U.S. patent application number 10/654332 was filed with the patent office on 2004-03-18 for splice protection system.
This patent application is currently assigned to Chemque, Inc.. Invention is credited to Hershkowitz, Elliott E..
Application Number | 20040050575 10/654332 |
Document ID | / |
Family ID | 25387538 |
Filed Date | 2004-03-18 |
United States Patent
Application |
20040050575 |
Kind Code |
A1 |
Hershkowitz, Elliott E. |
March 18, 2004 |
Splice protection system
Abstract
A splice protection system including a water resistant material
disposed on a flexible wrapper that retains the water resistant
material is disclosed. The splice protection system is useful for
preventing unwanted entry of external elements into the splice
regions of signal transmission devices, thus preserving the
integrity and function of the signal transmission devices.
Inventors: |
Hershkowitz, Elliott E.;
(Fair Lawn, NJ) |
Correspondence
Address: |
BANNER & WITCOFF, LTD.
28 STATE STREET
28th FLOOR
BOSTON
MA
02109-9601
US
|
Assignee: |
Chemque, Inc.
Rexdale
CA
|
Family ID: |
25387538 |
Appl. No.: |
10/654332 |
Filed: |
September 3, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10654332 |
Sep 3, 2003 |
|
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09885712 |
Jun 20, 2001 |
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Current U.S.
Class: |
174/76 ;
156/48 |
Current CPC
Class: |
G02B 6/255 20130101;
G02B 6/3801 20130101 |
Class at
Publication: |
174/076 ;
156/048 |
International
Class: |
H01B 013/00 |
Claims
What is claimed is:
1. A closure for use with signal transmission devices comprising: a
flexible wrapper, and a water resistant material.
2. The closure of claim 1 wherein the flexible wrapper is water
resistant.
3. The closure of claim 1 wherein the flexible wrapper is water
impermeable.
4. The closure of claim 1 wherein the flexible wrapper comprises
paper, plastic or rubber.
5. The closure of claim 1 wherein the wrapper comprises an adhesive
material at its edge.
6. The closure of claim 1 further comprising a delivery device.
7. The closure of claim 6 wherein the delivery device comprises a
porous medium being open-celled.
8. The closure of claim 7 wherein the porous medium is
compressible.
9. The closure of claim 8 wherein the delivery device comprises one
or more layers of the porous medium.
10. The closure of claim 6 wherein the porous medium has a porosity
of between about 4 to about 25 pores per square inch.
11. The closure of claim 1 wherein the water resistant material is
selected from the group consisting of a gel, a grease, an
encapsulant and a potting material.
12. The closure of claim 11 wherein the water resistant material is
water resistant.
13. The closure of claim 11 wherein the water resistant material is
water impermeable.
14. The closure of claim 11 wherein the water resistant material is
a self-healing conformable gel.
15. The closure of claim 11 wherein the water resistant material
fills about 80% of the delivery device.
16. The closure of claim 11 wherein the delivery device comprises a
top surface which is substantially free of the water resistant
material.
17. A method of protecting a splice of a signal transmission device
comprising: providing a closure comprising a flexible wrapper and a
water resistant material; arranging the splice in contact with the
water resistant material; wrapping the flexible wrapper around the
splice to bring the water resistant material into 360.degree.
contact with the splice; compressing the wrapped flexible wrapper
in a manner to force the water resistant material into voids in the
splice; and securing the closure to the signal transmission
device.
18. The method of claim 17 wherein the flexible wrapper is water
resistant.
19. The method of claim 17 wherein the flexible wrapper is water
impermeable.
20. The method of claim 17 wherein the flexible wrapper comprises
paper, plastic or rubber.
21. The method of claim 17 wherein the flexible wrapper comprises
an adhesive material at its edge.
22. The method of claim 17 wherein water resistant material is
retained within a delivery device including a porous medium.
23. The method of claim 17 wherein the porous medium is
open-celled.
24. The method of claim 17 wherein the porous medium is
compressible.
25. The method of claim 17 wherein the delivery device comprises
one or more layers of the porous medium.
26. The method of claim 17 wherein the porous medium has a porosity
of between about 4 to about 25 pores per square inch.
27. The method of claim 17 wherein the water resistant material is
selected from the group consisting of a gel, a grease, an
encapsulant and a potting material.
28. The method of claim 17 wherein the water resistant material is
water impermeable.
29. The method of claim 17 wherein the water resistant material is
a self-healing conformable gel.
30. The method of claim 17 wherein the water resistant material
fills about 80% of the delivery device.
31. The method of claim 17 wherein the delivery device comprises a
top surface that is substantially free of the water resistant
material.
32. A kit for use with signal transmission devices comprising a
closure including a flexible wrapper, a delivery device attached to
the flexible wrapper, and a water resistant material retained in
the delivery device; a water impervious covering; and one or more
binders for securing the water impervious covering and the closure
to the signal transmission device.
33. The closure of claim 6 wherein the delivery device comprises a
breakable container.
