Abstract:
A self-supported jacket seal designed for a cable connector so that after a cable is inserted into the cable connector, the integrated jacket seal protects any exposed portion of the cable without requiring any additional installation steps. The self-supported feature is provided by a plurality of rigid ridges positioned on the outer surface of the jacket seal. The ridges strengthen the construction of the component so that the jacket seal substantially maintains its shape when a cable is slidably inserted therewithin. Because the seal does not buckle when installed, it does not require any additional installation steps as found in other similar inventions known in the art.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent app. Ser. No. 13/843,960, filed Mar. 15, 2013, now U.S. Pat. No. 9,071,004, issued Jun. 30, 2015, and the foregoing application is herein incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to cable and connector adapters used in the field of power distribution. More particularly, the invention relates to cable and connector adapters with an integrated jacket seal that does not buckle when a prepared cable is slidably inserted therewithin. 
       BACKGROUND OF THE INVENTION 
       [0003]    Electrical distribution networks are critical for the delivery of electricity to consumers and businesses from the generation and transmission systems. Such a network can include power lines, substations, transformers, and meters that are interconnected by thousands of miles of cables. Existing cable adapters that are used to fit “(one) size fits all” splice housings to different cables are well known in the art. Generally, in order to attach a cable to an electrical joint or splice it is necessary to peel back the protective layers of the cable, so that the conductor portion of the cable can be attached to the cable connector. The protective layers consist of an outer jacket, an insulation shield system (typically semi conductive and metallic), insulation, strand shield, and finally the conductor. The stripping procedure exposes the cable metallic shielding, which provides pathways for return power in the system. 
         [0004]    Although a portion of the exposed cable is within the cable adapter, another portion of the cable is external to the connection. In most instances, this external portion of the cable can be exposed to water, dirt, and other elements that can cause the cable to degrade in quality. The exposed cable metallic shielding is particularly susceptible to moisture, due to oxidization and corrosion. Over extended periods of time the buildup of oxidation results in the degradation or total loss of the proper return circuit for the load current. As a result, electricity can be interrupted to residential and commercial areas until the cable is either repaired or replaced. Furthermore, if water is allowed to enter under the cable jacket material it will be in closer proximity to the cable primary insulation causing a more rapid degradation and eventual failure of the insulation and loss of power. 
         [0005]    Due to the critical need for the continual operation of electrical distribution networks, such problems have not been entirely ignored in the industry. Cable jacket sleeves provide protection for the exposed cable portion between the end of the accessory (such as a cable adapter, insulating plug, etc.) and the cable jacket sleeve. Typically, cable jacket sealing sleeves are hollow cylindrical shapes and come in a pre-molded slide on, heat shrink, or cold shrinkable variety. 
         [0006]    Pre-molded slide-on jacket sleeves require the splicer to pre-install the sleeve on the cable prior to installation of the accessory. Once the accessory is attached to the cable, a water-resilient resin or gum-like mastic and/or electrical tape is placed over the exposed portion of the cable. The jacket sleeve is then pulled over the mastic and/or electrical tape, exposed cable, and a portion of the accessory, thereby providing protection for the exposed portion of the prepared cable. Small tabs were placed on the side of slide-on jacket sleeve to assist splicers with pulling such sleeves up and down. 
         [0007]    Heat shrink jacket sleeves are placed over the exposed portion of the cables as described above. The splicer subsequently applies heat to the connecter to shrink the sleeve around the exposed portion of the cable to create a tighter fit. 
         [0008]    Cold shrinkable jacket sleeves are expanded and placed onto a removable core. Once the splicer has placed the cold shrinkable sleeve over the accessory and prepared cable, the core is removed and the sleeve shrinks to its original size. Due to various power cable varieties such as Jacketed Concentric Neutral (JCN), Drain wire shielded, and Tape shielded, a splicer must choose the applicable cold shrinkable jacket, thereby adding additional complexity to the process of attaching a cable to a cable adapter. 
         [0009]    A disadvantage of using a heat or cold shrink seal is that they are designed to be permanently installed. Therefore, the process of removing a heat or cold shrink seal involves destroying the seal, generally by cutting it from the cable. As a result, the splicer may inadvertently damage the cable by cutting too deep. 
         [0010]    An inherent problem with the multi-step process of installing pre-molded slide-on, heat shrinkable, and cold shrinkable jacket sleeves is that when an electrical distribution network is interrupted, the ability to quickly troubleshoot and repair the cause of the interruption is hampered by the complexities of the existing systems, particularly in situations where multiple sections of a cable are simultaneously damaged or compromised. Furthermore, multi-step procedures combined with the pressure for results, since electricity is interrupted to homes and businesses until the network is repaired, can lead to the improper field repair performance which could deviate from applicable field standards. As a result, an improperly repaired cable can repeatedly fail, resulting in an unreliable electrical distribution network to homes and businesses in the area. 
