A junction box

Abstract

A junction box comprising: a base 10 and a lid 20 that defines a cavity (fig 1E, 5); at least one opening 30 through the base to the cavity through which a wire or cable is received. Base has at least

Description

Field of the Invention The present invention relates to junction box, in particular a junction box for lever wire connectors. Background Junction boxes are used as a container in which wires are connected together, in some cases by means of an electrical connector to make the electrical connection. It is increasingly common to use lever action electrical connectors to connect a wire. However different electrical connectors have the levers in different positions which can mean that the lever movement may be restricted once an electrical connector is positioned in a junction box. Furthermore, it is often preferable to use different size electrical connectors that have a different number of ports and to be able to position electrical connectors at selected locations in a junction box. However many junction boxes only have fixed slots for an electrical connector which may make some connections more difficult to complete. The present invention overcomes these problems. Prior Art UK Patent GB2592480 (HUSSAIN) discloses a wire connection terminal apparatus. Summary of the Invention According to a first aspect of the present invention there is provided a junction box comprising: a base and a lid that defines a cavity; at least one opening through the base to the cavity through which a wire or cable is received; wherein the base has at least one slot for receiving electrical connectors and each slot has a bed, a securing bar and an engagement means for locating an electrical connector in a fixed orientation. In this way one or more electrical connector can be positioned in a selected position in the slot provided within the junction box and positioned in a fixed orientation for receiving wires by the engagement means. This enables a user to select where in the slot an electrical connector is positioned and to orientate the connector so that the opening that receives the wire is easily accessible and remains fixed. Advantageously the securing bar may also be shaped and / or positioned in some embodiments for electrical connectors that use a lever to make a connection, so that the lever can still be moved freely whilst the electrical connector is fixed in position by the engagement means. The base has at least one slot with a bed (lower surface) on which the electrical connector is seated and securing bar (upper surface) with an engagement means. The electrical connector is received between the bed and securing bar so that it engages with both surfaces and the electrical connector is supported and held in position. The slot may be wider than a typical single electrical connector so the electrical connector can be positioned at a selected location along the width of the slot. This allows for different electrical connectors to be placed at different positions in the slot for receiving different wires and for multiple electrical connectors to be arranged in the same slot. The engagement means fix the position and orientation of the electrical connector in the slot preventing lateral movement of twisting of the electrical connector once inserted to the slot. The engagement means is preferably one or more recess for receiving a projection on the electrical connector or vice-versa. The engagement of the recess and projection fixes orientation of the electrical connector. In a preferred embodiment the recesses and optionally the projections are elongate to define an axis along which the electrical connector is orientated. For example, the recess may be an elongate groove that receives an elongate ridge on an outer upper surface of the electrical connector. Preferably the elongate recess may taper from a wider opening at one end of the elongate recess that corresponds to a side of the securing bar from which the electrical connector is inserted. Having a wider opening of the recess means that it is easier to align a projection into the recess and guide it along the elongate groove (recess) to a narrower region of the groove so that the electrical connector becomes more securely fixed during inserting and has no, or extremely limited, lateral movement of the projection within the groove. In a preferred embodiment the elongate recess (groove) runs across the securing bar from front to back so that there is a continuous groove. Preferably an end of the groove at the back of the securing bar has the wider opening for receiving the projection on the electrical connector that is inserted from the back of the securing bar towards the front of the slot. In another embodiment the engagement means is a clip at a front region of the slot that engages an edge of the electrical connector so that it is seated in a fixed orientation in the slot. In some embodiments the clip may be provided at a rear region of the slot. The electrical connector may be held into the clip by an urging means, such as a resiliently deformable leg that acts to push the edge of the electrical connector into the slot. In some embodiments the securing bar is at a