This invention relates to methods of sealing cables, a seal for a cable, a sealed cable and a cable gland.

Cable glands are commonly used for sealing around a cable or conduit passing through an opening in a wall or bulkhead. For example, cable gland assemblies may be used to seal around a cable entering an enclosure such as a junction box, containing electrical equipment, to prevent fluids entering the enclosure or explosive forces exiting the enclosure. In some instances, cable glands can be used in harsh environments, such as underwater, in high temperatures, or harsh chemical environments.

Typically, a cable gland includes a body, through which the cable passes. The body is formed of a number of parts, that are fixed together to assemble the gland. Each joint can provide a source of leakage. A clamp to grip the cable, and prevent it being pulled out of the gland is provided in the body, along with a number of seals.

In a barrier gland, typically one of the seals may be formed by a settable sealing material that is introduced into a sleeve (or pot) through which the cable passes. The sleeve is then received in the body. During assembly, the settable material is allowed to set in the sleeve. The sleeve is then slid out of the body, to allow inspection of the seal formed around the cable, and then slid back in, before the assembly is continued.

It is possible, and often required where cables run from an environment where combustible gasses may be present to areas which are required to be free of such gasses, to use cables which prevent the flow of gasses or other materials within the cable, between typically the outer sheath and the cores. However, such cables are expensive and complex to manufacture. Less expensive cables are available, but they will potentially allow the flow of such gasses. As such, it is known to use barrier glands in such cases.

According to a first aspect of the invention, we provide a method of sealing a cable, the cable having at least one core and at least one sheath surrounding at least one core, the method acting to seal each core relative to each sheath, the method comprising exposing each core from each sheath to form an exposed part of each core, with an unexposed part of a core remaining with each sheath, positioning the exposed part of each core and the unexposed part of each core within a tube, and filling the tube with a settable sealing material.

Thus, by filling the tube with a settable sealing material, a seal can be made around the cores and the junction between the exposed and unexposed parts of the cores. Thus, this can seal the end of the cable against any gas or other matter travelling within each sheath. The tube can then be sealed in a cable gland, without needing to use a barrier gland.

The tube may be rigid, in that it may have a Young’s modulus greater than 3.5MPa, 3.8MPa or 5MPa. The tube may be transparent, so that it can be seen that the settable sealing material has filled the tube. The tube may be formed of two parts that can be repeatedly separated and reconnected; as such, the step of positioning the parts within the tube can comprise placing the two parts around the exposed and unexposed parts. The two parts can be separate, or can be hinged together, typically via a living hinge moulded into the material of the two parts.

There may also be provided at least one end wall to cap at least one end of the tube and to stop the settable sealing material from escaping. Each end wall may have at least one orifice for the cable or each core.

There may be at least one twisted pair of cores, each twisted pair of cores comprising two cores, twisted around each other, typically in a helix. Each twisted pair may remain twisted through the tube. As such, this allows a twisted pair to be sealed before being passed through a cable gland; at present, most cable glands require that a twisted pair be untwisted, which can deleteriously affect the electronic performance of such a twisted pair.

According to a second aspect of the invention, there is provided a seal for a cable having at least one core and at least one sheath surrounding at least one core, the seal comprising a tube arranged to be placed over an exposed part of each core where the sheath has been removed from around the core and an unexposed part of each core where the sheath surrounds the core, and a settable sealing material arranged to fill the core. The tube may be rigid, in that it may have a Young’s modulus greater than 3.5MPa, 3.8MPa or 5MPa. The tube may be transparent, so that it can be seen that the settable sealing material has filled the tube. The tube may be formed of two parts , split along a length of the tube, that can be repeatedly separated and reconnected. The two parts can be separate, or can be hinged together, typically via a living hinge moulded into the material of the two parts.

There may also be provided at least one end wall to cap at least one end of the tube and to stop the settable sealing material from escaping. Each end wall may have at least one orifice for the cable or each core.

According to a third aspect of the invention, there is provided a cable sealed by the seal of the second aspect of the invention, the cable comprising at least one core and at least one sheath surrounding at least one core, the tube surrounding an exposed part of each core where the sheath has been removed from around the core and an unexposed part of each core where the sheath surrounds the core and being filled with the settable sealing material. The cable may comprise at least one twisted pair of cores, each twisted pair of cores comprising two cores, twisted around each other, typically in a helix. Each twisted pair may remain twisted through the tube. As such, this allows a twisted pair to be sealed before being passed through a cable gland; at present, most cable glands require that a twisted pair be untwisted, which can deleteriously affect the electronic performance of such a twisted pair.

The seal may prevent the flow of gas or other material through the cable between each sheath and each core. According to a fourth aspect of the invention, there is provided a cable gland sealed onto an outer surface of the tube of the sealed cable of the third aspect of the invention.