34. The closure of claim 6 wherein the delivery device comprises a
breakable bead.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention relate generally to
systems for protecting signal transmission devices from adverse
conditions that could alter operation of the signal transmission
device, such as adverse environmental conditions including dirt,
moisture, insects, local chemical and biological contaminants, and
microorganisms. More particularly, embodiments of the present
invention relate to the protection of a splice or other connection
in a signal transmission device, such as an electrical or optical
cable. Even more particularly, embodiments of the present invention
relate to a novel closure for protecting splice connections from
exposure to moisture or other environmental elements that may harm
or otherwise interfere with operation of the signal transmission
device.
[0003] 2. Description of Related Art
[0004] Changes in plant construction philosophy and methods have
often led to the need for new products. The telephone subscriber
loop presents one such case. The initial deployment of buried drop
wires envisioned a continuous, monolithic run between the terminal
and the customer premises. It was expected that, due to the low
cost of materials, faulty or faulted runs would be replaced rather
than repaired. Today, with the high costs involved with disrupting
existing landscaping, the practice of splicing buried drop wire has
become common enough to require a special system to protect the
integrity of the connection.
[0005] The initial distribution plant in coaxial cable used a
mechanical connector that was thought to be weather resistant by
design. Over the years, these connections have shown themselves to
be prone to failure from water intrusion and corrosion. The
protection of existing splice connections can require a "split
sleeve" system that can be placed mid-span in an existing cable
run. The complex geometry of the mechanical connector or
connector/tap oftentimes requires the system to be capable of
having an encapsulant that will penetrate thoroughly, exclude
oxygen to reduce oxidative corrosion, exclude water to prevent
signal degradation and electrolysis. A complete potting of the
entire connection will help prevent the formation of differential
aeration cells. Encapsulants should not exhibit any creep over time
since these connections are often made in aluminum conductors and
the aluminum can be prone to cold flow. Encapsulant entry could
cause an increase in resistance that would lead to cable heating
and signal loss at the potentials that are imposed on coaxial
cable.
[0006] There are several types of systems used for the protection
of a buried drop wire splice. The first kind of system uses a two
part chemical system that is mixed in the field in a container that
may also serve as the final closure. The wires are immersed in the
container or the mixture may be poured over the wires in an
additional enclosure. There is considerable worker and
environmental exposure and hence, resistance to handling small
chemical mixes in the field. They can be messy, difficult to handle
and apply. There is also the related expense in time lost while
waiting for the system to cure. In cold climates the time can be
appreciable relative to the entire repair operation.
[0007] A second system uses a grease or polymeric filling material
confined in a multi-part rigid closure. The joined wires and
bonding are inserted in the closure and the parts manually pressed
or mechanically forced together to distribute the filling material
into all of the void spaces. This approach is vulnerable to the
effects of temperature on the flow of filling compound and the
volume of wirework placed. Also, quality of work is difficult to
monitor since there is no indication of completeness of the
interstitial fill. Historically, inadequate filling leaves these
systems vulnerable to water ingress from without and via the core
of the drop wire. They exhibit severely limited life spans relative
to the 40 years expected of most outside plant equipment.
[0008] A third system involves a rubber, generally cylindrical,
elongated tubular member the inside surface of which is coated with
a sealant. The tubular member is secured around the splice with the
sealant on the inside surface used to secure the tubular member to
the splice and to itself. No filling material is used to
encapsulate the splice and prevent the ingress of water from
without and via the core of the drop wire.
[0009] A fourth system commonly used is a heat-shrinkable sleeve.
In addition to requiring special heating tools, there is the
potential for deterioration of the integrity of the material due to
overheating. Also, the available heat shrinkable materials for such
applications are typically of high durometer to withstand the
hostile environment, making re-entry as by slitting more difficult
and limiting the flexibility of the spliced area. It is for these
reasons that heat shrinkable materials have found little acceptance
in the coaxial plant as well.
[0010] The nature of the mechanical connectors used in coaxial
plant may necessitate periodic adjustment of the connector. Hence,
any protective device must be easily removed and replaced. An
advantage is gained if the same device can be reused as in the case
where the encapsulant gel would return into the storage media
leaving the connector clear and clean.
[0011] In the case of optical fibers, the present systems use large
closures to house splices and provide mechanical strain relief and
fiber alignment against micro bending losses. The use of mechanical
connectors for fiber connections will increase as wider use of
fiber is made in distribution plant and single fibers, rather than
bundles or cables, are brought to the end use point. These
connections will require protection from many environments from the
weather to industrial environments on the factory floor to ordinary
housekeeping activities in offices. The constant rearrangement of
devices will require a protective device that is easily removed and
that removes cleanly.
SUMMARY OF THE INVENTION
[0012] Splice protection systems of the present invention are
useful for preventing unwanted entry of external elements into the
splice regions of signal transmission devices, thus preserving the
integrity and function of the signal transmission devices. In
addition, embodiments of the present invention relate to closures
for protecting signal transmission devices from adverse
environmental conditions such as dirt, moisture, chemical
contaminants and microorganisms that may adversely affect the
operation of the signal transmission device. The adverse effects of
dirt and moisture are of concern especially when the signal
transmission devices are buried underground or placed in
contaminated micro environments such as machine tool housings.
