Note: Descriptions are shown in the official language in which they were submitted.
CA 02843982 2015-12-03
NON-METALLIC EXPANSION/DEFLECTION COUPLING MODULES
[0001]
FIELD OF THE INVENTION
[0002] The present invention is generally directed toward a device for
joining
electrical conduits. More specifically, it is directed toward an expansion and
deflection
coupling that allows a greater range of movement of the conduits relative to
each other.
BACKGROUND OF THE INVENTION
[0003] When joining two pieces of electrical conduit together, a
simple straight
coupling is sufficient if the conduits are in axial alignment, and a rigid
connection is
acceptable. However, at junctions where the two conduits do not line up
perfectly, such as in
instances of axial misalignment or parallel misalignment, angled couplings are
required to
join the conduit together.
[0004] Certain installations further require that the coupling be
flexible in order to
accommodate movement. For example, a flexible conduit may be required where a
raceway
crosses a structural joint intended for expansion, contraction or deflection,
such as in
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buildings, bridges, parking garages, or across adjacent sections of pavement.
Conduit
couplings that are installed in these locations need to be able to flex in
order to accommodate
the movement due to changes in temperature and the weight of vehicles.
Currently available
couplings have limited ability to adjust for axial expansion and contraction
movements.
Furthermore, prior known expansion and deflection couplings do not offer an
increase in
movements when being installed on site. If a greater range of movement is
desired, the
device has to be custom designed for this at the factory.
[0005] The presently disclosed conduit couplings are able to provide a
wider range
of axial and angular movement than was previously available.
SUMMARY OF THE INVENTION
[0006] A new coupling device that allows greater range of motion is
disclosed.
The coupling device can accommodate axial expansion and contraction, as well
as angular
and parallel deflection. The claimed device is also capable of angular
movements while
expanding/contracting without resulting in a decreased inner diameter. The
claimed device is
constructed in a modular fashion such that additional couplings can be added
to further
increase the range of motion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Further advantages of the invention will become apparent by
reference to
the detailed description of preferred embodiments when considered in
conjunction with the
drawings:
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[0008] FIG. 1 depicts a perspective view of the claimed device in an
angled
formation with a rigid center joint.
[0009] FIG. 2 depicts a perspective view of the claimed device in a
linear
formation.
[0010] FIG. 3A depicts the claimed device with a boot surrounding the
joints.
[0011] FIG. 3B is a cross sectional view of the claimed device as
viewed along
line 3B-3B of FIG. 3A.
[0012] FIG. 4A depicts an elevation view of the claimed device without
an outer
jacket.
[0013] FIG. 4B is a cross sectional view of the claimed device without
an outer
jacket as viewed along line 4B-4B of FIG. 4A.
[0014] FIG. 4C is another view of the claimed device without an outer
jacket.
[0015] FIG. 5A depicts an elevation view of another embodiment of the
claimed
device with an outer jacket.
[0016] FIG. 5B is a cross sectional view of the claimed device with an
outer jacket
as viewed along line 5B-5B of FIG. 5A.
[0017] FIG. 5C depicts a perspective view of an embodiment of the
claimed
device with an outer jacket.
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[0018] FIG. 6A is an elevation view of another embodiment of the
claimed device
with an expandable outer jacket.
[0019] FIG. 6B is a cross sectional view of the claimed device with an
expandable
outer jacket as viewed along line 6B-6B of FIG. 6A.
[0020] FIG. 6C depicts a perspective view of the claimed device with
two
coupling ends and an expandable outer jacket.
[0021] FIG. 6D depicts a perspective view of the claimed device with
one
coupling end, one male end, and an expandable outer jacket.
[0022] FIG. 6E depicts a perspective view of the claimed device with
two male
ends and an expandable outer jacket.
DETAILED DESCRIPTION
[0023] The following detailed description is presented to enable any
person skilled
in the art to make and use the invention. For purposes of explanation,
specific details are set
forth to provide a thorough understanding of the present invention. However,
it will be
apparent to one skilled in the art that these specific details are not
required to practice the
invention. Descriptions of specific applications are provided only as
representative examples.
