Patent Publication Number: US-8981224-B2

Title: Cable connector systems and methods including same

Description:
RELATED APPLICATION(S) 
     The present application is a continuation of and claims priority from U.S. patent application Ser. No. 13/450,227, filed Apr. 18, 2012, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to electrical cables and, more particularly, to connections and covers for electrical transmission cables. 
     BACKGROUND OF THE INVENTION 
     Covers are commonly employed to protect or shield electrical power cables and connections (e.g., low voltage cables up to about 1000V and medium voltage cables up to about 65 kV). Mastic is commonly used to provide electrical stress relief in areas proximate connectors that might otherwise present voids or other undesirable irregularities. 
     One application for such covers is for splice connections of metal-sheathed, paper-insulated cables such as paper-insulated lead cable (PILC). A PILC typically includes at least one conductor surrounded by an oil-impregnated paper insulation layer, and a lead sheath surrounding the conductor and insulation layer. Alternatively, the metal sheath may be formed of aluminum. In some cases, it is necessary to contain the oil. It is known to use a heat shrinkable sleeve made of a polymer that does not swell when exposed to the oil. Examples of such heat shrinkable sleeves include heat shrinkable oil barrier tubes (OBT) available from TE Connectivity. The sleeve is placed over the oil impregnated paper and heat is applied to contract the sleeve about the insulation layer. Mastic or other sealant material may be used at each end of the sleeve to ensure an adequate seal and containment of the oil. 
     SUMMARY OF THE INVENTION 
     According to embodiments of the present invention, a cable connection assembly includes an electrically conductive cable, an electrically conductive connector, and a flowable sealant. The electrical cable includes a conductor. The connector includes a connector body having an outer surface and a lengthwise connector axis. The connector body defines a conductor cavity receiving the conductor of the electrical cable. The connector further includes a sealant flow blocking wall on the connector body and extending radially outwardly from the outer surface of the connector body. The flowable sealant surrounds a portion of the connector body. The sealant flow blocking wall is configured to inhibit flow of the sealant on the outer surface along the lengthwise connector axis. 
     According to embodiments of the present invention, a cable connector system kit for electrically and mechanically connecting an electrical cable includes an electrically conductive connector. The connector includes a connector body and a sealant flow blocking wall on the connector body. The connector body has an outer surface and a lengthwise connector axis. The connector body defines a conductor cavity to receive a conductor of the electrical cable. The sealant flow blocking wall extends radially outwardly from the outer surface of the connector body. The sealant flow blocking wall is configured to inhibit flow of a sealant on the outer surface along the lengthwise connector axis. 
     According to method embodiments of the present invention, a method for forming an electrical and mechanical connection with an electrical cable includes providing an electrically conductive connector including: a connector body having an outer surface and a lengthwise connector axis, the connector body defining a conductor cavity to receive a conductor of the electrical cable; and a sealant flow blocking wall on the connector body and extending radially outwardly from the outer surface of the connector body. The method further includes mounting a flowable sealant on the connector such that the flowable sealant surrounds a portion of the connector body. The sealant flow blocking wall is configured to inhibit flow of the sealant on the outer surface along the lengthwise connector axis. 
     Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments that follow, such description being merely illustrative of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of an exemplary PILC cable having three cable cores. 
         FIG. 2  is a side view of the PILC cable of  FIG. 1  and three polymeric cables prepared for splicing. 
         FIG. 3  is an exploded, perspective view of a connector according to embodiments of the present invention along with one of the PILC cable cores (covered by an oil barrier tube) and one of the polymeric cables to be coupled. 
         FIG. 4  is a perspective view of the connector of  FIG. 3  connecting the PILC cable core and the polymeric cable, wherein shear bolts of the connector have been sheared off. 
         FIG. 5  is a perspective view of the assembly of  FIG. 4  further including a layer of mastic applied around the connector and the oil barrier tube on the PILC cable core. 
         FIG. 6  is a perspective view of the assembly of  FIG. 5  further including a restricting tape applied around the connector and mastic. 