front face of the slot and a back face of the slot is partially open. In some embodiments the securing bar is at a back face of the slot and the back face of the slot is partially open to permit access. The position of the securing bar may alter the direction of insertion for the electrical connectors. For example when the securing bar is at a front face this arrangement may permit insertion of an electrical connector from back to front of the slot and when the securing bar is at a rear face the electrical connector may be inserted front towards the back of the slot. It is appreciated that in some embodiments the securing bar may be at a mid-region between the front and rear of the slot so that electrical connectors may be inserted from either direction. The front face is of the slot is considered to be where wires are received. The back face is at least partially open to permit access to the electrical connectors when installed. The access at the back face also helps enable movement of a lever on the electrical connector between first (closed) and second (open) positions. This arrangement is preferable for lever electrical connectors with a distal end of the lever at the back of the electrical connector, such as Ideal (RTM) connectors. In this way on a front facing region of the electrical connector is positioned in contact between the bed and the securing bar and the rear region is open to permit access to the connectors. In a preferred embodiment the slot has at least one back stop, rather than a back wall that prevents the electrical connector passing completely through the slot and out the back of the slot. In this way the rear region of the slot is partially open making it possible to access where the electrical connector and back stop engage. By having the rear region open it is also possible in some embodiments for the electrical connector to be inserted from the rear region and maintaining clear access to levers that may be on the electrical connectors. In some embodiments the back stop(s) may be adapted to engage with part of the electrical connector. In a preferred embodiment the back stop may be a resiliently deformable leg, with a lip that engages with the electrical connector. For example the lip and leg may be displaced as the electrical connector is inserted to allow the lip to engage with part of the electrical connector once correctly inserted. In another embodiment the back stop is a resiliently deformable leg that acts to force the electrical connector against a front clip on the slot to hold the electrical connector in place by the resistive force of the resiliently deformable leg applied against the electrical connector towards the front clip. In a preferred embodiment each slot has opposed side walls so that the bed, securing bar and side walls define a rectangular opening through which electrical connectors are secured. Preferably the engagement means may be arranged to ensure electrical connectors are received square in relate to side walls of the slot. It is appreciated that in some embodiments the engagement means may enable the electrical connector(s) to be fixed at an angle in the slot, for example so that the wire receiving part of the electrical connector is present towards an opening through which a wire or cable is received, thereby making connection easier and avoiding kinks in the wire. The openings for the wires / cables are in the base of the junction box so that wires or cables received through the openings are not displaced by opening the lid to access the cavity. Each opening is arranged in a side of the base so that wires are received through a side of the base into the cavity defined between the opening in the base and the lid. The openings are preferably extended through at least part of the depth of the base and in some embodiments the whole depth of the base so that wires can be received at different levels in the opening. In a preferred embodiment the lid includes wedges that are received into an upper region of the cavity as the lid is closed. Advantageously the wedges act to prevent deflection of the junction box when the lid is closed and thereby helps to maintain the position of the cables as the opening and the sprung arm do not deform. In preferred embodiments the number of openings corresponds to the number of slots. In this way each opening may direct a wire or a cable to a particular slot so that each wire or cable has a separate pathway from an opening to a slot. This has the advantage that separate wires or cables can be easily visually identified and tangling is limited or prevented since there is no requirement for any wire or cable to cross. Furthermore this may help prevent overloading at the junction box by only providing the intended number of openings for the number of wires / cables to be received. In a preferred embodiment each opening has at least one sprung arm for retaining the wire or cable. The sprung arm is biased to close the opening, so that the arm must be displaced to insert a wire or cable and thus once the sprung arm(s) is released the wire / cable is gripped to prevent movement through the opening without disengaging the sprung arm. Preferably each sprung arm is anchored