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, 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, and wherein the part of the exposed portions of the cores surrounded by compacted powder material after compaction with the first plunger comprises about half of the exposed portions;

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.

2. The method of claim 1 , wherein the end portions of the jackets of the insulated conductors fit snugly in the openings in the box.

3. The method of claim 1 , wherein the electrically insulating powder material comprises a mixture of magnesium oxide and boron nitride.

4. 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 desired level and a desired amount of compaction:

placing electrically insulating powder material into the box;

inserting the first plunger through the open top of the box; and

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

5. The method of claim 1 , further comprising repeating the following steps until the compacted powder material surrounds the exposed portions of the cores to a desired level and a desired amount of compaction:

placing electrically insulating powder material into the box;

inserting the second plunger through the open top of the box; and

applying the force to the second plunger to compact the powder material.

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

7. The method of claim 1 , wherein the box comprises at least two portions clamped together around the end portions of the insulated conductors.

8. The method of claim 1 , wherein the sleeve is welded to the jackets of the insulated conductors.

9. The method of claim 1 , 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.

10. The method of claim 1 , 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.

11. 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.

12. 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.

13. The method of claim 1 , wherein at least one of the insulated conductors comprises a core at least partially surrounded by an electrical insulator and an outer jacket, the outer jacket at least partially surrounding the electrical insulator.

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.

15. The method of claim 1 , further comprising forming at least one chamfer on an end portion of at least one of the insulated conductors.

16. The method of claim 1 , further comprising applying the force to the first plunger hydraulically.

17. The method of claim 1 , further comprising applying the force to the second plunger hydraulically.

18. 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.

19. The method of claim 18 , wherein the electrically insulating powder material comprises a mixture of magnesium oxide and boron nitride.

20. The method of claim 18 , wherein at least one of the insulated conductors comprises a core at least partially surrounded by an electrical insulator and an outer jacket, the outer jacket at least partially surrounding the electrical insulator.

21. 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.

22. The method of claim 21 , wherein the electrically insulating powder material comprises a mixture of magnesium oxide and boron nitride.

23. The method of claim 21 , wherein at least one of the insulated conductors comprises a core at least partially surrounded by an electrical insulator and an outer jacket, the outer jacket at least partially surrounding the electrical insulator.

24. 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.

25. The method of claim 24 , wherein the electrically insulating powder material comprises a mixture of magnesium oxide and boron nitride.

26. The method of claim 24 , wherein at least one of the insulated conductors comprises a core at least partially surrounded by an electrical insulator and an outer jacket, the outer jacket at least partially surrounding the electrical insulator.