GB2465813A - A method and device for repairing and extending cables - Google Patents

A method and device for repairing and extending cables Download PDF

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Publication number
GB2465813A
GB2465813A GB0821944A GB0821944A GB2465813A GB 2465813 A GB2465813 A GB 2465813A GB 0821944 A GB0821944 A GB 0821944A GB 0821944 A GB0821944 A GB 0821944A GB 2465813 A GB2465813 A GB 2465813A
Authority
GB
United Kingdom
Prior art keywords
cables
housing
connector device
cable
setting material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0821944A
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GB0821944D0 (en
Inventor
Rex Edward Michau
Paul Andrew Fish
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB0821944A priority Critical patent/GB2465813A/en
Publication of GB0821944D0 publication Critical patent/GB0821944D0/en
Publication of GB2465813A publication Critical patent/GB2465813A/en
Withdrawn legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/22Bases, e.g. strip, block, panel
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46Bases; Cases
    • H01R13/52Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/521Sealing between contact members and housing, e.g. sealing insert
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/22Bases, e.g. strip, block, panel
    • H01R9/223Insulating enclosures for terminals
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/22Bases, e.g. strip, block, panel
    • H01R9/226Bases, e.g. strip, block, panel comprising a plurality of conductive flat strips providing connection between wires or components
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/14Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for joining or terminating cables
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00Cable fittings
    • H02G15/013Sealing means for cable inlets
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00Cable fittings
    • H02G15/08Cable junctions
    • H02G15/10Cable junctions protected by boxes, e.g. by distribution, connection or junction boxes
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00Cable fittings
    • H02G15/08Cable junctions
    • H02G15/10Cable junctions protected by boxes, e.g. by distribution, connection or junction boxes
    • H02G15/113Boxes split longitudinally in main cable direction
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02Details
    • H02G3/08Distribution boxes; Connection or junction boxes

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Installation Of Indoor Wiring (AREA)

Abstract

A method of repairing an electrical cable such as in a domestic building comprises removing the damaged section of cable, resulting in two cables, and then connecting the ends of the cables with a connector device 1. The connector device 1 is configured to provide an electrical connection between the cables, and ideally may bridge the gap left by removing the damaged section of cable such that the wires can be reconnected even when they cannot be pulled towards each other for example if they are embedded within a wall, floor or ceiling. The connector device 1 comprises a housing 2 for enclosing the ends of the cables and the housing is filled with a setting material so as to set the ends of the cables within the housing 2 for a safe connection. The connector device 1 may also be used to provide a safe connection for extending a cable. The connector device ideally comprises a conductor extending between cable entry openings 12 which may include seals 14. The conductor may be adjustable in length to accommodate varying spaces left by removal of the faulty cable. The housing may comprise of a base 4 and lid 6 having ports 16 for injection of setting material which preferably hardens around the cables to provide strain relief. The housing is provided with mounting means 10.