at an outer edge of the base and the arm extends inwards, towards the cavity so that the distal end of the arm is naturally displaced as a wire is pulled into the cavity but so that attempting to pull the wire from the opening will not act to release the sprung arm. In a preferred embodiment an upper face of each sprung arm is angled and / or profiled to assist with easily receiving a wire or cable that is placed over the sprung arm and then pushed down by a user into the cavity. For example the upper face of each sprung arm may be angled downwards from the proximal end of the sprung arm towards the distal end so that a wire or cable is easily guided into the opening and fixed by the sprung arm. Additionally or alternatively the upper face may be radiused to present a smooth curved surface that will not kink or damage the cable or wire during fitting. It is appreciated that the cable is not intended to rest against the upper face of the sprung arm but is positioned against a side face that is arranged opposite to a side wall of the base. In a preferred embodiment the side wall of the spring arm has raised and lowered portions to grip the cable. In addition the side wall of the base may also include raised and lowered portions to grip the cable. The grip portions help to ensure the cable remains connected and does disconnect overtime due to vibration or through unintended movement of the junction box. In preferred embodiments the raised and lowered portions are spikes that extend towards where the cable is received. Preferably the spikes on the side wall sprung arm are equilateral triangular projections. Preferably the spikes on the side wall of the base are right angled triangles with the hypotenuse side directed to where the cable enters through the opening so that the cable is guided in but will snag on the spikes of attempted to be pulled out without first deflecting the sprung arm off the cable. In some embodiments the size of the spikes vary to enhance grip. For example spikes on the side wall of the base may be of two or more difference sizes so that multiple cables that may be of difference sizes can be securely held. In some embodiments each sprung arm has at least one raised node that is presented to the wire or cable. The node provides a region of enhanced contact. In some embodiments the at least one node has a raised and lowered surface. For example the node may be toothed or have an array of projections that act to further engage with and grip the wire or cable. In some embodiments a wall of the at least one opening has a raised and lowered surface to also help to grip the wire or cable. For example the wall may have an array of elongate teeth. In this way the grip of the wire is enhanced and at the time of fitting and over time movement of the wire or cable is prevented, thereby providing enhanced safety to the electrical connections within the junction box. Preferred embodiments of the invention will now be described, by way of example and with reference to the Figures in which: Brief Description of Figures Figure 1A shows a top view of a first embodiment of an open junction box; Figure 1B shows a side view of the first embodiment of the open junction box; Figure 1C shows an underside view of the first embodiment of the open junction box; Figure 1D shows a front view of the first embodiment of the open junction box; Figure 1E shows a cross section of the first embodiment of the open junction box; Figure 1F shows an isometric view of the first embodiment of the open junction box; Figure 2A shows a top view of the first embodiment of the closed junction box; Figure 2B shows an isometric view of the closed junction box; Figure 2C shows a right side view of the closed junction box; Figure 2D shows a front view of the closed junction box; Figure 2E shows a left side view of the closed junction box; Figure 2F shows a cross section of the closed junction box; Figure 2G shows an underside view of the closed junction box; Figure 3A shows an underside view of a second embodiment of the open junction box; Figure 3B shows an isometric view of the second embodiment of the open junction box; Figure 3C shows a rear view of the second embodiment of the open junction box; Figure 3D shows a left side view of the second embodiment of the open junction box; Figure 3E shows a top view of the second embodiment of the open junction box; Figure 3F shows a right side view of the second embodiment of the open junction box; Figure 3G shows a front view of the second embodiment of the open junction box; Figure 4A shows a top view of the first embodiment of the closed junction box; Figure 4B shows an isometric view of the closed junction box; Figure 4C shows a right side view of the closed junction box; Figure 4D shows a front view of the closed junction box; Figure 4E shows a left side view of the closed junction box; Figure 4F shows a cross section of the closed junction box; Figure 4G shows an underside view of the closed junction box; Figure 5A shows a third embodiment of an open junction box with the securing bar at a rear region; Figure 5B shows a cross section of Figure 5A; Figure 6A shows a fourth embodiment of an open junction box with the securing