GB2529247A - Joint shell - Google Patents

Abstract

A shell holds liquid resin as it cures around an electrical joint. The shell may be biodegradable as it is not needed after the resin has solidified. The shell may have an end cap 38 which is cut off before use to make a cable port. The shell may also have ribs. A sleeve may be provided to hold the shell closed or to package a kit containing the shell and resin. A cover (86, Fig 10) may cover an entry port for the resin and also hold two halves of the shell together. Alternatively the cover may be made from a rupturable panel in the housing. The shell may be provided with tabs (76, Fig 5) which wrap around the other half.

Description

Joint Shell

FIELD:

The present disclosure generally relates to joint shells for electrical joints. More specifically, joint shells made according to some embodiments of the present disclosure may provide a more convenient and user-friendly product which has a lower environmental impact compared with traditional solutions.

BACKGROUND:

Joint shells are frequently used to facilitate the insulating and protecting of exposed electrical connections. The area surrounding medium/low voltage electrical joints is often encased in a specific volume of resin. Examples of suitable resins may include, but are not limited to, polyurethane based resin and acrylic based resin. The resin acts to mechanically protect the joint and associated components -including any exposed cable and associated connectors -against any impacts or external pressure; seal the joint from the environment -preventing the ingress of any dirt or moisture into the joint; and electrically insulate the joint.

In order to produce this encapsulation, a joint shell is installed around the completed joint and liquid resin is poured into the shell. These shells are currently typically made of a thermoplastic material, often ABS or HIPS. The shell keeps the liquid resin in place until it polymerises. The shell serves very little purpose (and thus is functionally obsolete) once the resin has set, as the mechanical, electrical and sealing properties of the joint casing discussed above are suitably provided for by the set resin. However, the set resin is strongly adhered to the shell and so the shell -despite being functionally obsolete once the resin has set -is usually buried or sealed off while the resin is drying, leaving the plastic shell underground.

Thermoplastics such as ABS and HIPS do not readily decompose. As such, the plastic shell may be located underground, providing no function, for a prolonged period of time. It is thus desirable to provide a shell which has less of an environmental impact when buried, while still fulfilling all the necessary functions of a joint shell.

The shipping of joint shell kits is often done in two parts. The joint shell may be packaged with associated electrical connectors and shell sealing components. The resin may be shipped separately in a membrane-compartmentalised bag shipped in a polymer bucket. This bag may allow a user to initiate the reaction which causes the resin to set, by mixing the two resin components, before pouring the mix from the bag.

One of the reasons the resin is shipped separately to the shell is to ensure that, should the polymer shell become damaged during transit, the resin bag will not be ruptured by a sharp fragment or exposed edge of the damaged shell -causing the resin to mix, react and set unintentionally. It is, therefore, desirable to provide a system whereby a joint shell and resin bag can be more reliably shipped together, if required.

Components -in addition to the joint shell and resin -that are often shipped as part of a complete joint kit include: suitable mechanical connectors for making the physical joint between the cables, mechanical/electrical connectors, edge clips, foam sealing strips, mastic tape or compound, heat sink tubing/sleeves, and an instruction leaflet or pamphlet. Kits for some of the larger joints may also require earthing components (conventionally consisting of aluminium collars for the cable, worm drive clips and/or constant force springs).

The packaging required to support the plastic shells and the above associated components and protect them from external or internal impacts is often undesirably high compared to the cost of the shell and resin. It is also desirable to provide a means of more efficiently packaging joint kits.

DESCRIPTION OF SPECIFIC EMBODIMENTS:

Figure 1 is an example of an electrical joint with which embodiments of the present

disclosure may be used;

Figure 2 is a plan view of one embodiment of the present disclosure in an open configuration; Figure 3 is a perspective view of the embodiment of figure 2 in an open configuration; Figure 4 is a side view of the embodiment of figure 2 in an open configuration; Figure 5 is a perspective view of a further embodiment according to the present

disclosure in an open configuration;

Figure 6 is a top view of the embodiment of figureS in an open configuration; Figure 7 is a view of the embodiment of figure 5 in a closed configuration; Figure 8 is an end view of the embodiment of figure 5 in a closed configuration; Figure 9 is a perspective view of the embodiment of figure 5 in a closed configuration; Figure 10 is a further perspective view of the embodiment of figure 5 in a closed configuration; Figure 11 is a partial section view of the embodiment of figure 9; Figure 12 is a perspective view of a further embodiment of the present disclosure; Figure 13 is a section view of the embodiment of figure 12 in a closed configuration; Figure 14 is a further perspective view of the embodiment of figure 12 in a closed configuration; Figure 15 is a perspective view of one part of the shell of the embodiment of figure 12; Figure 16 is a perspective view of the component of figure 15, partially in a shipping or packed configuration; Figure 17 is a perspective view of the embodiment of figure 12 with a sleeve according

to an embodiment of the present disclosure;

Figure 18 is an exploded view of the embodiment of figure 17; Figure 19 is a perspective view of the embodiment of figure 17 with one side of the sleeve removed; Figure 20a and 2Db are views of one part of the sleeve of the embodiment of figure 17; Figure 21a and 21b are views of a further part of the sleeve of the embodiment of figure 17; Figure 22 is a perspective view of the embodiment of figure 12 with a sleeve according

to a further embodiment of the present disclosure;

Figure 23 is an end view of the embodiment of figure 22; and Figure 24 is a plan view of a blank of the sleeve of figure 17.

The term joint, as used herein, may be used to describe a connection between two or more electrical cables. The term joint may additionally be used to describe the termination of a single cable by means of a resin-filled shell. The term joint may be used generally to refer to the area of the electrical connection (or termination) and may be understood to include the exposed electrical wires, all of the components shipped with the jointing kit (as discussed above), any surrounding insulation (e.g. resin) and the casing, as well as a short section of the outer cable or sheath, immediately adjacent to the electrical connection. The terms shell, joint shell and electrical joint shell may all be used interchangeably.

A first embodiment of a shell for use as an electrical joint mould according to the present disclosure may comprise: a body defining a mould cavity; the body having at least one cable port for receiving a cable or an end thereof into the mould cavity; the body further defining an access port to allow entry of resin into the mould cavity; wherein the shell is at least partially made of a biodegradable material..

A joint shell may be placed around an exposed electrical connection and used as a mould to hold liquid resin which, once set, insulates and protects the electrical joint.

The shell may, therefore, comprise a mould cavity which is sufficiently sized so as to contain the exposed electrical components of the joint and also provide space for enough liquid resin to insulate and protect the electrical components. The dimensions of joint shells according to the present disclosure may vary according to the size of joint with which the shell is used (and therefore the size of cables joined).

Embodiments according to the present disclosure may provide for a range of joint shell products, of varying sizes, to accommodate and be used with different sizes of joined cables.

The joint shell may have an open and a closed configuration or arrangement. The open configuration may be for arranging the shell around the joint. The closed configuration may be for arranging the shell to provide an (at least partially) enclosed volume or mould cavity suitable for being filled with liquid resin to seal, protect and insulate the joint. As such, any component or feature associated with a joint shell of an embodiment described herein, may be suitable for or compatible with the joint shell having an open and closed configuration.

The shape of the joint shell according to embodiments of the present disclosure may vary depending on the type of joint required. It is to be understood that the principles taught herein are equally applicable to a wide range of different joint shells. Examples of electrical connections or terminations which may require a joint shell include, but are not limited to: 1-to-i connections; 1-to-2, i-to-3, 1-to-4 etc., connections; 2-to-2, 3-to-3, 4-to-4 etc., connections; and i-to-0 connections. Joint shells and kits may, therefore, be suitable for use with mains, straight, branch, service and pot joints.

