Gel-filled casing for an electrical connection and associated method

• US 6,265,665 B1
• Filed: 11/30/1999
• Issued: 07/24/2001
• Est. Priority Date: 11/30/1999
• Status: Expired due to Term

• Current Assignee: Thomas & Betts International LLC (ABB Limited)
• Original Assignee: Homac Mfg Company (ABB Limited)
• Inventors: Zahnen, James L.
• Primary Examiner(s): Reichard, Dean A.
• Assistant Examiner(s): Mayo, III, William H
• Application Number:
  US09/451,055
• Time in Patent Office: 602 Days
• Field of Search: 174/92, 174/84.R, 174/93, 174/72.C, 174/70.A, 174/95
• US Class Current: 174/92
• CPC Class Codes: H01R 13/501 comprising an integral hinge or a frangible part
• CPC Class Codes: H01R 13/506 assembled by snap action of the parts
• CPC Class Codes: H01R 13/5216 characterised by the sealing material, e.g. gels or resins
• CPC Class Codes: H01R 4/70 Insulation of connections end caps H01R4/22
• CPC Class Codes: H02G 15/003 Filling materials, e.g. solid or fluid insulation
• CPC Class Codes: H02G 15/18 protected by sleeves, e.g. for communication cable two-part covers H02G15/10 ; preforms having internal stresses B29C61/00

Abstract

A gel-filled casing for an electrical connection includes lower and upper housing portions, and a hinge connecting the lower and upper housing portions along respective edges thereof. First and second bodies of sealing gel are in respective interiors of the lower and upper housing portions. The gel-filled casing further includes at least one partial closure member for securing the lower and upper housing portions in a partially closed position with the first and second bodies of sealing gel being separated from one another. This allows the gel-filled casing to be shipped in the partially closed position. At least one full closure member is also included for securing the lower and upper housing portions in a fully closed position with the first and second bodies of sealing gel being brought together and surrounding the electrical connection for ensuring that the gel surrounds the exposed conductors for preventing contact with moisture.

Claims

1. A gel-filled casing for an electrical connection comprising:

first and second housing portions, and a hinge connecting the first and second housing portions along respective edges thereof;

first and second bodies of sealing gel in respective interiors of said first and second housing portions;

at least one partial closure member for securing said first and second housing portions in a partially closed position with said first and second bodies of sealing gel being separated from one another; and

at least one full closure member for securing said first and second housing portions in a fully closed position with said first and second bodies of sealing gel being brought together and surrounding an electrical connection positioned within the gel-filled casing.

2. A gel-filled casing according to claim 1 wherein said hinge urges said first and second housing portions toward an open position to thereby cooperate with said at least one partial closure member to secure said first and second housing portions in the partially closed position.

3. A gel-filled casing according to claim 1 wherein said first and second housing portions and said hinge comprise integrally molded plastic.

4. A gel-filled casing according to claim 1 wherein said first and second housing portions each has a generally rectangular shape.

5. A gel-filled casing according to claim 1 further comprising first and second flanges extending outwardly from respective edges of said first and second housing portions opposite said hinge.

6. A gel-filled casing according to claim 5 wherein said at least one partial closure member comprises a plurality of partial closure tabs extending generally perpendicularly outwardly from said first flange;

and wherein said second flange has a plurality of corresponding partial closure tab receiving notches in an outer edge thereof.

7. A gel-filled casing according to claim 6 wherein said at least one full closure member comprises a plurality of full closure tabs extending generally perpendicularly outwardly from said first flange;

and wherein said first flange has a plurality of corresponding full closure tab receiving notches in an outer edge thereof.

8. A gel-filled casing according to claim 7 wherein each of said partial closure tabs has a greater length than each of said full closure tabs.

9. A gel-filled casing according to claim 7 wherein said partial and full closure tabs each comprises a body portion and locking end portion connected thereto.

10. A gel-filled casing according to claim 1 wherein each of said first and second housing portions comprises opposing flexible end walls conforming to cables passing therethrough.

11. A gel-filled casing according to claim 1 wherein each of said first and second housing portions comprises an outer wall opposite said hinge;

wherein the outer wall of said first housing portion has a recess therein; and

wherein the outer wall of said second housing portion comprises a barrier lip extending downwardly therefrom for confining the sealing gel as said first and second housing portions are moved to the closed position with the electrical connection therein.

12. A gel-filled casing according to claim 11 wherein said barrier lip partially engages said recess in the partially closed position.

13. A gel-filled casing according to claim 1 further comprising respective electrical connection retaining members on interior portions of said first and second housing portions.

14. A gel-filled casing for an electrical connection comprising:

first and second housing portions each having a generally rectangular shape, and a hinge connecting said first and second housing portions along respective edges thereof;

first and second bodies of sealing gel in respective interiors of said first and second housing portions;

at least one partial closure member for securing said first and second housing portions in a partially closed position with said first and second bodies of sealing gel being separated from one another; and

at least one full closure member for securing said first and second housing portions in a fully closed position with said first and second bodies of sealing gel being brought together and surrounding the electrical connection positioned within the gel-filled casing;

each of said first and second housing portions comprising an outer wall opposite said hinge, the outer wall of said first housing portion having a recess therein, and the outer wall of said second housing portion comprising a barrier lip extending downwardly therefrom for confining the sealing gel as said first and second housing portions are moved to the closed position with the electrical connection therein.

