A sealing system for forming an environmentally sealed joint with an elongate member includes a tubular substrate, a pre-expanded cover unit, and a flowable sealant. The tubular substrate includes an integral guide feature and defines a substrate bore to receive a portion of the elongate member. The pre-expanded cover unit includes a holdout and a tubular cover sleeve. The holdout includes a helically wound strip forming a tubular holdout body and a rip cord. The holdout body defines a holdout passage extending axially therethrough. The tubular cover sleeve is mounted on the holdout body. The holdout maintains the cover sleeve in a radially elastically expanded state. With the elongate member positioned with a portion thereof extending from the tubular substrate and a layer of the sealant mounted on an outer surface of the tubular substrate and/or on an outer surface of the elongate member, the pre-expandable unit can be mounted around the layer of sealant and the holdout can then be removed from the cover sleeve by withdrawing the rip cord through the holdout passage between the layer of the sealant and the holdout body to remove the holdout body and thereby permit the cover sleeve to radially contract about the tubular substrate and the elongate member, and the guide feature serves to prevent or inhibit the rip cord from contacting the layer of the sealant as the rip cord is withdrawn through the holdout passage.

A method of manufacturing an electrical conductor assembly includes attaching a substrate and at least one electrical conductor to a cable assembly machine, tensioning the substrate, and holding the substrate stationary while wrapping the at least one electrical conductor around the substrate. The at least one electrical conductor is wrapped around the substrate independent of the tension on the substrate.

A tool system for mounting an elastic sleeve includes a holdout tube supporting the elastic sleeve prior to and during mounting, the holdout tube having a longitudinal axis, an interface element movable along the longitudinal axis and transferring pressure onto the elastic sleeve to push the elastic sleeve off the holdout tube during mounting, and an actuation lever engaging the holdout tube at a fulcrum region of the actuation lever. The actuation lever has a pair of load arms partly encompassing the holdout tube. A load region is arranged at a peripheral end of each of the load arms. The actuation lever actuates the interface element by pressing the load regions of the actuation lever against the interface element.

An integral, unitary pre-expanded cover assembly unit for covering an electrical connection between first and second electrical cables each having a primary conductor and a neutral conductor includes a cover assembly, a holdout and a holdout support. The cover assembly includes an elastomeric sleeve and a duct. The elastomeric sleeve defines a cable passage to receive the electrical connection and the primary conductors of the first and second cables. The duct overlies the elastomeric sleeve. The duct defines a duct passage configured to receive at least one of the neutral conductors therethrough. The holdout is removably mounted within the cable passage of the elastomeric sleeve. The holdout defines a holdout passage. The holdout maintains the elastomeric sleeve in an expanded state. The holdout support is removably mounted within the holdout passage. The holdout support reinforces the holdout.

A pre-expanded cover assembly unit for covering an electrical connection between first and second cables includes a cover assembly in a folded state including an elastomeric outer sleeve defining a cable passage to receive the electrical connection. The outer sleeve includes an intermediate section and first and second outer sections. The first outer section is folded at a first annular fold and is on the intermediate section and/or the second outer section. The cover assembly includes a first retention layer between the intermediate section and the first outer section. The cover assembly includes a first friction reducing layer between the first retention layer and the first outer section. The cover assembly unit includes a removable holdout mounted within the outer sleeve. The cover assembly is movable from a folded state to an unfolded state by sliding the first outer section in a first axial direction away from the intermediate section.

An integral, unitary pre-expanded cover assembly unit for covering an electrical connection between first and second electrical cables each having a primary conductor and a neutral conductor includes a cover assembly and a removable holdout. The cover assembly includes an elastomeric inner sleeve, an elastomeric outer sleeve, and a duct. The inner sleeve defines a cable passage to receive the electrical connection and the primary conductors of the first and second cables. The outer sleeve surrounds the inner sleeve. The duct is interposed radially between the inner and outer sleeves. The duct defines a duct passage configured to receive at least one of the neutral conductors therethrough. The holdout is mounted within the inner sleeve. The holdout is operative to temporarily maintain the inner sleeve in an expanded state and the outer sleeve in an expanded state. The duct is flexible. The duct is operative to resist radial collapse of the duct and to bend radially inwardly as the holdout is axially removed from the inner sleeve.

A pre-expanded breakout boot assembly for protecting a cable joint, the cable joint including a trunk and a plurality of cables extending from the trunk, includes a breakout boot assembly and plurality of removable finger holdouts. The breakout boot assembly includes a cold-shrinkable, electrically insulative, elastomeric breakout boot and plurality of finger sealant layers of a conformable medium. The breakout boot includes a tubular main section having an interior surface defining a main passage, and a plurality of tubular fingers extending from an end of the main section, each of the fingers having an interior surface defining a finger interior passage. Each of the finger sealant layers is pre-mounted on the interior surface of a respective one of the fingers. The conformable medium is a flowable material. Each of the finger holdouts is mounted in the finger passage of a respective one of the fingers such that the finger holdout maintains the finger in an elastically radially expanded state, and the finger holdout is selectively removable from the finger to permit the finger to elastically radially contract. Each finger sealant layer is positioned and configured such that, when the pre-expanded cover assembly is positioned on the cable joint with a cable extending through each finger passage, the finger holdouts are removed from the breakout boot assembly, and each finger elastically radially contracts about a respective one of the cables, each finger sealant layer will be radially interposed between each of the interior surface of the finger and the cable extending through the finger.

Provided are devices, methods and systems. A cover system may include a unitary cold shrinkable, tubular, elastomeric cover sleeve defining a cover sleeve through passage that is configured to receive the electrical cable. The cover sleeve may include a first type of stress control element and a second type of stress control element that is different from the first type of stress control element. A holdout maintains the cover sleeve in an expanded state in which the cover sleeve is elastically expanded and when removed, permits the cover sleeve to radially contract to a contracted state about the electrical cable. The first type of stress control element includes a geometric stress cone that includes an electrically conductive and/or semiconductive portion that is configured to conductively engage a semiconductor layer of the electrical cable. The second type of stress control element includes a high-K stress relief element.

A pre-expanded cover assembly for protecting a cable splice connection including a cable, the cable including an electrical conductor surrounded by a cable insulation layer, includes a splice body assembly and a removable holdout. The splice body assembly includes a tubular, cold-shrinkable, electrically insulative, elastomeric splice body having an interior surface defining an interior passage. The splice body assembly further includes a tubular layer of a conformable medium pre-mounted on the interior surface of the splice body. The conformable medium is a flowable material having a high electrical permittivity. The splice body assembly is mounted on the holdout such that the holdout maintains the splice body in an elastically radially expanded state, and the holdout is selectively removable from the splice body to permit the splice body to elastically radially contract. The layer of the conformable medium is positioned and configured such that, when the pre-expanded cover assembly is positioned adjacent the cable splice connection, the holdout is removed from the splice body, and the splice body elastically radially contracts onto the cable splice connection, the layer of the conformable medium will be radially interposed between and engage each of the interior surface of the splice body and an opposing interface surface of the cable insulation.

A cold shrinkable termination has an electric power cable, an insulation body, and a stress control tube. The electric power cable has a conductor core, an insulation layer covering the conductor core, and a conductive shielding layer covering the insulation layer. The insulation body has a first end portion and an opposite second end portion. The stress control tube is disposed in the insulation body adjacent to the second end portion of the insulation body. The stress control tube has a first tube portion directly overlapped on the insulation layer of the electric power cable, and a second tube portion directly overlapped on the conductive shielding layer of the electric power cable and extending a predetermined length thereon when the cold shrinkable termination is mounted on the electric power cable.