Joint shells and kits according to embodiments described herein may be suitable for use with low voltage and medium voltage joints. Joint shells and kits according to embodiments described herein may be suitable for use with specialist cables, e.g. multi-core industrial and VU hazardous area cables (petro-chemical/mining etc.). Multi-core industrial cables may include armoured/unarmoured, multi-cored 0.6/1kV and i.9/3,3kV XLPE/PVC cables. Joint kits suitable for use with multi-core industrial cables may comprise mechanical connectors to cover 1.5 to 400mm2 cable cores.

Joint shells and kits according to the present disclosure may be suitable for use with cable sizes of between i.5mm2 and 400mm2. Joint shells and joint shell kits may be suitable for use with cables up to 630mm2. Joint shells and joint shell kits may be configured for use with cable sizes depending on the application, and may be defined to match a customer's specs and type of cable used.

Joint shells and kits according to the present disclosure may be suitable for all types of existing electrical cable (inc. polymeric, paper etc.). In some instances the joint and kit may be designed and assembled to meet the customer's specific requirements.

Cable ports may be arranged so that the electrical cables to be connected can access the mould cavity. Each cable port may be defined as an aperture in the body.

The number of cable ports may depend upon the type of connection the joint shell is used with. One cable port may be required for each cable that is part of the connection. The cable ports may be sized so as to fit the diameter of the electrical cable. Example sizes of cables are discussed above.

In use (i.e. when the joint shell is installed around the cables), the cable ports and protruding cable section may be wrapped with tape to seal the joint shell at the, or each, cable port. As such, the end portions of the outer sheath of the cables may be roughened, as may the outer surface of each cable port. Each cable port may comprise a closed end or end cap once manufactured. The end cap may need to be removed after manufacturing or before the joint shell is used.

The shell may comprise a body. The body may be separable for defining an open and a closed state. The body may be entirely separable, or partially separable. The body may be largely defined as two or more equivalent parts which combine to make a cavity. Two parts of the body may be connected by means of a hinge or other joint type.

The body may define a hollow mould cavity. The mould cavity may be suitable for being filled with liquid resin for protecting and insulating a joint. The body may be sized so as to be able to enclose the joint and provide ample additional space for sufficient resin to be set around the joint to insulate and protect the joint. The shape of a body according to embodiments of the present disclosure can vary. The body may be any shape which defines a mould cavity suitable for use. Additionally, the body may be of a shape to allow cable ports to be located at locations corresponding to existing cable input locations.

The body may define an access port. An access port may allow a user to fill the shell with resin when the shell is in a closed position. More than one access port may be provided. The access port may allow access to the mould cavity formed by the body, allowing the body to be filled with liquid resin. As such, the access port may be suitable for allowing passage of liquid resin. The access port may aid, by directing or funnelling, the passage of liquid resin into the body.

The access port may be provided on what is, in use, a top surface of the joint shell.

The access port may be a hole or aperture, into the mould cavity. Alternatively, the access port may be a funnel or channel into the mould cavity. The access port may be suitable for being closed or covered. The access port may be closed by rotating a feature such as a panel or disk. The access port may be covered or closed by placing a cover over the access port; as such, the access port may be adapted to support, house or restrain a cover or panel.

The shell may be at least partially made of a biodegradable material.

A material may be considered biodegradable if it meets one or more of a number of criteria.

For instance, a material may be considered biodegradable if it can be broken down by the metabolism of micro-organisms.

A material may be considered biodegradable if it can be digested by micro-organisms.

A material may be considered biodegradable if it will break down into mostly C02, water and organic matter within six months, a year, or 5 years of being put into a composting facility.

A material may be considered biodegradable if it will completely break down and return to nature within a year.

A material may be considered biodegradable if its degradation is caused by biological activity, especially by enzymatic action, leading to a significant change in the chemical structure of the material.

A biodegradable material may comprise a lignocellulosic material.

A biodegradable material may comprise at least one of: recycled paper, wood pulp based, or paper pulp based.

The shell may be at least partially made out of a compostable material.

The shell may be at least partially made out of recycled material. The shell may be at least partially made out of a recycled material mixed with water to form a pulp. The shell may be at least partially made out of post-consumer recycled pulp (e.g. board/paper). This pulp may be made from clean waste from a corrugated board corrugator or clean waste from British Retail Consortium approved paper suppliers.

Alternatively, the shell may be at least partially made of a wood-based pulp. This recycled wood or paper/board pulp may be biodegradable. The material may be 100% recyclable.

The shell may be at least partially made out of a material that fully meets PAS 29 maceration standards.

The shell may be at least partially made out of a lignocellulosic fibrous material. The shell may be at least partially made out of a material which is derived from the cells of wood and/or plants. A lignocellulosic fibrous material may be biodegradable.

The joint shell may be at least partially made out of a carbon neutral material using a carbon neutral process. The joint shell may be at least partially made out of a non-plastic material. The joint shell may be at least partially made out of a non-petroleum based material. The joint shell may be at least partially made out of a natural fibrous material. The joint shell may at least partially be made out of a material that is not a polymer. The joint shell may be made out of a material that is not petroleum based.

The material that the joint shell is at least partially made out of may be a static neutral material.

The shell may be at least partially made out of a material that is compliant with ISO 140000 and the European Green Dot standards.

The shell, the body, the ribs or any component thereof may be at least partially made out of a biodegradable material.

The joint shell, or body thereof, may comprise equal to, or more than 10%, 25%, 50%, 75%, 90%, or 99% by volume or weight of any of the materials discussed herein. The joint shell, or body thereof, may be mostly or entirely made out of any of the materials discussed herein.

The part made out of any of the materials discussed herein may comprise at least 10%, 25%, 50%, 75% or 100% of the jointshell orthe bodythereof.

The joint shell, or body thereof, may be made substantially entirely out of any of the materials discussed herein.

It is to be understood that small traces of dyes or water-resistant materials may be included in the joint shell. A small amount of water-resistant material may be used to coat the shell. The water-resistant material may be wax. Dyes may be included in the shell material for aesthetics. These, and other, minor additives are to be understood to not substantially affect the composition of the joint shell material. Additionally, liquid resin may ingress into or partially permeate through the joint shell during use. Liquid resin which has been partially absorbed by the shell is not considered to form part of the shell's composition in relation to the above discussion.

Furthermore, a pulp moulding process can also utilise, or the pulp may also comprise materials such as feathers, wheat, rice, bamboo and other plant/organic placed products. Such materials may form, and thus be considered as, part of the pulp, rather than additional components. These additives may be biodegradable.

A shell made out of recycled paper, paper mache or cardboard will be lighter than a comparative shell made out of a polymer. As such, shipping costs are reduced, further reducing the environmental footprint of the shell.

A shell made out of paper-based materials may be more forgiving than plastic equivalents. This may enable a user to more easily modify the shell to ensure it is adequate for the respective job. A shell according to the present disclosure may be more readily and easily configured or adapted on-site to accommodate job-specific complications. A shell made out of the materials discussed herein may be more forgiving than plastic equivalents. This may enable a user to more easily prepare the joint for its respective job. Service apertures could be cut with a knife as opposed to a saw.

Additionally, a more malleable and impact resistant shell may allow the shell to be used as an item of packaging. The shell may package a number of the other components.

The shell may be configured so as to support, encase or protect other joint components. The body of the shell may be used to hold and protect the bag of liquid resin during packaging and shipping. The shell may support connectors during shipping. The shell may house components during shipping. This feature of shells according to the present embodiment is enabled through the use of materials with better shock-absorption properties than previously. Shells according to the present disclosure may also not splinter or crack and form sharp edges in the event that they are damaged.