Various modifications to the preferred embodiments will be readily apparent to
one skilled in
the art, and the general principles defined herein may be applied to other
embodiments and
applications without departing from the scope of the invention. The present
invention is not
intended to be limited to the embodiments shown, but is to be accorded the
widest possible
scope consistent with the principles and features disclosed herein.
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[0024] Referring to the drawings, FIG. 1 illustrates one embodiment of
the
invention. The device consists of a male end 2 and a coupling end 1. The male
end 2 is
configured such that it can be inserted into the standard bell-end of a rigid
non-metal conduit.
At the opposite end of the device, coupling end 1 is configured to receive the
male end 2 of a
rigid non-metallic conduit. The coupling end 1 may be secured to the rigid non-
metallic
conduit through the use of adhesive, such as PVC cement.
[0025] FIG. 2 illustrates one embodiment of the invention in a non-
deflection
position. The device consists of a male end 2 and a coupling end 1. As can be
appreciated in
FIG. 2, the male end 2 is configured such that it can be inserted into the
standard bell-end of a
rigid non-metal conduit. FIG. 2 depicts the device's male end 2 inserted into
the standard
bell-end of a rigid non-metal conduit. As can be appreciated in FIG. 2, the
coupling end 1 is
configured to receive the male end 2 of a rigid non-metallic conduit. FIG. 2
depicts the
device's coupling end 1 receiving the male end 2 of a rigid non-metallic
conduit. The ends
1,2 may be secured to the rigid non-metallic conduit through the use of
adhesive, such as PVC
cement.
[0026] As can be appreciated in FIG. 4, an embodiment of the invention
can
expand and/or deflect at an angle from the axis of the ends 1,2 as needed,
while retaining
continuous identity. FIGS. 4A-4C depict one embodiment of the invention fully
deflected
along the axis of the ends 1,2, such that the plane of male end 2 conduit path
is elevated above
the plane of the coupling end 1 conduit path. As shown in FIG. 4B, the inner
sleeve 4 may be
constructed by connecting or fixing two non-metallic rigid conduit pieces
together. As can be
seen from FIG. 4B, the inner sleeve 4 has an inner diameter large enough for
the conduit to
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accommodate the wires that pass through it. The diameter of the inner sleeve 4
is larger at the
ends than in the middle of the inner sleeve 4. At the male end 2 of the
coupling, the larger end
of the inner sleeve 4 is housed within male end adapter sub-assembly 3. At the
coupling end 1
of the coupling, the larger end of the inner sleeve 4 is housed within
coupling end adapter sub-
assembly 5. As can be appreciated from FIGS. 4B and 4C, the male end adapter
sub-
assembly 3 and coupling end adapter sub-assembly 5 partially surrounds the
larger end of
inner sleeve 4. The diameter of the male end adapter sub-assembly 3 and the
coupling end
adapter sub-assembly 5 is larger than the diameter of inner sleeve 4, but
smaller than the
larger end of inner sleeve 4. As a result, inner sleeve 4 can move axially
relative to the male
end 2 and coupling end of the coupling, or it can pivot within male end
adapter sub-assembly
3 and/or coupling end adapter sub-assembly 5. The inner surface of the male
end adapter sub-
assembly 3 and coupling end adapter sub-assembly 5 may be a curved surface.
The male end
2 and/or coupling end of the inner sleeve 4 may also have a surface that is
curved inward
toward the axis of the inner sleeve 4. The angle of curvature of each of the
curved surfaces is
selected so that contact between the edge of the inner sleeve 4 and the inner
surface of the
male end adapter sub-assembly 3 and coupling end adapter sub-assembly 5 is
minimized. The
curvature of the two surfaces allows the coupling to accommodate greater
angular movement
of the inner sleeve 4 relative to the conduit even as the coupling is
simultaneously
accommodating axial movement of the conduits. As can be appreciated in FIG. 4,
the unit
provides a continuous ID by coupling two sections of a conduit run that could
be subjected to
movements. Therefore, as a unit is subjected to movements and deflects, there
will be no
stress to conductors passing through the conduit run.
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[0027] An inner sleeve 4 is located between the coupling end 1 and the
male end 2
of the device. As can be seen from FIG. 3B, the inner sleeve 4 has an inner
diameter large
enough for the conduit to accommodate the wires that pass through it. The
diameter of the
inner sleeve 4 is larger at the ends than in the middle of the inner sleeve 4.
