AU2013203414B2

AU2013203414B2 - Improvements in conduit boxes

Info

Publication number: AU2013203414B2
Application number: AU2013203414A
Authority: AU
Inventors: Roger Donovan
Original assignee: VYNCO INDUSTRIES NZ Ltd
Current assignee: Vynco Industries (nz) Ltd
Priority date: 2012-04-10
Filing date: 2013-04-10
Publication date: 2015-01-29
Anticipated expiration: 2033-04-10
Also published as: AU2013203414A1; WO2013154438A1

Abstract

The invention provides a recloseable box selected from the range of conduit boxes, junction boxes, corner boxes and joiner boxes, for protection of one or more conduit pipes, cables or other elongated objects that are laid upon a structure such as a building; wherein each box has a base capable of being mounted on to a fixed structure such as a wall, and each box has a matching openable and recloseable lid capable of forming a secured covering over the base of the conduit box, and at least two internally connected side apertures providing channels into and out of the box; each aperture being comprised of a portion of the lid and a portion of the base ,f2

Description

IMPROVEMENTS IN CONDUIT BOXES Field of Invention 5 The invention relates to means for protecting cables laid in conduits; the means including joiners, conduit boxes, junction boxes and corner protectors that are used as part of conduits for electrical or fibre optical cabling; and may be applicable to tubing and pipes. Background to the Invention 0 It is often desired, or required by regulations or statutes that electrical wiring shall be contained within a casing; preferably made of insulating material, so that a further safety barrier is placed between the conductors and any outside object. This is particularly required in non-domestic buildings. The term "wiring" includes without limit electrical cables carrying electric power, 5 control wiring, telephone wiring, computer network wiring, coaxial cables such as television or other radio-frequency cables, and also fibre-optic cables. The present invention may also be applicable to pipes carrying air, other gases, or liquids. Stringent regulations apply to some forms of cable. Accordingly, pipes made of a high-impact plastics material are often used to carry wiring from place to place. Where there is a corner or a junction, specially constructed 0 corners or two-way conduit or junction boxes are included between lengths of pipe. Any pipe has a maximum length and must be joined to another. Alternatively, metal pipes, corners and conduit boxes have been used where fire or explosion is a hazard. One problem that arises with wiring installations of this type is that the cables themselves must .5 be threaded through closed apertures, since existing conduit boxes do not have apertures that can be opened so that the apertures are opened along their long axes. They are, topologically speaking, toruses. Existing pipes, and existing two, three or four-way conduit boxes, joiners and connectors cannot open out so that the cable can be simply dropped down so as to lie inside the protective means and then be covered. Each aperture completely surrounds the cable, even 30 if the lid of the conduit box is off. There is no provision to avoid the threading-through action which can be quite tedious in an adverse environment or when the thickness of the cables becomes a tight fit through the holes and passes through with difficulty. Also, fibre-optics cable simply cannot tolerate being bent, even temporarily, around too small a radius. It may not be feasible to revert to a larger size of prior-art conduit box, especially if deadlines are drawing 35 close. The problem is seen as one of overcoming or at least minimising the difficulty of installing 1 wiring within conduits while at the same time retaining all of the safety attributes of the use of conduits, corners and junction boxes. Object of the Invention 5 An object of the present application is to provide a fully openable corner, joiner and conduit box, or at least to provide the public with a useful choice. Summary of the Invention 0 Preferred aspects of the invention are set forth in the appended claims. Particular embodiments are described below in non-limiting terms. In a first embodiment the invention provides a version of conduit boxes, junction boxes and 5 corners or joiners each having a base and a matching lid which may be separated so as to form, topologically speaking, two surfaces against the base surface of which one or more elongated objects may be laid, and then closed again around the object or objects by applying the lid so as to form, topologically speaking, a structure having a toroidal shape having at least one internally connected apertures that encloses at last a part of said one or more elongated objects. 0 More specifically the invention provides a recloseable box selected from the range of conduit boxes, junction boxes, corner boxes and joiner boxes, for protection of one or more conduit pipes, cables or other elongated objects that are laid upon a structure such as a building; wherein each box has a base capable of being mounted on to a fixed structure such as a wall, .5 and each box has a matching openable and recloseable lid capable of forming a secured covering over the base of the conduit box, and at least two internally connected side apertures providing channels into and out of the box; each aperture being comprised of a portion of the lid and a portion of the base. 30 Optionally the base adjacent each aperture includes conduit pipe or cable strapping means. Optionally each aperture includes an externally elongated extension, each extension including a lid portion and a base portion, for sealing around the conduit pipe or cable. 