[0013] The protective sheathing or other coating (collectively
"coating") of signal transmission devices, such as electrical or
optical cables, are oftentimes opened to fix the conductors, i.e.
wires or optical fibers, therein or otherwise splice additional
signal transmission devices together. Once the integrity of the
protective coating is breached, dirt and moisture will penetrate
the signal transmission device oftentimes causing failure unless
steps are taken to seal out dirt and moisture and restore the
original integrity of the cable.
[0014] In its simplest embodiment, the closures of the present
invention include a wrapper, such as a flexible sheet of plastic,
in combination with a water resistant material deposited onto or
otherwise connected, affixed or adhered to the preferably flexible
wrapper. The flexible wrapper with the water resistant material is
then wrapped around the desired portion of the signal transmission
device, such as a splice, and the water resistant material is
manually massaged into the splice connection. The massaging of the
material may be accomplished using numerous methods, such as, for
example, manually massaging the material or massaging the material
using mechanical tools, such as pliers, compression rings, and the
like. The water resistant material is typically disposed on the
wrapper and acts to invasively fill any spaces or voids after the
closure is wrapped around the signal transmission device. That is,
after wrapping the closure around a splice portion of a signal
transmission device, which connects two or more signal transmission
wires or cables, the closure is compressed to force the water
resistant material into the spaces surrounding the connection
portion. The closure may comprise innumerable geometric shapes and
dimensions, and the shape is preferably chosen such that the
closure can envelope the splice area to encapsulate the splice
region. One skilled in the art, given the benefit of this
disclosure, will be able to select shapes and geometries suitable
for use in wrapping splices of signal transmission devices.
[0015] According to one embodiment of the present invention, the
water resistant material is retained within a flexible delivery
device attached to the wrapper or backing sheet and from which
water resistant material is forced. The delivery device acts to
hold the water resistant material prior to wrapping and compression
of the closure around the splice. The flexible wrapper is of
sufficient dimensions to encircle or otherwise enclose the splice
and, in certain embodiments, is impermeable to the migration of the
encapsulant and/or is water resistant, water impermeable or water
impenetrable. In certain embodiments, the delivery device is a
porous material that retains the water resistant material or is one
or more breakable packages, bags or beads or other container
containing the water resistant material. The delivery device can be
secured to the flexible wrapper using adhesives, epoxies, removable
fasteners such as double-sided tape, Velcro.RTM., and the like.
Also, the delivery device can be adhered to the flexible wrapper by
the water resistant material itself that is contained within the
delivery device. According to one embodiment, the water resistant
material is self-healing, and the self-healing property of the
material allows for the formation of a single mass of water
resistant material with no paths for the ingress of water or other
chemical or biological contaminants. That is, the water resistant
material is chosen such that compression of the water resistant
material results in occupancy of any and/or all spaces or cavities
contained within the closure.
[0016] According to the present invention, the splice is surrounded
by the closure and then the water resistant material is forced into
and around the desired portion of the signal transmission device
(such as a splice), according to one embodiment, by applying
pressure to the closure and, if present, the delivery device, such
as manual pressure or radial force applied by an over-wrapping,
elastomeric media. The water resistant material encapsulates or
otherwise surrounds the splice thereby restricting penetration of
dirt and moisture into the splice and at a location where dirt and
moisture can adversely affect the operation of the conductors in
the signal transmission device. The user can determine the nature
and extent of manual pressure, such as by squeezing by hand, needed
to effectuate the desired amount of water resistant material
required to surround the splice for adequate protection. The
closure can be securely attached to the splice and also covered
with a suitable water or other environmentally or mechanically
resistant covering.
[0017] In accordance with preferred embodiments, the backing sheet
or wrapper comprises a sheet of plastic, rubber, paper, metal, or
other flexible material. Preferably, any material that is capable
of being wrapped around a cylindrically shaped object, such as a
electrical cables, coaxial cables, fiber optic cables, category 5
cables and the like, may be used in the backing sheet. Preferably
the backing sheet or wrapper is a flexible, water impenetrable
material such as polyethylene, polypropylene, rubber and the like.
In certain embodiments, the water resistant material is retained
within a flexible delivery device from which water resistant
material is forced using compression. In preferred embodiments, the
water resistant material is typically any suitable commercially
available gel, grease or encapsulant that is used in the
telecommunications industry as a water resistant material. Examples
of such materials include commercially available lubricants and
greases, such as those available from Nye Lubricants (New Bedford,
Mass.). The water resistant material need not be formulated prior
to application to the splice, such as is the case of commercially
available two part mixtures. The water resistant material typically
is ready for use as deposited on or otherwise connected to the
flexible wrapper or as contained within the delivery device. The
water resistant material may exit the delivery device by the
application of pressure, heat, or other mechanical forces capable
of forcing the water resistant material out of the delivery
device.
[0018] In accordance with preferred embodiments, the delivery
device typically comprises a porous structure suitable for
retaining the water resistant material. Such porous structures
typically have sponge-like properties yet have the ability to
release the water resistant material if compressed. The delivery
device may comprise numerous pores having similar or different
sizes, geometries, and shapes. That is, the number, size, and
geometries of the pores may vary depending on the intended use of
the delivery device and on the properties and characteristics of
the water resistant material to be disposed on or in the delivery
device. Preferably, the delivery device comprises at least about 2
pores per square inch. More preferably the delivery device
comprises about 4 to 50 pores per square inch. In certain
embodiments, the pores preferably have a diameter of less than
about 1 inch, more preferably less than about 0.5 inches, and most
preferably less than about 0.1 inches, for example 0.01 inches or
less. One skilled in the art, given the benefit of the disclosure,
will be able to select suitable pore diameters and sizes depending
on the properties and characteristics of the water resistant
material.