Description

A METHOD AND DEVICE FOR REPAIRING
AND EXTENDING CABLES
The present invention relates to a connector device for connecting two electrical cables together. The invention also relates to a method of repairing a damaged cable using the connector device and to a method of extending an existing cable using the connector device.
Domestic electrical cables, such as those used to supply power to lights, electrical wall sockets and switches, are often routed through the walls, floors and ceilings of buildings. Such cables are frequently damaged by nailing, screwing or drilling into these structures. Repairing such cables is problematic for two main reasons. Firstly, it is undesirable to completely sever the cable and reconnect the two portions in the wall, floor or ceiling of a building since the connection provides fire and electrocution hazards.
Secondly, removal of the damaged portion of the cable creates a gap that often cannot be bridged by simply pulling the two portions of cable back together and reconnecting them. This is because the portions of the cable are usually embedded in plaster or cement, or are restricted by some other means.
For the above reasons, damaged cables are not repaired. In contrast, the whole of the damaged cable has conventionally been stripped out of the wall, floor or ceiling alt the way back to its power source and then replaced with a new single continuous cable. This obviously requires both skilled and time consuming work.
Similar problems occur to those mentioned above when it is desired to move the location of an existing electrical socket; light, switch or other electrical device.
It is therefore desired to provide an improved method of connecting electrical cables in a building.
The present invention provides a method of connecting electrical cables running through a building comprising: connecting the ends of said cables with a connector device; wherein said connector device is configured to engage an end of each of the two cables and provide an electrical connection therebetween, and wherein the device comprises a housing for enclosing said ends of said cables; said method further comprising filling the housing with a setting material so as to cover the ends of the cables and allowing or causing said material to set to a solid such that said ends of the cables are set within the housing.
The method of the present invention provides a permanent connection between two áables that eliminates the fire and electrocution hazards previously associated with connecting two wires within a building.
Furthermore, when a damaged length of cable is removed the connector device serves to bridge the gap left between the two resulting cables. This is particularly beneficial when the cables are set in plaster or cement, or when their axial movement is restricted or prevented by other means. As such, the present invention eliminates the need to replace the entire cable when it is desired to repair or extend a pre-existing cable in a building power circuit.
According to the preferred embodiments, the method comprises connecting electrical cables in a domestic power circuit. For example, the cables may form part of a lighting circuit, a switch circuit, a power socket circuit or any other type of electrical circuit. Preferably, the electrical cables are cables running through a house and are part of a household circuit.
In the preferred embodiments, each cable comprises a plurality of wires therein. Preferably, each cable comprises live and neutral wires and preferably also an earth wire. Therefore, each cable is preferably a "twin and earth cable" containing only three wires. It will be appreciated that each of the live, neutral and earth wires may be formed from a plurality of filament wires or may instead be a single wire. In the preferred embodiments, the method comprises connecting two low voltage cables.
Each of the above-mentioned cables and/or wires preferably has a dimension transverse to its longitudinal axis of 1.5 cm; 1.2 cm; . 1.0 cm; <0.8 cm; < 0.6 cm; <0.4 cm; <0.2 cm or < 0.1 cm. Preferably, the cables and/or wires therein have a circular or elliptical cross-section.
Preferably, at least the ends of the cables being connected are at least partially embedded in a building material. Preferably, the cables are embedded in a structural element of the building. In the preferred embodiments, at least the ends of the cables are at least partially embedded in a wall, floor or ceiling of the building.
In a particularly preferred set of embodiments, the present invention relates to a method of replacing a damaged or faulty section of an electrical cable. The method comprises locating the damaged or faulty section of the cable and completely severing the cable at the damaged or faulty section, resulting in the provision of two cables. The cable is completely severed at two locations on either side of the damaged or faulty section and the damaged length of cable is removed and discarded. The thus formed two cables have two adjacent ends which must be electrically reconnected.
The method preferably comprises removing a damaged section of cabIehavingalengthof 5mm;10 mm;, 15 mm;20 mm;30 mm;, mm; > 60 mm or> 80 mm. Preferably, the damaged length of cable removed has a length ôf$100 mm; 80 mm; 60 mm; 40 mm; 20 mm; <15 mmor< 10mm.
Preferably, each cable has an outermost cladding which is electrically insulating. Preferably, the wires within the cables also each have an electrically insulating cladding. In the preferred embodiments, the cladding on each cable and wire therein is stripped back so as to expose the ends of the wires in each cable which are to be reconnected.
