Method and apparatus for splicing tubular heater sections

A method of splicing a tubular heater comprising a heatable section and a cold section, said heatable and said cold sections each having an outer sheath with respective first and second ends, said heatable section having a heating element for generating heat and said cold section having a cold pin for conducting an electrical current using a splicing apparatus comprising an enclosure defining a chamber, said enclosure further defining opposed openings in communication with said chamber, at least one welding tip extending into said chamber, said at least one welding tip being capable of melting said cold pin and then welding said first ends of said heatable and cold sections together, comprising the steps of:

• a) directing said first ends of said heatable and cold sections toward each other through respective said opposed openings to a predetermined depth;
• b) placing said at least one welding tip in close proximity with said cold pin;
• c) melting a portion of said cold pin along said first end of said cold section with said at least one welding tip;
• d) pressing said first ends of said heatable section and said cold section together forming a juncture therebetween;
• and
• e) welding along said juncture of said outer sheaths with said at least one welding tip to form a weld joint therebetween.

A system for splicing a tubular heater comprising:

• a tubular heater a heatable section and a cold section, said heatable section having opposing ends including an outer sheath and a heating element, said cold section having opposing ends including an outer sheath and a cold pin,
• a splicing apparatus including an enclosure defining a chamber, said enclosure further defining opposed openings in communication with said chamber for receiving said heatable section in one of said opposed openings and said cold section in the other said opening;
• a roller assembly having first and second rollers, said roller assembly further including a staging portion in communication with said enclosure and a placement portion extending from said staging portion, said first and second rollers being aligned with said opposed openings,
• a platform extending from said enclosure, said platform having a groove formed therein which is aligned with said first and second rollers for carrying said heatable section therealong;
• an actuator resting between said first and second rollers along said placement portion for directing said cold section therealong, and
• at least one welding tip extending into said chamber and capable of melting said cold pin and connecting the ends of said heatable and cold sections together,
• wherein upon respective ends of said heatable and cold sections being placed in each of said opposed openings, said actuator directing said cold section so that said at least one welding tip may be placed in close proximity with said cold pin for forming a molten pool thereon, said ends of said heatable and cold sections then being brought into contact with one another such that said molten pool and said heating element form a connection therebetween as said molten pool solidifies.

A system for splicing a tubular heater comprising:

• a tubular heater including a heatable section and a cold section, said heatable section including an outer sheath having a heating element therein substantially extending the length of said outer sheath, said cold section including an outer sheath having a cold pin therein substantially extending the length of said sheath,
• a splicing apparatus including an enclosure defining a chamber, said enclosure further defining opposed openings in communication with said chamber for receiving one of said heatable section in one of said opposed opening and one of said cold section in the other of said opped opening,
• a platform having a notch formed therein extending from said enclosure,
• first and second rollers having a staging portion in communication with said enclosure and a placement portion extending therefrom in an opposing direction from said platform, said first and second rollers and said notch being aligned with said opposed openings,
• an actuator positioned along said placement portion, and
• a rotatable welding tip and a fixed welding tip extending into said chamber, said rotatable welding tip capable of melting said cold pin, said fixed welding tip capable of welding the ends of said heatable and cold sections together.