         FIG. 7  is a side view of the PILC cable of  FIG. 1 , the three polymeric cables, and the assembly of  FIG. 6 , and further including a joint body installed about the connector and portions of the spliced PILC cable core and polymeric cable. 
         FIG. 8  is a cross-sectional view of the assembly of  FIG. 7  taken along the line  8 - 8  and  FIG. 7 . 
         FIG. 9  is an enlarged, fragmentary, cross-sectional view of the connector of  FIG. 3 . 
         FIG. 10  is a side view of the assembly of  FIG. 7  with a re-jacketing sleeve mounted thereon. 
         FIG. 11  is a fragmentary, perspective view of a connection assembly according to further embodiments of the present invention. 
         FIG. 12  is a perspective view of a connector according to further embodiments of the present invention. 
         FIG. 13  is an enlarged, fragmentary, cross-sectional view of the connector of  FIG. 12  taken along the line  13 - 13  of  FIG. 12 . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention. 
     Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90° or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
     As used herein, “monolithic” means an object that is a single, unitary piece formed or composed of a material without joints or seams. 
     With reference to  FIG. 6 , a cable connector system  101  according to some embodiments of the present invention is shown therein. The connector system  101  can be used in combination with additional components to form a cover system  104  ( FIG. 7 ). The cover system  104  may in turn be used to form a protected connection assembly  102  including two or more connected cables, as shown in  FIG. 10 . In some embodiments, the connector system  101  is provided as a pre-packaged kit of components for subsequent assembly by an installer (e.g., a field installer) using a method as described herein. 
     The connector system  101  can be used to electrically and mechanically couple or splice a pair of electrical power transmission cables. The spliced cables may include polymeric insulated cables, paper-insulated lead cables (PILC), or one of each. In the embodiment illustrated in  FIGS. 1-10  and described hereinbelow, the connector system  101  is used to couple (i.e., provide a transition joint or transition splice between) an oil-containing cable (PILC)  30  and a polymeric cable  60 . However, it will be appreciated that other combinations of conductors may be joined in accordance with embodiments of the invention. 
     The cable  30  ( FIG. 1 ) as illustrated is a three-phase cable including three electrical conductors  32 , which may be formed of any suitable material such as copper, and may be solid or stranded. Each conductor  32  is surrounded by a respective oil-impregnated paper insulation layer  34 . The oil impregnating each layer  34  may be any suitable oil such as a mineral oil. A respective metal screen  36  may surround each paper layer  34 . A metal sheath  38  surrounds the three conductors  32 , collectively. According to some embodiments, the metal sheath  38  is a lead sheath and the cable  30  may be commonly referred to as a paper-insulated lead cable (PILC). According to other embodiments, the metal sheath  38  is formed of aluminum. A polymeric jacket  39  surrounds the metal sheath  38 . 
     In the illustrated embodiment, the three conductors  32  of the cable  30  are each spliced to a respective one of three polymeric cables  60 . As shown in  FIG. 2 , each polymeric cable  60  includes a primary electrical conductor  62 , a polymeric conductor insulation layer  64 , a semiconductive layer  65 , one or more neutral conductors  66 , and a jacket  68 , with each component being concentrically surrounded by the next. According to some embodiments and as shown, the neutral conductors  66  are individual wires, which may be helically wound about the semiconductive layer  65 . The primary conductor  62  may be formed of any suitable electrically conductive materials such as copper (solid or stranded). The polymeric insulation layer  64  may be formed of any suitable electrically insulative material such as crosslinked polyethylene (XLPE) or EPR. The semiconductive layer  65  may be formed of any suitable semiconductor material such as carbon black with silicone. The neutral conductors  66  may be formed of any suitable material such as copper. The jacket  68  may be formed of any suitable material such as EPDM. 
     However, it will be appreciated that polymeric cables of other types and configurations may be used with the connector system  101 . For example, the polymeric cable may include three conductors, each surrounded by a respective polymeric insulation and a respective semiconductive elastomer, and having a metal shield layer collectively surrounding the three conductors and a polymeric jacket surrounding the shield layer. 