         [0011]    The combination of a jacket sleeve integrated with an accessory was created to reduce the time of attaching cables to an accessory. In this known combination, the jacket sleeve is rolled over a portion of the accessory. In the field, once the splicer inserts the prepared cable into the accessory the integrated jacket sleeve is pulled over the remaining exposed wire. An example of an accessory with an integrated jacket sleeve can be found in Hughes et al. U.S. Pat. No. 7,883,356 entitled “Jacket Sleeve with Grippable Tabs for a Cable Connector.” In this particular example, tabs are introduced in the assembly to provide a gripping point for the splicer to pull the jacket sleeve over the exposed cable. 
         [0012]    A disadvantage of current elbow adapters with the integrated jacket sleeve is that the coupling with the prepared cable is not complete until the splicer pulls the jacket sleeve over the exposed portion of the prepared cable. This can be difficult in the restricted space in which cables are installed. Even with various improvements over the years in the relevant art, such as the incorporation of tabs as presented in Hughes et al., it still remains difficult for a splicer to properly secure the jacket sleeve over the exposed cable, even after inventions have improved the size of the tabs and various ways to pull the jacket sleeve. The assembly is difficult for a myriad of reasons including the requirement of substantial force to properly form the connection which often results in various components being compromised or damaged and the restricted space such connections are generally performed. 
         [0013]    Further, integrated jacket sleeves are composed of flexible materials that provide little to no mechanical support. Therefore, for power cables that span large distances, external mechanical supports are required to resist mechanical stress from bending the power cable where it connects with the cable adapter with integrated jacket sleeve. 
         [0014]    Therefore, there is a need in the art for a self-supported jacket seal that does not buckle when an exposed cable is inserted into the jacket seal. Furthermore, there is a need for a jacket seal which can be utilized in restricted space whereby the seal is complete after inserting the cable, instead of requiring the user to pull the jacket seal over an exposed portion of the wire to complete the seal. 
         [0015]    In addition, there is a need for a self-supported jacket seal that can be removed, without utilizing a cutting tool that can damage the cable. As a result, the self-support jacket seal can be reused. 
         [0016]    Further, there is a need for a self-supported jacket seal that provides mechanical support. 
       SUMMARY OF THE INVENTION 
       [0017]    One embodiment according to the present invention involves a self-supported jacket seal that can be utilized in the restricted environments common in cable installations which will not buckle when a cable is inserted therein. In this preferred embodiment, the self-supported jacket seal is designed in the form so that after a cable is inserted into the accessory, the integrated jacket seal protects any exposed portion of the cable without any additional steps. This results in improved field installation over the current operations known and utilized in the existing art. 
         [0018]    In one embodiment, the self-supported feature is provided by a plurality of ridges positioned on the outer surface of the jacket seal. The ridges can be comprised of a rigid material, designed to strengthen the construction of the component so that the jacket seal substantially maintains its shape when a cable is slidably inserted. In a further embodiment of the present invention, an end of the jacket seal is flared to allow inserting a cable therein in a sliding movement. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    A further understanding of the present invention and the objectives other than those set forth above can be obtained by reference to the various implementations set forth in the illustrations of the accompanying figures. Although the illustrated implementations illustrate certain aspects of the present invention, the apparatus and method of use of the invention, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings, examples, and the following description. The examples and figures are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention. The detailed description makes reference to the accompanying figures wherein: 
           [0020]      FIG. 1  depicts a prepared cable end designed to carry electrical currents common in the art. 
           [0021]      FIG. 2  is a perspective view of a loadbreak connector having an integrated jacket seal in accordance with an exemplary embodiment of the present invention. 
           [0022]      FIG. 3  is a side view of a loadbreak connector having an integrated jacket seal in accordance with an exemplary embodiment of the present invention. 
           [0023]      FIG. 4  is a perspective view of a cable adapter having an integrated jacket seal in accordance with an exemplary embodiment of the present invention. 
           [0024]      FIG. 5  is a side view of a cable adapter having an integrated jacket seal with a prepared cable positioned therein in accordance with an exemplary embodiment of the present invention. 
           [0025]      FIG. 6A  is a longitudinal cross-sectional view of a cable adapter having an integrated jacket seal with a prepared cable positioned therein in accordance with one exemplary embodiment of the present invention. 