bar at a rear region; Figure 6B is a cross section of Figure 6A; Figure 7A is a side view of the third embodiment; Figure 7B is a cross section of Figure 7A; Figure 8A is a side view of the fourth embodiment; Figure 8B is a cross section of Figure 8A; Figure 9 is a top view of the third embodiment of the junction box; Figure 10 is top view of the fourth embodiment of the junction box; Figure 11 is an isometric open view of the third embodiment; Figure 12 is an open isometric view of the fourth embodiment; Figure 13 is a front view of the third embodiment with the lid and Figure 14 is a front view of the fourth embodiment with the lid etessdopen. Detailed Description of Figures Figures 1 and 2 show a first embodiment 100 of a junction box with three slots and securing bar 42 at a front region of the slots 40. Figures 3 and 4 show a second embodiment 200 of a junction box with four slots and securing bar 42 at the front region of the slots 40. Figures 5A, 5B, 7A, 7B, 9, 11 and 13 show a third embodiment 300 of the junction box with four slots 40 and a securing bar 42 at the rear region of the slots 40. Figures 6A, 6B, 8A, 8B, 10, 12 and 14 show a fourth embodiment 400 of the junction box with three slots 40 and a securing bar 42 at a rear region of the slots 40. Like parts have like references. Both junction boxes 100, 200 have a base10 and a lid 20 that defines a cavity 5 in which wires are received to electrical connectors to form an electrical connection within the junction box. The lid 20 has a clip 21 that engages with a ledge 12 the base 10. The base 10 and lid 20 are connected by a hinge 15 so that the parts remain together at all times. The hinge 15 is a living hinge. There are two openings 30 through each side of the base 10 for receiving wires or cables (not shown). The openings 30 are substantially the depth of the base 10 which can allow the wire or cable to be passed through at a different height in the opening and can also accommodate larger cables. The openings 30 have grip means 31, 35 to hold wires / cables in place to prevent them from being pulled from the junction box, or working free over time, for example due to vibration. Each opening 30 has a grip means in the form of a sprung arm 31. A proximal end 32 of the sprung arm 31 is connected to a side wall 11 of the base 10 and the arm 31 extends towards the cavity 5. The spring arm 31 is substantially S-shaped. A distal end 33 of the sprung arm 31 extends towards a wall 34 of the opening 30. In this way the sprung arm 31 acts as a barrier across the opening 30 that must be displaced to receive a wire / cable and which applies a force to the wire to cable to hold it in place. The orientation of the sprung arms 31 enables wire or cable to be pulled into the junction box cavity 5 as the sprung arm 31 will naturally displace under urging in the direction towards the cavity but will lock against the wire or cable if force is applied to pull the cable away from the junction box cavity, thereby providing enhanced safety. The distal end 33 of the sprung arm 31 and the wall 34 of the opening 30 both have a raised and lowered surface formed from a plurality of spikes 35 that engage with the surface of the wire / cable to provide enhanced grip. The spikes 35 have a triangular cross section. The spikes 35 on the side wall sprung arm 31 are equilateral triangular cross section projections. The spikes 35 on the side wall 34 of the opening 30 right angled triangular cross sections with the hypotenuse side directed to where the cable enters through the opening 30 so that the cable is guided in but will snag on the spikes 35 if attempted to be pulled out without first deflecting the sprung arm 31 off the cable. In the pictured embodiments the size of the spikes 35 on the side wall 34 of the opening 30 varies to enhance grip. In Figures 1A, 5A and 5B there is one larger spike 35A and then two smaller spikes 35B, followed by a larger spike 35A and two smaller spikes 35B and then a larger spike 35A. This allows curvature in the cable for enhanced grip. The sprung arms 31 are visible on the underside views (Figures 1C, 2G) of the base as there are holes through the base 10 in the shape of the sprung arms. The upper face 36 of each sprung arm 31 is angled and profiled to allow easy insertion of the cables / wires. This shaping allows the openings 30 to easily accommodate thick and thin cables / wires. The upper face 36 is angled downwards from the proximal end of the sprung arm 31 towards the distal end and the upper face 36 is radiused to present a smooth curved surface that will not kink or damage the cable or wire. The lower face of the base 10 has a plurality of blank apertures 22 which provide ribs for structural support. There are also a plurality of through holes 23 that enable a tool to be inserted to displace the resiliently deformable legs 45 and lips 46 of the back stops 44 to release an electrical connector. The base 10 in the first embodiment 100 has three slots 40A, 40B, 40C for receiving electrical connectors (not shown). In the first embodiment each slot is labelled for a different connection. Slot 40A is intended for a ‘Live’ wire, slot 40B is intended for an earthing wire and