     In the illustrated embodiment, three connector systems  101  may be employed (one for each phase). The three connector systems  101  may be constructed in the same or similar manner and therefore only one of the connector systems will be described in detail hereinbelow, and this description will likewise apply to the other connector systems. However, the connector systems  101  employed to splice a group of cables need not be identical. 
     The connector system  101  includes a mechanical and electrical connector  130  ( FIG. 3 ), a mass of a flowable sealant material  170  ( FIG. 5 ), and a mastic pressure retention or restricting tape  160  ( FIG. 6 ). According some embodiments and as described hereinbelow, the flowable sealant material  170  is a mastic. 
     According to some embodiments and as shown, the connector  130  ( FIGS. 3 ,  8  and  9 ) is a shear bolt connector  130 . The shear bolt connector  130  includes an electrically conductive (e.g., metal) connector body  132  and a plurality of shear bolts  144 . The connector  130  may also include one or a pair of spacer inserts (not shown). The connector body  132  has a lengthwise axis L-L ( FIG. 3 ) and opposed ends  132 A,  132 B. The connector body  132  has an intermediate or central oil stop wall  134  ( FIG. 8 ) and a tubular sidewall  135  forming opposed body portions  131 A,  131 B. The inner surface of the sidewall  135  and the oil stop wall  134  define opposed conductor cavities or bores  136 A,  136 B ( FIG. 8 ) on either side of the wall  134 , as well as opposed entry openings  138 A and  138 B ( FIG. 3 ) on each end  132 A,  132 B communicating with the bores  136 A and  136 B, respectively. An annular end face on the end  136 A surrounds the entry opening  138 A. An annular end face on the end  136 B surrounds the entry opening  138 B. Threaded bolt bores  142  ( FIG. 8 ) are defined in the sidewall  135  of the connector body  132 . 
     Each bolt  144  ( FIG. 3 ) includes a shank  146  and a head  148 . The head  148  may be configured to operably engage a driver to be forcibly driven by the driver. The shank  146  includes a threaded section  146 A configured to threadedly engage an associated one of the bolt bores  142 . The shank  146  also includes a breakaway section  146 B between the threaded section  146 A and the head  148 . Each bolt  144  is adapted to be screwed down into its respective bolt bore  142  to clamp a conductor  32 ,  62  in the underlying conductor bore  136 A or  136 B. The head  148  on the bolt  144  is configured to shear off of the threaded shank  146 A at the breakaway section  146 B when subjected to a prescribed torque. According to some embodiments, the bolt  144  is formed of copper or aluminum. 
     An annular seat or groove  152  ( FIGS. 3 and 9 ) is defined in the outer surface  135 A of the connector body  132 . The groove  152  may be generally U-shaped in cross-section. In some embodiments, the groove  152  is located substantially axially coincident with or proximate the oil block wall  134 . An endless ring member  150  is seated in the groove  152 . According to some embodiments and as shown, the ring member  150  is an O-ring. The O-ring  150  serves as a sealant flow block wall, as discussed herein. 
     The O-ring  150  circumferentially surrounds the connector body  132  and extends radially outwardly from the outer surface  135 A a distance or height H1 ( FIG. 9 ). According to some embodiments, the height H1 is substantially uniform, about the full length of the O-ring  150 . According to some embodiments, the height H1 is at least 0.25 mm and, in some embodiments, is in the range of from about 1 mm to 5 mm. 
     The O-ring  150  may be formed of any suitable material. According to some embodiments, the O-ring  150  is formed of a resiliently deformable material. According to some embodiments, the O-ring  150  is formed of an elastomeric material. According to some embodiments, the O-ring  150  is formed of silicone rubber. Other suitable elastomeric materials may include ethylene-propylene-diene-monomer (EPDM) rubber, butyl rubber or nitrile rubber. However, silicone rubber may be particularly advantageous because silicone rubber is stable over a wide service temperature range, is highly resistant to oil absorption, and will not degrade when subjected to oil (in particular, mineral oil from the cable  30 ). 
     According to some embodiments, the O-ring  150  has a Shore A hardness in the range of from about 30 to 80. 
     The O-ring  150  may be formed using any suitable technique. According to some embodiments, the O-ring  150  is molded or extruded and, according to some embodiments, injection molded. Alternatively, the O-ring  150  may be stamped. According to some embodiments, the O-ring  150  is monolithic. 
