GROOVED SEAM SEAL FOR CABLE SPLICE CLOSURE
Background of the Invention
This invention relates generally to a cable splice closure body and more particularly to an elongated closure body joined by a bonded groove arrangement which also provides mechanical support to form a lengthwise seam seal.
There are various methods for joining or splicing telecommunication cable ends together. In so doing, there are many important considerations such as the use of compatible materials, how many cables are being spliced, is the spliced cable to be buried in soil, immersed in water or suspended in the air, what heat source is required to make the joint, i.e. , flammable gasses, will the splice need to be reopened and remade without interruption of working circuits, will the joint have sufficient mechanical strength and is the cost feasible? Communication cables are typically constructed of a conductor bundle, surrounded by a metal strength and interference sheathing and an outer protective coating, typically of polyethylene. When such cables are spliced and rejoined, the strength and integrity of the rejoined cable is critical. An enclosure or a closure body is used to sealingly surround the splice. One persistent problem in the use of splice closures involves the need for a complete seal about the splice or closure body. Many prior art splice closures accomplish sealing by providing a complex array of nuts and bolts, clamps, gaskets and heat shrink tubing, as well as potting gels and resins, in various combinations. Besides the fact that these closure methods require significant assembly time, the closures still often suffer leaks or ruptures, particularly along their seals. This problem is even more acute at the sealing of the closure to the cable jacket, where even the slightest defect can result in the migration of moisture along the jacket or the inner surface of the closure. A lack of a complete (hermetic) seal can also be particularly detrimental for pressurized closures.
Although these seals may be strengthened by the use of adhesives. the adhesive bonds formed are normally relatively weak due to the low surface
energy of the material of the closure and cables, typically polyethylene. An alternative technique for sealing thermoplastic polymers such as polyethylene is that of fusion bonding. This technique generally involves the heating of the material until it becomes molten at its sealing surfaces, causing it to flow together at the interfaces, and can be used for butt welds, coupling joints and repair sleeves. Two specific methods of fusion bonding: (i) direct heating, and
(ii) induction heating, may also be used to activate thermoset and thermoplastic
(hot-melt) adhesives, as well as thermoplastic (heat-shrink) tubing. Induction heating is sometimes referred to as electromagnetic bonding (EMB). In direct heating (also known as resistance heating), heat is applied to the thermoplastic article to be bonded by directly attaching heating elements to the article. Current flowing through the elements heats them. The current is supplied by a power source directly connected to the elements, but the heating is not always efficient. One advantage of such a system is that it does not involve emission of radiation, but there are disadvantages such as non-uniform heating of the material.
Induction heating has been widely used to seal and bond polymeric materials. A composite bonding material (CMB) is formed by dispersing magnetically reactive susceptors in a thermoplastic carrier which is compatible (miscible) with the thermoplastic bodies to be welded. When this material is placed in an alternating electromagnetic field, the H field induces heating in the magnetic material. Heating may be caused by one of two effects: hysteresis loss, or resistive loss from induced eddy currents. The E field does not interact with the magnetic particles. Direct and induction heating techniques may be combined.
The prior an related to splice cable closures or terminations is replete with systems for sealingly enclosing cable splices. One of these systems comprises an enclosure having a single tongue and groove arrangement. Another system comprises an enclosure having multiple tongue and groove enclosures. Still another system comprises a splice case enclosure providing sealed protection for splices such as in telephone cables situated in adverse environmental conditions. The case includes a shell defining a cavity for
enclosure of a splice. The shell is longitudinally split and includes openings at the ends thereof along the longitudinal split for receiving incoming cable. Thermally responsive sealant extends along the longitudinal split and a heating element is provided for causing the sealant to effectively seal the enclosed splice. A multiple cable adapter of thermally responsive sealant is sized to fit within a cable opening in the splice case and includes a plurality of longitudinally extending channels for accommodation of multiple incoming cables. Sheets of material exhibiting high thermal conductivity extend from the adapter such that the heat of the heating elements may be conveyed to the body of the adapter. One of the persistent difficulties with using electromagnetic, or resistive wire heating, to melt material for the purpose of providing a horizontal bond line seal, has been to confine the melted material in place with sufficient pressure to form the desired lengthwise seal upon cooling.