35 Alternatively each aperture includes an internally elongated extension, each extension including a lid portion and a base portion, for sealing around the conduit pipe or cable. 2 In a related embodiment the lid is completely removable and is reversibly secured to the body by use of a fastening means selected from a range including without limitation straps, screws, bolts, and snap fasteners. 5 Optionally the lid is manufactured as an attachment to the body and joined to the body by means of a structural link selected from a range including without limitation a moulded hinge comprised of a thinned layer of a flexible plastics, a moulded flexible strap, and an articulated hinge. 0 In a further embodiment each box comprises a joiner for joining, end to end two lengths of conduit pipe of a standard diameter that carry one or more cables or other elongated objects by enclosing an end of each pipe within a reversibly openable aperture. 5 In a related embodiment the conduit pipes run in a straight line, or, meet at a bend or corner. In one option each box has more than two apertures each capable of receiving and closing over an end of a conduit pipe of a standard diameter. o In a subsidiary embodiment the apertures are of different internal diameters. Optionally any box includes an internal space capable of holding jointing or processing equipment. .5 In a second broad embodiment the invention provides a method for using a conduit box or junction box as previously described in this section including the steps of: mounting the base upon a substrate, placing, one or more conduit pipes, cables or other elongated objects to be protected over the base and against the opened base portion of at least one aperture, 30 optionally of restraining the conduit pipe or cable within the box by means of a conduit pipe or cable strap, and closing the lid around said one or more conduit pipes or cables or other elongated objects so that each aperture is closed around a part of said one or more conduit pipes or cables or other elongated objects. 35 Preferably the apparatus is provided as two at least partially separable parts; one of which 3 serves as a body for the apparatus and includes means for mounting the body on to a fixed structure such as a wall, and a lid which can in one state form a secured covering over said one or more conduit pipes or cables, and in another state can be opened so that said one or more conduit pipes or cables can be laid over the conduit box and into the temporarily exposed 5 channels of the apparatus. In a related embodiment a larger part of the circumference of a circular orifice is comprised of a first partially separable part and a smaller part of the circumference is comprised of the second partially separable part. In one embodiment the larger part includes from 60 to 80% of the 0 circumference (or around 2000 to 3000 for a circular orifice), and the "lip" so formed along the length of the orifice when opened serves when in use as a convenient retainer for conduit pipes or cables. In a subsidiary embodiment the apparatus comprises a conduit box for joining more than two 5 lengths of conduit pipe, including wall mounting means; the conduit box having more than two apertures each capable of receiving and closing over an end of a conduit pipe of a standard diameter. In one option the conduit box has three apertures thereby forming a "T" or three-way 0 conduit box. In another option the conduit box has four apertures thereby forming a four-way or "+" junction. Preferably each box includes one or more pairs of mounting apertures within the base, capable .5 of receiving strapping means (including without limit a cable strap) for conveniently restraining one or more conduit pipes or cables during or after installation. The description of the invention to be provided herein is given purely by way of example and is not to be taken in any way as limiting the scope or extent of the invention. 30 Throughout this specification unless the text requires otherwise, the word "comprise" and variations such as "comprising" or "comprises" will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. Each document, reference, patent application or patent cited 35 in this text is expressly incorporated herein in their entirety by reference. Reference to cited material or information cited in the text should not be understood as a concession that the 4 material or information was part of the common general knowledge or was known in New Zealand or in any other country. Brief Description of the Drawings 5 One or more embodiments of the invention will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which: Figure 1 shows a perspective view of a simple or end-to-end conduit box according 0 to the invention, such as for insertion between lengths of conduit. Figure 2 is an elevation view of the simple conduit box of Fig 1. Figure 3 is a cross section in plan view through the simple conduit box of Fig 1, 5 with internalised receiving means for conduit pipes. Figure 4 is a cross section in plan view of a variant conduit box of Fig 1, with externalised receiving means for conduit pipes. o Figure 5 shows a perspective view of a curved corner protector box according to the invention. Figure 5a shows a cross-section of Fig 5 at lines A-A. .5 Figures 6a-6e show aspects of another style of curved corner protector box. Figure 7 shows a sectional plan view of a four-outlet or " + " conduit box. Detailed Description