slot 40C is intended for a neutral wire. The base 10 in the second embodiment 200 has four slots 40A, 40B, 40C, 40D for receiving electrical connectors (not shown). In the second embodiment each slot is labelled for a different connection. Slot 40A and 40B is intended for a ‘Live’ wire, slot 40B is intended for an earthing wire and slot 40C is intended for a neutral wire. Each slot has a bed 41 and a securing bar 42 with an engagement means 50 for locating an electrical connector in a fixed orientation. The engagement means 50 is an elongate groove along with a projection on an electrical connector is received. In a preferred embodiment each slot has opposed side walls 43 so that the bed 41, securing bar 42 and side walls 43 define a rectangular opening in which fronts of electrical connectors are received. Each slot 40 has a plurality of back stops 44, rather than a back wall that prevents the electrical connector passing completely through the back of the slot 40. In this way the back region of the slot 40 is partially open making it easier for insertion of the electrical connector from this direction shown by arrow ‘B’ in Figure 1E, whilst also maintaining clear access to levers that may be on the electrical connectors. The back stop(s) 44 are adapted to engage with part of the electrical connector. Each back stop has a resiliently deformable leg 45, with a lip 46 that engages with the electrical connector. The lip 46 and leg 45 are displaced as the electrical connector is inserted to allow the lip 46 to engage with a ledge on the electrical connector once correctly inserted. The upper and back region of the slots 40 is open so that part of the electrical connector beyond the securing bar 42 is visible and accessible. In this way, a lever on a lever operated electrical connector is accessible. The pictured embodiments are intended for use with electrical connectors that a lever with a distal end of the lever arm towards a rear region of an electrical connector, such as Ideal (RTM) connectors. Figures 5 to 14 show two sizes 300, 400 of an embodiment with a securing bar 42 at a back face of the slots 40. In all embodiments, a back face of the slots 40 is partially open to permit access allowing a user to reach the electrical connectors. In Figures 6A, 6B, 8A, 8B, 10, 12 and 14 the base 10 in the third embodiment 300 has three slots 40A, 40B, 40C for receiving electrical connectors (not shown). In the first embodiment each slot is labelled for a different connection. Slot 40A is intended for a ‘Live’ wire, slot 40B is intended for an earthing wire and slot 40C is intended for a neutral wire. In Figures 5A, 5B, 7A, 7B, 9, 11 and 13 the base 10 in the fourth embodiment 400 has four slots 40A, 40B, 40C, 40D for receiving electrical connectors (not shown). In the second embodiment each slot is labelled for a different connection. Slot 40A and 40B is intended for a ‘Live’ wire, slot 40B is intended for an earthing wire and slot 40C is intended for a neutral wire. In the third and fourth embodiments 300, 400 each slot has a bed 41 and a securing bar 42 with an engagement means 50 for locating an electrical connector in a fixed orientation. The engagement means 50 in the third and fourth embodiments is a clip 50 at a front region of the slot that engages an edge of the electrical connector so that it is seated in a fixed orientation in the slot 40. Each slot 40 has opposed side walls 43 so that the bed 41, securing bar 42 and side walls 43 define a rectangular opening in which electrical connectors are received. As the securing bar 42 is at a back face of the slot 40 in the third and fourth embodiments, the electrical connectors can be inserted from the front of the slot to arrange the electrical connector under the securing bar 42 and to deform the backstop 44. The electrical connector is then pushed downwards to engage with the front clip 50 and the resiliently deformable leg 45 acts to force the electrical connector towards the clip 50 to maintain a secure fitting. Each slot 40 has a partial back wall 44 with a plurality of resiliently deformable leg 45 extending therefrom that are in contact with the electrical connector when fitted. A proximal end of each resiliently deformable leg 45 extends from a top edge of the back wall 44 at an angle towards the base 10. The distal end of the legs 45 are displaced as the electrical connector is inserted. The upper and back region of the slots 40 is open so that part of the electrical connector beyond the securing bar 42 is visible and accessible. In this way, a lever on a lever operated electrical connector is accessible. The pictured embodiments are intended for use with electrical connectors that have a lever with a distal end of the lever arm towards a rear region of an electrical connector, such as Ideal (RTM) connectors. The lid 20 has wedges 24 that are shaped and dimensioned to be received into part of the openings 30. These wedges 24 slot into the upper part of the opening 30 to help prevent deflection of the junction boxes in use, in particular when larger cables are used. The invention has been described byway of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention as defined by the claims.