[0019] In accordance with another aspect, a kit is provided that
includes a closure, a water impervious covering and binders for
securing the water impervious covering over the closure. The water
impervious covering can be any commercially available rubber sleeve
or wrapper and the binders can be commercially available tape such
as butyl tape. Additional elements of the kit can include
additional tapes, such as vinyl tape, clamps, cable ties and rigid
enclosures into which the closure is placed. According to the
present invention, the rigid enclosure can be fashioned from
plastic, metal or other rigid material and encloses the splice
protection system of the present invention.
[0020] In accordance with a method aspect, the closure is used to
protect a signal transmission device from dirt and moisture by
application of the closure to the splice area of the signal
transmission device. The method typically comprises contacting and
wrapping the splice with the closure and compressing the closure to
force the water resistant material into voids in the splice. In
certain embodiments, a user positions a splice on the delivery
device and then positions the wrapper around the splice. The user
then applies manual pressure to force the water resistant material
from the delivery device as the wrapper is folded around the
splice. The user then secures the closure around the splice using
tape while continually applying pressure to the closure, for
example manually massaging the closure, in a manner to provide for
maximum distribution of the water resistant material around and
into the splice. The water resistant material advantageously
maintains its properties regardless of the ambient temperature.
Tactile feedback to the user aids in determining the completeness
of the fill of the water resistant material around the splice. The
closure may then be secured to the signal transmission device using
any of the methods and apparatus described here or other suitable
methods known to those skilled in the art.
[0021] Unlike prior, conventional two part systems that require the
user to mix separate solutions to create the gel used to
encapsulate the splice, the closure of the present invention is
particularly advantageous because premixing of the water resistant
material is not required by the user. The present invention avoids
the difficulties of having to mix chemical ingredients in the field
and also eliminates the use of a separate container that surrounds
the splice and into which the mixed chemical system is poured.
Also, certain embodiments of the present invention prevent any
unnecessary hand or component contact with the water resistant
material during application.
[0022] Accordingly, it is an object of the present invention to
provide a simple and easy to use system for the protection of a
signal transmission device from adverse environmental conditions
such as dirt and moisture. It is another object of the present
invention to provide a closure for a splice of a signal
transmission device to protect the splice from adverse
environmental conditions such as dirt and moisture. It is yet
another object of the present invention to provide a system for the
protection of a splice that is directly buried underground or is in
an underground plant. It is still yet another object of the present
invention to provide a system for the protection of a splice that
uses a water resistant material that need not be premixed prior to
application to the splice. It is a further object of the invention
to provide a system for the protection of a splice that allows for
easy determination of completeness of fill prior to burial.
[0023] These and other objects, features and advantages of the
present invention will become apparent from the following
description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Certain preferred embodiments of the invention will be
described below with reference to the attached drawings in
which:
[0025] FIG. 1 is a side perspective view of a closure in accordance
with a first embodiment.
[0026] FIG. 2 is a top view of a closure in accordance with a first
embodiment.
[0027] FIGS. 3a and 3b are cut-away side views of a closure in
accordance with a first embodiment.
[0028] FIG. 4 is a top view showing adhesive disposed on a surface
of a closure in accordance with preferred embodiments.
[0029] FIGS. 5a and 5b are top views of several of many possible
embodiments of a closure in accordance with preferred
embodiments.
[0030] FIG. 6 is a cut-away side view of a closure in accordance
with a second embodiment.
[0031] FIGS. 7a-7c are cut-away side views of a container suitable
for holding a water resistant material and a backing sheet suitable
for receiving a water resistant material in accordance with
preferred embodiments.
[0032] FIGS. 8a-8c are embodiments of the closure comprising a
delivery device.
[0033] FIGS. 9a and 9b are side views of a closure comprising a
delivery device in accordance with preferred embodiments.
[0034] It will be apparent that the closures, signal transmission
devices, and the elements of the closures and signal transmission
devices, shown in FIGS. 1-9 are not necessarily to scale. Certain
dimensions, such as the thickness of the water resistant material,
may have been enlarged relative to other dimensions, such as the
thickness of the protective covering or backing sheet, for clarity
of illustration and ease of understanding.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
[0035] It will be recognized from the above, that the closure
disclosed herein can be assembled and formed using innumerable
materials, shapes, and sizes. The precise sizes and configurations,
including the choice of materials and properties of the wrapper,
water resistant material, protective covering, rigid closure and
delivery devices will depend in large part on the particular
application for which the closure is intended. For convenience in
this more detailed description of certain preferred embodiments,
the closure will generally be of a type suitable for use in
wrapping splices of signal transmission devices, such as the splice
region of two or more drop wires. However, it will be understood by
those skilled in the art that the closures can be used with coaxial
cable splices, mechanical connections between signal transmission
devices, soldered, twisted or metallurgical joints or connections,
fiber optic splices, devices used to make optical connections or
any other application where it is desirable to protect a device
from adverse conditions. It will be within the ability of those
skilled in the art, however, given the benefit of this disclosure,
to select suitable materials and designs, as well as manufacturing
techniques, for production and use of closures in accordance with
the principles of the present invention, suitable for these and
other types of applications.
