This invention relates to weather resistant power outlets. This invention has particular application to weather resistant general power outlets (GPO), and for illustrative purposes the Invention will be described with reference to this application. However we envisage that this invention may find use in other applications such as weather resistant power outlets mounted on plant and equipment, and portable power outlets (PPO).
The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the referenced prior art forms part of the common general knowledge in Australia.
The provision of GPOs for exterior use requires providing the GPO with a degree of weather resistance. By regulation, the power sockets and switches used in wet/damp areas and in outdoor areas require waterproofing in order to prevent fluid, dust particles or third party from getting inside the socket and inner assembly. Conventional weatherproof power sockets or switches are generally surface mounted and accordingly bulky to maintain weatherproof rating. Currently, there is no weatherproof model comparable in profile and presentation to interior GPOs such as flush mount GPOs.
Prior art weatherproof GPOs are shown in comparative
In a third embodiment of prior art GPOs, in order to prevent accidental insertion of object into power socket by children, a safety shutter may be employed by some designs. The safety shutter is a mechanical stop that is moved and opened by correct insertion of the plug pins. Upon insertion of the (longer) earth pin, shutters inside the active and neutral apertures are opened. The safety shutter is constructed of hard plastic that it is not waterproof and dustproof. Due to the nature of design, the power sockets have tight aperture and insertion of power plug is difficult.
In one aspect the present invention resides broadly in a weather resistant power outlet including:
The plate may be a wall plate, a plate adapted for use with a surface mount box, a plate adapted for mounting to plant or equipment, or may be a plate adapted for incorporation in a tradesman's remote power outlet. The mounting means may comprise a pair, of mounting screws, either located in pluggable screw wells through the plate front face or concealed under a snap-on ring. The plate may be a single point plate or a double point plate. The plate may include glued or snap-in lens/diffusers for an on-indicator lamp. In the case of a snap-in lens/diffuser, this may be replaced by an on-indicator lamp including an elastomeric seal located in an aperture and into which an indicator lamp may be pressed. For example a top hat section elastomeric seal, into which an indicator LED may be pressed, may provide a weatherproof indicator lamp configuration.
The array of pin apertures may take any form mandated by regulations governing power outlets including presence or absence of an earth pin (for double insulated appliances), pin section and pin geometry.
The means securing the plate to a surface may take any form determined at least in part by the substrate and including but not limited to screws, metal threads and the like. Penetrating fixings may be associated with O-rings or resilient washers to enhance water tightness of the plate-to-substrate enclosure.
The gasket means may be selected having regard to the shape of the mating surface of the plate and/or the nature of the substrate surface. The gasket may be of an elastomeric material such as natural or synthetic rubber, or may be a compressible gasket material such as cork composition. The gasket may comprise a chemically resistant elastomeric material selected from but not limited to silicone rubber, nitrite rubber or Thiokol rubber.
The socket assembly may be a switched or unswitched socket assembly. In the case of a switched socket assembly, this may be formed integrally with a switch such as a rocker switch or may be wired to a separate switch assembly. The plate may be of the type where the pin apertures are part of an underplate and the rocker switch aperture(s) are provided in a trim panel that snaps over the underplate. Alternatively the plate may be of the more conventional type where the rocker switch aperture(s) and the pin apertures are provided in the dress face of a unitary ABS chassis and where the fixings are through pluggable screw recesses.
The elastomeric body may be formed of any elastic and durable material which can stand for reasonably high voltage and temperature. For example, the elastomer may be selected from elastomers of rated dielectric strength such as selected natural or synthetic rubber compositions such as neoprene, and elastomeric artificial polymers such as silicone and polyurethane rubbers. The elastomeric body may be located between the plate and the socket assembly. That is, the body may be secured by entrapment between the plate and the socket assembly. Alternatively or additionally the elastomeric body may be adhered to one or both of the plate and socket assembly.
Clearance between the elastomeric body and one or the other of the plate and socket assembly may be employed to allow working room for a conventional safety shutter mechanism.
In a yet further embodiment or combination, the elastomeric body may be engaged with the plate and/or socket assembly by complementary engagement means. By any of these means the terminals of the socket assembly may be sealingly isolated from the pin apertures to provide a first level of weather resistance.
The openings through the body may comprise slits that are naturally closed in a weatherproof manner by the resilience of the elastomeric body. The closing of the slits may be achieved or enhanced by mounting the elastomeric body under compression. The body remains closed when a plug is not in use thus preventing exposure to air, fluid, dust particles, insect and metal. When a plug is inserted, the flexibility of the gasket acts as a firm enclosure holding all pins, leaving no gap surrounding the plug pins and limiting exposure to air, fluid, dust particles, insect and metal. The elastomeric body yield strength, dimensions and opening characteristics may be selected to resist insertion of foreign objects by children.