The ends of the two cables to be connected are placed into the connector device. In the preferred embodiments the cables are inserted into the connector deviôe such that the exposed wires within the cables are in contact with conductors. The conductors electrically connect each wire in one cable with its corresponding wire in the other cable so as to provide electrical continuity between the two cables. Preferably, the connector device is provided with engagement members which are used to grip or clamp the wires in place on the conductors.
In the preferred embodiments the cables are inserted into two opposite sides of the connector device. The electrical conductors preferably extend between the two opposite sides so as to electrically connect the cable wires arranged at a first side of the device with the cable wires arranged at a second opposite side of the device. This embodiment is particularly advantageous when the method involves removing a length of damaged cable as the electrical conductors serve to bridge the gap left by removal of the damaged section. In less preferred embodiments, the wires in the cables may be directly connected to each other within the connector device housing.
Preferably, the connector device comprises cable restraining members for preventing axial movement of the cables relative to the connector device. Therefore, according to the preferred embodiments, the method comprises clamping each cable to the connector device so as to prevent axial movement relative thereto.
In the preferred embodiment the connector device is provided with a base portion and a lid portion. Preferably, the base and lid portions are configured to engage each other so as to form a housing having a cavity therein. In the preferred embodiments, the cables are secured to one of the lid or base portions so as to provide the electrical connection between the cables via the conductors. The lid and base are then engaged so as to form the housing. The lid is preferably then secured to the base. However, in less preferred embodiments the housing is a single-piece housing into which the cables are inserted.
Once the cables have been electrically connected to each other and preferably also clamped to the connector device so as to prevent their axial movement, the housing of the connector device is filled with the setting material. The setting material surrounds the ends of the cables and preferably the exposed wires. Preferably, the setting material fills substantially the whole of the cavity within the housing. Preferably, the method comprises allowing the setting material to set to a solid within the housing. In some embodiments the method comprises activating the setting material so as to cause it to set or to accelerate the rate at which it sets. This may be achieved, for example, by heating the material or by causing a chemical reaction in the setting material. When the setting material is set it mechanically strengthens the physical connection between the two cables and the housing. In the preferred embodiments the setting material is initially in a liquid state and sets to a solid within the housing. Preferably, the setting material is a liquid resin, plastic or polymer and more preferably a quick-setting resin. In less preferred embodiments the setting material may be particulate matter that is caused to fuse together around the cables and set within the housing.
The setting material is preferably an electrically insulating material, at least when it is in its set condition. As such, the material electrically insulates the ends of the cables and the wires therein.
In the preferred embodiments, the setting material is injected or poured into the housing of the connector device through a port. Preferably, the port is arranged in a vertically upper portion of the housing when being filled with the setting material so that the setting material does not leak out of the port.
According to preferred embodiments, at least the ends of the cables to be connected are at least partially embedded in a building material or structure. Preferably, the ends of the cables are at least partially embedded in a wall, floor, ceiling, woodwork, brickwork, plaster, cement or other building material. In these embodiments, the method comprises chasing out the damaged or faulty portion of the cable to be repaired. A slot is then preferably formed in the building material or structure for inserting the connector device into the building material or structure. Preferably, the connector device is secured to the building material or structure within the slot. Screws, nails, rivets, adhesives or any other securing means may be used for securing the connector device. Preferably, the slot is formed such that the connector device is recessed within the material or structure. In the preferred embodiments, once the cables are reconnected and the setting material inserted into the housing then the volume of the slot around and/or over the connector device is filled, e.g. with plaster or other means. The filling is preferably performed until it is flush with the surface of the material or structure in which the ends of the cables and the connector device are embedded.
In less preferred embodiments the ends of the cables are not embedded in a material and the connector device may be secured to the outside surface of a material, e.g. using screws, nails, rivets, adhesives or any other means.
From another aspect the present invention provides a method of repairing, a damaged or faulty section of electrical cable comprising: removing a length of said cable which includes said section; bridging the gap between the two cables created by removal of said length of cable with a connector device such that electrical continuity is provided between the cables, wherein the connector device receives the cables within a housing; and filling the housing with a setting material so as to secure the ends of the cables within the housing.