     The mastic  170  ( FIGS. 5 and 8 ) is a sealing material that is flowable within its intended service temperatures. According to some embodiments, the intended service temperatures are in the range of from about −40° C. to 140° C. According to some embodiments, the mastic  170  has a viscosity in the range of from about 50 to 100 mooney units at 100° C. 
     The mastic  170  may be any suitable sealing mastic. According to some embodiments, the mastic  170  is resistant to chemical attack from oil, and resistant to migration of oil therethrough. According to some embodiments, the mastic  170  is formed of nitrile rubber, epichlorhydrin rubber, or fluorinated rubber. The mastic  170  may include a stress relief material such as carbon black. According to some embodiments, the mastic  170  has a permittivity of about 7 or higher. Suitable mastics include the S1189 and SRM mastics available from TE Connectivity. 
     The restricting tape  160  ( FIGS. 6 and 8 ) may be any suitable tape. According to some embodiments, the restricting tape  160  is self-adhesive or otherwise adherent to the material (e.g., copper or aluminum) of the connector  130  and the material (e.g., silicone rubber) of the O-ring  150 . According to some embodiments, the restricting tape  160  is a self-amalgamating sealing tape. In some embodiments, the tape  160  is a fiber-reinforced silicone tape. According to some embodiments, the restricting tape  160  includes a silicone tape impregnated with a substrate (in some embodiments, a fabric mesh) that limits the permitted extent of elongation of the restricting tape  160 . In some embodiments, elongation of the restricting tape  160  is limited to from about 5 to 25%. Suitable restricting tapes may include EXRM-3020 tape available from TE Connectivity. 
     The cover system  104  may further include three tubular oil barrier tubes (OBTs)  110  ( FIG. 2 ), a PILC breakout  112  ( FIG. 2 ), three tubular splice or joint bodies  120  ( FIGS. 7 and 8 ), a polymeric cable breakout  117  ( FIG. 2 ), and a re-jacketing sleeve  118  ( FIG. 10 ). The cover system  104  may also include shielding material (e.g., mesh or tape), sealants (e.g., mastic), tapes, spacer(s), ground conductors, and/or other components as appropriate to effect the desired electrical and mechanical joint. 
     Each OBT  110  ( FIG. 2 ) may be formed of any suitable material. According to some embodiments, each OBT  110  is formed of an electrically insulative material and may include an electrically conductive semiconductive layer  110 A (which may be integrally formed with the OBT  110  or a separate tube mounted thereover). According to some embodiments, each OBT  110  is formed of an elastically expandable material, which may be an elastomeric material. Suitable materials for the OBTs may include EPDM, neoprene, butyl or polyurethane. Each OBT  110  may be initially mounted on a holdout (not shown). 
     The breakout  112  ( FIG. 2 ) may include a main tubular body  112 A and three circumferentially distributed tubular fingers  112 B integral with the main body. The breakout  112  may be formed of any suitable material. According to some embodiments, the breakout  112  is formed of an electrically insulative material. According to some embodiments, the breakout  112  is formed of an elastically expandable material such as an elastomeric material. Suitable materials may include EPDM, neoprene, butyl, polyurethane, silicone or fluorosilicone. 
     The joint bodies  120  ( FIGS. 7 and 8 ) may be of any suitable construction and materials, and may function as electrical stress control tubes. With reference to  FIG. 8 , each joint body  120  may include a tubular elastomeric, electrically insulative layer  122  and one or more integrated electrically semiconductive layers, for example, as known in the art for controlling electrical stresses, providing electrical shielding and bridging the electrically semi-conductive layers of the cables. In particular, the joint body  120  may include an electrically conductive region in the form of electrically conductive geometrical Faraday cage  124 . The joint body  120  may further include electrically conductive regions in the form of electrically conductive geometrical stress cones  126 . A semiconductive coating or layer  128  may be provided on the outer surface of the layer  122 . The components  122 ,  124 ,  126 ,  128  may be formed of any suitable materials. According to some embodiments, the layer  122  is formed of silicone rubber. According to some embodiments, the Faraday cage  124  and the stress cones  126  are formed of conductive polymers (according to some embodiments, having a resistivity of 100 ohm-cm or less). According to some embodiments, the outer layer  128  is formed of silicone, EPR, EPDM or polyethylene. 