Unfortunately, a suitable solution to the problems associated with ease of installation, seal integrity and strength has not been satisfactorily addressed by the prior art. Therefore, what is needed is a sealed closure, or terminal, through which cables are positioned, and sealing the closure to restrict moisture or other contamination from entering. It is also highly desirable to provide a device which is easy to install and is capable of maintaining seal integrity and strength and can accommodate various numbers of cables and cable sizes.
Summary of the Invention The present invention, accordingly, provides a cable splice closure apparatus utilizing abutting flanges which are fusion bonded together by an elongated seam seal in a groove along the length of the flanges. To this end, a cable splice closure comprises an elongated tubular member having first and second portions. The first and second portions have opposed ends and parallel sides. The sides extend between the ends and are spaced apart by an arcuate section. Each side has an adjacent flange extending along the length thereof. The flanges of the first portion are provided for matched abutment with the flanges of the second portion. At least one groove extends along each flange. Means are provided to extend along the groove for bonding the abutting flanges together.
A principal advantage of the present invention is that a cable splice closure is joined by a fusion bonded groove connection and simultaneously by a mechanically connected arrangement. The cable closure may be in the form of a one piece closure with a separating seam or may be two pieces which are mirror images of each other. The fusion bonding is accomplished by electromagnetic or resistive wire means while the mechanical connection provides support to form a lengthwise seam seal. This can also be used to assist in bonding end seals to the closure.
Brief Description of the Drawings Fig. 1 is an isometric view illustrating an embodiment of a separated cable splice closure according to the present invention.
Fig. la is an isometric view illustrating an embodiment of a one-piece body having a lengthwise seam and a pair of mating flanges.
Fig. 2 is an enlarged partial isometric view illustrating an embodiment of a separated end portion of the cable splice closure according to the present invention.
Fig. 3 is an enlarged partial isometric view illustrating an embodiment of a connected end portion of the cable splice closure including an end seal according to the present invention. Fig. 4 is an enlarged partial isometric view illustrating an embodiment of a separated portion of the flanges according to the present invention.
Fig. 4A is an enlarged partial isometric view illustrating the embodiment of Fig. 4 showing the flange portions connected according to the present invention. Fig. 5 is an enlarged partial isometric view illustrating another embodiment of a separated portion of the flanges according to the present invention.
Fig. 5A is an enlarged partial isometric view illustrating the embodiment of Fig. 5 showing the flange portions connected according to the present invention.
Fig. 6 is an enlarged partial isometric view illustrating an embodiment of a sealing resistive wire according to the present invention.
Fig. 7 is an enlarged partial cross-sectional view illustrating a further embodiment according to the present invention.
Fig. 8 is an enlarged partial cross-sectional view illustrating bonded flanges according to the Fig. 7 embodiment. Description of the Preferred Embodiment
Referring to Fig. 1, a cable splice end closure is generally designated 10 and comprises a closure body 12 (shown separated) which is an elongated tubular member having a first portion 14 and a second portion 16. First portion 14 includes a pair of opposed ends 14a, 14b and a pair of elongated parallel sides 14c, 14d which extend between the ends 14a, 14b. Sides 14c, 14d are spaced apart by an arcuate section 18. Side 14c has an elongated closure surface in the form of a flange 20. Side 14d has a closure surface in the form of a flange 22. The flanges 20, 22 extend along the length of their respective sides 14c, 14d. Second portion 16 includes a pair of opposed ends 16a, 16b and a pair of elongated parallel sides 16c, 16d which extend between the ends 16a, 16b. Sides 16c, 16d are spaced apart by an arcuate section 24. Side 16c has an elongated closure surface in the form of a flange 26. Side 16d has a closure surface in the form of a flange 28. The flanges 26, 28 extend along the length of their respective sides 16c, 16d. It can be appreciated from Fig. 1 that flanges 20, 26 and flanges 22, 28, respectively, are provided to interconnect for matched abutment to form mating closure surfaces. Fig. 1A illustrates that an alternate construction includes a body 12a which is a one piece body including a single lengthwise seam 13 separating adjacent mating flanges 20a, 22a which each include a laterally spaced apart tongue c and groove d. A pair of spaced apart, parallel friction connectors extend along the length of each flange for connection with the connectors of each matched flange.