[0036] In accordance with preferred embodiments, a closure 10
includes a wrapper or backing sheet 12, a water resistant material
14 disposed or otherwise deposited on the wrapper 12, and an
optional protective covering 16 removably disposed on the backing
sheet and covering the water resistant material 14 (see FIG. 1).
The backing sheet 12 typically is formed from a plastic or other
polymeric based material suitable for supporting the water
resistant material 14. In certain embodiments, the backing sheet
comprises polyethylene, polypropylene, rubber and the like. The
backing sheet preferably is substantially flexible to allow for
wrapping of the closure around a cylindrical, rectangular,
circular, or other geometric shape device, such as a splice
resulting from the joining of two or more coaxial cables, a splice
resulting from joining of two or more phone or communication wires,
such as fiber optic cabling, category 5 cabling and the like, etc.
In certain embodiments, the backing sheet is formed from a clear
material, such as a clear, flexible plastic, that allows for
visualization of the splice during the wrapping process (described
below). In other embodiments, the backing sheet is colored or is
opaque. In preferred embodiments the backing sheet comprises a
water impermeable or impenetrable material that will provide added
protection to the splice after wrapping of the splice with the
closure. Suitable water impermeable plastics include polyethylene,
polypropylene, and the like. One skilled in the art, given the
benefit of this disclosure, will be able to select other suitable
clear or colorless and flexible or rigid plastics and polymers
suitable for an intended use of the closure. Examples of suitable
water-resistant materials include greases and lubricants with
similar properties to National Lubricating Grease Institute Greases
in the 0-3 range. Preferably, the water resistant material is
non-flowable and is sufficiently tacky so as to adhere to itself
and the flexible backing sheet and the splice components. In
accordance with preferred embodiments, certain useful water
resistant materials, such as petroleum, silicone or synthetic
greases will exhibit electrical properties that will not
significantly alter or interfere with any signals to be transmitted
using the signal transmission device. Useful water resistant
materials such as petroleum, silicone or synthetic greases will
also not be corrosive to or incompatible with the materials of
construction in the signal transmission device and will operate in
the temperature range of interest. In certain embodiments, these
greases are hydrophobic and water resistant and also optionally
contain elements or ingredients that passivate or absorb water that
may contact the greases. Marine grade greases are also useful
greases and can be stabilized for long-term exposure with
anti-oxidant and anti-fungal additives. Several electrical grade
greases or gels are commercially available as sealers and
insulating materials. One example of a commercially available water
resistant material is Dow Corning 5 Compound. One skilled in the
art, given the benefit of this disclosure, will be able to select
other suitable water resistant materials.
[0037] In accordance with preferred embodiments, the protective
covering 16 is removably disposed on the water resistant material
and is designed to prevent the water resistant material from
directly contacting other physical devices and is also designed to
protect the water resistant material from environmental elements.
The protective covering 16 typically is disposed in a manner to
cover the entire surface of the water resistant material 14 and
removably contacts the backing sheet 12 (see FIG. 2). That is, the
protective covering typically has slightly larger dimensions, e.g.
height, width, and/or thickness, than the planar dimensions of the
water resistant material, and the protective covering may be
attached to the surface of the backing sheet such that the water
resistant material is disposed between the protective covering and
the backing sheet. For example, in embodiments where the water
resistant material is disposed in a generally planar manner on a
planar backing sheet (see FIGS. 1-3), a planar protective covering,
having dimensions larger than the dimensions of the water resistant
material, typically overlies the water resistant material (see
Inset of FIG. 3a). In certain embodiments, the protective covering
is made of a flexible plastic, or other polymeric composition,
which typically is clear, colorless, or colored. In other
embodiments, the protective covering comprises more rigid and less
flexible plastics or other polymeric compositions.
[0038] In accordance with preferred embodiments, the protective
covering typically is removed prior to use of the closure (see FIG.
3b). Because the protective covering is removably disposed on the
water resistant material, the protective covering may be peeled
away to expose the water resistant material preferably without any
of the water resistant material attaching to the peeled away
protective covering (see FIG. 3b). Non-stick coatings, such as
Teflon.RTM., may be deposited onto the surfaces of the protective
covering to prevent any of the water resistant material from
sticking to the protective covering. Therefore, a maximum amount of
water resistant material remains disposed on the backing sheet for
use in enclosing a splice.
[0039] In accordance with preferred embodiments, the protective
covering is typically removed by peeling of the protective covering
from the backing sheet. Attachment of the periphery of the
protective covering to the surface of the backing sheet using an
adhesive, epoxy, double-sided tape, etc., is preferred to
facilitate removal of the protective covering. Therefore, the
protective covering may be removed and subsequently reattached (if
necessary) using the same adhesive on the backing sheet (see FIG.