At the male end 2
of the coupling, the larger end of the inner sleeve 4 is housed within male
end adapter sub-
assembly 3. As can be appreciated from FIG. 3, this male end adapter sub-
assembly 3
partially surrounds the larger end of inner sleeve 4. The diameter of male end
adapter sub-
assembly 3 is larger than the diameter of inner sleeve 4, but smaller than the
larger end of
inner sleeve 4. As a result, inner sleeve 4 can move axially relative to the
male end 2 of the
coupling, or it can pivot within male end adapter sub-assembly 3. The inner
surface of the
male end adapter sub-assembly 3 may be a curved surface. The male end 2 of the
inner sleeve
4 may also have a surface that is curved inward toward the axis of the inner
sleeve 4. The
angle of curvature of each of the two curved surfaces is selected so that
contact between the
edge of the inner sleeve 4 and the inner surface of the male end adapter sub-
assembly 3 is
minimized. The curvature of the two surfaces allows the coupling to
accommodate greater
angular movement of the inner sleeve 4 relative to the conduit even as the
coupling is
simultaneously accommodating axial movement of the conduits.
[0028] A similar range of motion exists between the inner sleeve 4 and
the
coupling end 1 of the device. At the coupling end 1 of the device, the larger
end of inner
sleeve 4 is housed within coupling end adapter sub-assembly 5. As can be
appreciated from
FIG. 3B, this coupling end adapter sub-assembly 5 partially surrounds the
larger end of inner
sleeve 4. The diameter of coupling end adapter sub-assembly 5 is larger than
the diameter of
inner sleeve 4, but smaller than the larger end of inner sleeve 4. As a
result, inner sleeve 4 can
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move axially relative to the coupling end 1 of the coupling, or it can pivot
within coupling end
adapter sub-assembly 5. The inner surface of the coupling end adapter sub-
assembly 5 may
also be a curved surface. The coupling end 1 of the inner sleeve 4 may also
have a surface
that is curved inward toward the axis of the inner sleeve 4. The angle of
curvature of each of
the two curved surfaces is selected so that contact between the edge of the
inner sleeve 4 and
the inner surface of the coupling end adapter sub-assembly 5 is minimized. The
curvature of
the two surfaces allows the coupling to accommodate greater angular movement
of the inner
sleeve 4 relative to the conduit even as the coupling is simultaneously
accommodating axial
movement of the conduits.
[0029] In one embodiment, inner sleeve 4 may be one solid piece, as
depicted in
FIGS. 1 and 2. In another embodiment, multiple inner sleeves 4 may be joined
together using
one or more center joint 7, as depicted in FIG. 3. Center joint 7 allows an
even larger range
of motion, both in an axial direction and angularly. As can be seen from FIG.
3B, center
joint 7 has a convex inner surface such that the larger ends of inner sleeve 4
are trapped within
it due to the smaller diameter at the outer surface of the center joint 7
relative to the middle of
center joint 7.
[0030] As can be appreciated from FIG. 313, in a preferred embodiment,
the inner
surfaces of the inner sleeve 4 are smooth and void of sharp edges. The smooth
surface
prevents the wires from being pinched as the coupling flexes and moves to
accommodate the
stresses of its environment. The smoother inner surfaces also allow the wires
to move within
the coupling without becoming snagged or restricted by an interior edge.
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[0031] The disclosed coupling has a significantly greater range of
motion in both
the axial and angular directions compared to other known coupling devices. As
a result, the
device can be used where axial expansion or contraction is anticipated, where
there is angular
movement between conduits, or where there is parallel deflection between the
conduits. It
should be appreciated that the inner diameter of the disclosed coupling does
not decrease as
the coupling moves. The wires, therefore, do not get pinched as the coupling
moves.
[0032] Due to the modular construction of the device, multiple
couplings may be
directly attached to each other to achieve an even greater range of motion. To
connect one
coupling to another, the male end 2 of one device is inserted into coupling
end 1 of a second
device. The modular construction of the couplings allows the wires that pass
through it to be
protected as the building, bridge, or other structure moves in any direction
and over any
distance. It should be appreciated that the modular construction further
allows the device to
simultaneously accommodate movement in the axial direction and angularly from
any
direction, not just one fixed direction.
