PRESSURIZED CABLE JUNCTION CLOSURE AND METHOD FOR ITS PRODUCTION

Abstract: A pressurized closure for enclosing a junction in a pressurized cable includes a pressure-retaining vessel therewithin, the vessel comprising a liner, a reinforcing layer, and activatable adhesives situated such that upon the application of heat the adhesives flow and form, in conjunction with the liner and the reinforcing layer, a pressure-retaining vessel around the junction thus isolating a member around the reinforcing layer from pressure within the cables.

Description: Background of the Invention 1. Field of the Invention The present invention relates to a pressurized closure for bracing a junction between cables which,in use, are pressurized, and in particular to a pressure-retaining vessel within the closure for withstanding pressure in the cables when in use. 2. Description of the Prior Art Oftentimes it is necessary to interconnect pressurized cables thus forming a junction therebetween or to repair a cable which, in use, is pressurized, thus forming a junction region in a vicinity of the repair. Subsequent to forming the junction, which junction typically includes splices, it is necessary to enclose the junction so as to environmentally isolate it and keep contaminants therefrom, e.g., water, and the enclosing means must necessarily be capable of withstanding the pressure maintained within the cables when in use for a considerably long period of time. Prior art methods and apparatuses for enclosing such a junction are relatively complicated in design, include a relatively large number of elements, and must normally be prepared from relatively expensive creep-resistant materials throughout. Such closures are not only expensive to manufacture but also relatively complicated to install due to the complicated structure of the closure, thus requiring an undue amount of craft-sensitivity, which often results in improper installation and premature pressure leakage. Summary of the Invention Accordingly, it is an object of the present invention to provide a pressure-retaining vessel and closure which is relatively simple in construction and inexpensive to form. These and other objects are achieved by the provision of a structure capable of forming a pressure-retaining vessel around a junction when heat is applied to a member in an amount sufficient to activate adhesives used in the structure. Specifically, the structure includes a liner made of a relatively heat-stable material and which has a first adhesive disposed on a surface thereof in a vicinity of overlapping sides thereof, the liner optionally having multiple finger extensions extending from opposite ends thereof; a reinforcing layer disposed adjacent the liner and having a second adhesive formed theron so as to be adjacent to ends of the liner; and a member disposed around the liner and the reinforcing layer, the member optionally containing a hot-melt adhesive on an inner surface thereof. Upon applying heat to the member, the first and second adhesives melt and flow and, together with the liner and the reinforcing layer, form a pressure-retaining vessel around the junction which is capable of withstanding all anticipated internal pressures existing within the cables connected by the junction when the cables are in use. Accordingly the materials forming the member can be less expensive than otherwise required since they do not need to be overly creep-resistant and capable of handling any significant amount of the pressure within the cables, and can also be made thinner. Preferably, the reinforcing layer is disposed outside the liner though an opposite configuration wherein the reinforcing layer is disposed within the liner is possible, and preferentially the liner and the reinforcing layer are integrally connected during manufacture and prior to installation though they can be separately supplied and applied at the junction. In addition, the first adhesive can be disposed on entire opposite surfaces of the liner, including the vicinity of the overlapping sides thereof, alternatively the first adhesive can be formed on portions of the liner in a vicinity of the overlap region. The reinforcing layer preferentially comprises a fibrous mat, fabric, or film impregnated throughout with the second adhesive so as to insure that an adequate amount of adhesive is present in a vicinity of overlapping sides of the liner as well as the finger extensions thereof to insure that a pressure-retaining vessel is formed therewith, though other embodiments are possible wherein the second adhesive is only impregnated within the reinforcing layer at specific portions thereof, e.g., portions which confront the opposite ends of the liner. Brief Description of the Drawings Figures 1 and 2 illustrate perspective views of first and second preferred embodiments of a pressure-retaining vessel, constructed in accordance with the teachings of the present invention; Figure 3 illustrates one preferred embodiment of an open closure including the pressure-retaining vessel of Figure 1; Figures 4 and 6 llustrate partial cross-sectional views of closures including pressure-retaining vessels, the closures being closed; and Figures 5 and 7 illustrate alternative preferred embodiments of a liner for use with the pressure-retaining vessel of the present invention. Description of the Preferred Embodiments Figures 1 and 2 illustrate alternative preferred embodiments of a pressure-retaining vessel 1 constructed according to the present invention. The general unfolded structure of the vessel is schematically illustrated in Figure 3 in conjunction with a member 14 thus forming a closure 8, and Figures 4 and 6 illustrate partial cross-sectional views of closures 8,8' in an applied state about a junction 2,2'. In Figure 3, the member 3 corresponds to a rail and channel type heat-shrinkable sleeve, which can be adapted to be heated with a flame, with an oven, or with electric current. In the embodiment of Figures 1 and 2, the vessel 1 includes an adhesive-coated, creep-resistant liner 10 and an adhesive-coated, reinforcing layer 12. The creep-resistant liner 10 is preferably formed of a material capable of withstanding internal pressures over prolonged periods of time without substantially deforming or exhibiting any significant ballooning effect. Suitable materials for forming the liner are