4). The adhesive is not required to be continuous on the backing
sheet but instead may be deposited intermittently to facilitate
attachment of the protective covering to the backing sheet. For
example, FIG. 4 shows adhesive strips 24 disposed on a backing
sheet 20 that comprises a water resistant material 22. One skilled
in the art, given the benefit of this disclosure, will recognize
that an adhesive, adhesive strips, double-sided tape and the like
need not be attached only to the backing sheet. For example, an
adhesive strip can be attached along the periphery of the
protective covering instead to facilitate attachment of the
protective covering to the backing sheet. Adhesive may also be
attached to both the protective covering strip and the backing
sheet. Additionally, other removable fasteners, such as Velcro.RTM.
and the like, may be used to removably attach the protective
covering to the backing sheet. Such removable fasteners provide for
reuse of the protective coverings. After removal of the protective
covering, the closure may then be used to wrapper a splice for
protection of the splice from environmental and biological
elements. In other embodiments, after the closure is wrapped around
the splice area, the protective coating is wrapped around the
closure and attached using the adhesive fixed to the protective
coating. That is, the protective coating may be wrapped over and
around the closure to provide an additional barrier to prevent
penetration of water or chemical or biological contaminants.
[0040] In accordance with preferred embodiments, the shape of the
closure is not limited to planar or rectangular shapes. That is,
the closure may comprise other suitable dimensions and shapes, such
as a circular backing sheet 30 and a circular protective covering
34 overlying the water resistant material 32 (see FIG. 5a). In
other embodiments, the closure comprises a cross-shaped backing
sheet 40 and a rectangular protective covering 44 overlying the
water resistant material 42. (see FIG. 5b). According to the
cross-shaped embodiment shown in FIG. 5b, the backing sheet or
wrapper 40 has first, second, third, and fourth flaps for wrapping
around a wire or cable splice. Furthermore, certain embodiments of
the wrapper may be cut or tried to a shape suitable for an intended
use. One skilled in the art, given the benefit of this disclosure
will be able to select other suitable shapes and dimensions for an
intended use.
[0041] In accordance with preferred embodiments, the water
resistant material is not required to be deposited or disposed onto
the backing sheet in a planar manner. In certain embodiments, the
water resistant material comprises a generally non-planar irregular
shape 52 disposed on a planar backing sheet 50 (see FIG. 6). An
optional protective covering 54 of suitable shape covers the water
resistant material 52. Because protection of the splice requires
substantially covering the splice with the water resistant
material, numerous shapes and geometries may be designed depending
on the shape of the splice (or splice area) to be covered.
[0042] In accordance with certain embodiments and with reference to
FIGS. 7a-7c, the water resistant material 70 may be initially
located within a protective container 75, or other containing
device, removably attached to the backing sheet 90, which can then
be removed leaving the water resistant material adhered to the
backing sheet. The protective container 70 may be removed with the
water resistant material remaining adhered to the backing sheet 90.
Preferably, the container is coated with a non-stick material, such
as Teflon.RTM. and the like, such that when the container is
removed, the maximum amount of water resistant material is retained
on the backing sheet (see FIG. 7c). The container may comprise any
suitable device for holding the water material, such as a plastic
cup and the like.
[0043] In accordance with preferred embodiments, FIG. 8a is a side
view of a closure according to a second embodiment. The closure 100
comprises a wrapper or backing sheet 102, a delivery device 104
suitable for holding a water resistant material, and a protective
coating 110. As shown in FIG. 8b, delivery device 104 is depicted
as a porous media with a top surface 106 and a bottom surface 108
(See Inset of FIG. 8b). Preferably, the porous media is
open-celled, although closed-celled media such as sponges may have
certain desirable applications. The bottom surface 108 is typically
positioned adjacent to a surface of the wrapper 102. According to
one embodiment, the bottom surface 108 of the delivery device 104
contacts the top surface of the wrapper 102. A water resistant
material 120 is loaded into the delivery device which is adjacent
the wrapper 102 by simply pouring the water resistant material onto
the delivery device or by other means such as a pump, syringe or
other suitable device 130 that is capable of forcing, or injecting
as the case may be, the water resistant material into the pores of
the delivery device 104 such that the water resistant material 120
is retained in the delivery device 104 (see FIGS. 9a and 9b).
Alternatively, the delivery device may simply be allowed to contact
the water resistant material and absorb the water resistant
material into the delivery device. According to one embodiment, the
water resistant material 120 has a tacky consistency so as to
removably adhere to the wrapper 102 to secure the delivery device
104 to the wrapper 102.
[0044] In accordance with preferred embodiments, the porous media
of the delivery device is compressible so that the water resistant
material may be forced from the delivery device upon application of
external pressure. Open-celled porous media is commercially
available from TMP Technologies, Buffalo, N.Y., in the form of a
reticulated foam sheet (RFS) having various sizes, thicknesses and
porosities. As shown in FIGS. 8b and 9a, the delivery device
typically has a rectangular-like shape, although one skilled in the
art, given the benefit of this disclosure, will recognize that the
delivery device can take any shape suitable for use in retaining
and delivering the water resistant material. In certain
embodiments, the porosity of the reticulated foam sheet is at least
about 2 pores per square inch, more preferably about 4 pores per
square inch, for example, between about 4 to about 25 pores per
square inch. One skilled in the art, given the benefit of this
disclosure, will recognize the delivery device can have any
porosity suitable for use to retain and deliver water resistant
materials. The delivery device 104 should be of sufficient length,
width and thickness to retain enough water resistant material 120
to fully surround or otherwise encapsulate the desired splice.