[0033] In one embodiment, as shown in FIGS. 3A and 3B, the disclosed
device
may additionally include a boot or jacket that surrounds the hubs at both ends
of the coupling.
The boot may be made of rubber or neoprene, or any other flexible material
that can be used
to create a water-tight seal. The boot may be secured to the exterior surfaces
of the coupling
end adapter sub-assembly 5 and the male end adapter sub-assembly 3 by use of
jacket strap 8,
preferably a stainless steel tamperproof strap or plastic ties, such as TY-RAP
brand cable ties
or CATAMOUNT brand cable ties. Although the boot does limit the degree of
movement in a
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wet environment, the boot allows the inner mechanisms of the conduit and the
electrical
wiring to remain dry.
[0034] In another embodiment, as shown in FIGS. 5A, 5B, and 5C, the
disclosed
device may include a boot or jacket that surrounds the hubs at both ends of
the coupling. The
boot may be made of rubber or neoprene, or any other flexible material that
can be used to
create a water-tight seal. The boot may be secured to the exterior surfaces of
the end bodies
by use of jacket strap 8, preferably a stainless steel tamperproof strap or
plastic ties, such as
TY-RAP brand cable ties or CATAMOUNT brand cable ties. Although the boot does
limit the
degree of movement in a wet environment, the boot allows the inner mechanisms
of the
conduit and the electrical wiring to remain dry. The device may be configured
to have two
male end bodies (as shown in FIG. 5B), or two female end bodies (not shown),
or one male
and one female end body (as shown in FIG. 5C). In a preferred embodiment, the
end bodies
are constructed of a single piece of non-metallic rigid material.
[0035] As shown in FIG. 5B, the inner sleeve may be constructed of a
single piece
non-metallic rigid material to reduce manufacturing costs and time. As can be
seen from FIG.
5B, the inner sleeve has an inner diameter large enough for the conduit to
accommodate the
wires that pass through it. The diameter of the inner sleeve is larger at the
ends than in the
middle of the inner sleeve. At each end of the coupling, the larger end of the
inner sleeve is
housed within end adaptor bodies. As can be appreciated from FIG. 5B, a lip
member seated
in a groove of the interior portion of each end body partially surrounds the
larger end of inner
sleeve. The diameter of the lip member is larger than the diameter of inner
sleeve, but smaller
than the larger end of inner sleeve. As a result, inner sleeve can move
axially relative to the
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ends of the coupling, or it can pivot within the end bodies. The ends of the
inner sleeve may
also have a surface that is curved inward toward the axis of the inner sleeve.
The angle of
curvature of each of the curved surfaces is selected so that contact between
the edge of the
inner sleeve and the inner surface of the end bodies is minimized. The
curvature of the two
surfaces allows the coupling to accommodate greater angular movement of the
inner sleeve
relative to the conduit even as the coupling is simultaneously accommodating
axial movement
of the conduits.
[0036] In yet another embodiment, as shown in FIGS. 6A-6E, the
disclosed device
has an expandable and contracting jacket or boot 9. The expandable and
contracting jacket or
boot 9 can be made of any suitable material allowing for expansion and
contraction of the
device, such as rubber, neoprene, or other flexible material, while also
creating a water-tight
seal. In a preferred embodiment, the expandable and contracting jacket or boot
9 is made of
rubber. The expandable and contracting jacket or boot 9 is fastened to the
terminal end bodies
11 of the device by jacket straps 8, preferably one jacket strap 8 on each
terminal end body 11.
The fastening jacket straps 8 can be made of any suitable material, preferably
metal. In a
preferred embodiment, the straps are constructed of stainless steel. The
expandable and
contracting jacket or boot 9 is also flexible to allow for axial and angular
motion of the device
in practice. Other embodiments of the disclosed device may lack an expandable
and
contracting jacket or boot 9, while retaining the lip 13 portion fastened to a
terminal end body
11 by a jacket strap 8, to allow for an even greater range of axial and
angular motion.