According to the preferred embodiments, the ends of the cables are not pulled closer towards each other after removal of the damaged length.
According to another set of embodiments, the method comprises extending an existing cable. These embodiments are particularly useful in the event that a light, power socket, switch or any other electrical device is required to be moved from its current location and without having to strip out the whole of the existing cable to replace it.
According to these embodiments, the method comprises locating a first end of an existing cable or severing an existing cable to create a new first end, wherein the second end of the cable is connected to a power source. The method then comprises connecting the first end of the existing cable to the first end of an extension cable using the connector device. The second end of the extension cable is then connected to an electrical device, such as a light, power socket, switch or any other electrical device. This enables the first cable to be extended so that the electrical device can be moved, but without having to strip out the entire original cable and without providing a hazardous connection between two cables.
The embodiments relating to extending an existing cable may include any one or combination of the method steps described above in relation to repairing a damaged orfaultywire.
The connector device which is preferably used in the above-described methods will now be described.
From another aspect the present invention provides a connector device for electrically connecting the ends of two spaced apart electrical cables, said device comprising: a housing having two ports for receiving the ends of the cables and which provides an enclosure for being filled with a setting material in order to set the ends of the cables within the housing; at least one conductor extending in a direction between the ports for electrically connecting the ends of said cables; and mounting means for securing said device to a surface.
In the preferred embodiments the housing is an elongated housing extending longitudinally in a direction between first and second opposing ends. One of said ports is preferably located at each of the opposing ends of the housing such that a cable can be received at each end of the housing.
Preferably, the at least one conductor extends a distance in the direction between the first and second ends of the housing. The conductors preferably extend in this direction by a distance of. 5 mm;? 10mm;? 15 mm; ? 20 mm; > 30 mm; ? 40 mm; 60 mm or> 80 mm. Alternatively, or additionally, the conductors preferably extend a distance in this direction of mm; <80mm; <60mm; <40 mm; <20mm; <15mm or<1O mm.
Similarly, the housing preferably has a length between the cable receiving >80mm;<1O0mm;80mm;60 mm;<40 mm;<2Omm;$.15 mmor< 10mm.
This is particularly advantageous in the event that two cables are to be reconnected after a damaged or faulty section is removed from a cable leaving two cables separated by a gap. It is often not possible to pull the cables towards each other to bridge the gap as the cables may be set in plaster or cement, or movement may be restricted due to other reasons.
The relatively long conductors of the preferred embodiments enable this gap to be bridged without pulling the ends of the cables closer together.
Preferably, the electrical conductors are electrically isolated from each other. As such, the connector device is able to connect cables which each contain multiple wires. According to the preferred embodiments, a plurality of the conductors extend in a direction between the ports for electrically connecting wires within the cables. Preferably, only three conductors are provided which may connect the live, neutral and earth wires in the two cables in the preferred embodiment, commonly known as "twin and earth" cables. The conductors electrically connect each wire in one cable with its corresponding wire in the other cable so as to provide electrical continuity between the two cables.
According to the preferred embodiments, each end of each conductor comprises an engagement portion for engaging the end of a wire in each cable. Preferably, each engagement portion is configured to grip or clamp the wire in place to maintain an electrical connection between the wires at opposite ends of the conductor.
In a preferred set of embodiments the electrical connectors have an adjustable length so as to be able to accommodate different sized gaps between the cables to be connected. Alternatively, the engagement portion on at least one end of each conductor may be slideable along the length of the conductor so as to accommodate different sized gaps.
According to the preferred embodiments the connector device also comprises cable restraining members for restraining the cables from moving axially relative to the connector device. Preferably, the cable restraining members are provided inside of the housing and,preferably adjacent to the ports. Preferably, the restraining members are cable clamps configured to clamp the cables to the connector device.
The housing of the connector device provides an enclosure for filling with the setting material in order to permanently join the ends of the cables.
The housing is preferably configured such that the setting material can surround the ends of the cables within the housing and preferably such that the setting material can fill substantially the whole of the housing.