A shell made out of some of the materials described herein (e.g. paper pulp, wood pulp etc.) may be more flexible than traditional plastic shells. Plastic shells are rigid and thus susceptible to breakages when deformed under impact/load. The material could shatter, crack and/or splinter, exposing sharp edges that could rupture a bag of liquid resin during transit. This would not happen with any of the present embodiments.

Embodiments of the present disclosure may be less likely to break during shipping and would not leave sharp edges if they were to break. Additionally, the shell may be better at providing padding and absorbing shock during shipping, further protecting a bag of liquid resin.

The joint shell and the body as a whole may be impermeable so as to prevent liquid resin from being absorbed by, or passing through, the joint shell. The joint shell may be impermeable. The joint shell may be slightly permeable. The joint shell may absorb a small amount of liquid -for example rain caught in the shell during installation, or liquid released from the ground during installation -such that the liquid does not form a pool at the bottom of the mould cavity, which could result in an absence of resin at that point (and a potential source of weakness). Joint shells made out of paper-based materials may absorb a small amount of liquid. Joint shells made out of paper-based materials may absorb a small amount of liquid but not let resin soak through, or leave the joint shell. Joint shells made out of paper-based materials may absorb a small amount of water so that rain caught in the shell during installation, or liquid released from the ground during installation, does not sit in the bottom of the shell to mix with the liquid resin, but is rather absorbed by the shell.

The shell may be made using standard manufacturing processes for the material of manufacture. For example, shells according to the present disclosure may be made using the transfer mould" process, wherein the product is formed by transferring a material to be moulded, under compression, into a mould from which it is transferred.

The shell may comprise at least one rib. The shell may comprise at least one rib, protruding from the body.

The body may comprise at least one rib.

The ribs may be elongated protrusions. The ribs may be reinforcing members. The ribs may run substantially horizontally or vertically. The ribs may run substantially longitudinally or hoop-wise, if the shell is considered a cylinder. The ribs may protrude from the body, and may protrude from the outer and/or inner surface of the body. The ribs may protrude from the outer or inner surface of the mould cavity.

The ribs may provide structural rigidity, i.e. the ribs may allow the joint shell to be self-supporting (e.g. the shell can be placed on a flat surface and hold shape).

The shell may comprise at least one hollow for supporting at least one connector.

A hollow may define a recess, hole or vacancy in the outer surface of the shell, e.g. body. A hollow may be shaped so as to grip a corresponding connector or other component. A hollow may be shaped to locate a corresponding connector or other component.

A hollow may accommodate or support other components required in creating and maintaining an electrical joint.

A hollow may be defined with respect to the ribs, and will be referred to as a cut-out. At least one of the ribs may comprise at least one cut-out. The at least one hollow may be a cut-out in at least one of the ribs. The ribs may comprise at least one cut-out. A cut-out may be suitable for supporting connectors. A cut-out may require the adaptation of a single rib, or of a plurality of ribs. A cut-out may be adapted to support joint components other than connectors. A cut-out may be a reduction in height (the distance of protrusion) of a rib, or multiple ribs. A cut-out may be a reduction in width of a rib, or multiple ribs. A cut-out may coincide with, or be a hollow to provide sufficient space to support a connector or other component.

A shell may comprise two, four, six or more than 6 hollows. A shell may comprise two, four, six or more than 6 cut-outs.

A shell may further comprise a cover for covering the access port.

A cover, when in a closed position, may close the access port. A cover may seal the access port The cover may be shaped so as to rest over the access port, which may be in the form of an aperture or hole. Alternatively, the cover may be shaped so as to close an access port which is in the form of a funnel.

The cover may rest on top of the access port, preventing liquid of debris from falling into the joint shell. Alternatively, the cover may provide a more robust seal; the cover may have a friction fit with the access port. The cover may be restrained relative to the access port by means of locking tabs or methods that would be apparent to a skilled reader.

The cover may be independent and removable from the joint shell or may be part of, integral, or connected to the joint shell.

A cover may be adapted so as to prevent the joint shell from going from a closed configuration to an open configuration while the cover is in place. A cover may prevent shell parts from separating from each other.

The body may comprise a rupturable access panel which can be removed to form the access port, the access panel forming the cover once removed.

The rupturable access panel may be manufactured so as to be integral with the shell, particularly the body. The rupturable access panel may be capable of being removed from the body. The rupturable access panel may be cut from the body. Removal of the rupturable access panel may produce an opening or aperture. The opening or aperture may form the access port. A cover may be formed by all, or part of, a panel removed from the body. The removed panel may then be used as a cover, and may be rested on the access port (e.g. hole or aperture) to act as a cover and prevent debris or liquid from unintentionally entering the body.

The rupturable panel may be shaped so that, once removed, it can be rested on the hole created and not fall into the body. The removed panel may be substantially roof-shaped. The removed panel may be a trapezoidal prism. The removed panel may be inverted before being able to locate on the access port.

The shell may comprise at least two cable ports, at least one on each of two substantially opposite sides of the shell.

The shell may comprise more or less than two cable ports. The cable ports may be located so as to correspond to each cable in a respective cable arrangement.

The body may be separable into at least two sections. The body may comprise at least two separable sections.

The body may be separable into two, three, four or more than four sections. The body may be separable into multiple sections to allow the shell body to enclose the electrical connection. The body may be separable so as to open the mould cavity to locate the electrical joint inside the mould cavity. Separable refers to the ability of the body to be separated from a single cavity-forming shape, to allow the body to open and be located around the connection.

The shell may comprise at least two separable parts. Each part may comprise a section of the body.

The shell may comprise two, three, four or more than four parts. The shell may comprise multiple parts to allow the shell to be set to an open configuration, in which it can be arranged to surround the joint, before being moved to a closed position. Each shell part may comprise a body section. There may the same number of shell parts as body sections.

The parts of the shell may be completely independent of each other. The parts may be arranged so as to be openable, or suitable for opening to allow the shell to be positioned around a joint.

The shell may be at least partially separable into at least two parts, each part comprising a body section.

Separable may be used to mean that the sections and parts of the body and shell are completely independent of each other, or that the two sections/parts are arranged so as to be openable, or suitable for opening to allow the shell to be positioned around a joint.

At least two of the shell parts may be connected by means of a hinge or fold line.

At least two of the body sections may be connected by means of a hinge or fold line.

The separable parts of the shell or sections of the body may be interconnected by means of a hinge or fold line. The hinge or fold line may be directly connected to either, both, or all of the shell parts and/or body sections, or may be indirectly connected to the shell parts and/or body sections by means of a panel, flange or extension part.

The hinge or fold line may be provided as a folding or bendable region, rather than a line per se.

The hinge or fold may allow the body sections or shell parts to be sufficiently moved apart or separated, for the body to be positioned around a joint, before being closed again to provide a substantially closed shell.

At least one shell part may comprise a rim extending out from at least part of the circumference of its respective body section.

The rim may constitute the panel, flange or extension part separating the hinge or fold line from the body of the parts, discussed above.

A rim may extend from the entire circumference of the edge of the body section of the part. Alternatively, the rim may extend from only a portion of the body section. The rim may extend from only a portion of the body section and be in the form of a tab.

A rim may provide a surface on which a further part may rest or against which a further part may abut. Alternatively, the rim may facilitate easier handling by a user. A rim may comprise text, e.g. instructions. A rim may comprise further informative features such as a rule or scale for use when making the joint or connection.

At least two shell parts may comprise a rim.

The at least two rims may abut when the parts are together, i.e. when the shell is in a closed configuration. The two rims may be apart when the shell is in an open configuration. Each rim may be according to the discussion above or below.