15. A gel-filled casing according to claim 14 wherein said hinge urges said first and second housing portions toward an open position to thereby cooperate with said at least one partial closure member to secure said first and second housing portions in the partially closed position.

16. A gel-filled casing according to claim 14 wherein said barrier lip partially engages said recess in the partially closed position.

17. A gel-filled casing according to claim 14 wherein said first and second housing portions and said hinge comprise integrally molded plastic.

18. A gel-filled casing according to claim 14 further comprising first and second flanges extending outwardly from respective edges of said first and second housing portions opposite said hinge.

19. A gel-filled casing according to claim 18 wherein said at least one full closure member comprises a plurality of full closure tabs extending generally perpendicularly outwardly from said first flange;

and wherein said first flange has a plurality of corresponding full closure tab receiving notches in an outer edge thereof.

20. A gel-filled casing according to claim 18 wherein said at least one partial closure member comprises a plurality of partial closure tabs extending generally perpendicularly outwardly from said first flange;

and wherein said second flange has a plurality of corresponding partial closure tab receiving notches in an outer edge thereof.

21. A gel-filled casing according to claim 14 wherein each of said first and second housing portions comprises opposing flexible end walls conforming to cables passing therethrough.

22. A gel-filled casing according to claim 14 further comprising respective electrical connection retaining members on interior portions of said first and second housing portions.

23. A gel-filled casing for an electrical connection comprising:

first and second housing portions, and a hinge connecting said first and second housing portions along respective edges thereof;

first and second bodies of sealing gel in respective interiors of said first and second housing portions; and

at least one closure member for securing said first and second housing portions in a partially closed position with said first and second bodies of sealing gel being separated from one another.

24. A gel-filled casing according to claim 23 wherein said hinge urges said first and second housing portions toward an open position to thereby cooperate with said at least one closure member to secure said first and second housing portions in the partially closed position.

25. A gel-filled casing according to claim 23 wherein said first and second housing portions and said hinge comprise integrally molded plastic.

26. A gel-filled casing according to claim 23 further comprising first and second flanges extending outwardly from respective edges of said first and second housing portions opposite said hinge.

27. A gel-filled casing according to claim 26 wherein said at least one closure member comprises a plurality of partial closure tabs extending generally perpendicularly outwardly from said first flange;

and wherein said second flange has a plurality of corresponding partial closure tab receiving notches in an outer edge thereof.

28. A gel-filled casing according to claim 23 wherein said at least one closure members comprises a body portion and locking end portion connected thereto.

29. A gel-filled casing according to claim 23 wherein each of said first and second housing portions comprises opposing flexible end walls conforming to cables passing therethrough.

30. A gel-filled casing according to claim 23 wherein each of said first and second housing portions comprises an outer wall opposite said hinge;

wherein the outer wall of said first housing portion has a recess therein; and

wherein the outer wall of said second housing portion comprises a barrier lip extending downwardly therefrom for confining the sealing gel as the first and second housing portions are moved to the closed position with the electrical connection therein.

31. A gel-filled casing according to claim 30 wherein said barrier lip partially engages said recess in the partially closed position.

32. A gel-filled casing according to claim 23 further comprising respective electrical connection retaining members on interior portions of said first and second housing portions.

33. A method for using a gel-filled casing comprising first and second housing portions joined along respective edges by a hinge, first and second bodies of sealing gel in respective interiors of the first and second housing portions, the casing having a partially closed position with the first and second bodies of sealing gel being separated from one another and a fully closed position with the first and second bodies of sealing gel being brought together, the method comprising the steps of:

assembling and shipping the gel-filled casing in the partially closed position;

opening the gel-filed casing and placing the electrical connection therein; and

bringing the first and second housing portions together about the electrical connection to the fully closed position.

34. A method according to claim 33 wherein the hinge urges the first and second housing portions toward an open position to thereby cooperate with the at least one partial closure member to secure the first and second housing portions in the partially closed position.

35. A method according to claim 33 wherein each of the first and second housing portions comprises opposing flexible end walls conforming to cables passing therethrough.

36. A method according to claim 33 wherein each of the first and second housing portions comprises an outer wall opposite the hinge;

wherein the outer wall of the first housing portion has a recess therein;

wherein the outer wall of the second housing portion comprises a barrier lip extending downwardly therefrom; and

wherein the step of bringing the first and second housing portions together comprises confining the sealing gel as the first and second housing portions are moved to the closed position with the electrical connection therein.

37. A method according to claim 36 wherein shipping the gel-filled casing comprises partially engaging the barrier lip in the recess for placing the gel-filled casing in the partially closed position.