[0037] The terminal end bodies 11 of the disclosed device can be
configured to
include two coupling ends 1 (FIGS. 6A-6C), two male ends 2 (FIG. 6E), or one
coupling end
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1 and one male end 2 (FIG. 6D). In a preferred embodiment, as shown in FIG.
6B, both
terminal end bodies 11 of the disclosed device are configured to include
coupling ends 1. The
terminal end bodies 11 of the disclosed device may be made of any suitable
rigid non-metal
material, such as molded ABS plastic or PVC, for example. In a preferred
embodiment, the
terminal end bodies 11 are made of PVC. The coupling ends 1 may be secured to
a rigid non-
metallic conduit (16,17) with male end 2 through the use of a suitable
adhesive, such as PVC
cement. Likewise, a male end 2 may be secured to a rigid non-metallic conduit
(16,17) with
coupling end 1 through the use of a suitable adhesive, such as PVC cement.
[0038] The inner sleeve 4 may include a center joint 7, a solid joint,
or be
constructed of one single piece as shown in FIG. 6B. In a preferred
embodiment, the inner
sleeve is a single piece dual funneled (flared) rigid non-metallic conduit
tube. The expandable
and contracting jacket or boot 9 is designed to create a lip 13 in the jacket
or boot 9 at or near
the internal end 14 of the terminal end bodies 11, configured such that a
terminal end 15 of the
inner sleeve 4 does not enter the internal jacket space 12 as the device
expands or contracts.
The lip 13 of the expandable and contracting jacket or boot 9 is further
configured to maintain
continuous identity for the conduit pathway from the first terminal end body
11 through the
inner sleeve 4 to the second terminal end body 11 in the relaxed or non-
expanded state. This
feature allows for ease of use in threading electrical wires through the
disclosed device. In the
expansion/deflection state, the lip 13 of the expandable and contracting
jacket or boot 9 is
configured to prevent stress on the electrical wires running through the
device.
[0039] The disclosed device is preferably constructed of a molded ABS
plastic or
PVC. If the inner sleeve 4 is one solid piece, it may be formed from a tubular
piece of plastic
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that has been heated and placed over a mold to form the larger ends. In
preferred
embodiments, the inner sleeve 4 is a single injection-molded, solid PVC tube
with flared ends.
Alternatively, it may be made from two half pieces of molded plastic that are
fused together
with heat or an adhesive. If the inner sleeve 4 is constructed of two or more
pieces joined
together at a center joint 7, the center joint 7 would be made from two
separate portions of
molded plastic that are fused together around the larger end of the inner
sleeve 4.
[0040] While the invention has been described with respect to a
limited number of
embodiments, those skilled in the art, having benefit of this disclosure, will
appreciate that
other embodiments can be devised which do not depart from the scope of the
invention as
disclosed herein. Accordingly, the scope of the invention should be limited
only by the
attached claims.
[0041] The terms "comprising," "including," and "having," as used in
the claims
and specification herein, shall be considered as indicating an open group that
may include
other elements not specified. The terms "a," "an," and the singular forms of
words shall be
taken to include the plural form of the same words, such that the terms mean
that one or more
of something is provided. The term "one" or "single" may be used to indicate
that one and
only one of something is intended. Similarly, other specific integer values,
such as "two," may
be used when a specific number of things is intended. The terms "preferably,"
"preferred,"
"prefer," "optionally," "may," and similar terms are used to indicate that an
item, condition or
step being referred to is an optional (not required) feature of the invention.
[0042] The invention has been described with reference to various
specific and
preferred embodiments and techniques. However, it should be understood that
many
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variations and modifications may be made. It will be apparent to one of
ordinary skill in the
art that methods, devices, device elements, materials, procedures and
techniques other than
those specifically described herein can be applied to the practice of the
invention as broadly
disclosed herein without resort to undue experimentation. All art-known
functional
equivalents of methods, devices, device elements, materials, procedures and
techniques
described herein are intended to be encompassed by this invention. Whenever a
range is
disclosed, all subranges and individual values are intended to be encompassed.
This invention
is not to be limited by the embodiments disclosed, including any shown in the
drawings or
exemplified in the specification, which are given by way of example and not of
limitation.
[0043]
The scope of the claims should not be limited by the preferred
embodiments set forth in the examples, but should be given the broadest
interpretation
consistent with the description as a whole.
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