           [0026]      FIG. 6B  is an enlarged cross-sectional view of a section of cable adapter having an integrated jacket seal with a prepared cable positioned therein in accordance with one exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0027]    A detailed description of the various embodiments of the present invention is disclosed herein. However, techniques of manufacture and resulting structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiments. Consequently, the specific structural details disclosed herein are merely representative, yet in that regard, they are deemed to represent suitable implementations for purposes of disclosure and to provide a basis for the claims herein, which define the scope of the present invention. Well known methods, procedures, and substances for both carrying out the objectives of the present invention and illustrating the preferred embodiment are incorporated herein but have not been described in detail as not to unnecessarily obscure novel aspects of the present invention. 
         [0028]    Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, electronic or otherwise, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the Detailed Description of the Embodiments using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list. 
         [0029]    Referring initially to  FIG. 1 , shown is a typical prepared cable end  100 . As illustrated, prepared cable end  100  comprises an outer jacket  110 , neutral wires  108 , extruded shield  106 , cable insulation  104 , and cable conductor  102 . Typically, a prepared cable  100  is created by removing the outer cable jacket  110  and folding back the neutral wires  108  from the extruded shield  106 . Extruded shield  106  is also removed to partially expose cable insulation  104 . Furthermore, cable insulation  104  is removed to expose cable conductor  102 . Although a jacketed concentric neutral cable is depicted in  FIG. 1 , the present invention is not limited to such a cable. One skilled in the art would understand that other cable constructions such as jacketed drain wire, lead jacketed, copper tape shielded, and the like may be utilized with the component of the present invention without departing from the spirit of the invention as disclosed. 
         [0030]    Turning next to  FIG. 2 , shown is a perspective view of a jacket seal sleeve integrated with a loadbreak connector  200  in accordance with an exemplary embodiment of the present invention. A loadbreak connector  200  includes an insulated conductor receiving portion  204  which can receive a high voltage conductor or prepared cable therein, and a substantially right-angled probe retainer  202 . The loadbreak connector  200  further includes grounding eye  220  that can be molded or affixed along the exterior surface of loadbreak connector  200 . Grounding eye  220  is capable of receiving and being connected to an external ground in order to ensure that the outer surface of loadbreak connector  200  remains at ground potential. While the loadbreak connector  200  is illustrated as having an elbow-like design, the loadbreak connector  200  can be of other types and configurations known to one skilled in the art. 
         [0031]    The loadbreak connector  200  can further include a test point  206 . It is known to one skilled in the art to use a high-impedance voltage sensing device at test point  206  to determine the circuit condition of loadbreak connector  200 . Test point  206  can include a cap (not shown) that is capable of being snapped onto and cover test point  206 . Therefore, access to test point  206  is prevented from elements external to loadbreak connector  200 . 
         [0032]    The loadbreak connector  200  can further include a pulling eye  208 . The pulling eye  208  is positioned substantially in line with the longitudinal-axis of probe retainer  202 . The pulling eye  208  provides a location to connect a hotstick or other device for engaging or disengaging elbow connector  200 . In one exemplary embodiment, pulling eye  208  is manufactured of stainless steel. One skilled in the art will readily recognize that other metallic and non-metallic elements can be employed in place of stainless steel. The external surface of pulling eye  208  is typically surrounded by a shield layer consisting of semi-conductive EPDM or like material commonly utilized in the art. 
         [0033]    Jacket seal  210  includes a jacket seal body  214  and neck  212  which are integrally formed. In one example, jacket seal  210  and conductor receiving portion  204  are integrally formed. In the present example, jacket seal  210  has a substantially hollow cylindrical shape with an inner diameter that tapers to form a compression fit. Those of ordinary skill in the art will recognize that the present invention is not limited to the use of a compression fitting connection within loadbreak connector  200  for coupling a prepared cable  100  (not shown) inserted into receiving portion  216 , and that other types of connection fittings, such as a slide on interference, can be used without departing from the spirit and the scope of the present invention. In the present embodiment, the length of jacket seal  210  is designed to be greater than the length of prepared cable  100 , thereby enclosing some of the outer jacket of prepared cable  100 . 
         [0034]    A plurality of ridges  218  are attached to the outer surface of the conductor receiving portion  204  and jacket seal  210 , thereby providing longitudinal support for the structure of jacket seal body  214  when prepared cable  100  (not shown) is inserted into receiving portion  216 . In various embodiments, the length of ridge  218  begins at one end of receiving portion  216  and substantially extends to the other end of conductor receiving portion  204 . In the present embodiment ridge  218  is composed of a rigid material, while jacket seal body  214  is composed of a pliable material. Thereby jacket seal body  214  can stretch over the exposed cable conductor  102  of prepared cable  100 , while ridges  218  provide longitudinal support, so that jacket seal body  214  will substantially maintain its shape during and after prepared cable  100  is inserted into receiving portion  216 . 