Preferably, the delivery device comprises one or more layers of
porous materials, such as the porous media described above. More
preferably the delivery device comprises two or more layers of
porous materials.
[0045] In accordance with preferred embodiments, the water
resistant material can occupy the delivery device prior to use. In
certain embodiments, the water resistant material has a viscosity
sufficient to resist significant flowing of the water resistant
material from its position on the wrapper. As discussed above,
prior to use of the closure and during shipment or storage, the
closure can have a suitable container or covering disposed on the
water resistant material and removably attached to the backing
sheet. The container can be removed leaving the water resistant
material connected to the wrapper. In certain embodiments, during
shipment or storage, the water resistant material can be contained
within the closure by a flexible sheet that adheres to the wrapper
thereby containing the water resistant material therebetween. The
flexible sheet is removed from the wrapper to reveal the water
resistant material adhered, affixed or otherwise attached to the
wrapper for application to the signal transmission device.
Preferably, the flexible sheet can be peeled away from the wrapper
to reveal the water resistant material prior to usage. In addition
to flexible sheets, other containers can also be used (with or
without a delivery device contained in the container) such as cups
or other receptacles which can constrain or contain a given amount
of water resistant material and which would be removably adhered to
the flexible wrapper. The container is removed leaving the water
resistant material adhered or otherwise disposed on the
wrapper.
[0046] In accordance with preferred embodiments, the wrapper is
preferably flexible and rectangular so that the wrapper can be
configured to the normally substantially cylindrical design of a
signal transmission device or splice connection. In certain
embodiments, the wrapper is a sheet of paper and more particularly,
paper coated with plastic or other suitable material so as to
prevent the water resistant material from seeping or leaking out of
the delivery device. The wrapper is preferably impermeable to the
migration of the water resistant material and maintains flexibility
at the operating temperature range and further meets the signal
carrying standards for the operating cable. For example, a foil
lined paper wrapper, which may be a useful wrapper in certain
applications, may be less advantageous in certain electrical
systems. Similarly, paper wrappers may be advantageous for uses at
low temperatures, and plastic wrappers may be advantageous at
higher temperatures. One skilled in the art, given the benefit of
this disclosure, will be able to select materials for the wrapper
suitable for an intended use.
[0047] In accordance with preferred embodiments, the wrapper also
serves to facilitate retention of the water resistant material
within the delivery device. In certain embodiments, the wrapper can
be made of material that is water resistant or water impenetrable
to prevent the ingress of moisture into the closure. In other
embodiments, the wrapper is made of a suitable material that is
resistant to water and any components contained therein, such as
ionic species contained in seawater. In additional embodiments, the
wrapper is made of a suitable material that is resistant to entry
of gaseous species. Such materials prevent oxidation (or other
chemical reactions) of any conducting materials, such as copper,
semi-conducting materials and the like, contained inside the signal
transmission device. While the wrapper can be made out of plastic
or rubber, paper can be advantageous because it is inexpensive and
typically inelastic. In other embodiments, the wrapper comprises
paper with a plastic coating on one surface of the paper. Depending
on the intended use of the wrapper, the water resistant material
may be in contact with either the paper surface or the plastic
surface. One skilled in the art, given the benefit of this
disclosure, will be able to identify and select other suitable
materials useful as wrappers. The wrapper should preferably be of
sufficient size to support the water resistant material and, if
present, the delivery device, and have enough water resistant
material for wrapping around the signal transmission device at the
desired location, e.g. the splice.
[0048] In accordance with preferred embodiments and as discussed
above, the wrapper may comprise an adhesive material at its
perimeter or edge which allows the wrapper to be self sealing when
surrounding the signal transmission device at the desired location.
That is, in embodiments where the wrapper comprises a self-sealing
material, an external covering or device is not required to attach
the wrapper to the splice area. In certain embodiments, the
adhesive material may be coated along the entire surface of the
wrapper or may be coated intermittently along the surface of the
wrapper. Suitable adhesives are commercially available in the form
of adhesive strips that can be attached to the edges of the wrapper
either in the field at the time of use or at the time of
manufacture. The adhesive material can then be exposed prior to
application to a signal transmission device. Other suitable
adhesives and water resistant adhesives, such as polyvinyl alcohol
adhesives, for example, the Elvanol.RTM. family of adhesives
manufactured by Dupont, may be applied to the wrapper prior to
wrapping the splice. In certain embodiments, such adhesives can
have a dual use. That is, the adhesive may initially function to
maintain the protective covering over the water resistant material
and delivery device. After removal of the protective covering, the
exposed adhesive may then be used to seal the wrapper around the
splice and signal transmission device. One skilled in the art,
given the benefit of this disclosure, will be able to select
suitable adhesives and suitable devices for applying the adhesives,
such as syringes, brushes, and the like, to the wrappers.
