GB2474931A

GB2474931A - Watertight electrical connector casing

Info

Publication number: GB2474931A
Application number: GB201017044A
Authority: GB
Inventors: Phillip Andrew Gooch; Jason Chen Mun Mak
Original assignee: Scolmore International Ltd
Current assignee: Scolmore International Ltd
Priority date: 2009-10-12
Filing date: 2010-10-11
Publication date: 2011-05-04
Anticipated expiration: 2030-10-11
Also published as: GB201017044D0; GB0917841D0; GB2474931B

Abstract

A watertight casing (e.g. for garden use) for a connector assembly (e.g. electrical connector) comprises: a back-box 1; an insert 3 (e.g. electrical socket) fitted in the back-box 1 to hold at least part of the connector assembly; a lid 4 which moves between an open position, to allow access to the connector assembly, and a closed position; and a main seal 5 of resilient deformable material positioned so that it forms a watertight seal between the insert 3 and the back-box 1 and between the lid 4 and the back-box 1 when the lid 4 is closed. The lid 4 and back-box 1 cooperate to form at least one opening to accommodate at least one cable such that, when the lid 4 is closed, the casing is watertight, with or without a cable being received in the opening. In another embodiment, the main seal 5 is positioned such that, when in use, it is not exposed to outside elements (e.g. sunlight, rain, etc.). The lid and back-box are provided with respective partial housings 10, 12 that fit together to form a housing to allow the cable(s) to pass through. Complementary elastomeric brushes 7 are located within the housing and the cable(s) pass through the opening between them.

Description

CONNECTOR CASING

This invention relates to a novel water-tight casing, particularly for use with electrical fittings although it could also be used for other media e.g. TV or telecom equipment or any other medium requiring moisture protection.

Casings for outside use, e.g. garden sockets, have been available for years and these aim to be water-tight, as moisture ingress causes damage to the socket and may result in injury to the user. Typically the known casings consist of: 1. A bottom box, closed on the back face, which holds the electric cables and the back of the switch module, 2. An open-faced top box that holds the switch plate, and sits on top of the bottom box, and 3. A hinged lid which covers and seals the front of the top box.

To try to prevent water ingress between the bottom and top boxes there is a seal between them, referred to here as the main seal. For the same reason there is a seal between the lid and the top box, herein referred to as the lid seal.

There are several disadvantages with the known design in that the main seal must be an exact fit, it is exposed to the elements so can deteriorate with time, and its very presence creates a potential leak point for water.

Furthermore, there are three main components to fit together so the product is time-consuming and expensive to make.

According to one aspect of the present invention, there is provided a casing for a connector assembly which comprises a back box, an insert fitted in the back box to hold at least a first part of the connector assembly, a lid moveable between an open position allowing access to the first part of the connector assembly and a closed position where the first part of the connector assembly is covered by the lid, and a main seal of resilient deformable material positioned so that it forms a water-tight seal between the insert and the back box and between the lid and the back box when the lid is closed, arranged so that the lid and the back box cooperate to form at least one opening to accommodate at least one cable such that when the lid is closed the casing is water-tight with or without a cable being received in the opening.

According to another aspect of the present invention, a casing for a connector assembly comprises a back box, an insert fitted in the back box to hold at least a first part of the connector assembly, a lid moveable between an open position allowing access to the first part of the connector assembly and a closed position where the first part of the connector assembly is covered by the lid, a main seal of resilient deformable material positioned so that it forms a water-tight seal between the insert and the back box, a lid seal positioned between the lid and the back box when the lid is closed, arranged so that the lid and the back box cooperate to form at least one opening to accommodate at least one cable such that when the lid is closed the casing is water-tight with or without a cable being received in the opening, characterised in that the main seal is positioned so that when in use it is not exposed to the outside elements. In a preferred embodiment, a single component constitutes the main seal and the lid seal.

The invention is particularly useful where the connector assembly comprises an electric socket into which at least one electric plug fits. The description is directed to that arrangement but it will be appreciated that the invention would be equally applicable to any connector assembly requiring water-resistance e.g. other types of electrical connections or telephone connections.