Accordingly, in the preferred embodiments the housing is substantially sealed when the cables are inserted into the ports. Preferably, seals are provided in the ports which are arranged and configured to provide a seal between the housing and the cables. The seals are preferably a resilient material, such as a polymer or rubber. Preferably, the seals are 0-rings through which the cables are inserted.
In the preferred embodiments, the ports for receiving the cables and/or the apertures through the port seals for receiving the cables have an open area of: 225 mm2; 220 mm2; 175 mm2; < 150 mm2; 125 mm2; mm2; < 75 mm2; 50 mm2; or < 25 mm2.
According to the preferred embodiments, the housing comprises a base portion and a lid portion which are configured to engage each other so as to form the enclosure. The base portion and lid portion are preferably releasable engageble. For example the lid may be screwed to the base or may clip onto the base, although it will be appreciated that any means of releasable engagement may be provided. In the preferred embodiments a seal is also provided around the interface between the lid and base so as to prevent the setting material leaving the housing through the interface.
According to the preferred embodiments the housing is completely sealed apart from at the cable receiving ports. Preferably, the housing has at least one removable portion for removal when filling the housing with the setting material. In the preferred embodiments, one or both of the seals around the cable ports is removable so as to enable filling the enclosure with the setting material when the cables are In place. In another embodiment a seal may be provided on only one of the ports whIch receives a cable so as to allowthe setting material to be Introduced passed the cable In the non-sealed port.
AddItionally, or alternatively, one or more removable portions may be provided In the housing wall at a location other than at the cable ports. For example, In the embodiments having a lid portion the removable portion may be provided In the lid portion. The at least one removable portion Is preferably adjacent to a side wall of the housIng and preferably at the ends of the housing. Thle allows the removable portion to be located at the vertically upper end of the housing In use so that the setting material can be poured or Injected Into the upper part of the housIng. Less preferred embodiments are also contemplated wherein an open filling port Is provided Instead of the removable portion.
The connector device comprises mounting means for mounting the connector to a surface, such as a wall or ceiling. Preferably the mounting means comprises at least one apertured mounting plate and at least one mounting member for securing the mounting plate to the surface through the aperture. The mounting member may be a screw, naIl, tack, rivet, bolt, plug or any other member suItable for securing the mounting plate to the surface through the aperture. In the preferred embodIments a plurality of apertures and mounting members are provided for each mounting plate. In the preferred embodiments mounting plates are provided extendIng from opposite ends of the connector device. Preferably the mounting plates extendfromabaseportlonofthehouslng.
Other embodiments are contemplated whereIn different or addItional mounting means are provided. For example, the connector device may be provided with an adhesIve strIp for securIng the connector device to the surface. It will be appreciated that any mounting means may be provided accordIng to the Invention.
Preferably, the housing is formed from an electrically insulating material. The housing is preferably formed from a plastic and in a particularly preferred embodiments is formed from polycarbonate.
The connector device is preferably configured for connecting cables S together in the methods described above, i.e. for connecting cables in a building and preferably in a domestic power circuit.
In another aspect of the invention, the connector device forms part of a kit with the setting material. Preferably, the setting material is in a liquid or gel state and is configured so as to set to a solid for setting the cables within the housing. The setting material may have any of the features described above and is preferably configured to set to a solid when exposed to air and/or when activated, e.g. by heat or a chemical reaction.
In a less preferred set of embodiments, it is contemplated that the connector device may be used to provide a junction in a power supply cable so that the cable can supply power to two separate electrical devices, such as lights, power sockets or switches etc. Preferably, the power supply cable initially extends to a first electrical device. The method comprises severing the power supply cable and reconnecting the cable with the connector device so as to maintain power supply to the first electrical device.
However, in these embodiments, the connector device is configured to engage the end of a further cable that is connected to a second electrical device, and such that the power supply cable also supplies power to the second electrical device via the further cable. In these embodiments, the end of the further cable is set in the housing by the setting material in the same way that the ends of the other two cables are.
These embodiments enable a new electrical device to be installed by providing a relatively short length of new cable.
In these less preferred embodiments, the housing has a port for receiving the end of a third cable. In these embodiments the electrical conductors also extend to the third port so as to electrically connect the wires in the third cable with their respective wires in the other cables.