The apparatus may be waterproof in terms of environmentally isolating the inside of the power outlet from the ingress of water impinging on the outside of the mounted power outlet, or the apparatus may be weather resistant in terms of actively and/or passively resisting the effects of weather. For example there may be provided a drain hole or the like as a lower water trap portion of the power outlet assembly. This may be especially applicable in embodiments where the elastomeric body is sealed to the socket assembly allowing possible passage of moisture through the pin apertures.
In the case of switched power outlets, the integral or separate switch assembly may be exposed for use through a switch aperture formed in the plate. In conventional GPO switchgear this is a rocker switch, although in specialist applications a rotary switch, toggle switch, push switch or momentary switch may be used.
The type of switch may influence the nature of weather-resisting modification that is appropriate. For example where the socket assembly is switched by a rocker switch exposed through a switch aperture in the plate, there may be provided an elastomeric weather seal having a web extending over the rocker switch and a peripheral edge adapted to sealingly engage the periphery of the switch aperture. The peripheral edge may comprise a substantially continuous, re-entrant edge adapted to pass over and sealingly engage the periphery of the switch aperture.
The weather resistant power outlet may further include a cover to provide further weatherproofing.
In the case of at least conventional rocker switches, there are two levels of resistance that need to be achieved, which are resistance to weather infiltrating the switch per se, and resistance to weather infiltrating past the switch assembly to the interior of the mounted plate to affect other components. It is known to stick an elastomeric cover to the plate and overlaying the rocker switch finger button. However, this solution is prone to failure.
It has surprisingly been determined that a historical artefact of GPO manufacture is that increasing precision of moulded components has not resulted in close tolerances in the relatively moving parts of the rocker switch assembly and the wall and other plates. With a corresponding increase in the available precision of rubber mouldings, the present applicant has determined that a functional weatherproofing cover for a rocker switch is possible.
Accordingly in a further aspect the invention resides in a rocker switch assembly including a rocker switch mounted to said switch mounting plate, a rocker exposed through an aperture in said switch mounting plate, and an elastomeric weather seal having a web extending over said rocker and a substantially continuous, re-entrant edge adapted to sealingly engage the periphery of said aperture.
The elastomeric weather seal may be used in conjunction with the weatherproof GPO described above. The elastomeric weather seal may be formed integrally with the elastomeric body.
The elastomeric weather seal acts as an insulated cover to prevent exposure to fluid and dust particles. The elastomeric weather seal acts as an insulated cover to protect the user from electric arc and potential shock when the button is used to turn on/off under adverse weather conditions for electrical switches.
In alternative uses the elastomeric weather seal may be used for light switch plate weatherproofing, whether in association with a plate-to-substrate gasket as described above or other weatherproofing features.
GPO and light switches in accordance with the present invention may be used with or without a cover and still provide a high waterproof rating. Where a cover is desirable to provide additional resistance and/or physical protection, this may be conventional. However, as the assemblies of the present invention are slim-line, there are improvements to covers to be made to maintain the slim-line look and increase cover functionality.
Accordingly, in a further aspect the invention relates to an electrical switch assembly including:
The plate may be a wall plate as described above. The plate may be slim-line. The peripheral edge may be fitted off with a gasket as described above. The upper wall portion may extend about the periphery at a substantially constant width or may include tapered side portions and a relatively narrow bottom portion. The drainage rib may be integrally moulded with the plate and may comprise an upstanding rib or a rib remaining after relief of the upper wall portion behind the front face. The upper wall portion may extend between two side wall portions whereby the rib may confine water flow to either side of the upper wall portion.
The electrical component may comprise one of more of a switch, a socket or and indicator light. The electrical component may comprise a weather resistant power outlet as described above.
The cover may be formed of rigid or resilient polymer material or be of metal or FRP. The flange portion may extend substantially about the periphery of the cover.
The cover preferably hinges about an axis as close as possible to the outer edge of the flange, and the corresponding pivot axis on the upper wall is preferably intermediate the rib and the peripheral edge inner junction of the flange and cover, the intermediate position may be selected to be far enough from the substrate whereby the cover is opened to at least the horizontal before the flange contacts the substrate and is as close to the substrate as allows the cover to close over the plate with the flange edge adjacent the substrate.
In embodiments of the present invention the plate and cover assembly when installed may project as, little as 19 mm from the substrate, close to the width and height of a normal indoor power socket or switch. This is opposed to the 16 mm in thickness of the inventive plates without a cover, representing a depth penalty of only 3 mm. this is to be contrasted with the conventional covered weatherproof power socket with a 72 mm thickness. The hinge on the lid of the invention is not visible externally, it result in sleek appearance.