More specifically, flange 20 includes a first elongated friction connector in the form of a tongue 20a extending from a surface 20c. Tongue 20a is parallel to and spaced from a second elongated friction connector in the form of a groove 20b recessed in surface 22c. Mating flange 26 includes a first elongated friction connector in the form of a tongue 26a extending from a surface 26c. Tongue 26a is parallel to and spaced from a second elongated friction connector in the
form of a groove 26b recessed in surface 26c. Flange 22 includes a first elongated friction connector in the form of a tongue 22a extending from a surface 22c. Tongue 22a is parallel to and spaced from a second elongated friction connector in the form of a groove 22b recessed in surface 22c. Mating flange 28 includes a first elongated friction connector in the form of a tongue
28a extending from a surface 28c. Tongue 28a is parallel to and spaced from a second elongated friction connector in the form of a groove 28b recessed in surface 28c. It can be seen in the Fig. 1 embodiment, that the flanges are provided to have a single projecting tongue (male member) and a single recessed groove (female member), best illustrated in Figs. 4 and 4A, wherein flanges 22, 28 are partially illustrated including their respective tongue and grooves 22a, 22b and 28a, 28b. Thus when tongue 22a becomes mechanically engaged in groove 28b and tongue 28a becomes mechanically engaged with groove 22b, surfaces 22c, 28c, of flanges 22, 28, respectively are immediately adjacent each other. Although not shown, the same occurs with flanges 20 and
26.
According to the present invention, one of the mechanically engaged tongue and groove engagements can also be bonded together in a sealing engagement. For example, in Fig. 1 , a wire 30 can be extended in an opening through the length of tongue 26a and another wire 32 can be extended through the length of tongue 22a. Electrical stimulation of wires 30, 32 can cause tongues 26a, 22a, respectively, to be fusion bonded in their respective grooves
20b, 28b. The wires 30, 32 can be a resistance wire forming a closed circuit in which alternating current (AC) or direct current (DC) is applied for power. In Fig. 2, ends 114a, 116a are illustrated. End 114a includes flanges
120, 122 and end 116a includes flanges 126, 128. In this embodiment, flange
120 includes tongue 120a extending from surface 120c. Tongue 120a is parallel to and spaced from a groove 120b which is formed by groove walls 120d, 120e also extending from surface 120c. The mating flange 126 includes tongue 126a extending from surface 126c. Tongue 126a is parallel to and spaced from a groove 126b which is formed by groove walls 126d, 126e also extending from surface 126c. Similarly, flange 122, Fig. 2, includes tongue 122a extending
from surface 122c. Tongue 122a is parallel to and spaced from groove 122b which is formed by groove walls 122d, 122e also extending from surface 122c.
The mating flange 128 includes tongue 128a extending from surface 128c.
Tongue 128a is parallel to and spaced from groove 128b which is formed by groove walls 128d, 128e also extending from surface 128c. It can be seen from the Fig. 2 embodiment, as is best shown in Figs. 5 and 5 A, wherein flanges 122, 128 are partially illustrated, for example, that when tongues 122a and 128a become mechanically engaged with grooves 128b and 122b, respectively, surfaces 122c and 128c are spaced from each other. Although not shown, the same occurs with flanges 120 and 126. Similarly, in Fig. 2, a wire 130 can be extended through the length of tongue 126a and another wire 132 can be extended in an opening through the length of tongue 122a. Electrical stimulation of wires 130, 132 can cause tongues 126a, 122a, respectively, to be fusion bonded to their respective grooves 120b, 128b. The wires 130, 132 can be a resistance wire forming a closed circuit in which AC or DC is applied for power as mentioned above.
Referring to Fig. 3, ends 214a and 216a are illustrated. End 214a includes flanges 220, 222 and end 216a includes flanges 226, 228. In this embodiment, flange 220 includes tongue 220a extending from surface 220c. Tongue 220a is parallel to and spaced from groove 220b. The mating flange 226 includes tongue 226a extending from surface 226c. Tongue 226a is parallel to and spaced from groove 226b. Similarly, flange 222 includes tongue 222a extending from surface 222c. Tongue 222a is parallel to and spaced from groove 222b. The mating flange 228 includes tongue 228a extending from surface 228c. Tongue 228a is parallel to and spaced from groove 228b. Also, in Fig. 3, a wire 230 as described above, extends through an opening which passes through the length of tongue 220a, and a wire 232 extends through an opening which passes through the length of tongue 228a. The wires 230, 232 can be a resistance wire using an AC or DC power source as previously described. In addition, along an inside edge of flange 220 is a groove 220d engaged with a mating tongue 226d, which is along a mating inside edge of flange 226. A similar tongue 222d and mating groove (not easily viewable in
Fig. 3) are provided on inside edges of flanges 222, 228.
