert in the splice is positioned around the electrical coupling, which creates a Faraday cage around the coupling. The Faraday cage maintains the electrical potential on all sides of any air 313 between or around the coupled components to prevent a partial discharge therein.
Two factors that influenced the length of the splice were the length of the splice to effectively seal the electrical coupling and create a proper Faraday cage verses the minimization of length of the splice to facilitate installation of the splice. These two competing interests can impact the effectiveness of a splice. If the splice is too long, then installation becomes difficult as more of the splice has to pass over the first cable. If the splice is too short, then the electrical coupling or the insulation is exposed, or internal conductive portions of the splice are not properly positioned to electrically shield the coupled conductors of the cables, thereby leading to potential electrical arcing. If the splice is at the optimum size, it may still prove ineffective if not properly centered and covering the cables. Previous attempts to reconcile these issues used rolled splices, but those connectors can introduce foreign contamination to the electrical connection.
One conventional method for attempting to properly center a splice over electrically coupled cables is to make the entire walls of the splice relatively thin. With a thin-walled splice, the positioning of the cables within the splice can be detected based on visual deformations of the shell caused by the contact with the cables therein. However, a thin-walled splice has several deficiencies. For example, a thin-walled splice is more likely to tear or split when being installed over the cables, which usually involves stretching the splice over the cables. Additionally, a thin-walled splice is more likely to tear along the parting lines of a mold during the manufacturing process, thereby creating additional scrap material. A thin-walled splice also may be damaged by a fault current such that the splice fails to conduct a fault current to ground. In this case, the damaged splice does not allow “fault reinitiation,” and a utility lineperson may be injured by touching the energized splice (or nearby components).
Therefore, a need exists in the art for a splice that is positionable over the cables and the electrical connector with a minimal length to ease installation and with sufficient thickness to avoid the deficiencies of conventional splices, while still maintaining proper positioning of the splice with regard to the spliced cables.
The disclosed apparatus relates generally to electrical connections. More particularly, the disclosed apparatus relates to a device that allows a connection between two physically separate cables in a manner that allows electrical coupling and external protection for the electrical coupling.
According to one exemplary aspect, a splice comprises a hollow receptacle housing with a first end and a second end, where a first observation port is disposed in the first end and a second observation port is disposed in the second end. The observation ports aid the user in positioning of the cables in the splice by allowing the user to observe the transition between the semi-conductive layer and the insulating layer of cables when coupled via the splice.
According to another exemplary aspect, two cables are connected using the splice. Each cable is prepared by removing a section of the semi-conductive outer layer and the insulating inner layer to expose the electrical conductor of the cable. The splice is coupled to a first cable in a preparatory position and the two conductors are coupled together. Once the conductors are coupled together, the splice is placed in a cover position where the appearance of the cables in the first observation port and the second observation port mirror each other, showing their respective semi-conductive and insulating layers of the respective cables.
These and other aspects, objects, features, and embodiments of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of illustrated embodiments exemplifying the best mode for carrying out the apparatus as presently perceived.
The invention may be better understood by reading the following description of non-limitative, exemplary embodiments with reference to the attached drawings, wherein like parts of each of the figures are identified by the same reference character, and which are briefly described as follows.
The splice 100 comprises a semi-conductive main body 120 acting as an outer shell with a first cross sectional area with two connector ends 140a-b having a smaller, second cross sectional area than that of the main body 120. As used throughout this specification, a “semi-conductive” material can refer to rubber or any other type of material that carries current, and thus can include conductive materials. The main body 120 comprises a fill sprue 112 via which insulation 312 (
Observation ports 102a-b are located in the connector ends 140a-b of the splice 100. The observation ports 102a-b are located near the distal ends 144a-b of the connector ends 140a-b in an exemplary embodiment. In an exemplary embodiment, the observation ports 102a-b are translucent, allowing a user to perceive the opposite side of the observation port 102a-b. In alternative exemplary embodiments, the observation ports 102a-b can be a hole through the outer conductive layer of the splice 100, thereby allowing a user to see through the observation ports 102a-b, or the observation ports 102a-b can be a thin membrane, thereby allowing the user to perceive a change in the layers of materials of a cable contained with the splice 100. The observation ports 102a-b facilitate the centering function of the splice 100. As shown in
The method of splicing cables involves placing a splice 100 on a first cable 104a, electrically coupling the first cable 104a and a second cable 104b using an electrical coupling device, and positioning the splice 100 such that the splice 100 covers the electrical coupling device and the coupled conductors of the cables 104a-b.
