Compaction of electrical insulation for joining insulated conductors

A method for coupling ends of two insulated conductors, comprising:

• coupling an end portion of a core of a first insulated conductor to an end portion of a core of a second insulated conductor, wherein at least a part of the end portions of the cores are at least partially exposed;
• locating the exposed portions of the cores inside a box with an open top, wherein an end portion of a jacket of the first insulated conductor is located in an opening on a first side of the box and an end portion of a jacket of the second insulated conductor is located in an opening on a second side of the box, the second side of the box being opposite the first side of the box;
• placing electrically insulating powder material into the box;
• inserting a first plunger through the open top of the box;
• applying a force to the first plunger to compact the powder material, wherein an end of the first plunger used to compact the powder material comprises a recess with a shape substantially similar to the shape of the exposed portions of the cores, and wherein the powder material is compacted into compacted powder material that at least partially surrounds a part of the exposed portions of the cores;
• placing additional electrically insulating powder material into the box;
• inserting a second plunger through the open top of the box;
• applying a force to the second plunger to compact the powder material, wherein the powder material is compacted into compacted powder material that surrounds the exposed portions of the cores;
• forming the compacted powder material into a cylindrical shape with an outside diameter similar to an outside diameter of at least one of the insulated conductors;
• and
• placing a sleeve over the compacted powder material and coupling the sleeve to the jackets of the insulated conductors.

A method for coupling ends of two insulated conductors, comprising:

• coupling an end portion of a core of a first insulated conductor to an end portion of a core of a second insulated conductor, wherein at least a part of the end portions of the cores are at least partially exposed;
• locating the exposed portions of the cores inside a box with an open top, wherein an end portion of a jacket of the first insulated conductor is located in an opening on a first side of the box and an end portion of a jacket of the second insulated conductor is located in an opening on a second side of the box, the second side of the box being opposite the first side of the box;
• placing electrically insulating powder material into the box;
• inserting a first plunger through the open top of the box;
• applying a force to the first plunger to compact the powder material, wherein the powder material is compacted into compacted powder material that at least partially surrounds a part of the exposed portions of the cores;
• placing additional electrically insulating powder material into the box;
• inserting a second plunger through the open top of the box;
• applying a force to the second plunger to compact the powder material, wherein an end of the second plunger used to compact the powder material comprises a recess with a shape substantially similar to the shape of the end portions of the jackets, and wherein the powder material is compacted into compacted powder material that surrounds the exposed portions of the cores;
• forming the compacted powder material into a cylindrical shape with an outside diameter similar to an outside diameter of at least one of the insulated conductors;
• and
• placing a sleeve over the compacted powder material and coupling the sleeve to the jackets of the insulated conductors.

A method for coupling ends of two insulated conductors, comprising:

• coupling an end portion of a core of a first insulated conductor to an end portion of a core of a second insulated conductor, wherein at least a part of the end portions of the cores are at least partially exposed;
• locating the exposed portions of the cores inside a box with an open top, wherein an end portion of a jacket of the first insulated conductor is located in an opening on a first side of the box and an end portion of a jacket of the second insulated conductor is located in an opening on a second side of the box, the second side of the box being opposite the first side of the box;
• placing electrically insulating powder material into the box;
• inserting a first plunger through the open top of the box;
• applying a hydraulic force to the first plunger to compact the powder material, wherein the powder material is compacted into compacted powder material that at least partially surrounds a part of the exposed portions of the cores;
• placing additional electrically insulating powder material into the box;
• inserting a second plunger through the open top of the box;
• applying a force to the second plunger to compact the powder material, wherein the powder material is compacted into compacted powder material that surrounds the exposed portions of the cores;
• forming the compacted powder material into a cylindrical shape with an outside diameter similar to an outside diameter of at least one of the insulated conductors;
• and
• placing a sleeve over the compacted powder material and coupling the sleeve to the jackets of the insulated conductors.