         [0035]    The loadbreak connector  200  also includes a cable receiving portion  216  positioned on one end of jacket seal  210 . In various embodiments of the present invention, receiving portion  216  has a substantially cylindrical shape that has an inner diameter dependent on the size of prepared cable  100  that receiving portion  216  is intended to receive. In the present example, the receiving portion  216  is flared, thereby facilitating prepared cable  100  slidably inserting into jacket seal body  214 . The cable conductor  102  of prepared cable  100  is slidably inserted into receiving portion  216 , until it abuts and is connected to conductor receiving portion  204 . 
         [0036]    Turning next to  FIG. 3 , shown is a side view of a loadbreak connector having an integrated jacket seal in accordance with an exemplary embodiment of the present invention depicted in  FIG. 2 . As shown in the present embodiment of  FIG. 3 , ridge  218  does not contact the outer surface of jacket seal  210  and insulated conductor receiving portion  204  throughout the length of ridge  218 . As a result, less material is required to form ridge  218 , and provide longitudinal support for jacket seal body  214  to maintain its shape while inserting prepared cable  100  within receiving portion  216 . Alternatively, in another embodiment, ridge  218  can contact the outer surface of jacket seal  210  and insulated conductor receiving portion  204  throughout the length of ridge  218 . 
         [0037]    Referring now to  FIG. 4 , shown is a cable adapter  300 , in accordance with an exemplary embodiment of the present invention. The cable adapter  300  includes an integrated insulated conductor receiving portion  302  and jacket seal  304 . Both insulated conductor receiving portion  302  and jacket seal  304  are positioned on a primary longitudinal axis of cable adapter  300 , whereby insulated conductor receiving portion  302  is located on a first end of cable adapter  300 , while jacket seal  304  is located on a second end of cable adapter  300 . A receiving portion  312  is located on an end of jacket seal  304  (i.e., at an end opposing the receiving portion  302 , which is located on a first end of cable adapter  300 ). In the present example, insulated conductor receiving end  302  has a substantially hollow cylindrical shape of sufficient design and dimension to accept prepared cable  100  as described in  FIG. 1 , herein. 
         [0038]    As depicted, the jacket seal  304  includes a jacket seal body  308  and neck  306 . Jacket seal body  308  and neck  306  can be made of semi-conductive rubber, silicone, EPDM or other suitable materials known to those of ordinary skill in the art. A plurality of ridges  310  are integral with and disposed along the longitudinal axis of the outer surface of jacket seal  304 . The introduction of the plurality of ridges  310  from a rigid material, provides longitudinal support allowing the jacket seal body  308  to maintain its shape, as a prepared cable (not shown) is forced and slidably inserted into receiving portion  312 . 
         [0039]    In one embodiment, the material of ridge  310  is substantially plastic-like. In another embodiment the material of the outer surface of ridge  310  is the same as jacket seal  304  (i.e., semi-conductive rubber, silicone, EPDM or other suitable materials known to those of ordinary skill in the art), thereby saving manufacturing material and processes. 
         [0040]    In the present embodiment, the length of ridge  310  is substantially the length of jacket seal  304 ; however, one of ordinary skill in the art will readily recognize that ridges may be manufactured of any length which allowed for the improved installation accomplished by the present invention. Furthermore, the plurality of ridges  310  can be evenly spaced around the outer surface of jacket seal  304 . In an alternative embodiment, the plurality of ridges  310  are not evenly spaced depending on the desired configuration of the component and the environment the component is installed. For example, the spacing of ridges  310  can be altered in the event the confined installation space allows for other components which might interfere with the jacket seal. Although the structure depicted for providing support for jacket seal  304  is a plurality of ridges  310  positioned parallel to one another, it should also be apparent to one skilled in the art that other external support structures can be used. For example, a criss-cross shape can be used to provide longitudinal and latitudinal support for the structure of jacket seal  304 . 
         [0041]    In the present example, ridges  310  are shaped such that it substantially traces the contour of jacket seal  304 . It is well known in the art that the installation of such electrical components requires the use of substantial force to make a complete and strong contact. As a result, a ridge  310  is in contact with jacket seal  304  throughout the length of jacket seal  304 , thereby providing longitudinal support, so that jacket seal  304  does not buckle when prepared cable  100  is inserted into receiving portion  312 . 