of Preferred Embodiments of the Invention 30 In this invention, topologically speaking, the prior-art torus through which any conduit pipe, cable or like elongated object must be passed is temporarily divided into two topological surfaces which face each other. In practice, at least one surface is deformed in order to receive the part of the elongated object intended for protection. Then the two surfaces are rejoined around the 35 elongated object. As a result the elongated object does not have to be laboriously passed through the aperture within the torus, starting at a free end. 5 The invention provides a set of conduit boxes, junction boxes and corners or joiners having bases and lids, for mounting and protecting electrical cabling in particular. For a straight or bent corner box the conceptual torus has a single aperture. Conduit boxes providing several outlets are the equivalent of a more complex topology including several apertures. Again, all apertures 5 are split apart during conduit pipe or cable installation. When the lid is removed, part of each aperture is also removed. Conduit boxes according to the invention may include an enlarged central area to contain apparatus such as a cable joint or connector, an in-line amplifier, or other equipment. The point of the invention is to have separable lids and bases that may be opened up to receive middle parts of elongated objects such as conduit pipes or cables within internal 0 grooves and then be sealed again to a legally required effectiveness around the elongated objects, without having to thread a substantial portion of the entire length of the conduit pipe or cable through an unseparable opening. Throughout this description reference will be made to cables. It will be understood that cables 5 are referred to by way of example only and any elongate object, for example conduit pipes, wires, or other piping may be used with the conduit boxes of the invention in similar manner. In a common example in an electrical context, electrical cables may first be threaded through a conduit pipe before the conduit pipe is inserted into the conduit box of the invention. 0 EXAMPLE 1 Fig 1: shows a perspective view of a simple end-to-end dual-aperture conduit box 100 according to the invention, such as for insertion between lengths of conduit. This illustrates the principles of the invention, for which it is evident that the apertures for receiving cables (and .5 conduit pipes) 104 and 105 become completely open if the lid 101 is removed. A cable can be laid straight through and placed between the sides 102 of the box, and later the lid is secured. (It should be noted that for simplicity none of the illustrations include fastening means either for attaching the box to a surface or rail or for fastening the lid to the box. Fastening means will be readily apparent to those skilled in the art, and include screws, glue, fusible (weldable) plastics, 30 tape, and both reversible and non-reversible clips.) This type of conduit box has two apertures 104, 105 each capable of admitting and holding an adjacent end of a conduit (not illustrated). The extension 106 below the lid is intended to match with the remainder of a corresponding aperture such as 104 and form a complete ring when the 35 box is closed. Fig 2: is an elevation view that clearly shows the base of the box. All of Figs 1-4 include an internal constriction 108 which serves to prevent the conduit pipe from being pushed 6 too far through the aperture of the box. Conduit piping comes in a series of standard sizes. In this view the lid 101 includes a projection 106 which may be embellished with a shroud or seal capable of closing off the interior of the box from vermin or dust or water. The flat surface of the lid 101 is a convenient place for a label. In this example this lid is made as a separate item to 5 the body 101 of the box, although it might be moulded as a connected pair of items with a frangible sprue (not shown) or flexible strap (not shown) between the two, so that the installer always has the pair to hand when installing cables and may break them apart at the time of use. It has been found that if a larger part of the circumference of a circular orifice (104) is comprised of a first partially separable part, preferably the base (102), and a smaller part of the 0 circumference is comprised of the other partially separable part; the lid (101), the constriction at the side of the opened orifice helps an installer to hold a cable in place while placing the cable through the box. Preferably the larger part includes from 60 to 80% of the circumference, and Figs 2 and 5a show 75%. This is equivalent to the larger part defining a sector of between around 2000 and 3000 in the case of a circular orifice. More generally, any angle of greater than 5 1800 may help to hold the cable in place. Note that the lid 101 is reversibly secured to the body 102 after the installation is completed and perhaps inspected, by use of a fastening means, not shown, as stated above. The lid can be used to carry a label, and in some cases the lid can be drilled in order to support an indicator 0 lamp, or a control means such as a switch. A translucent lid will allow light from an indicator lamp within to be seen. Fig 3: is a cross section in plan view through the simple end-to-end conduit box of Fig 1. This version has internal receiving means for conduit pipes and thereby consumes the least surface .5 area. There is an internal space 109. A variant is shown in Fig 4: which has externalised receiving means for conduit pipes. This alteration provides the installer with significantly more space for placing ancillary equipment such as wire joining means (crimp terminals or "chocolate strip" connectors), line filters, fibre-optic relays, and the like. 30 Fig 5 shows a more practical design of two-aperture conduit boxes, the corner protector variant 500. This is a perspective view with the lid raised. 