-12 -An embodiment of the present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of an electrical connector device according to a preferred embodiment of the present invention; Figure 2 shows a view of the components of the connector device; and Figure 3 shows a view of the inner side of the lid of the electrical device.
Referring to Figure 1, the connector device I comprises an elongated housing 2 formed from a base portion 4 and a lid portion 6. The base 4 has a flat bottom surface which extends beyond first and second opposed ends of the housing to form mounting plates 8. The mounting plates 8 comprise apertures 10 that enable the base 4 to be screwed to a surface behind the connector device 1. The first and second opposed ends of the housing comprise ports 12 for receiving the ends of first and second cables respectively (not shown). The ports 12 comprise resilient seals 14 for sealingly engaging the cables. The lid 6 further comprises removable portions 16 for filling the cavity in the housing 2 with a resin.
Figure 2 shows the components of the connector device I of Figure 1.
Like reference numerals indicate the same components in the figures. The connector device I comprises three conductors 20 for electrically connecting the wires within the first and second cables (not shown). The conductors 20 are elongated members that extend between the ports 12 in a direction between the first and second ends of the housing 2. Each end of each conductor 20 is bent back on itself so as to comprise a horseshoe portion 22, with the open end of the horseshoe 22 at the end of the conductor 20.
The connector device 1 also comprises two attachment members 24 for attaching each of the conductors 20 to the base 4. Each attachment member 24 comprises a box portion 26 through which a horseshoe portion 22 of the conductor 20 is inserted. As such, the horseshoe portions 22 of the conductors 20 are arranged within the box portions 26 of the attachment -13-members 24. The box portion 26 also has a screw-threaded aperture 28 for receiving a screw 30. The attachment members 24 also comprise a foot 32 which engages a foot receiving member 34 on the inner surface of the base 4, so as to couple the conductors 20 to the base portion 4.
The connector device I further comprises cable clamp-plates 36 to be screwed onto clamp-plate receiving members 38 by screws 40 so as to clamp the first and second cables in place. The connector device I comprises seals 14 arranged at the first and second ends of the housing 2.
The seals 14 comprise axial apertures 12a for receiving the cables therethrough and the seals 14 are housed in recessed side walls of the base 4 and lid 6. The seals 14 ensure that the housing 2 is liquid tight when the cables are inserted and the lid 6 is screwed to the base 4 by screws 42.
Seals may also be provided between the remainder of the lid 6 and base 4 interface.
Figure 3 shows a view of the inside of the lid 6. The lid 6 comprises separating members 44 which extend longitudinally between the first and second ends of the housing 2 and which project into the cavity of the housing 2. These separating members 44 serve to separate the conductors from each other when the lid 6 is on the base 4.
A preferred embodiment of the present invention will now be described in which the preferred connector device I is used to repair a cable that is embedded in a wall and which has been damaged by nailing, screwing or drilling into the wall.
Firstly, the wall is recessed in the vicinity of where the damage has been caused in order to expose the damaged portion of the cable. The damaged length of the cable is then cut out, leaving two cables and a gap therebetween. The wall is then cut back to a sufficient size and depth so as to insert the base portion 4 of the connector I behind the cables and to span the gap between the two cables.
Referring back to Figure 2, the base portion 4 of the connector device 1 is screwed to the wall through the apertures 10 in the mounting plates 8.
The ends of the two cables are then inserted through the apertures 12a in -14-the seals 14. The cladding on the ends of the two cables is cut back so as to expose the wires therein and the cladding on the wires is also cut back.
The seals 14 are then placed in the recesses 12 in the end walls such that the cables extend into the housing base 4 and the exposed wires extend into the horseshoe portions 22 of the conductors 20. The horseshoe portions 22 of the conductors 20 are themselves each arranged in a box portion 26 of an attachment member 24. The screws 30 are then screwed into the apertures 28 on the box portions 26 so as to force the horseshoe portions 22 of the conductors 20 to flex and clamp the ends of the exposed wires in the horseshoes 22. The length of the conductors 20 bridges the gap left by removal of the damaged portion of the cable. The cable clamp-plates 36 are then screwed onto the clamp-plate receiving members 38 by screws 40 with the cables arranged therebetween so as to prevent axial movement of the cables relative to the base 4.
One of the removable portions 16 in the lid 6 is removed and the lid 6 is screwed onto the base 4 with screws 42. Quick sethng resin is then injected into the housing 2 so as to fill the housing 2 with resin. The recessed portion of the wall is then plastered over so as to hide the connector device 1 and cables.
It will be appreciated that the same technique can be used to extend an existing cable by connecting a new cable to the end of the existing cable using the technique described above, although it will be appreciated that in this embodiment the new cable would not necessarily already be embedded in the wall. -15-