polypropylene (PP), nylon, polyethylene (PE), polyetheleterephthalate (PET), polyvinylchloride (PVC), polyimide, and composite laminates thereof. Liners constructed according to the invention have been demonstrated to satisfactorily withstand internal pressures between 0 and 15 psi at 60°C. A meltable material 16, e.g., a thermosetting or thermoplastic material, preferably a hot-melt adhesive, is coated on at least one side 18, 20 of the liner 10 in a vicinity of longitudinal edges 19, 21 respectively thereof so that the adhesive 16 is disposed between the sides 18, 20 by wrapping the first liner 10 around the junction 2 so that the side 18 confronts the side 20, as generally illustrated in Figure 5. If desired, entire opposite sides 18, 20 of the liner 10 can be coated with the first adhesive 16 (as shown in Figure 7), or alternatively, the first adhesive 16 may be coated on the sides 18, 20 so that the adhesive 16 confronts and contacts the adhesive 16 when the liner 10 is wrapped around a junction 2 to assure a good bond, this specific embodiment being illustrated in Figure 5. It is preferred to treat the liner prior to applying the first adhesive to facilitate adhesion thereto. The first liner can have a uniform continuous configuration for use with a nonenlarged junction 2' as shown in Figure 6, or alternatively can have a nonuniform noncontinuous configuration for use with an enlarged junction 2 as shown in Figure 4. For the enlarged junction 2 a preferred liner includes a plurality of finger extensions 22 on opposite ends thereof adjacent opposite ends of the edges 19, 21. The finger extensions 22 taper outwardly as shown in Figures 1-3 so that when the liner 10 is wrapped around the junction 2, which is generally enlarged in size relative to the cables 4, 6, the liner 10 provides a smooth-sized transition in a vicinity of an interface 24 between the cables 4, 6 and the junction 2, as illustrated in Figure 4. Accordingly, sharp bends in a profile of the member 14 are avoided during and after installation thereof. The finger extensions 22 optimally can have some of the first adhesive coated on either or both upper and lower surfaces thereof to facilitate sealing of the finger extensions. Optionally, the liner may include a gas impermeable layer, such as metalized film. The reinforcing layer 12 comprises a reinforcing film(s) having a meltable material, e.g., again a thermosetting or thermoplastic material, preferably another hot-melt adhesive, disposed on a surface thereof confronting the finger extensions or liner ends 27, 29, or alternatively can comprise a fibrous mat or fabric having the second adhesive 26 impregnated therein. Preferred materials for constructing the second liner when it is a film comprise PE, PET, ethylene vinyl acetate (EVA), and nylon. If the second liner is a fibrous mat or fabric, preferred constructions are to use a cotton, glass, carbon, or synthetic (e.g., PET, nylon) fibers impregnated with the second hot-melt adhesive 26. When reinforcing layer 12 is used, it is so constructed that heat generated subsequent to applying the member 14 causes the second adhesive to melt and flow to seal areas adjacent to and between the finger extensions 22, or alternatively adjacent ends 27, 29 (for the embodiment of Figure 4) as well as an overlap formed between the liner sides 18, 20 with the aid of the first adhesive. Reinforcing layer 12 can be omitted for straight, continuous junction configurations such as that shown in Figure 6. However, side 20 of liner 10 has to be completely coated with adhesive (Figure 7) so that when heat is applied to member 14, this adhesive can bond to the cable surface thus sealing the junction. The liner 10 and the reinforcing layer 12 can comprise separate, individual elements which are applied around the junction in a sequential manner, or alternatively the reinforcing layer 12 can be joined to the liner during manufacture, thus requiring that only the resulting composite structure be wrapped around the junction 2. In addition, whether the liner 10 and layer 12 are provided separately or as a composite structure, the layer 12 can be disposed inside or alternatively outside the liner 10, these two separate embodiments being shown in Figures 1 and 2 respectively. However, the reinforcing layer 12 should be formed so as to have a longitudinal length which exceeds that of the liner 10, including the length provided by any finger extensions 22, so that the reinforcing layer 12 can provide sufficient adhesive 26 so as to guarantee that the finger extensions 22 or ends 27, 29 form pressure-tight seals around the cables 4, 6. It should be understood that various other elements can also be used for the member 12 these other elements including, but not being limited to, an adhesive-coated tape, a reactive putty, a reactive two-part liquid held inside a flexible bag, an adhesive coated tube, etc., with the term "member" including all such elements. After applying the member 14 and melting the first and second adhesives 16, 26, the liner and layer 10, 12 together form a pressure-retaining vessel around the junction 2, 2' and ends of the cables 4, 6 adjacent thereto such that the liner and layer 10, 12 and adhesives 16, 26 independently are capable of retaining pressure within the junction 2, 2' when the cables 4, 6 are pressurized. Accordingly, the member 14 does not "see" the pressure within the junction 2 and cables 4, 6 subsequent to bracing the junction 2 since the liner and layer 10, 12 are capable of handling the entire pressure load, and accordingly a relatively inexpensive member 14 can be utilised in accordance with the teachings of the present invention which is not required to be creep-resistant since this function is handled by the liner and layer 10, 12. Therefore,the member 14 can be formed of less expensive materials and can be made thinner as compared with prior art pressurized closures. Preferably, best results are obtained if the liner and layer 10, 12 are formed of heat-stable materials excluding the adhesives 16, 26. Though the invention has been described with reference to certain preferred embodiments thereof, it should be readily understood that modifications thereto can be made within the spirit and scope of the present invention, and accordingly, the scope thereof is to be limited only by the appended claims.