     The breakout  117  ( FIG. 2 ) includes a main tubular body and three circumferentially distributed tubular fingers integral with the main body. The breakout  117  may be formed of any suitable material. According to some embodiments, the breakout  117  is formed of an electrically insulative material. According to some embodiments, the breakout  117  is formed of an elastically expandable material such as an elastomeric material. Suitable materials may include EPDM, neoprene, butyl, polyurethane, silicone or fluorosilicone. 
     The re-jacketing sleeve  118  ( FIG. 10 ) may be of any suitable construction and materials. Suitable materials for the re jacketing sleeve  118  may include polyethylene, thermoplastic elastomer (TPE), or silicone rubber, for example. Suitable re-jacketing sleeves may include a heat shrinkable re-jacket (as shown) or the GMRS Rejacketing Sleeve available from TE Connectivity, for example. 
     The constructions of the connector system  101  and the cover assembly  102  may be further appreciated in view of methods for forming the connection assembly  104  ( FIGS. 7 and 8 ) according to embodiments of the present invention, as discussed in further detail below. However, it will be appreciated that certain of the steps and components disclosed hereinbelow may be altered or omitted in accordance with further embodiments of the invention. 
     With reference to  FIGS. 1 and 2 , the cable  30  is prepared by progressively trimming back or removing end sections of the jacket  39 , the metal sheath  38 , and the metal screen  36  as shown. The paper insulation  34  of each conductor  32  may also be trimmed back or may be subsequently trimmed prior to installing the connectors  50 . Each conductor  32  and the paper insulation  34  surrounding the conductor  32  may be referred to herein as a cable core  40 . The metal sheath  38  has a terminal edge  38 A defining an end opening  38 B through which extended sections  42  of the three cable cores  40  extend. The paper insulation  34  of each cable core  40  is trimmed back as shown in  FIG. 2  to expose a terminal or engagement section  32 A of the conductor  32 . 
     As shown in  FIG. 2 , an OBT  110  is mounted on each cable core  40  and the breakout  112  is mounted over the OBTs  110 . 
     Each cable  60  is prepared by cutting each layer  62 ,  64 ,  65 ,  66  and  68  such that a segment of each layer  62 ,  64 ,  65  and  66  extends beyond the next overlying layer  64 ,  65 ,  66  and  68  as shown in  FIG. 2 . A terminal or engagement section  62 A of the conductor  62  extends outwardly beyond the insulation  64 . 
     The following procedure can be executed for each of the cable core  40 /polymeric cable  60  pairs in turn. 
     The end segment of the conductor  62  is inserted into the bore  136 A. The bolts  144  overlying the bore  136 A are driven into the bore  136 A via their heads  148  until sufficient torque is applied to shear the head  148  off at the breakaway section  146 . The intruding bolts  144  may tend to forcibly radially displace the conductor  64  in the offset direction O with respect to the bore centerline. At this time, the end segment of the conductor  62  is secured in the bore  136 A by the remainder of each bolt  144 , as shown in  FIGS. 4 and 7 . 
     The cable core  40  is likewise coupled to the connector  130 . More particularly, the end segment of the conductor  32  is inserted into the bore  136 B and captured therein by the bolts  144  as shown in  FIGS. 4 and 7 . 
     The mastic  170  is then wrapped about the cable core  40  and the connector  130  as shown in  FIG. 5 . More particularly, a strip or strips of the mastic  170  can be wrapped or wound onto the cable core  40  and the connector  130  such that a portion  172  of the mastic  170  fully circumferentially surrounds the portion  131 B of the connector body  132  and a portion  174  of the mastic  170  overlaps (fully circumferentially surrounding) a portion of the OBT  110  adjacent the connector  130 . According to some embodiments, the mastic  170  directly engages and adheres to the overlapped outer surfaces of the connector  130  and the OBT  110 . The mastic  170  extends from a terminal end  170 A to a terminal end  170 B. The terminal end  170 A is located proximate the O-ring  150  on the side of the O-ring  150  facing the connector end  132 A. 