Claims

1. A junction box comprising: a base and a lid that defines a cavity; at least one opening through the base to the cavity through which a wire or cable is received; wherein the base has at least one slot for receiving electrical connectors and each slot has a bed, a securing bar and an engagement means for locating an electrical connector in a fixed orientation.

2. A junction box according to claim 1 wherein the engagement means is a clip to locate the electrical connector in the slot.

3. A junction box according to claim 1 or claim 2 wherein the engagement means is one or more recess on the securing bar for receiving a projection on the electrical connector.

4. A junction box according to claim 3 wherein the recess is an elongate groove.

5. A junction box according to claim 4 wherein one end of the elongate groove has a wider opening to receive and guide a projection.

6. A junction box according to any preceding claim wherein the engagement means is one or more projection for receiving a recess on the electrical connector.

7. A junction box according to any preceding claim wherein each slot has opposed side walls.

8. A junction box according to any preceding claim wherein the securing bar is at a front face of the slot and a back face of the slot is partially open to permit access.

9. A junction box according to any of claims 1 to 7 wherein the securing bar is at a back face of the slot and the back face of the slot is partially open to permit access.

10. A junction box according to any of claims 1 to 7 wherein the securing bar is at a mid-region between the front region and back region of the slot.11 .Ajunction box according to any preceding claim wherein the slot has at least one back stop to prevent the electrical connector passing through the back of the slot.

12. A junction box according to claim 10 wherein the back stop has a resiliently deformable leg with a lip.

13. A junction box according to claim 10 wherein the base has holes at locations corresponding to each back stop for insertion of a tool to displace the back stop to release an electrical connector.

14. A junction box according to any of claims 2 to 9 wherein the slot has back wall with a plurality or resiliently deformable legs that act to force each electrical connector against the clip provided at a front region of the slot to hold the electrical connector in place by the resistive force of the resiliently deformable leg applied against the electrical connector towards each clip.

15. A junction box according to any preceding claim wherein an upper face of each sprung arm is angled.

16. A junction box according to any preceding claim wherein an upper face of each sprung arm is profiled.

17. A junction box according to any preceding claim wherein a side wall of the spring arm has raised and lowered portions to grip the cable.

18. A junction box according to any preceding claim wherein a side wall of the base has raised and lowered portions to grip the cable.

19. A junction box according to claims 17 or 18 wherein the raised and lowered portions are spikes that are triangular in cross section.

20. A junction box according to acclaim 19 wherein the spikes size varies.

21. A junction box according to any preceding claim wherein the lid includes wedges that are received into an upper region of the cavity as the lid is closed to minimise deformation of the junction box.

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