A rim may comprise interlocking features. Each rim may comprise interlocking features.

The rim may comprise a profile. Each rim may comprise a profile. The profile may be an interlocking feature. The profile may interlock with a rim, a further profile, or the edge of the body of a further part against which it abuts. Every rim may comprise a profile, suitable for interlocking with profiles on a neighbouring part when the shell is in a closed configuration.

A profile, or two mutually engaging profiles on neighbouring parts, may be configured so as to provide a friction fit. Profiles may therefore be adapted to ensure that once the parts of the shell are interlocked, or connected (thus the shell being in a closed configuration), they do not come apart (thus putting the shell in an open configuration) without being pulled apart.

A shell part may comprise a locking tab. Each shell part may comprise a locking tab.

A joint shell part may comprise one, two, three, four or more than four locking tabs. A locking tab may be rectangular, elongated, triangular or part circular. A body section may comprise a locking tab.

The locking tab may enable shell parts to be kept in a closed, or abutting, configuration.

The locking tab may enable body sections to be kept in a closed, or abutting, configuration. A locking tab may be connected to the body, a rim, or any other part of a shell part or body section. A locking tab may be arranged at any position on a joint shell part or body section. A locking tab may be positioned so as to be adjacent a neighbouring joint shell part or body section when the shell is in a closed configuration.

A locking tab may comprise a fold line. A locking tab may be configured to wrap around a neighbouring joint shell part or body section to restrain the neighbouring part or section with respect to the tab-comprising part or section. A locking tab may comprise a locking means or device which may interact with a further locking tab, rim or profile on a neighbouring joint shell part or body section.

A locking tab may comprise two fold lines.

A first portion of a tab may be connected to the body or rim of a part of the joint shell by way of a first fold line. A second portion of the tab may be connected to the first portion by means of a second fold line. The second fold line may be arranged perpendicularly to the first. The second tab portion may be arranged adjacent the first tab portion and the body or rim to which the first tab portion is connected.

The first tab portion, located on a first joint shell part or body portion, may be configured so that when the joint shell is in a closed configuration, the first tab portion can be arranged to be adjacent a neighbouring joint shell part or body section by folding the first line. The second tab portion may be arranged such that when the second fold line is then folded, the second tab portion is arranged adjacent the first joint shell part or body section.

A cover, when in use, may prevent at least two of the shell parts or body sections from separating. The cover may prevent the at least two shell parts or body sections from separating.

A cover may be arranged so that it prevents at least two shell parts or body portions from separating when it is in position covering an access port. A cover may comprise an outer lip which can act to retain at least two shell parts or body portions in a closed configuration. A cover may comprise alternative means to keep the shell in a closed configuration, for example a clip, tab and slot or fastener.

Further methods of maintaining the shell in a closed configuration, without the need of tabs or rims may include using an elastic band, a tie strap, separate clips or interlocking components; all of which are felt to be within the scope of the present disclosure. Alternatively a sleeve may be used to maintain the shell in a closed configuration.

Also according to some embodiments of the present disclosure is a kit comprising at least two joint shell parts suitable for making a shell as described herein. The kit may comprise any of the components listed herein as being required to form a joint shell.

The kit may comprise two, three, four, or more than four shell parts configured to form a joint shell as described anywhere herein.

Embodiments described herein may also provide a sleeve suitable for at least partially enclosing an electrical joint shell.

Embodiments may also provide a sleeve for at least partially enclosing a shell as described anywhere herein.

Embodiments may also define a sleeve suitable for at least partially enclosing a kit as described anywhere herein.

A sleeve according to any embodiments describe herein may allow access to the access port and each cable pod.

A sleeve may comprise a thin jacket-type surround for a shell.

A sleeve may be adapted to prevent a shell from opening when in use. A sleeve may be adapted to prevent the two shell pads or body podions from moving away from each other when the shell is in a closed configuration.

Access to access pods and/or cable pods may be achieved by means of a hole in the sleeve, a specific design to not encroach upon the region of the access pod and/or cable pod, or simply a removable section of the sleeve.

The sleeve may be substantially tubular. The sleeve may have two open ends. The sleeve may comprise one, two, or three holes which may provide access to an access pod.

The sleeve may be at least partially made out of paper, card or plastic.

The sleeve may be at least partially made out of recyclable materials. The sleeve may be at least padially made out of corrugated cardboard. The sleeve may be entirely made out of the same material.

The sleeve may be adapted to retain a shell as described anywhere herein in a closed configuration.

The sleeve may, when in an in-use position installed around the joint shell, prevent the shell from opening. The sleeve may be sized so that, when in use, the sleeve does not permit the movement required for separation of parts of the shell or sections of the body, or the movement required for the shell to enter an open configuration. The sleeve may be adapted to prevent liquid resin from leaking out of the joint shell due to the shell parts or body sections separating from each other.

The sleeve may be sized so as to only fit on or around the shell when the shell is in a closed configuration. The sleeve may be adapted to incorporate a tightening means or device allowing the sleeve to be tightened around the shell.

The sleeve may be adapted to retain at least one joint component against a shell. The shell may be as described anywhere herein.

The sleeve may be adapted so it can be used as packaging during shipping. The sleeve may be suitable for containing the shell, liquid resin and/or other components.

The sleeve may be suitable for holding joint components e.g. connectors against the exterior of the shell. The sleeve may be suitable for preventing joint components from moving relative to the shell.

A joint component may refer to any item used to create the electrical cable joint and may refer to any of the components described above as potentially being shipped with and/or required for manufacture of a joint. Examples of joint components may include a bag of liquid resin, connectors and tools required to produce the joint. A joint component may be considered to be any item which may be shipped with a cable joint kit described herein.

The sleeve may be adapted to, when in use, hold a joint component against the outer surface of the joint shell or a joint shell part. A joint component may, therefore, be sandwiched between the sleeve and the joint shell or part.

The sleeve may be used to support and retain a joint component. The sleeve may be used to support and retain more than one joint component. This may be useful for when the joint shell, or joint shell kit, is being packaged and shipped. The sleeve may be used to package the joint shell kit, which may contain a joint shell, a bag of resin (which may be stored in the joint shell) and one or a number of joint components, which are stored on the outside of the joint shell and held in place by the sleeve.

A sleeve may be used as a quality control measure -thus a sleeve may only be put on a joint shell kit for sending once all the other components have been included in the kit and it is ready to be shipped. A sleeve may be the packaging or container for a joint shell or a joint shell kit.

A sleeve may be used as an anti-tamper measure, wherein if the sleeve has been removed and/or damaged, an end user of the joint shell or joint shell kit may know that the shell or kit has been opened, damaged or tampered with.

The sleeve may be suitable for keeping a joint component located in a hollow or cut out on the joint shell surface. The sleeve may hold the joint component(s) in position, in a hollow or cut out of the joint shell, joint shell body or ribs thereon.

A sleeve may comprise at least two sleeve parts.

A sleeve may comprise two, three, four or more than four parts. The sleeve parts may be separate or interlinked. The sleeve parts may be separable. The sleeve being in a plurality of sleeve parts may simplify manufacture, storage or assembly of the sleeve.

Each part of the sleeve may be folded flat. Each part of the sleeve may be suitable for being flat packed. A sleeve may be folded flat. The sleeve or each sleeve part may be configured to fold flat.

Each part of the sleeve may be substantially tubular. Each sleeve part may comprise a substantially hollow interior, for housing the joint shell. Each sleeve part may comprise two open ends. One end may be suitable for encircling a cable and, in use, may be located by a cable port. The other end may be larger, and be suitable for encircling a shell or a body-portion thereof.

