We connect conductive aluminum CV cables (cross-linked polyethylene-insulated vinyl sheath cables) to each other. These cable connections may be subject to temperatures as high as 230°C or higher. We need to make these connections in ways that prevent the formation of aluminum oxide, can withstand these high temperatures, and that can remain stable for over 30 years.

Background

We currently use aluminum sleeves to connect conductive aluminum CV cables. We manually apply a compound to the inner surface of the sleeve and to the surface of the aluminum conductive cables, and then polish those surfaces with a wire brush to remove the aluminum oxide film. Then the compound is applied again in order to prevent future aluminum oxide film from forming.

Aluminum sleeve connects aluminum CV cables

Using the compound on cable and connector is labor-intensive and time-consuming, but the compound serves several purposes — it cleans oxide from the aluminum cables and aluminum connectors, and prevents reformation of the oxide.
We cannot continue to use the current compound because it is not stable at the temperatures of 230°C or higher that the connections may reach.

We would like to consider improved compound durable with temperature above 230 °C or some other connection techniques, if your proposed connection technology can eliminate the problem of aluminum oxide and prevent it reforming.

Constraints

  • Must eliminate the problem of aluminum oxide and prevent it from re-forming. Cannot cause the cable to increase its electrical resistance.
  • Must be compatible with conductive aluminum CV cables and not deteriorate the crosslinked polyethylene sheath, ethylene propylene rubber, or silicone rubber.
  • Must withstand and remain stable at temperatures of 230°C or higher. That is, the solution must not undergo a state change, drip, or volatize at temperatures of around 230°C.
  • Must remain stable for more than 30 years.
  • Must cause no environmental issues.
  • Your proposed solution must have a long-term supply.

We would like to discover ready-to-use solutions that can be implemented immediately. However, if your proposed solution is exceptionally promising, we may be willing to undertake joint development.

Possible Solution Areas

  • Chemical or materials technologies.
  • Rust-preventives, aluminum cleaners, lubricants, etc.
  • Aluminum processing-related technologies.

Desired Timeframe

Within 12 months

Field of Use and Intended Application

Electrical connections.

Desired Outcome

Ideally, we would find a connection and aluminum oxide prevention technology that is stable at high temperatures (without undergoing a state change), and without liquefying, dripping, or volatizing. The proposed solution cannot increase electric resistance of the cable or affect crosslinked polyethylene, ethylene propylene rubber, or silicone rubber. It cannot cause environmental issues. The supply of the proposed solution must be long-term.

Previously Attempted Solutions

Grease. Not stable at high temperatures.

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