     According to some embodiments, the mastic  170  overlaps the connector  130  by a distance D1 ( FIG. 5 ) of at least about 0.25 inch and, in the event a potential leak path is present such as a bolt hole, the mastic  170  should overlap at least 0.25 inch of solid portion of the connector  130 . According to some embodiments, the mastic  170  overlaps the OBT  110  by a distance D2 of at least about 0.25 inch. According to some embodiments, the mastic  170  does not overlap any of the connector body portion  131 A. 
     With reference to  FIGS. 6 and 8 , the restricting tape  160  is then installed on the connector  130 . Beginning with a lead end  162 A of the tape  160  and ending with a trailing end  162 B, the tape  160  is wound helically in a self-overlapping or imbricated pattern about the connector  130 , the mastic  170 , and the OBT  110 . More particularly, a first winding  164  of the tape  160  directly engages and adheres to the outer surface  135 A ( FIG. 3 ) of the connector body portion  131 A, a subsequent (e.g., third, as shown) winding  166  directly engages and adheres to the O-ring  150 , further subsequent windings  168  surround the mastic  170 , and finally one or more windings  169  directly engage and adhere to the OBT  110 . Optionally, one or more additional full windings  164 A may be wrapped about the first winding  164 . According to some embodiments, the tape  160  is wound on under tension so that, once installed, the tape  160  applies a persistent radially compressive load or pressure on the mastic  170 . 
     As will be appreciated from  FIG. 8 , the connector body portion  131 B, the tape  160 , the O-ring  150 , and the OBT  110  envelope and collectively define a chamber containing the mastic  170 , and thereby contain the mastic  170  in the region of the interface between the OBT  110  and the connector  130 . The mastic  170  retained in this region is thus in place to serve as an oil barrier seal, and may also serve as an electrical stress control layer. Notably, a portion  135 C ( FIG. 6 ) of the outer surface  135 A on the connector body portion  131 A remains exposed. 
     According to some embodiments, the thickness T1 ( FIG. 9 ) of the mastic  170  at the terminal end  170 A is in the range of from about 1 mm to 4 mm. According to some embodiments, the height H1 of the O-ring  150  is equal to or greater than the thickness T1 of the mastic  170  to prevent or inhibit the mastic  170  from flowing over the O-ring  150 . According to some embodiments, the outer diameter E1 of the O-ring  150  is equal to or greater than the mastic outer diameter E2 ( FIG. 9 ). 
     According to some embodiments, the nominal thickness of the mastic  170  in the region surrounding the connector body portion  131 B is in the range of from about 1 mm to 3 mm. 
     According to some embodiments, the tape  160  has a width W1 ( FIG. 8 ) in the range of from about 0.5 inch to 1 inch. According to some embodiments, the thickness T2 ( FIG. 9 ) of the restricting tape  160  at the beginning of first wind  164  is in the range of from about 0.25 mm to 2 mm. According to some embodiments, the height H1 of the O-ring  150  is equal to or greater than the tape thickness T2 ( FIG. 9 ). According to some embodiments, the height H1 is at least 0.5 mm greater than the tape thickness T2. According to some embodiments, the height H1 is at least twice the tape thickness T2. 
     The joint body  120  is then mounted around the connector  130 , the mastic  170 , the restricting tape  160 , and adjacent portions of the cables  30 ,  60  as shown in  FIGS. 7 and 8 . The joint body  120  may be provided on and deployed from a holdout, for example. The joint body  120  overlaps a portion of the semiconductive layer  65  on one end and a portion of the OBT semiconductive layer  110 A on the other end. More particularly, one stress cone  126  overlaps the semiconductive layer  65  and the insulation layer  64  at their interface, the other stress cone  126  overlaps the OBT semiconductive layer  110 A and the exposed OBT  110  at their interface, and the faraday cage  124  surrounds the full length of the connector  130  and adjacent portions of the cable insulation  64  and the OBT  110 . A portion of the Faraday cage  124  directly engages the bare or exposed connector outer surface  135 C to provide electrical continuity therebetween. 