         [0042]    The jacket seal  304  of the present invention further includes a receiving portion  312 . Prepared cable of the nature described in  FIG. 1  of the present disclosure is slidably inserted into cable adapter  300  through receiving portion  312 , thereby creating a compression fit when the prepared cable abuts with insulated conductor receiving portion  302 . After insertion of prepared cable  100  (not shown) into cable adapter  300  a portion of the cable conductor may protrude from cable adapter  300 . In yet another embodiment, jacket seal body  308  can utilize a slide-on interference fit to couple prepared cable  100  (not shown) to a cable adapter  300 . In the present embodiment, the length of jacket seal  304  is designed to be greater than the length of prepared cable, thereby enclosing a portion of outer jacket of prepared cable. 
         [0043]    Referring now to  FIG. 5 , depicted is a side view of the cable adapter  300  with prepared cable  100  slidably inserted therewithin. As shown, receiving portion  312  is flared to facilitate outer jacket  110  of prepared cable  100  sliding into jacket seal  304 . The dimensions of receiving portion  312  is such that it facilitates prepared cable  100 , with folded back exposed concentric neutral wires  108 , which is slidably inserted therewithin. 
         [0044]    Referring now to  FIG. 6A , a longitudinal cross-sectional side view of cable adapter  300  with prepared cable  100  slidably inserted therewithin is shown. In this depiction, jacket seal material  314  consists of a semi-conductive pliable material, while insulated conductor receiving portion material  316  is non-conductive and rigid. This allows jacket seal body  308  to expand and stretch over the outer dimensions of prepared cable  100  as prepared cable  100  is forced and slidably inserted into receiving portion  312 . It would be apparent to one skilled in the art that jacket seal material  314  and insulated conductor receiving portion material  316  can have the same rigidity, provided that jacket seal material  314  is pliable enough to slidably insert prepared cable  100  into receiving portion  312 . 
         [0045]    Turning next to  FIG. 6B , shown is an expanded detailed view of section B of  FIG. 6A . In this figure, sealing mastic  400  is wrapped both underneath and over the top of neutral wires  108 , providing a seal to prevent dirt, water, and other external elements from entering the cable adapter  300  or prepared cable  100 . Further, the electrical contact between jacket sleeve  304  and insulated conductor receiving portion  302  is made in area  318  when prepared cable (as shown in  FIG. 6A ) is slidably inserted therewithin. 
         [0046]    Jacket seal material  314  and insulated conductor receiving portion material  316  can be molded using techniques known to one skilled in the art. For example, a single molding can be made whereby jacket seal material  314  and insulated conductor receiving portion material  316  are injected into their respective sections. The sections can also be molded separately using known molding techniques and jacket seal  304  can be affixed to the insulated conductor receiving portion  302 . In another example, the molded jacket seal  304  can be placed in a second mold, so that insulted conductor receiving portion  302  is over-molded onto jacket seal  304 , thereby bonding the insulated conductor receiving portion  302  to the jacket seal  302 . 
         [0047]    Although the use of the present invention with a load beak adapter and cable adapter have been disclosed in detail it would be obvious to one skilled in the art that the jacket seal can be utilized with other accessories known in the field such as joints, elbows and terminators. Further, a splice can utilize the jacket seal of the present invention by attaching a jacket seal of the present invention to each end of the splice where prepared cables are slidably inserted therewithin. 
         [0048]    Thus, there has been summarized and outlined, generally in broad form, a plurality of the most important features of the present invention. While this summary is presented so that the novelty of the present contribution to the related art may be better appreciated, it will further be apparent that additional features of the invention described hereinafter (which will form the subject matter of the claims appended hereto) will further define the scope, novelty, and in certain instances the improvements upon any existing art. The following description provides specific details for a thorough understanding of, and enabling description for, various examples of the technology. One skilled in the art will understand that the technology may be practiced without many of these details and it is to be readily understood that the invention presented herein is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the various figures integrated and categorized herein. For example, in some instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the examples of the technology. It is intended that the terminology used in the description presented below be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain examples of the technology. Although certain terms may be emphasized below, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section. In addition, those of ordinary skill in the art will readily recognize that the headings of sections provided in this patent application and the title of this patent application are for convenience only, and are not to be taken as limiting the disclosure in any way. Those skilled in the art will appreciate that the disclosure of the present invention may readily be utilized as a basis for the designing of other similar structures, methods and systems for carrying out the various purposes and objectives of the present invention. Thus, the claims as set forth shall allow for such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention as described herein. While certain aspects of the device are presented below in certain claim forms, the inventor contemplates the various aspects of the system in any number of claim forms. Accordingly, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the system.