A sleeve may be in the form of a large number of separate components, each defining a thin strip of the sleeve.

Each sleeve part may comprise an interlocking device, for fixing the sleeve part relative to a second sleeve part.

Each sleeve part may comprise two, three, four or more than four interlocking devices.

Each interlocking device may be suitable for cooperating with an interlocking device of a neighbouring part, in order to keep the sleeve in a closed, or engaged, position during use.

Each interlocking device may comprise a hook or slot, adapted to interact with a hook or slot of a neighbouring sleeve part when in use. Each interlocking device may be arranged towards the end of a sleeve part.

Each sleeve part may be substantially tubular.

Each sleeve part may comprise a substantially tubular body with two ends. The two ends may be open. The first end may be for housing a cable which runs into the tubular body. The second end may be suitable for encircling the shell or shell body.

The second end may be adapted to interlock with a further sleeve part. The further sleeve part may be identical to the first.

Each part of the sleeve may be adapted to be located around an end of an electrical cable when the sleeve is not enclosing the joint shell.

Each sleeve part may be adapted to slide onto a cable to be connected, before the cables are connected. Once the cables are connected, each sleeve part may slide down its respective cable towards the joint. Each sleeve part may then meet and interlock with the other sleeve part(s) over the joint.

Embodiments disclosed herein may also provide a kit comprising a shell as described anywhere herein, liquid resin and at least one connector for joining electric power cables or wires. A kit may comprise any of items described as being part of an electrical jointing kit, Embodiments disclosed herein may also provide a kit comprising a shell as described anywhere herein, liquid resin, at least one connector for joining electric power cables or wires and a sleeve as described anywhere herein.

Embodiments disclosed herein may also cover a method of manufacturing a shell as described herein made of paper pulp, comprising pulping paper into paper pulp, moulding the paper pulp into a shell as described herein and drying the shell.

A further embodiment disclosed herein may comprise a method of manufacturing a shell as described herein made of paper pulp, the method comprising: mixing paper cuttings with water, thereby creating a pulp; compressing enough pulp in a mould to form a shell; at least partially drying the shell; releasing the shell from the mould; and placing the shell in an oven to cure.

The material process used may comprise mixing paper strands/cuttings with hot water and allowing the two to mix to create a pulp. The paper and water may be churned in a large mixing drum. Dyes and/or wax can be added to the mix to create colouring and/or enhance the water proof properties. This may create a slurry of paper pulp.

The pulp may then be used in the transfer mould process, in which a forming tool (made from a fine mesh) may suck up some pulp from a slurry and then compress the pulp via another forming tool. The amount of "some" pulp depends upon the desired size of the shell. The amount of pulp sucked up is enough to enable to the shell to be produced. The compression may remove excess water and moisture from the pulp, drying it and causing it to harden. The product may then be released from the tools and placed in an oven to cure (stiffen).

Embodiments disclosed herein may cover a shell for use as an electrical joint mould, the shell comprising: a body; at least one cable port for receiving a cable or an end thereof; at least one access port. The shell may comprise at least one rib. The shell may comprise at least one hollow for supporting at least one connector. A rib may comprise at least one cut-out. The at least one hollow may be a cut-out. The cut-outs may be suitable for supporting connectors. The shell may further comprise a cover for covering the access port. The access port may comprise a rupturable access panel which can be removed to provide an access port, the access panel forming the cover once removed.

An embodiment is a shell for use as an electrical joint mould, the shell may comprise: a body defining a mould cavity; the body having at least one cable port for receiving a cable or an end thereof into the mould cavity; the body further defining an access port to allow entry of resin into the mould cavity; the shell further comprising: at least one rib protruding from the body; and at least one hollow for supporting at least one connector..

Discussion of features with reference to one embodiment applies, mutatis mutandis, to discussion of similar features in relation to further embodiments.

Figure 1 is an example of an electrical joint with which embodiments described herein may be used. In order to create the joint, two or more opposing electrical cables 10 each have a section of their PVC sheath 12 cut to provide access to the internal wires.

An end portion, of length LR, of both PVC sheaths 12 may be roughened and degreased 14; this allows the gaps here-between the joint shell and the PVC sheaths 12 -to be sealed with tape to prevent the leakage of liquid resin, more easily. It can be seen that a joint shell suitable for use with the joint of figure 1 has a length of around L. With reference to the exposed wiring, it can be seen that neutral/earth strands 16 of opposing cables 10 is connected by neutral/earth connectors 18. Likewise, phase cables 20 are connected by phase connectors 22. The neutral/earth connectors 18 and phase connectors 22 may be supplied as part of a jointing kit, along with resin and a joint shell.

Figure 2 shows a joint shell 24 according to a first embodiment of the present disclosure. The joint shell 24 comprises two complementary pads -in this embodiment halves 26, 28; in the form of a hollow casing. When the two halves are arranged in a closed configuration, they define an internal mould cavity suitable for housing the joint (for example as shown in figure 1). The two cavity-defining portions of the joint shell 24 forms a body of the joint shell 24. The body defines a mould cavity which is suitable for housing the joint and containing resin.

Each of the two halves 26, 28 of the embodiment of figure 2 comprises a section of a cavity forming portion, or body, which protrudes from a common surface 30. The common surface 30 forms or comprises rims projecting from each of the two body sections. In the embodiment of figure 2, the two halves 26, 28 protrude in the same direction. The two halves 26, 28 and the common surface 30 may be made as a single unit. A first hinge 32 is present along line AA, running between the two halves 26, 28 of the joint shell 24. The first hinge 32 is positioned to allow the common surface 30 to be folded 1800 about the line AA, arranging the open surfaces of the two halves 26, 28 to be coplanar, thus positioning the two halves 26, 28 on top of each other to form the joint shell 24 in a closed configuration.

The joint shell 24, when in a closed configuration, defines two cable ports 34, 36 -one on either end of the joint shell. The cable ports 34, 36 may enclose a roughened and degreased section 14 of a PVC cable sheath during use. It is important that the two halves 26, 28 and the first hinge 32 are positioned correctly in the embodiment of figure 2; the outer profiles of the two halves 26, 28 -including the two halves of each cable port 34, 36 -should align so that the outlines of the two hollows (in the first 26 and second half 28 respectively) match up when the joint shell 24 is in a closed configuration. The two halves of each cable port 34, 36 match up to form a circular opening in either end of the joint shell 24. Before, or during, use (i.e. when the shell is installed around the cables, an end cap 38 (see figures 3 and 4) will need to be cut off to ensure the face of the cable ports 34, 36 is open. A portion of the cable ports 34, 36 may also need to be cut off along with the end caps 38.

One half 26 of the joint shell 24 comprises an access port. The access port is formed by the removal of an access panel 37. The access port, and thus access panel 37, may be arranged on what is the top face of the top half 26 of the joint shell 24 when in use. The access panel 37 of the present embodiment is removable. Once the access panel 37 is removed, an access port is defined as an aperture into the mould cavity, thus allowing a user to pour liquid resin into the mould cavity of the joint shell 24 once the joint shell 24 is in a closed configuration, enclosing the two cables to be joined.

The circumference of the access panel 37 is perforated or scored. The access panel 37 is configured so it is easily removed from the respective half 26 of the joint shell 24 in order to form the access port and provide sufficient access to the inside of the joint shell 24 to allow liquid resin to be poured therein. Alternatively, the access panel 37 may just have to be cut off with a knife or saw during use. The access panel 37 is configured so that once the joint shell 24 has been filled, or partially filled with resin; the removed section may sit/rest on, or fit inside of, the access port to prevent items falling into the joint shell 24. The access panel 37 may be designed so that, once it has been removed, it is of an extruded trapezoidal shape with a rectangular upper surface that is smaller than the projected surface of the lower rectangular side. This may allow the access panel 37 to be inverted once removed, and to be located back on the access pod with the smaller top surface fitting inside the access port and the larger bottom surface of the access panel 37 abutting the circumference of the access port and supporting the access panel 37 in a position which closes off the access pod.