     Each of the other cable pairs can be connected and covered in the same manner as described above using respective connector systems  101 . The assembly can thereafter be grounded, shielded and re-jacketed in known manner, for example. For example, grounding braids can be connected to the shield layers  68  of the polymeric cables  60  and the metal sheath  30  by clamps or the like. The entire joint assembly can be covered by the re-jacketing sleeve  118  ( FIG. 10 ), which overlaps the cable jacket  39  and the jackets  68 . 
     The connector system  101  can provide significant advantages and overcome or mitigate problems commonly associated with similar connections of the known art. In the case of the joint between the connector  130  and the cable  30 , the mastic  170  may be relied upon to prevent or inhibit oil from leaking from the cable  30  (e.g., by sealing the open end of the OBT  110 ). The mastic  170  may also be relied upon to provide electrical stress relief at the joint and the unintended loss of the mastic  170  from the sealing region can therefore risk failure or degradation of the splice due to electrical stresses. In known connection assemblies in which a restricting tape is used to contain the mastic, the configuration of the tape wraps may leave a flow path for the mastic to flow under the restricting tape and thereby compromise the seal. This is particularly the case where the lead end of the tape is located adjacent the end of the mastic on the connector (i.e., the end of the mastic layer nearest the polymeric cable) because the thickness of the tape end can create a step and a corresponding void between the tape and the connector. While this problem may be mitigated by providing additional wraps of the tape onto the connector portion adjacent the polymeric cable, such additional wraps are often undesirable because they reduce the exposed connector surface available for engagement by the joint body Faraday cage. 
     The O-ring  150  provides a continuous region to seal with the restricting tape  160  and restrict the flow of the mastic  170 . By preventing or inhibiting displacement of the mastic  170 , the connector system  101  (in particular, the O-ring  150  and the tape  160 , cooperatively) can preserve the integrity of the mastic oil stop seal to retain the oil in the PILC cable  30  even when relatively high oil internal pressures are induced, such as by increases in temperature or placement of the connection at lower elevation than other parts of the cable  30 . The constraint on the flow of the mastic  170  can also maintain the mastic  170  in place to provide electrical stress relief. By obviating or reducing the need for additional tape wraps on the connector  130 , the connector system  101  can provide a greater connector surface area  135 C to engage the Faraday cage  124  of the joint body  120 . According to some embodiments, the length D3 ( FIG. 8 ) of the contact region between the exposed outer surface  135 C and the Faraday cage  124  is at least 0.5 inch. 
     Various environmental parameters may encourage or induce flow of the mastic  170  toward the cable  60 . In service, environmental and electrical resistance heating of the connection and conductors heats the mastic  170 , thereby softening and reducing the viscosity of the mastic  170 . The joint body  120  applies radially inward compressive forces to the mastic  170  that tend to force the mastic  170  toward the connector end  132 A. Thermal expansion of joint components may also tend to force flow of the mastic  170 . 
     The connector system  101  according to embodiments of the present invention can prevent, limit or inhibit such unintended and undesirable flow, displacement or extrusion of the mastic  170 . The O-ring  150  blocks or dams the mastic  170  so that the mastic  170  is retained about the joint. According to some embodiments, the tape  160  adheres or bonds to the O-ring to provide a seal against mastic flow at the interface between the O-ring  150  and the tape  160 . 
     With reference to  FIG. 11 , a connector system  201  according to further embodiments of the present invention is shown therein. The connector system  201  can be constructed and assembled in the same manner as the connector system  101  (including incorporation into a cover system corresponding to the cover system  102  to form a protected connection assembly corresponding to the protected connection assembly  104 ), except as follows. The connector system  201  includes a restricting tube  260  in place of the restricting tape  160 . The restricting tube  260  engages and forms a seal with the O-ring  150  in the same or similar manner as described above to restrict flow of the mastic  170  down the length of the connector  130  toward the polymeric cable  60 . 