Claims (22)

  1. Claims: 1. A method of connecting electrical cables running through a building comprising: connecting the ends of said cables with a connector device; wherein said connector device is configured to engage an end of each of the two cables and provide an electrical connection therebetween, and wherein the device comprises a housing for enclosing said ends of said cables; said method further comprising filling the housing with a setting material so as to cover the ends of the cables and allowing or causing said material to set to a solid such that said ends of the cables are set within the housing.
  2. 2. A method as claimed in claim 1, whereinthe cables are electrical cables in a domestic power circuit.
  3. 3. A method as claimed in claim I or 2, comprising inserting the cables into two opposite sides of the connector device.
  4. 4. A method as claimed in any preceding claim, comprising forming a slot in a wall, floor or ceiling of the building and inserting the connector device into slot.
  5. 5. A method as claimed in claim 4, comprising securing the connector device to the wall, floor or ceiling within the slot.
  6. 6. A method as claimed in any preceding claim, comprising inserting the setting material into the housing in a liquid state and wherein said material sets to a solid within the housing. -16-
  7. 7. A method as claimed in any preceding claim, comprising arranging said setting material within said housing so that when it sets it mechanically strengthens the physical connection between the cables and the housing.
  8. 8. A method as claimed in any preceding claim, comprising inserting the setting material into the housing of the connector device through a port in the housing.
  9. 9. A method as claimed in any preceding claim, further comprising locating a damaged or faulty section of a cable and removing a length of the cable including said damaged or faulty section so as to provide said two cables to be connected.
  10. 10. A method as claimed in claim 9, wherein said damaged or faulty section of cable is at least partially embedded in a wall, floor or ceiling of the building prior to removal of the section from the cable.
  11. 11. A method as claimed in claim 9 or 10, wherein the ends of said two cables are not pulled closer towards each other after removal of the damaged or faulty section.
  12. 12. A method as claimed in any of claims 1-8, wherein the method comprises providing an end of an existing cable in the building, providing an end of a new extension cable, and connecting the ends of said existing and extension cables using the connector device.
  13. 13. A method of repairing a damaged or faulty sect;on of electrical cable comprising: removing a length of said cable which includes said section; bridging the gap between the two cables created by removal of said length of cable with a connector device such that electrical continuity is -17-provided between the cables, wherein the connector device receives the cables within a housing; and filling the housing with a setting material so as to secure the ends of the cables within the housing.
  14. 14. A connector device for electrically connecting the ends of two spaced apart electrical cables, said device comprising: a housing having two ports for receiving the ends of the cables and which provides an enclosure for being filled with a setting material in order to set the ends of the cables within the housing; at least one conductor extending in a direction between the ports for electrically connecting the ends of said cables; and mounting means for securing said device to a surface.
  15. 15. A connector device as claimed in claim 14, wherein one of said ports is located in one side of the housing and the other of said ports is located in an opposite side of said housing such that the cables can be received on opposite sides of the housing.
  16. 16. A connector device as claimed in claim 14 or 15, wherein the at least one conductor extends in a direction between the ports by a distance of 10 mm; > 15 mm; >20 mm; >25 mm; >30 mm; >40 mm; >60 mm or> 80 mm.
  17. 17. A connector device as claimed claim 14, 15 or 16, wherein the at least one conductor has an adjustable length so as to be able to accommodate different sized gaps between the cables to be connected.
  18. 18. A connector device as claimed in any of claims 14-17, wherein seals are provided in the ports and which are arranged and configured for providing a seal between the housing and the cables.
    -18 -
  19. 19. A connector device as claimed in any of claims 14-18, wherein the housing is formed by a base portion and a lid portion which are configured to releasably engage each other so as to form the enclosure.
  20. 20. A connector device as claimed in any of claims 14-19, wherein the housing has at least one removable portion for removal when filling the housing with the setting material.
  21. 21. A connector device as claimed in any of claims 14-20, wherein the mounting means comprises at least one apertured mounting plate and at least one mounting member for securing the mounting plate to said surface through the aperture.
  22. 22. A kit comprising a connector device according to any one of claims 14-21 and a setting material for setting the ends of the cables within the housing.
GB0821944A 2008-12-01 2008-12-01 A method and device for repairing and extending cables Withdrawn GB2465813A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0821944A GB2465813A (en) 2008-12-01 2008-12-01 A method and device for repairing and extending cables