The invention allows a casing to be constructed having only 2 main casing parts which in use are exposed to the outside elements such as rain, sunlight etc, rather than the 3 main casing parts which are similarly exposed in previously known products. Because the main seal can be positioned so that it is not exposed to the outside elements (e.g. direct sunlight or rain) i.e. is shielded, it will not degrade as fast as it would if it were exposed to those elements. The seal is preferably made from a silicon rubber but there are many other suitable materials known in this technical field for this type of application. By a resilient deformable' material is meant one which will give' when pressed but will then regain its original shape when the source of pressure is removed. Thus in use when the lid presses against the seal it will give' to form a water-tight seal but upon release of the lid it will regain its original configuration.

The casing is preferably of self-supporting substantially rigid construction and of plastic, but may alternatively be made from metal or a composite material e.g. fibre reinforced plastic.

The back box preferably has a plurality of weakened areas which can be removed to allow cables to pass through, with suitable individual seals to prevent water ingress. The closed face of the back box, i.e. the rear-most face for surface-mounting is preferably fitted into a deformable base e.g. of elastomeric material by means of screws in order to provide a seal between the box and the mounting surface.

The insert is preferably in the form of an open frame which may be slid into position within the back box so that at least 50 %, more preferably at least 75% of the insert is contained within the back box. Suitable stops' (e.g. plastic lugs or other protrusions) may be provided in the back box to aid positioning of the insert which may be glued into position in the back box or held by clips or by a press-fit. The edge of the insert preferably protrudes above the back box and the edge which in use will be at the top of the casing preferably is sloped so that any water will be deflected away from the interior.

Attachment means may be provided in the back box and the insert to permit attachment of the connector assembly e.g. aligned screw or bolt holes.

The lid is usually pivotally mounted (e.g. by means of hinge or hinges) at what would be the top of the casing when in use, and may be provided with spring means to bias it to an open or closed position. The external surface of the lid is preferably not flat but curved/sloped to encourage any surface water to run away. Usually the curve or slope would extend at least 25% and more preferably at least 40% of the length of the lid. Additional seals (e.g. complementary rubber brushes) are preferably provided to seal the hinge position between lid and back box. Preferably when the lid is closed it will compress against the main seal. The inner surface of the lid which contacts the main seal when closed is preferably provided with a rib or ribs which will press against the main seal and improve the efficiency of it.

Fastening/latching means is usually provided to connect and release the lid from the bottom box. This is to ensure the lid remains fully in contact with the main seal when the lid is closed and to allow continuation of waterproofing when a cable is in position in the opening. Examples of ways of achieving the fastening/latching means are the use of a sprung catch mechanism, a magnetic catch, a ratchet or clips.

It will be appreciated that certain features of the invention which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are for brevity described in the context of a single embodiment, may also be provided separately or in any suitable combination.

Embodiments of the present invention will now be described with reference to the accompanying drawings in which: Figure 1 is an exploded perspective side view of a casing according to the present invention suitable for a single (1 gang) socket.

Figure 2 is the casing shown in Figure 1 but as a perspective bottom view.

Figure 3 is a perspective view of parts of the casing of Figures 1 and 2, namely the insert and back box.

Figure 4 is a perspective view of the components of Figure 3 fitted together.

Figure 5 is a top view of the assembly in Figure 4.

Figure 6 is a section through Figure 4 but with the lid fitted.

Figure 7 is a sectional view to illustrate the seal made between the lid, insert and back box.

Referring to the drawings, a plastic back box 1 fits on a base 2 by means of screws. A plastic insert 3 is sized so that it slides into the back box 1 until it is seated upon plastic stops in the back box 1 to which it is glued. The insert 3 and back box 1 are provided with corresponding screw holes and screw threads so that part of an electrical connector e.g. the front part of a socket can be screwed into place using screws inserted through thread inserts 8. A curved plastic lid 4 is hinged to the back box 1 by means of a pivot bar 6 held by means of a spring 9 in such a way that the lid is biased to a closed position. The lid 4 has a rib 11 extending around three sides. An elongate main seal 5 of resilient plastic fits between the insert 3 and back box 1 around three sides, so that when the lid 4 is closed the rib 11 corresponds in position to the seal 5. Lid 4 is provided with a partial housing 10 and back box 1 is provided with a partial housing 12 in corresponding positions such that when the lid 4 is closed onto the back box 1 the housings 1 0 and 1 2 fit together to form a housing to allow a cable or cables to pass through. Complementary elastomeric brushes 7 are located within the housing 10/1 2 and the cable passes through the opening between them.