To verify that the splice 100 is properly positioned (in other words, centered and/or having the Faraday cage created by the interior semi-conductive portion 310 located around the coupled conductors 306a-b and around both insulating layers 304a-b), the user observes the position of the transition 114a-b between the semi-conductive outer layers 302a-b and the insulating inner layers 304a-b through the observation ports 102a-b. When the splice 100 is properly positioned, the transition 114a-b between the semi-conductive outer layers 302a-b and the insulating inner layers 304a-b will become visible through the observation ports 102a-b. When the user positions the splice 100, the user can have the position of the transition 114a-b between the semi-conductive outer layer 302a and the insulating inner layer 304a in observation port 102a mirror the position of the semi-conductive outer layer 302b and the insulating inner layer 304b in observation port 102b. When the observation ports 102a-b mirror each other, the splice 100 is properly positioned in the exemplary embodiment.
In an exemplary embodiment, the observation ports 102a-b comprise a membrane 406 (
Two exemplary embodiments for positions of the observation ports 102a-b will be described.
In the illustrated, exemplary embodiment, the connector end 140 has two observation ports 102a, 102c that facilitate observation from more than one direction. In the figures shown, observation ports 102a and 102c and membranes 406a and 406c are shown, with the understanding that observation ports 102b and 102d and membranes 406b and 406d are on the connector end 104b that is not shown.
The installed cable 104a pushes against the inner surface of the end connector 140a and the observation ports 102a, 102c, creating a seal that insulates the conductors 306a, 306c and the electrical coupling device 308 from the outside air. The displacement of the observation port 102 causes the thickness of the observation port 102 to adjust depending on where the cable 104a is installed.
An alternative embodiment has the observation port 102a located on the edge of the splice 100.
An observation port may be manufactured in a splice in any suitable manner. In one exemplary embodiment, a mold can include a boss that creates an area of lesser thickness in a side of the splice. In this case, the boss also provides an advantage of preventing or limiting deflection and movement of a mandrel within the main body 120 when the insulation layer 312 is injected therein during the molding process for manufacturing the splice. The area of lesser thickness is the observation port. In this embodiment, the observation port comprises the same material as the side of the splice. In an alternative exemplary embodiment in which the observation port is a hole in the splice, the mold can include solid components around which the splice is molded, thereby leaving a hole as the observation port. In yet another exemplary embodiment, a membrane material may be applied and press molded into the apertures in the splice, forming the membrane 406a (for example) from a material that is different from the material in the side of the splice. In this case, for example, the membrane may be made from an opaque material, a translucent material, or a transparent material.
Therefore, the disclosed apparatus is well adapted to attain the ends and advantages mentioned, as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the disclosed apparatus may be modified and practiced in different but equivalent manners apparent to those having ordinary skill in the art and having the benefit of the teachings herein. Having described some exemplary embodiments of the presently disclosed apparatus, various modifications are within the purview of those in the art without departing from the scope and spirit of the invention. While numerous changes may be made by those having ordinary skill in the art, such changes are encompassed within the spirit of the disclosed apparatus as defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular exemplary embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosed apparatus. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.
This Application is related to U.S. patent application Ser. No. ______ [Attorney Docket No. 13682.117402 (RTC-028415 U2)] entitled “Method of Using an Observation Port or Membrane to Assist the Proper Positioning of a Cable Accessory on a Cable” filed Mar. 5, 2009. The complete disclosure of the above-identified related application is hereby fully incorporated herein by reference.