The embodiment of figure 2 further comprises a folding panel 31. The folding panel 31 may be connected to, or integral with, one of the halves 26, 28. The folding panel 31 is pad of the common surface 30. A second hinge 35 is located between the folding panel 31 and the rest if the joint shell 24. The folding panel 31 comprises tabs 33 and two holes 42. Two lugs 40 protrude from the common surface 30 on the opposite side of the joint shell 24 to the folding panel 31. The two lugs 40 are arranged so as to mate with the two holes 42 once the first and second hinges 32, 35 have been folded. The first hinge 32 is folded first, aligning the two cavities of the two joint shell halves 26, 27.

The second hinge 35 can then be folded, bringing the folding panel 31 around to abut against the common surface of one of the joint shell halves 26. The two lugs 40 protrude through the two holes 42 and the tabs 33 are configured to interlock with, or fit around, the profile of the body of the respective half 26. Thus a self-locking mechanism is provided in the form of the lugs and holes and interlocking tabs.

The thickness of the shell of embodiments described according to the present disclosure may be between about 1mm and 5mm. The thickness of the shell wall of figure 2 is substantially 3mm.

With regard to the embodiment illustrated in figure 2, the common surface 30 is about 570mm x 500mm. The depth of each half 26, 28 (the distance each half protrudes from the common surface 30) is about 100mm. As such, the diameter, or depth of the joint shell 24 (and hence the mould cavity) when in a closed configuration is about 200mm.

The joint shell 24 of figure 2 is made entirely of paper pulp, similar to a conventional egg box. The joint shell 24 may be made using conventional paper pulp and paper mache manufacturing techniques, as described above. In other embodiments, however, the shell may not be made of a biodegradable material.

Figures 3 and 4 show further views of the embodiment of figure 2.

Figures 5 to 11 illustrate a further embodiment according to the present disclosure.

The joint shell 64 of this embodiment, like that of figures 2 to 4, comprises a first half 66 and a second half 68 protruding from a single plane with a fold, or hinge, line running between the two halves 66, 68.

The joint shell 64 comprises three cable ports 70, 72, 74. Two of the cable ports 72, 74 are located at substantially the same end of the joint shell 64, with a further cable port located on substantially the other side of the joint shell 64. The two cable ports 72, 74 located at substantially the same end of the joint shell 64 are parallel and adjacent each other. Alternatively, they may be mutually perpendicular, or parallel and collinear.

The joint shell 64 comprises tabs 76, 78, 80, 82. The joint shell 64 may one, two, three, four or more than four tabs. The joint shell 64 of figure 5 comprises two tabs on each half 66, 68 of the joint shell. The tabs 76-82 are adapted to maintain the joint shell 64 in a closed configuration. When the joint shell 64 is in a closed configuration, the tabs can be folded to wrap around the half other than the half to which it is attached, in order to maintain the joint shell in a closed configuration. Two of the tabs 76, 78 of the embodiment of figure 5 comprise two fold lines. These tabs 76, 78 comprise a first portion 76a, 78a connected to the respective joint shell half 66, 68 by means of a first fold line. These tabs 76, 78 further comprise a second portion 76b, 78b connected to the first tab portion by means of a second fold line. Figures 7 to 10 illustrate each of the fold lines being folded 180° so that when the joint shell 64 is in a closed configuration, the first tab portion of a first joint shell half 66 is wrapped around the edge of the second joint shell half 68 and located against a far surface of the second joint shell half 68 and the second tab portion is wrapped around the edges of both halves to be located adjacent the first joint shell half 66.

The joint shell 64 comprises an access port 84, defined by the body. The access port 84 may allow a user to pour liquid resin into the joint shell 64 when the joint shell 64 is in a closed configuration. The access port 84. Each half 66, 68 of the joint shell 64 comprises a section of the body and each section of the body defines half of the access port 84. The access port-defining portion of each joint shell half is on the edge of the half opposite the hinge between the two halves such that, when the joint shell is in a closed configuration, the two access port-defining portions are brought together to define a single access port 84. The access port 84 of the embodiment of figure 5 is rectangular.

As with the embodiment of figure 2, the joint shell 64 comprises end caps 38 on each of the cable ports 70, 72, 74.

Figures 9 to 11 illustrate the joint shell 64 in a closed configuration. An access port cover 86 is provided to partially, or entirely, cover, or seal the access port 84. The access port cover 86 may be attachable and detachable. Alternatively, the access pod cover 86 may be permanently attachable. The access port cover 86 can prevent debris or liquid from unintentionally entering the joint shell 64.

The access pod cover 86 partially overlaps, wraps around or encloses the edges of the access pod 84. Turning to figure 11, it can be seen that the access port cover 86 of the embodiment of figure 5 overhangs the edges of both halves 66, 68 which define the access port 84, thus preventing the two access port-defining edges from moving apart and maintaining the joint shell 64 in a closed configuration.

Figures 12 to 16 illustrate a further embodiment according to the present disclosure.

The joint shell 44 of this embodiment comprises two parts -a first half 46 and second half 48; the internal cavity -which may be defined by the body -may be of a similar, or identical design to that of the embodiment of figure 2. The three dimensional profile of the body may be identical to that of the embodiment of figure 2. In alternative embodiments, however, the internal cavity or three dimensional profile may not be similar to that of the embodiment of figure 2. When in use and in a closed configuration, the two halves 46, 48 of the embodiment of figure 12 form a top and bottom of the joint shell 44.

The two halves 46, 48 of this embodiment each comprise a cable port 34, 36 at either end of the half. These cable ports 34, 36 surround and seal-against a sheath on the outside of an electrical cable to be joined. When in a packed or shipping configuration, the face at the end of each cable port 34, 36 are sealed with an end cap 38. These end caps need to be cut off before the joint shell 44 is used. These features may be similar to those of the embodiment of figure 2.

Each half 46, 48 of the joint shell 44 comprises an outer rim 50 extending from a body section. A joint shell according to any embodiment of the present disclosure may comprise a rim 50. Each rim 50 comprises a profile 52. The profile 52 may not be flat.

The profile 52 may vary in a direction perpendicular to the interface surface between the two halves 46, 48. The profile 52 may project or undulate in a direction parallel to the depth of each half. The profile 52 may be square. The profile 52 may be zigzagged. The profile 52 may comprise sinusoids.

The profile 52 on a first half 46 is complementary to a profile 52 on a second half 48.

As such, the profiles 52 interlock, mate or engage to form a series of sweeps. These interlocking profiles 52, or sweeps, provide a narrow, extended and non-flat path for any liquid resin to have to travel before it is able to leak out from the joint shell 44 when in use. These interlocking profiles 52, or sweeps, may be sufficient to effectively seal the joint shell 44 against the leaking of resin or ingress of moisture when in a closed configuration.

The profiles 52 on the two halves 46, 48 provide a friction fit. The profiles are configured to provide a tight fit, so that once the halves 46, 48 are interlocked, or connected (with the shell in a closed configuration), they do not come apart (thus putting the shell in an open configuration) without being pulled apart.

Each half 46, 48 of the joint shell 44 may be approximately the same size.

