Compaction of electrical insulation for joining insulated conductors

1. 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, to form coupled end portions and cores, wherein at least a part of the end portions of the cores are at least partially exposed to form exposed portions;

locating the exposed portions of the cores inside a box, wherein an end portion of a jacket of the first insulated conductor is located in a first conductor opening on a first side of the box and an end portion of a jacket of the second insulated conductor is located in a second conductor opening on a second side of the box;

placing electrically insulating powder material into the box;

providing a first plunger in a first plunger opening of the box;

providing a second plunger in a second plunger opening 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;

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.

2. The method of claim 1 , wherein applying force to the first plunger causes the first plunger and the second plunger to simultaneously move toward a centerline of the cores.

3. The method of claim 1 comprising applying force to the second plunger.

4. The method of claim 3 , comprising applying substantially equal magnitude force to the first plunger and the second plunger.

5. The method of claim 3 , wherein applying the force to the first plunger comprises hydraulically applying a substantially horizontal force in a first direction, and wherein applying the force to the second plunger comprises hydraulically applying a substantially horizontal force in a second direction, substantially opposite the first direction.

6. The method of claim 1 , comprising fitting the end portions of the jackets of the insulated conductors snugly in the respective conductor openings.

7. The method of claim 1 , wherein placing the electrically insulating powder material into the box comprises placing a mixture of magnesium oxide and boron nitride in the box.

8. The method of claim 1 , further comprising repeating the following steps until the compacted powder material surrounds the part of the exposed portions of the cores to a predetermined level and a predetermined amount of compaction;

placing additional electrically insulating powder material into the box; and

applying additional force to the first plunger to compact the additional powder material.

9. The method of claim 1 , wherein forming the compacted powder material into the substantially cylindrical shape comprises removing at least some of the compacted powder material.

10. The method of claim 1 , comprising clamping at least two portions of the box together around the end portions of the insulated conductors.

11. The method of claim 1 , wherein coupling the sleeve to the jackets of the insulated conductors comprises welding the sleeve to the jackets of the insulated conductors.

12. The method of claim 1 , further comprising providing pressure on the sleeve to compress the sleeve into the compacted powder material and further compact the powder material.

13. The method of claim 1 , further comprising coupling one or more strain relief sleeves to at least one of the insulated conductors at or near the sleeve.

14. The method of claim 1 , further comprising exposing the core of at least one of the insulated conductors by removing a portion of an electrical insulator and an outer jacket surrounding the core at an end of at least one of the insulated conductors;

wherein exposing the core precedes coupling the end portion of the core of the first insulated conductor to the end portion of the core of the second insulated conductor.

15. The method of claim 1 , wherein applying the force to the first plunger comprises applying force hydraulically.