504 and 505 are the two apertures, 506 indicates one of two projections or lips from each end of the lid 501, 503 is the base, and 502 is the side wall. This type of corner protector may be provided with a more gentle curve than shown for some applications, such as fibre optic cables or coaxial power cables which lose data 35 or signal if bent too tightly. For ordinary electrical cables the radius of the curve need not be as gradual, although a gentle curve does allow cables to be pulled to and fro, or adjusted, more 7 easily after installation. Note that fastener holes are not shown. Fig 5a shows this type of box in assembled form. The seal may be assured by means of adhesives, ultrasonic welding, or by being screwed together. 5 EXAMPLE 2 Fig 6 which has five parts (6a - 6e) and illustrates a different practical design of the invention, using injection moulding for example. It should be noted that the millimetre dimensions included in Figs 6b, 6c and 6d are by way of example only. Other sizes suit other kinds of cable. Fig 6a o shows in perspective view a sharp 90 degree bend box having a top part 601 and a bottom part 602 both preferably made from injection moulded plastics. Part 602 is secured against part 601 by three screws passed through apertures for instance 603a and 603b. Tightening the screws also secures the cable. Fig 6b shows in elevation view the upper part of the sharp 90 degree bend box. Fig 6c shows in elevation view the lower part of the sharp 90 degree bend box. Note 5 that the upper and the lower parts each have a mating surface and the mating surface of part 601 includes a ridge 604 which fits into a matching groove 605 along the mating surface of part 602. This groove helps in providing a seal. Fig 6d shows a variant of the bottom half 607 in plan view, in which the bend is relatively gradual. Fig 6e shows a perspective view for the top half 608 of the variant of Fig 6d. 0 Fig 7 shows a sectioned plan view of a four-outlet conduit box 700 according to the invention having four internally surrounded channels (internally elongated extensions) (701, 702, 703 and 704). In an elevation view (not shown for this Example, there are again two parts as shown in Figs 1, 2 and 5, so that the cables, pipes or other elongate items can be laid across and into the .5 conduit box at the time of installation (or of maintenance) without threading through closed apertures. Note that aperture 704 is shown, in this example, with a smaller diameter than the other three. This option reflects the possibility that a wiring installation will include a main channel carrying many cables, while a side branch may carry one or a few cables and therefore a thinner conduit pipe is justified. A variety of aperture diameters can be made for any basic box 30 if the cost of different dies supports this; otherwise smaller apertures can be created by the use of part-cylindrical liners. Hole 705 in Fig 7 is for a fastening screw. These drawings illustrate the principles of the invention and most do not include provision for fasteners to attach the conduit boxes to a substrate. The materials from which these boxes may 35 be made include the usual options, such as without limit, cast or moulded plastics, folded or pressed sheet metal, diecast metal, and the like. Injection moulding is a likely manufacturing 8 method. Materials may comprise metals, even ceramic, or durable plastics. Polyvinyl chloride is widely used. VARIATIONS 5 Instead of providing a variety of boxes having different diameter openings, diameter-increasing adaptor collars may be provided for use on the end of any conduit pipes bar the largest of a range, and all apertures are made for that largest diameter. 0 Objects that may be included within each box at a junction include connectors, fuses, control devices and amplifiers, indicator lamps, and so forth. The base may include small holes for receiving a cable restraint such as a cable tie or cable ties, which assists for instance during installation of a network of cables. 5 Each lid may be moulded using a flexible plastics material as a pair with the corresponding base and permanently joined to the base along an edge, so that the lid is retained at all times. This concept of a lidded conduit box may be applied in automotive construction and in boat 0 construction, for example. RESULTS AND ADVANTAGES 1. These conduit boxes do not require a threading process of the cable or cables at the ?5 time of installation. That allows much easier and faster installation or alteration of cabling. 2. Labour costs are substantially reduced and more care can be applied to achieving a strain-free installation. 30 3. Specialised forms of cables, such as coaxial cables and fibre-optic cables can be handled and supported with more care. 4. Such specialised cables can be installed without being cut and rejoined. 35 9 Finally it will be understood that the scope of this invention as described and/or illustrated herein is not limited to the specified embodiments. Those of skill will appreciate that various modifications, additions, known equivalents, and substitutions are possible without departing from the scope and spirit of the invention as set forth in the following claims. 5 10