[0049] In accordance with preferred embodiments, the delivery
device can be loaded with water resistant material in a manner to
avoid the presence of the water resistant material at the top
surface of the delivery device, i.e. the top surface of the
delivery device is substantially free of the water resistant
material. For example, in certain embodiments, the water resistant
material fills only up to about 80% of the thickness of the
delivery device, preferably only up to about 70% of the thickness
of the delivery device and more preferably only up to about 50% of
the thickness of the delivery device. Because the top surface of
the delivery device is free of the water resistant material, the
splice may be positioned on the top surface and further adjusted
without contacting or disturbing the water resistant material and
otherwise tracking the water resistant material away from the
delivery device. That is, in embodiments, where the delivery device
is not completely filled with water resistant material, the splice
may be positioned above the wrapper without contacting any of the
water resistant material (prior to compression of the closure).
Alternatively, the delivery device can be filled up to 100% of its
thickness and a protective covering made of paper, plastic or other
suitable material may be used to cover the top surface of the
delivery device to retain the water resistant material. The
covering typically is removed prior to use of the closure. In other
embodiments, the device is filled up to about 80% and a protective
covering is used to prevent any loss of the water resistant
material. In preferred embodiments, the porosity of the
open-celled, porous media is sufficient to allow the flow of water
resistant material around the splice when the closure is
compressed.
[0050] In accordance with preferred embodiments, alternative
delivery devices include, but are not limited to breakable bags,
breakable bladders, breakable (imbiber) beads, or other breakable
containers containing the water resistant material and other
breakable media for releasing the water resistant material. In
certain embodiments, the protective covering is breakable such that
application of pressure to the protective covering allows the water
resistant material to squeeze through and surround the splice. That
is, the closure may be wrapped around the splice without removal of
the protective coating and subsequent application of external
pressure to the wrapped closure induces breakage of the protective
covering and sealing of the splice using the water resistant
material.
[0051] In accordance with preferred embodiments, the water
resistant material is loaded into the open celled porous media
delivery device by a suitable pumping device such as any syringe or
caulking device known in the art. According to one embodiment, the
tip of a caulking device is pressed against the open celled porous
media and the water resistant material is forced into the open
celled porous media in a desired amount. In certain embodiments,
the water resistant material is a self-healing conformable gel
adhesive/encapsulant (CGAE) which is unaffected by changes in
temperature. An example of such a gel has a cone penetration value
from about 100 to 350 (10.sup.-1 mm) and an ultimate elongation of
at least about 200%. One skilled in the art, given the benefit of
this disclosure, will be able to select suitable gel
adhesive/encapsulants for use in the closures disclosed here.
[0052] In accordance with preferred embodiments, the open-celled
porous media, having dimensions of about 5".times.5".times.3/4",
can be impregnated with the water resistant material by placing the
porous media into a solution of the water resistant material. The
water resistant material may be a conformable gel that is
preferably self-healing and is retained in the porous media filling
1/2" of the 1/4" depth of the porous media. Once the porous media
has been impregnated with the water resistant material, the porous
media can be attached to the backing sheet, comprising a coated
paper sheet having dimensions of about 10".times.14", with the
unfilled portion of the porous media facing away from the backing
sheet and providing a dry work surface. That is, the top of the
delivery device preferably does not have any water resistant
material disposed on its surface. The attaching of the porous media
to the backing sheet may be accomplished using any number of
suitable adhesives, epoxies, tapes, and the like known to those
skilled in the art. The water resistant material itself may be
tacky enough to provide adherence. Alternatively, the surface of
the backing sheet may be made rough or abrasive or comprise a
suitable surface for facilitating adherence of the water resistant
material. A protective covering having dimensions of about
8".times.12" may be disposed on the delivery device and attached to
the backing sheet.
[0053] In accordance with certain embodiments, a splice of a signal
transmission device is placed on the top surface of a delivery
device of a closure of the present invention. In practice the
spliced wirework including bonding connectors are placed on the
surface of the partially filled, porous media. This surface
typically is dry and allows the constituent components of the
splice to be arranged in any manner desired without either hand or
component contact with the viscous material, e.g. the water
resistant material, contained in the delivery device. The wrapper
is rolled or wrapped around the assembly to bring the compressible,
open cell, porous media into 360.degree. contact with the splice
components. The rolling/wrapping operation is continued until the
porous media is sufficiently compressed to have exuded the water
resistant material into all the voids in the splice. Typically,
tactile confirmation of the completeness of the fill is used to
determine the end of the operation. Taping the completed assembly
with one or more elastomeric tapes provides a continuous radial
force. Optionally, the taped unit is then placed in a secondary
rigid container. In alternative embodiments, the completed assembly
is wrapped with an additional enclosure, such as a rubber sleeve.
The additional enclosure may be fastened with tape or may be
fastened with an adhesive prior to burying the assembly. It should
be noted that the protection of drop wire splices is but one
example of a possible use for this system. The system may have
further use in any application that requires environmental
protection.
[0054] Although the present invention has been described above in
terms of specific embodiments, it is anticipated that other uses,
alterations and modifications thereof will become apparent to those
skilled in the art given the benefit of this disclosure. It is
intended that the following claims be read as covering such
alterations and modifications as fall within the true spirit and
scope of the invention.
* * * * *