     The restricting tube  260  may be provided on and deployed from a holdout, for example. According to some embodiments, the restricting tube  260  is a heat shrinkable tube and the procedure for installing the restricting tube  260  includes applying heat (e.g., using a heat gun) to the restricting tube  260  after the tube  260  has been positioned over the mastic  170 . According to some embodiments, the restricting tube  260  is a cold shrinkable tube. 
     According to some embodiments, the restricting tube  260 , when installed, is elastically stretched (i.e., has a relaxed diameter that is greater than its installed diameter) so that the restricting tube  260  applies a persistent radially compressive load or pressure on the mastic  170 . 
     The restricting tube  260  may be of any suitable construction and materials. Suitable materials for the tube  260  may include polyolefin or elastomeric materials, for example. In the case of a heat shrinkable tube  260 , the tube  260  may be formed of Kynar, polyethylene, or silicone, and may be electrical stress grading or insulating. In the case of a cold shrinkable tube  260 , the tube  260  may be formed of silicone or EPDM, and may be electrical stress grading or insulating. 
     With reference to  FIGS. 12 and 13 , a connector system  330  according to further embodiments of the present invention is shown therein. The connector system  330  can be constructed and assembled in the same manner as the connector  130  and used in the connector system  101  (including incorporation into a cover system corresponding to the cover system  102  to form a protected connection assembly corresponding to the protected connection assembly  104 ) in the same manner as the connector  130 , except as follows. The connector  330  corresponds to the connector  130  except that an annular sealant flow block wall  350  is provided in place of the O-ring  150  and the groove  152 . The sealant flow block wall  350  provides a continuous region to seal with the restricting tape  160  and restrict the flow of the mastic  170  in the same or similar manner as described about for the O-ring  150 . The connector  330  may likewise be used with the restricting tube  260  in place of the restricting tape  160 . 
     The sealant flow block wall  350  may have the same dimensions (i.e., height H1 and/or outer diameter E1) relative to the dimensions of the mastic  170  (i.e., T1 and E2) and the restricting tape  160  (i.e., T2) as discussed above with regard to the O-ring  150 . According to some embodiments, the sealant flow block wall  350  has an outer wall face  354  with a width W2 ( FIG. 13 ) of at least from about 0.5 mm to provide reliable engagement between the restricting tape  160  and the sealant flow block wall  350 . 
     According to some embodiments, the wall  350  is rigid. According to some embodiments, the wall  350  has a Rockwell hardness of at least 40 on E scale (HRE 40). 
     The sealant flow block wall  350  may be formed of any suitable material. According to some embodiments, the sealant flow block wall  350  is formed of metal. Suitable metals may include copper or aluminum. In some embodiments, the sealant flow block wall  350  is formed of the same metal as the connector body  132 . 
     The sealant flow block wall  350  may be formed using any suitable technique. According to some embodiments and as shown in  FIG. 13 , the sealant flow block wall  350  is integrally formed with the connector body  132 , such as by casting or machining, so that the connector body  132  and the sealant flow block wall  350  form a monolithic unit. In other embodiments, the sealant flow block wall  350  is separately formed from and affixed to the connector body  132  such as by adhesive bonding, welding or interference fit. 
     While sealant flow block walls in the form of an O-ring  150  and a rigid wall  350  have been shown and described herein, sealant flow block walls of other shapes, configurations and materials may instead be employed in accordance with other embodiments of the invention. 
     While a mastic has been shown and described herein, other flowable sealants (e.g., greases) may be employed with connectors of the present invention. 
     According to further embodiments of the invention, the connector (e.g., the connector  130 ) is a crimp-type connector rather than a bolt-type connector. 
     Connector systems according to embodiments of the invention may be used for any suitable cables and connections. Such connector systems may be adapted for use, for example, with connections of medium voltage cables (i.e., between about 8 kV and 46 kV). 
     While the connections to PILCs have been described herein with reference to PILC-to-polymeric cable transition splices, connector systems as disclosed herein may also be used in PILC-to-PILC splices and polymeric cable-to-polymeric cable splices. Connector systems according to embodiments of the invention may also be configured for non-splice cable terminations and elbows, for example, for PILC cables and polymeric cables. 
     The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the invention.