Claims

1. A recloseable box selected from the range of conduit boxes, junction boxes, corner boxes and joiner boxes, for protection of one or more conduit pipes or cables, selected from a range including electrical cables, optical cables, and pipes that are laid upon a structure such as a building; wherein the box has a base capable of being mounted on to a fixed structure such as a wall, and the box has a matching openable and recloseable lid capable of forming a secured covering over the base of the conduit box, and at least two internally connected side apertures providing channels into and out of the box, each aperture having a perimeter defined by a portion of the lid and a portion of the base; wherein a larger part of the perimeter of at least one of the apertures is defined by either the portion of the lid or the portion of the base.

2. A recloseable box as claimed in claim 1, wherein each aperture includes an externally elongated extension, each extension including a lid portion and a base portion, for sealing around the conduit pipe or cable.

3. A recloseable box as claimed in claim 1, wherein each aperture includes an internally elongated extension, each extension including a lid portion and a base portion, for sealing around the conduit pipe or cable.

4. A recloseable box as claimed in claim 1, wherein at least one of the apertures is circular, and the larger part of the perimeter, being from 60 to 80% of the circumference of the at least one circular aperture is defined by the base, thereby providing a constriction along the length of the opened orifice.

5. A recloseable box as claimed in claim 1, wherein the lid is reversibly secured to the body by use of a fastening means selected from a range including straps, screws, bolts, and snap fasteners.

6. A recloseable box as claimed in claim 1, wherein the lid is manufactured as an attachment to the body and joined to the body by means of a structural link selected from a range including a moulded hinge comprised of a thinned layer of a flexible plastics, a moulded flexible strap, and an articulated hinge. 11

7. A recloseable box as claimed in claim 5 or in claim 6, wherein the box comprises a joiner for joining, end to end two lengths of conduit pipe of a standard diameter that carry one or more conduit pipes or cables, selected from a range including electrical cables, optical cables, and pipes by enclosing an end of each conduit pipe within a reversibly openable aperture.

8. A recloseable box as claimed in claim 7, wherein the pipes run in a straight line.

9. A recloseable box as claimed in claim 7, wherein the box is placed at a bend or corner.

10. A recloseable box as claimed in claim 1, wherein the box has more than two apertures each capable of receiving and closing over an end of a conduit pipe of a standard diameter.

11. A recloseable box as claimed in claim 10, wherein the box has an internal space.

12. A recloseable box as claimed in any previous claim, wherein the base adjacent each aperture includes apertures capable of receiving conduit pipe or cable retaining means.

13. A method for using a recloseable box as claimed in claim 1; including the steps of a) mounting the base upon a substrate, b) placing one or more conduit pipes or cables or other elongated objects to be protected over the base and against the opened base portion of at least one aperture, and c) closing the lid around said one or more conduit pipes or cables or other elongated objects so that each aperture is closed around a part of said one or more conduit pipes or cables or other elongated objects.

14. A method as claimed in claim 13, wherein the conduit pipe or cable is restrained within the box by means of a conduit pipe or cable strap during installation.

15. A recloseable box as illustrated in any one of the accompanying drawings and as described in the accompanying text. 12