The cable gland may not be a barrier gland. There now follows, by way of example only, description of embodiments of the invention, described with reference to the accompanying drawings, in which:

Figure 1 shows a perspective view of a seal for a cable in accordance with a first embodiment of the invention;

Figure 2 shows an exploded view of a seal being made with the seal of Figure l ;

Figure 3 shows a plan view of the seal of Figure 1 having been used to make a seal of a cable;

Figures 4 and 5 show perspective cross-sectional views of the seal of Figure 1 in use in two different cable glands; and

Figure 6 shows a cross section through a tube for use in a seal in accordance with a second embodiment of the invention.

In a first embodiment of the invention illustrated in Figures 1 to 5 of the accompanying drawings, we provide a seal for sealing a cable 10. The seal acts to seal an end or part of a cable 10 against the passable of gasses or other matter through the sheaths of a cable 10.

The cable 10 with which this seal can be used can vary depending on the user’s requirements, but will generally be made up of at least an outer sheath 12 surrounding a number of conductive cores 11 each of which may have their own individual insulating sheathes 13. It is desirable to be able to seal the cable 10 against gasses or other material passing through the cable within the sheathes 12, 13, whether at a termination of the cable 10 or along its length.

As such, the seal comprises a tube 1 which can be placed over the cable 10. The tube 1 is formed of rigid plastics material, such as 1 mm thickness polyphenylene sulphide. The tube has first 2 and second 3 ends, with a seal 4 at the second end 3 and the first end 2 being open. The seal 4 has an orifice 5 for the cable 10 to pass through. In use, the tube 1 is placed over the cable 10 at a point where at least the outer sheath 12 has been stripped away from the cores 11, typically leaving the individual core sheathes 14 extant. The tube is then filled with a settable sealing material 6, such as a two part epoxy resin through the first end 2. Because the tube 1 is transparent, it can be verified (as in Figure 3) that the tube 1 is full of the settable sealable material 6. The seal 4 prevents the settable sealing material leaking out of the second end 3.

In an alternative embodiment, the first end 2 can be provided with a seal as for the second end 3, with orifices for each of the cores. This will retain the settable sealing material 6 no matter what orientation is used. The settable sealing material 6 will then need to be introduced into the tube 1 through a conduit, such as a needle piercing the tube 1 wall, with a similar exhaust conduit allowing the escape of air from within the tube 1 as it is filled with settable sealing material 6.

Returning now to the embodiment of Figures 1 to 5, once the settable sealing material sets (whether through the passage of time, or by heat or ultraviolet curing, depending on the material chosen), the cable 10 will be sealed against the passage of gas or other material between the outer sheath 12 and the individual sheaths 14. Thus, lower- quality cables can be used in situation that would otherwise require cables that had been manufactured to be so sealed.

The seal thus formed can be used in several situations. As shown in Figure 2 of the accompanying drawings, the tube is being used at a point along the length of the cable 10, not at an end. This is useful where the cable 10 is not terminating at a cable gland, but is passing through. Furthermore, the cores 11 are formed as twisted pairs. The seal of the present invention does not require that the pairs be untwisted in order to seal them, which can have a deleterious effect on their performance electronically; the settable sealing material 6 will simply flow around the cores 11 whilst they are still twisted.

As shown in Figure 3 of the accompanying drawings, the seal has sealed an end of a cable 10 having three cores 11. The settable sealing material 6 has filled the tube 1 so as to provide visual evidence that there are no voids of the settable sealing material 6. The seal can also be used within cable glands, such that a dedicated barrier gland is not required. Figure 4 of the accompanying drawings shows a cable gland 20 which has a bore 21 in which the tube 1 is placed. Typically, the tube 1 would contain the cable 10 and the settable sealing material, but they are not shown in Figure 4 or 5 for clarity’s sake. Rather than sealing against the cable 10, the cable gland seals against the outside of the tube 1. As such, any convenient cable gland, not necessarily a barrier gland, can be used; in Figure 4, a 501/421 cable gland from Hawke International (a division of Hubbell) of Ashton under Lyne, United Kingdom.

The tube 1 can be accommodated within the seal of any suitable cable gland. In Figure 5 of the accompanying drawings, the cable gland 30 is a “Universal” cable gland, available from Hawke International (a division of Hubbell) of Ashton under Lyne, United Kingdom. In this case, the tube 1 acts to push the gland’s internal seal 31 and seal support 32 radially outwards (as depicted by the bold arrows), which will seal against the outside of the tube 1.

In a second embodiment of the invention shown in Figure 6 of the accompanying drawings, the tube 50 is split along its length into two halves 51 which are semi - circular in cross section. These have cooperating tabs 52 which clip together. As such, an installer can take two halves 51 and clip them around an existing cable that is in need of, say, repair. The cable would need to have had at least the outer sheath(es) stripped back as before. The tube thus formed can be filled with sealable settable material as before, to prevent any transfer of gasses or other materials within the outer sheath(es). As such, this embodiment is particularly useful in “retrofit” situations where it is desired to fit the seal to a pre-existing (rather than newly installed) cable.