Alternatively, the two halves 46, 48 may be different sizes, to allow one half 48 to locate within the outer rim of the other half 46. In the embodiment of figure 12, one half 46, measures about 500mm-600mm x 300mm-350mm x lOOmm-lSOmm (length x width x depth). The other half 48 measures about SOOmm-550mm x 250mm-300mm x SOmm-lOOmm. More precisely, one half 46 of the joint shell of the embodiment of figure 12 measures 557.4mm x 313.6mm x 130mm and the other half 48 measures 534mm x 280mm x 89mm. The thickness of the wall of the joint shell 44 according to embodiments described herein may be between 1mm and 5mm. The thickness of the wall of the joint shell 44 of figure 12 is 3mm.

One half 46 of the joint shell 44 comprises an access port. The first half 46 of the joint shell 44 of the present embodiment comprises an access pod. The access pod is formed by the removal of an access panel 37. The access panel 37 is removably attached to one half 46 of the joint shell 44. The access panel 37 may be rupturably attached to one half 46 of the joint shell 44. The access panel 37 is configured so that once it is removed from the joint shell 44, an access pod is defined by the body where the access panel 37 was located. The access panel 37 is arranged to be on the uppermost surface of the joint shell 37 when in use. The access panel 37 is configured so as to be separable from the body of the joint shell, but suitable for subsequently covering the access port created by removal of the access panel 37. The access panel 37 is of a similar design to that in the embodiment of figure 2.

Figure 14 illustrates the embodiment of figure 12 in a closed configuration, from the underside (i.e. from the side of the second half 48). Figure 14 shows a second joint shell half 48 of the embodiment of figure 12, located inside the first half 46. The second half 48 of the present embodiment is similar to the first half 46. The second half 48 does not comprise an access panel 37. In other embodiments, the second half may be identical to the first half. The rim 50 of the first half 46 is larger than the rim of the second half 48. The outer edge of the rim 50 of the first half 46 encloses the rim of the second half 48. The second half 48 is, therefore, located partially within the rim 50 of the first half 46. As described above, the two halves fit together with a friction fit.

The friction fit is provided by the interlocking profiles 52 of the rims 50.

In figure 15 in padicular it can be seen that at least one of the halves 46, 48 comprises a series of external ribs 54. The ribs 54 may run substantially from one side of the half 46, 48 to the other. The ribs 54 may run only pad-way around the extruded half 46, 48.

There may be one, two, three, four or more than four ribs 54. In the embodiment of figure 15, a first half 46 comprises six ribs 54. The ribs provide structural rigidity, but may also be required for manufacturing purposes. Either, or both, of the halves 46, 48 may comprise a rib/ribs 54. One, more than one, or each rib 54 may comprise a cut-out 56. In the embodiment of figure 12, the cut-outs 56 are substantially ovular and reduce the height of the respective ribs 54.

In some embodiments, a cut-out 56 may reduce the depth or height of the rib 54 (e.g. the distance by which it protrudes from the surface). Each cut-out 56 may entirely negate or remove a rib 54 in the affected section. The depth of the cut-out 56 may vary along its length. The cut-out 56 may extend only pad way along the length of the rib 54 or, alternatively, may extend the entire length of the rib 54. The cut-out 56 may extend across the entire width of the rib 54 or, alternatively, may extend only pad way across the width of the rib 54.

In the embodiment of figure 12, a cut-out 56 is present in four of the six ribs. The ribs 54 with cut-outs 56 are arranged in two sets of two, at either end of the series of ribs 54. The embodiment of figure 12 comprises symmetrical cut-outs 56 on either side of the joint shell half 46, 48. Other embodiments may comprise cut-outs 56 on only one side of a joint shell half 46, 48. The purpose of these cut-outs 56 will become apparent when looking at figure 16.

Turning now to figure 16, a further view of the first half 46 of the embodiment of figure 12, can be seen. Figure 16 also shows connectors 22. The connectors 22 of figure 16 are located in the cut-outs 56.

In other embodiments according to the present disclosure, the connectors 22 may be located against, adjacent or in, the cut-outs 56. The cut-outs 56 may be suitable for housing one, some, or all of the connectors 22 required to create the joint. The cut-outs 56 may be suitable for supporting one, some, or all of the connectors 22 required to create the joint. The cut-outs 56 may be suitable for housing, supporting or locating one or each required connector 22 to allow the joint casing 44 and other required components (e.g. connectors 22) to be shipped more space-efficiently. The cut-outs 56 may be defined so as to facilitate the housing, or locating, of accessories required to create the joint other than the connectors 22, but which are also the joint case 44.

The connectors 22, housed within the cut-outs 56 can also be seen in figure 13. It can be seen in figure 13 that the connectors 22 do not protrude further horizontally or vertically (in the orientation of the figure) than the joint shell 44. This is advantageous when packaging and shipping the joint shells 44. The cut-outs 56 prevent the connectors 22 from protruding from the horizontal and vertical footprint of the joint shell 44. The cut-outs 56 allow the connectors 22 (or other component to be shipped with the joint shell 44) to be located in a compact, retracted and/or convenient location.

Figure 17 illustrates a joint shell 44 of the embodiment of figure 4 located in a sleeve 58. The sleeve 58, when assembled, entirely encircles one circumference of the joint shell 44. The sleeve 58 of figure 17 leaves two ends free and uncovered, to allow the cables to enter the joint shell 44 via the cable ports. The sleeve may, however, only leave one end free and uncovered, depending on the design of the shell. The sleeve 58, when assembled, also comprises at least one hole configured to allow access to an access panel 37.

The sleeve 58 is configured so that, when assembled, it encircles, supports, encloses and contains a joint shell. The sleeve 58 is configured so that, when assembled and installed around a joint shell in a closed configuration, the joint shell is unable to open.

Thus, the sleeve 58 is suitable to ensure a joint shell 44 does not open unintentionally, for example while the shell 44 is being transported, while the resin is being poured into the shell 44, or while the shell 44 is being buried. The sleeve 58 may be used to package a joint shell and associated components during transport. The sleeve 58 therefore provides sufficient space for connectors 22 and other devices to be located on the outside of the joint shell 44, for example as illustrated in figure 16, to be held in place against the joint shell 44 by the sleeve 58.

A sleeve 58 may also be used as a security measure, and may be seen as an anti-tamper device, allowing a person receiving a joint shell 44 and associated components to check if the kit has been opened during transport. Alternatively, or additionally, the sleeve 58 may be used as a quality management device -sealing the joint shell 44 and associated components. The presence of a sleeve 58 around a joint kit may indicate that the joint kit is complete and ready for shipping.

Figure 18 and 19 show that the sleeve 58 is made of two components, or halves 58a, 58b. In order to locate the sleeve 58 over a joint shell 44 enclosing a joint, one half 58a, 58b of the sleeve must be slid onto each of the free ends of the cables-to-be-joined, before the two ends have been joined. The cables may then be joined, and the two halves 46, 48 of the joint shell 44 can be applied on either side of the joint and closed. At this point, the two halves 58a, 58b of the sleeve 58 can slide towards each other, meeting -and joining -over the joint enclosed in the joint case 44, as shown in figure 17 (albeit without the cables).

Figures 20a, 2Db, 21a and 21b show both halves 58a, 58b of the sleeve 58, in a flat and an expanded state, respectively. The two halves 58a, 58b are identical. Each half 58a, 58b may be substantially conical, or a cup-shaped. Each half has a notch, recess or cut-out either on one side, or both sides, to provide access to the access panel 37 and hence access port. Each half 58a, 58b may be shaped like the curved surface of a frustum.

The two halves of the sleeve 58a, 58b are shaped so as to allow a portion of mutual overlay, or overlapping. This overlapping allows the two halves 58a, 58b of the sleeve to be fixed to each other, interconnected, or mutually restrained. Figure 20a and 21a illustrate that the two halves 58a, 58b of the sleeve of figure 17 each comprise a hook and a slot 62. The hook 60 is configured to locate in the slot 62 and resist movement in any direction except an unhooking direction. Other, equally applicable methods of interlocking the two halves 58a, 58b would be immediately apparent to a skilled reader.