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0821944A GB2465813A (en) 2008-12-01 2008-12-01 A method and device for repairing and extending cables

Publications (2)

Publication Number Publication Date
GB0821944D0 GB0821944D0 (en) 2009-01-07
GB2465813A true GB2465813A (en) 2010-06-02

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ID=40262498

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0821944A Withdrawn GB2465813A (en) 2008-12-01 2008-12-01 A method and device for repairing and extending cables

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GB (1) GB2465813A (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB474350A (en) * 1937-04-23 1937-10-29 Robert Valentine Macrory Improvements in or relating to junction boxes for insulated cables
GB1187920A (en) * 1968-04-05 1970-04-15 Greengate & Irwell Rubber Co L Jointing Electric Cables.
US4484022A (en) * 1980-11-05 1984-11-20 Hew-Kabel, Heinz Eilentropp Kg Method of making tensile-, pressure-, and moisture-proof connections
GB2232014A (en) * 1989-01-19 1990-11-28 Reginald John Serpell Electrical cable joint assembly
WO2002029932A1 (en) * 2000-10-06 2002-04-11 Tyco Electronics Uk Ltd Link box and method of manufacturing the same
WO2006055624A2 (en) * 2004-11-20 2006-05-26 Al-Cop Llc Junction failure inhibiting connector

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB474350A (en) * 1937-04-23 1937-10-29 Robert Valentine Macrory Improvements in or relating to junction boxes for insulated cables
GB1187920A (en) * 1968-04-05 1970-04-15 Greengate & Irwell Rubber Co L Jointing Electric Cables.
US4484022A (en) * 1980-11-05 1984-11-20 Hew-Kabel, Heinz Eilentropp Kg Method of making tensile-, pressure-, and moisture-proof connections
GB2232014A (en) * 1989-01-19 1990-11-28 Reginald John Serpell Electrical cable joint assembly
WO2002029932A1 (en) * 2000-10-06 2002-04-11 Tyco Electronics Uk Ltd Link box and method of manufacturing the same
WO2006055624A2 (en) * 2004-11-20 2006-05-26 Al-Cop Llc Junction failure inhibiting connector

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