An end seal 60, illustrated in phantom outline, including a plurality of cables 62, 64, 66 extending therethrough, is fusion bonded to ends 214a, 216a, and also to the opposite ends, not shown, to sealingly encapsulate cable splices in the closure body 212. Sealing of the end seal around a peripheral surface
60a and sealing of cables 62, 64, 66 in end seal 60 can also be accomplished by fusion bonding as described above. The heat generated in the vicinity of wires
230, 232 will cause some fusion bonding between body 212 and end seal 60, however, additional wire and sealant configurations (not shown) may be added to the peripheral surface 60a of seal 60 to provide a fusion bonded seal with ends 214a, 216a. Also, wire and sealant configurations (not shown) may be added to peripheral surfaces 62a, 64a, 66a of cables 62, 64, 66, respectively, to provide a fusion bonded seal with ports 60b of end seal 60. Also, additional wires can be placed in the above-mentioned tongues 226d and 222d to further seal closure body 212 to seal 60.
Material selection for the closure of present invention requires good bonding capabilities to provide proper sealing as well as providing resistance to contamination, moisture and pressure. Bonding of joints to be sealed involves bonding of the selected material to itself, to end seals, cables and to sealants which may be used. Since sealing is accomplished by heating, the selected material must also be suitably responsive to fusion bonding. As such, polyolefin or polyolefin elastomers are suitable and of that group, the flexible ethylene alphaolefin copolymer sold under the name ENGAGE by the Dow Chemical Company of Midland, Michigan, is preferred. Material selection for the sealant of the present invention requires an affinity to produce satisfactory fusion bonding. Thus, where a sealant is used in the present invention there are several alternatives. First, however, it should be understood that a suitable bond may be in some instances accomplished by resistance heating of abutting surfaces by the placement of a resistive wire at or near the abutting surfaces. Electrical stimulation of the wire will heat surrounding material sufficiently to bond all heated abutting surfaces, and with pressure applied through the curing process, suitable welds can be produced.
The resistive wire can be in the typical round wire form and can be coated with a suitable sealant material such as polyethylene. Electrical stimulation of the wire will heat the surrounding sealant material and the abutting surfaces to be sealed. All abutting surfaces can be sealed in this manner enhanced by the additional or surplus sealant material which will assist in providing suitable seals with pressure applied through the curing process.
In addition to using a wire coated by sealant material such as polyethylene, a susceptor containing material can be added to the sealant which absorbs RF energy and transfers it into heat energy. In this case, the wire is preferably copper and functions as an antenna. The heat produced causes the susceptor containing material including a polyethylene or polyolefin elastomer binder and the abutting surfaces to be sealed. Here again, sealing is enhanced by the additional or surplus material which will assist in providing suitable seals with pressure applied through the curing process. While it is not necessary to discuss every possible iteration of combining sealant material, susceptor material and wire types, it is clear that sealing is enhanced in view of the foregoing.
A further embodiment illustrates a fine diameter polymer rod 70, Fig. 6, spiral wound with a resistive wire 72. This configuration can be inserted in the openings through the entire length of the tongues in place of wires 30, 32, Fig. 1, to provide the fusion bonding previously described. Also, this configuration can be coated with a polymer material to encase the rod 70 and the spiral wound wire 72.
A still further embodiment utilizes the spiral wound wire concept by utilizing an enlarged diameter rod 70, Fig. 7, spiral wound with resistive wire 72 and placed in opposed grooves 74 in mating flanges 76. This configuration replaces the tongue and groove concept described above. Bonding is accomplished by energizing the resistive wire 72 using an AC or DC power source, as previously discussed, to fuse the rod 70 in the grooves 74. Pressure, applied by clamps 78, Fig. 8, will urge wire 72 into the mating flanges 76. Material 73 from rod 70 and flanges 76 will flow and create a seal between the enclosure body halves (not shown) attached to the flanges 76. Uniquely, the
spiral wound resistive wire 72 becomes embedded into the flanges 76 providing additional mechanical strength to the bond.