Claims: 1. A pressure-retaining vessel for bracing a junction which in use is pressurized, comprising: a liner having a first adhesive on a surface thereof in a vicinity of at least one edge thereof, the first adhesive being located so as to confront opposite side surfaces of the liner when the liner is wrapped around the junction; and means for disposing a second adhesive adjacent to opposite ends of the liner which are adjacent to opposite ends of the liner edge. 2. The vessel as claimed in Claim 1, the disposing means comprising a reinforcing layer formed of a heat-stable material and the second adhesive. 3. The vessel as claimed in Claim 2, the liner having a plurality of finger extensions at the opposite ends thereof for smoothing a transition betwen the junction and cables interconnected thereby. 4. The vessel as claimed in Claim 2, the liner having continuous profile opposite ends. 5. The vessel as claimed in Claim 4, the disposing means comprising the liner which has opposite sides thereof completely coated with the second adhesive. 6. The vessel as claimed in Claim 2, the first and second adhesives being hot-melt adhesives. 7. The vessel as claimed in Claim 2, the reinforcing layer being disposed around the junction inside of the liner, the reinfoceing layer comprising a heat-stable film having one or both surfaces coated with the second adhesive. 8. The vessel as claimed in Claim 7, the film being a material selected from the group consisting of nylon, polyethylene, polypropylene, polyetheleterephthalate, polyvinylchloride, polyimide, and composite laminates thereof. 9. The vessel as claimed in Claim 6, the reinforcing layer being disposed around the junction inside of the first liner, the reinforcing layer comprising a heat-stable fibrous mat or fabric impregnated with the second adhesive. 10. The vessel as claimed in Claim 9, fibers of the mat or fabric being cotton, glass, carbon, or synthetic. 11. The vessel as claimed in Claim 2, the reinforcing layer being disposed around the junction outside of the liner, the reinforcing layer comprising a heat-stable film having one or both surfaces in a region of the opposite liner ends coated with the second adhesive. 12. The vessel as claimed in Claim 11, the film being a material selected from the group consisting of nylon, polyethylene, polypropylene, polyetheleterephthalate, polyvinylchloride, polyimide, and composite laminates thereof. 13. The vessel as claimed in Claim 2, the reinforcing layer being disposed around the junction outside of the first liner, the reinforcing layer comprising a heat-stable fibrous mat or fabric impregnated with the second adhesive. 14. The vessel as claimed in Claim 13, the fibers of the mat being cotton, glass, carbon, or synthetic. 15. The vessel as claimed in Claim 2, the disposing means further comprising a member disposed around the liner and the reinforcing layer, the member having a hot-melt adhesive coated on an inside surface thereof. 16. The vessel as claimed in Claim 1, an entire surface of the liner being coated with the first adhesive. 17. The vessel as claimed in Claim 2, the liner and reinforcing layer being integrally connected prior to being installed around the junction. 18. The vessel as claimed in Claim 1, the junction including splices connecting first and second cables which, in use, are pressurized. 19. A method of forming a pressure-retaining vessel around a junction which, in use, is pressurized, comprising the steps of: wrapping a liner around the junction such that an activatable first adhesive is disposed between overlapping sides thereof, optionally disposing an activatable second adhesive in a vicinity of opposite ends of the liner respectively located adjacent opposite ends of the junction; and activating the first and second adhesives to seal the liner sides and ends so as to be capable of retaining pressure within the junction. 20. The method as claimed in Claim 19, the first and second adhesives being hot-melt adhesives, the first and second adhesives being activated by applying heat thereto, the second adhesive being disposed by wrapping a reinforcing layer around the liner. 21. The method as claimed in Claim 20, further comprising the steps of: disposing a member around the liner and reinforcing layer; applying heat to the member to shrink the member around the reinforcing layer and also to activate the first and second adhesives.

Inventors: GAMARRA, JOSE P.
Applicants: RAYCHEM CORPORATION (A DELAWARE CORPORATION)
Application year: 1986
Main classification: H02G15
IPC codes: H01R4, H02G15