The two halves 58a, 58b of the sleeve 58 are suitable for being made out of a flat blank of material, e.g. corrugated card. The two halves 58a, 58b of the sleeve 58 are designed so that each half 58a, 58b can be pressed flat, without damaging the half 58a, 58b. Each half 58a, 58b may be folded into a flat configuration. The sleeve 58 are designed so that once the two halves 58a, 58b are connected, the sleeve 58 can be pressed flat, without damaging the sleeve. The sleeve 58 can be folded into a flat configuration.

In the embodiment depicted in figure 20a, the marked dimensions may be approximately as follows: A = 820mm, B = 620mm, C = 140mm, D = 110mm, E = 250mm.

A further embodiment of the sleeve is depicted in figures 22 to 24. Figure 22 illustrates a joint shell 44 of the embodiment of figure 4 located in a sleeve 88. The sleeve 88, when assembled, encloses one circumference of the joint shell 44. The sleeve 88, when assembled, leaves two ends free and uncovered, to allow the cables to enter the joint shell 44. The sleeve 88, when assembled, may also comprise at least one hole, or open face, configured to allow access to an access panel 37 of the joint shell 44.

The sleeve 88 of figure 22 comprises 2 holes 90 to allow access to an access panel 37 of the joint shell 44. Unlike the sleeve of figures 17 to 21, the sleeve 88 of figures 22 to 24 is of a rectangular cross-section when viewed from the end of the joint shell 44. As such, the sleeve 88 is a rectangular tube.

The sleeve 88 could be made of corrugated cardboard or corrifluted board.

The discussion relating to the sleeve of figures 17 to 21 applies, mutatis mutandis, to the sleeve 88 of figures 22 to 24.

Figure 24 illustrates a blank suitable for making the sleeve 88. The sleeve 88 may comprise two holes 90 to allow access to an access pod located on either half 44, 46 of the joint shell 44. Alternatively, the sleeve 88 may comprise two holes 90 to allow access to an access port, regardless of which way up the sleeve 88 is used.

The sleeve 88 comprises complementary locking means at two locations on the blank, so that the sleeve 88 can be rolled or folded up and locked to form a rectangular tube.

The sleeve 88 (and blank therefor) are not restricted to specific dimensions. Rather, the sleeve 88 may be sized in accordance with the joint shell for which it is designed.

The dimensions of the blank of figure 24 are approximately 1040mm x 300mm, which can then be folded to form two a rectangular tube with two large sides of approximately 310-320mm x 300mm and two smaller sides of approximately 170-180mm x 300mm; a tab for interlocking purposes may therefore have dimensions of approximately 60mm x 300mm.

Two holes 90 of approximately 90mm x 170mm are provided on both of the large sides to allow access to an access panel 37 and hence access pod.

In order to make the sleeve 88 into its made-configuration, the sleeve 88 is folded to form a tube. The sleeve 88 may comprise a flap and catch or slot arrangement to allow the sleeve 88 to be maintained in a folded configuration. Alternative methods of achieving this would be apparent to a skilled reader.

While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and apparatuses described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and apparatuses described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.

Claims (33)

1. CLAIMS: 1. A shell for use as an electrical joint mould, the shell comprising: a body defining a mould cavity; the body having at least one cable port for receiving a cable or an end thereof into the mould cavity; the body further defining an access port to allow entry of resin into the mould cavity; wherein the shell is at least partially made of a biodegradable material.
2. 2. A shell according to claim 1, wherein the biodegradable material is a lignocellulosic material.
3. 3. A shell according to claim 1 or claim 2, wherein the biodegradable material comprises at least one of: recycled paper, a wood pulp based material, and a paper pulp based material.
4. 4. A shell according to any of the preceding claims, wherein the shell comprises at least one rib protruding from the body.
5. 5. A shell according to any of the preceding claims, wherein the shell comprises at least one hollow for supporting at least one connector.
6. 6. A shell according to claim 5 when dependent on claim 4, wherein the at least one hollow is a cut-out in at least one rib.
7. 7. A shell according to any of the preceding claims, further comprising a cover for covering the access port.
8. 8. A shell according to claim 7, wherein the body comprises a rupturable access panel which can be removed to form the access port, the access panel forming the cover once removed.
9. 9. A shell according to any of the preceding claims, wherein the shell comprises at least two cable ports, at least one on each of two substantially opposite sides of the shell.
10. 10. A shell according to any of the preceding claims, wherein the body is separable into at least two sections.
11. 11. A shell according to claim 10, wherein the shell comprises at least two separable pads, each part comprising a body section.
12. 12. A shell according to claim 11, wherein at least two of the shell pads are connected by means of a hinge or fold line.
13. 13. A shell according to claim 11 or claim 12 wherein at least one shell pad comprises a rim extending out from at least pad of the circumference of its respective body section.
14. 14. A shell according to claim 13, wherein at least two of the shell pads comprise a rim.
15. 15. A shell according to claim 13 or 14, wherein a rim comprises interlocking features.
16. 16. A shell according to any of claims 11 to 15, wherein a shell pad comprises a locking tab.
17. 17. A shell according to claim 16, wherein a locking tab comprises two fold lines.
18. 18. A shell according to any of claims 11 to 17 when dependent upon claim 7, wherein the cover, when in use, prevents the at least two shell parts from separating.
19. 19. A shell for use as an electrical joint mould, the shell comprising: a body defining a mould cavity; the body having at least one cable pod for receiving a cable or an end thereof into the mould cavity; the body further defining an access port to allow entry of resin into the mould cavity; the shell further comprising: at least one rib protruding from the body; and at least one hollow for supporting at least one connector.
20. 20. A kit comprising at least two joint shell parts suitable for making a shell according to any of the preceding claims.
21. 21. A kit comprising a shell according to any of claims ito 19, liquid resin and at least one connector for joining electric power cables or wires.
22. 22. A sleeve suitable for at least partially enclosing an electrical joint shell.
23. 23. A sleeve for at least partially enclosing a shell according to any of claims 1 to 19, the sleeve allowing access to the access port and each cable port.
24. 24. A sleeve suitable for at least partially enclosing a kit according to claim 20 or claim 21.
25. 25. A sleeve according to any of claims 22 to 24, wherein the sleeve is at least partially made out of paper, card or plastic.
26. 26. A sleeve according to any of claim 22 to 25, wherein the sleeve is adapted to retain a shell according to any of claims ito 19 in a closed configuration.
27. 27. A sleeve according to claim 26, wherein the sleeve is adapted to retain at least one joint component against the shell.
28. 28. A sleeve according to any of claims 22 to 27, wherein the sleeve comprises at least two sleeve parts.
29. 29. A sleeve according to claim 28, wherein each sleeve part comprises an interlocking device.
30. 30. A sleeve according to claim 28 or claim 29, wherein each sleeve part is substantially tubular.
31. 31. A sleeve according to any of claims 22 to 30, wherein the sleeve or sleeve part is configured to fold flat.
32. 32. A kit comprising a shell according to any of claims ito 19, liquid resin, at least one connector for joining electric power cables or wires and a sleeve according to any of claims 22 to 31.
33. 33. A method of manufacturing a shell in accordance with any one of claims 1 to 19, made of paper pulp, the method comprising: mixing paper cuttings with water, thereby creating a pulp; compressing enough pulp in a mould to form a shell; at least partially drying the shell; releasing the shell from the mould; and placing the shell in an oven to cure.