Cover assemblies for cables and electrical connections and pre-expanded units and methods including same

A method for forming a connection assembly, the method comprising:

• forming an electrical connection between first and second electrical cables, the first and second cables each including a primary conductor and at least one neutral conductor;
• providing an integral, unitary pre-expanded cover assembly unit including:
• a cover assembly including:
• an elastomeric inner sleeve defining a cable passage to receive the electrical connection and the primary conductors of the first and second cables;
• an elastomeric outer sleeve surrounding the inner sleeve;
• and
• a duct interposed radially between the inner and outer sleeves, the duct defining a duct passage configured to receive at least one of the neutral conductors therethrough;
• and
• a removable holdout mounted within the inner sleeve, wherein the holdout is operative to temporarily maintain the inner sleeve in an expanded state and the outer sleeve in an expanded state, and is removable from within the inner sleeve to permit the inner sleeve and the outer sleeve to contract radially inwardly;
• wherein:
• the duct is flexible;
• and
• the duct is operative to resist radial collapse of the duct and to bend radially inwardly as the holdout is axially removed from the inner sleeve;
• mounting the cover assembly on the cables such that the electrical connection and the primary conductors of the first and second cables extend through the cable passage;
• inserting the at least one neutral conductor of the first cable through the duct passage;
• axially removing the holdout from the inner sleeve such that duct bends radially inwardly as the holdout is removed;
• and
• coupling the at least one neutral conductor of the first cable with the at least one neutral conductor of the second cable.

An integral, unitary cover assembly for covering an electrical connection between first and second electrical cables each having a primary conductor and a neutral conductor, the cover assembly comprising:

• an elastomeric inner sleeve having a sleeve axis and an inner surface defining a cable passage to receive the electrical connection and the primary conductors of the first and second cables;
• an elastomeric outer sleeve surrounding the inner sleeve;
• and
• a duct system including a plurality of ducts disposed in series and interposed radially between the inner and outer sleeves, wherein each of the ducts has a lengthwise axis extending substantially parallel to the sleeve axis, the ducts are arranged serially in end-to-end alignment, and each of the ducts defines a duct passage configured to receive at least one of the neutral conductors therethrough.

A method for forming a connection assembly, the method comprising:

• forming an electrical connection between first and second electrical cables, the first and second cables each including a primary conductor and at least one neutral conductor;
• providing an integral, unitary cover assembly including:
• an elastomeric inner sleeve having a sleeve axis and an inner surface defining a cable passage to receive the electrical connection and the primary conductors of the first and second cables;
• an elastomeric outer sleeve surrounding the inner sleeve;
• and
• a duct system including a plurality of ducts disposed in series and interposed radially between the inner and outer sleeves, wherein each of the ducts has a lengthwise axis extending substantially parallel to the sleeve axis, the ducts are arranged serially in end-to-end alignment, and each of the ducts defines a duct passage configured to receive at least one of the neutral conductors therethrough;
• mounting the cover assembly on the cables such that the electrical connection and the primary conductors of the first and second cables extend through the cable passage;
• inserting the at least one neutral conductor of the first cable through the duct passages of the ducts;
• and
• coupling the at least one neutral conductor of the first cable with the at least one neutral conductor of the second cable.