In use, an electrical accessory such as a socket is connected to the electrical supply by removal of a small section of the back box 1-a knock-out'-and fitment of a suitable proprietary water tight connection such as a rubber washer. A knock-out' is a section that has been manufactured in such a way that it can be easily removed without affecting the strength of the back box 1.

Once connected to the supply, the socket is fitted inside the back box 1 by means of screws. A removable connection such as a plug may then be used to connect the socket to an external device by means of a length of cable. The cable is positioned to exit the back box 1 through the opening defined between the elastomeric brushes 7. The lid 4 is designed in such a way that a wide variety of common electrical plugs may be used whilst allowing the lid to be fully closed and hence, maintain the waterproof seal. When the lid 4 is in the closed position, the rib 11 presses and seals against the main seal 5, this provides excellent protection against water ingress. The external curvature of the lid 4 is designed to encourage water to run off rather than collect on the casing and possibly seep inside.

The edge of the insert 3 which in use will be uppermost is sloped so that water entering the casing will be deflected away from the interior and out of the back box 1 at the bottom. The brushes 7 define the opening through which the cable protrudes and are designed to prevent water ingress. Because the main seal 5 is protected from the weather, particularly sun and rain, it is more resistant to degradation and leakage than it would be if it were exposed.

Claims

CLAIMS1. A casing for a connector assembly which comprises a back box, an insert fitted in the back box to hold at least a first part of the connector assembly, a lid moveable between an open position allowing access to the first part of the connector assembly and a closed position where the first part of the connector assembly is covered by the lid, and a main seal of resilient deformable material positioned so that it forms a water-tight seal between the insert and the back box and between the lid and the back box when the lid is closed, arranged so that the lid and the back box cooperate to form at least one opening to accommodate at least one cable such that when the lid is closed the casing is water-tight with or without a cable being received in the opening.
2. A casing for a connector assembly according to claim 1 which comprises an electric socket into which at least one electric plug fits.
3. A casing for a connector assembly according to claim 1 or 2 in which the main seal is positioned so that when in use it is not exposed to the outside elements.
4. A casing for a connector assembly according to any preceding claim in which the casing is of substantially self-supporting rigid construction.
5. A casing for a connector assembly according to any preceding claim in which the insert is in the form of an open frame.
6. A casing for a connector assembly according to any preceding claim in which the insert can be slid into position in the back box.
7. A casing for a connector assembly according to any preceding claim in which stops are provided in the back box to aid positioning of the insert.
8. A casing for a connector assembly according to any preceding claim in which the insert is slid into position within the back box so that at least % of the insert is contained within the back box.
9. A casing for a connector assembly according to any preceding claim in which the insert is slid into position within the back box so that at least 75% of the insert is contained within the back box.
1O.A casing for a connector assembly according to any preceding claim in which the edge of the insert which in use will be at the top of the casing is sloped so that water will be deflected away from the interior.
11.A casing for a connector assembly according to any preceding claim in which the external surface of the lid is curved or sloped to encourage surface water to run away.
1 2. A casing for a connector assembly according to any preceding claim in which the inner surface of the lid which contacts the main seal is provide with at least one rib which when the lid is closed will press against the main seal.
13. A casing for a connector assembly according to claim 1 and substantially as herein described with reference to any one of Figures 1 to 7.
14. A casing for a connector assembly according to claim 1 and substantially as herein described
15. A casing for a connector assembly comprises a back box, an insert fitted in the back box to hold at least a first part of the connector assembly, a lid moveable between an open position allowing access to the first part of the connector assembly and a closed position where the first part of the connector assembly is covered by the lid, a main seal of resilient deformable material positioned so that it forms a water-tight seal between the insert and the back box, a sealing means positioned between the lid and the back box when the lid is closed, arranged so that the lid and the back box cooperate to form at least one opening to accommodate at least one cable such that when the lid is closed the casing is water-tight with or without a cable being received in the opening, characterised in that the main seal is positioned so that when in use it is not exposed to the outside elements. In a preferred embodiment, a single component constitutes the main seal and the sealing means.