In operation, wires are placed in openings provided in a tongue of two mating flanges on one side of the closure body halves and in a tongue of two mating flanges on the opposite side of the closure body halves. The double tongue and groove connections are mechanically engaged on opposite sides of the closure body. Heat applied to the wires bonds one of the tongue and groove connections and a parallel, spaced apart tongue and groove connection provides mechanical support and pressure until the bond cures to form a seam seal along both sides of the length of the closure body. Alternately, a rod having a spiral wound resistive wire thereon, is placed along a groove formed in mating flanges of closure body halves. Clamps are used to urge the flanges together. Heat applied to the wire causes the rod, and groove adjacent the rod, to flow and create a seal between the flanges. The resistive wire becomes imbedded into the flanges providing mechanical strength to the bond.
As it can be seen, the principal advantage of the present invention is that it provides a double tongue and groove connection on each side of the cable splice closure body, whereby one interlocked tongue and groove serves as a mechanical engagement providing support and pressure until electromagnetic or resistive wire melting of the other interlocked tongue in the corresponding groove cools to form a lengthwise seal. The space between the parallel tongue and groove connections is sufficient to isolate the unheated tongue and groove connection and limit the bonding to the heat applied tongue and groove, i.e. , where the wire extends through the tongue. One projecting tongue can contain a resistive wire encased in a suitable thermoplastic or heat fusible material having a useful softening or melting temperature, such as low density polyethylene or an ethylene/alpha-olefin copolymer. The resistive wire could be of stainless steel or nickel/chromium or any other suitable material with a round, oval or rectangular cross section. Alternately, the projecting tongue could include a cooper wire encased in a coating of suitable material, as described above, containing susceptor composite flakes. The term susceptor composite flakes refers to radio frequency
power absorbing materials comprising plurality of multilayered flakes made of thin film crystalline ferromagnetic metal layers, such as a NiFe alloy, stacked alternately with thin film dielectric layers, such as SiO. The coating refers to dispersing about 1 to about 10 percent susceptor composite flakes in a suitable binder, such as polyethylene. The use of the susceptor composite flakes provides a method of bonding two objects together using radio frequency power at a frequency of about 5 to about 6000 MHz in the form of an oscillating magnetic field which intersects the susceptor composite flakes so that heat is generated which melts the coating and fuses, bonding the objects together. The two double tongue and groove parts should be snapped together in an interlocked fashion and sealing accomplished, for example, by energizing the resistive wire in the tongue with direct or alternating current necessary to soften or melt the tongue to cause it to flow into the grooved gripping slots. The other interlocked tongue and groove would then serve as a mechanical device providing support and pressure until the first interlocked melted tongue cooled to form a horizontal or lengthwise seam seal into the grooved slot.
Alternately, the susceptor coated wire in the projecting tongue could be activated by an oscillating magnetic field from a radio frequency power source to soften or melt the tongue to cause it to flow and create a seal into the grooved slot after cooling. Also, a bead of low energy surface adhesive could be placed in each grooved slot and the projecting tongue from the other corresponding part interlocked in place. The interlocked assembly would provide mechanical support and pressure until the adhesive cured to form rigid horizontal or lengthwise seam seals. The term low energy surface adhesive refers to an adhesive based on standard acrylic monomers with organo borane/amine complexes, and may include a polyurethane, an epoxy or a polyaziridine. The above-described adhesive provides bond strengths similar to fusion bonding. The closure body portion could be prepared from any semirigid or flexible material, such as polyethylene, polypropylene, an ethylene/alphaolefin copolymer or any other suitable material.
Another alternative provides for a polymer rod including a spiral wound resistive wire, to create a fusion bond between mating flanges of the splice
closure body halves, and the wire becomes imbedded in the flanges to provide mechanical strength to the bond.
Utility of the invention allows the cable splice closure to form an air tight, pressure and moisture seal to external elements. Basic features of the closure provide total seal integrity between the two main portions which comprise the closure body, end seal body portions and the cables extending therethrough. Furthermore, the use of a fusion bonded sealant provides for facilitated installation.
Although illustrative embodiments of the invention have been shown and described, a wide range of modifications, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the present invention may be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.