Features in accordance with the foregoing may be incorporated into portable power outlets (PPO). For example, a conventional PPO carcase may be retrofitted with one or more of a weatherproof GPO and/or rocker switch assembly and/or electrical switch assembly as described above.
In a further aspect the invention resides in a portable power outlet including:
The pair of body portions may be the carcass of a conventional PPO. Such devices may include a partition line defined by complementary interengagement portions formed on the mating edges of the parts. The gasket may be configured to engage with one or both of the complementary interengagement portions. The gasket may be unitary or formed of two or more gasket portions.
The RCD mount will be determined by the type of RCD to be used. The weather resistant power outlet may be selected from the above described weather resistant power outlets. The weather resistant power outlets may include a cover which may be selected from the covers described above.
The RCD may be a conventional RCDMCB, incorporating the functions of both residual current (earth leakage) protection and current-overload protection. Such units generally comprise a standard DIN-rail mountable RCDMCB where integral opposed projections formed on each of the body portions engage the DIN mount of the RCD on assembly of the body portions. The body portions may each include a recess forming in assembly the opposed pivot points for a conventional RCD protective cover. The sealing portion about said RCD mount may be configured as a compression seal or as a lip seal.
The invention will be described with reference to the following non-limiting embodiment of the invention as illustrated in the drawings and wherein:
In the comparative
In the example of
In the comparative example of
In the
Located behind the pin apertures 16 is an elastomeric body 17 having self-closing, lead-in pin slots 25.
The cover 10 covers the inserted plug 26 as depicted in
A clearance between the rocker switch button 15 and the body of the switch is necessary to permit rocker movement, but this gap also allows fluid and dust particles to enter the switch mechanism. During the switching of the switch rocker 15, electric spark is sometimes generated, through this gap; the user runs the risk of electrocution, especially in an outdoor area or wet area. The invention has a flexible button enclosure 14 that completely insulates the user from the internal switching mechanism while allowing rocker movement. The flexible button enclosure 14 covers the top of the rocker button 15. In addition, a skirt flange 27 surrounds the bottom of the flexible button enclosure 14. The skirt flange 27 is pressed and held by an enclosure holder 21 which is constructed of hard plastic and having a one-way retaining barb 30. In the alternative embodiment of
The lid on a conventional weatherproof enclosure box with a hinge cannot fully open to a horizontal position. The lid is stopped by the contact to the wall opening to a full horizontal position. The invention moves back the pivot 20 8 mm away from the top side of the body of the switch, and bevels and rounds the top of the back of the lid at 33. This allows the top 32 of lid 11 to be level with the wall and the base of the body 10 when it is fully opened at horizontal position. This is depicted in
The hidden hinge 20 is depicted in
A latch 12 is positioned at the central bottom of lid 10. The latch 12 hooks the lid 10 to the body of the switch. This prevents the movement of the lid 10 when it is closed.
A wall gasket 31 serves as a weatherproof sealer between socket body 10 and the wall when the invention is installed.
In embodiments where an indicator lamp is required, as illustrated in
Apparatus in accordance with the foregoing embodiment provides a high waterproof rating of, say, over IP55, in a power socket or switch that is less than 20 mm thick from wall. The high waterproof rating power socket or switch does not rely on extra save, or an external enclosure box to achieve its rating. The high waterproof rating power socket offers front facing direct plug insertion rather than at an angle. The high waterproof rating power socket or switch may have or not have a cover. It is weatherproof with or without plug inserted. It allows a power plug to be inserted while maintaining a tight seal around the power plug pins to achieve waterproof rating. It resists children from inserting metallic object into power sockets. The embodiment has an elastomeric body that is fixed and secured to the body of the power point or switch, not glued. The embodiment has its switch mechanism enclosed by an enclosure that is flexible and allows the covered switch button enclosed within to move. The lid of the preferred embodiment has substantially no gap between wall and power socket or switch, while able to open up to a horizontal position without the lid impinging on the wall.
In the embodiment of
A double insulated cable 47 is terminated by a three-pin plug 50 and is wired appropriate to the RCD 45 and a pair of weatherproof power outlets 51 mounted on gaskets to a respective recesses platform 52 formed on each housing portion 40. The cable 47 passes thought a weatherproof gripper labyrinth cable entry 53.
It will of course be realised that while the above has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is set forth in the claims appended hereto.
Number | Date | Country | Kind |
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2011204973 | Jul 2011 | AU | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/AU2012/000873 | 7/24/2012 | WO | 00 | 3/5/2014 |