Integral Weatherproof Cover Sealing for Wiring Devices
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Solution Overview
Problem
Existing weatherproof covers for outdoor electrical devices fail to prevent water from penetrating between the cover and the structure, leading to potential short circuits due to moisture ingress.
Innovation Solution
A sealed device with an integral weatherproof cover that integrates the wiring device and weatherproof cover housing, using environmentally sealed openings and a rotatable door to prevent moisture from entering, and includes a gasket for additional sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a weatherproof cover with openings for cable access is used, then ease of operation is improved, but reliability deteriorates due to water penetration through the openings
Solution Approach 1:
The patent implements nested sealing by placing a grommet inside the cable opening, creating a multi-layer protection system where the grommet is nested within the opening structure to seal around the cable while maintaining access functionality
Solution Approach 2:
The grommet acts as an intermediary element between the cable opening and the weatherproof cover body, providing a sealing interface that allows cable passage while blocking water penetration paths
2Object-affected harmful factors
If a weatherproof cover attached to a wallbox is used, then protection against elements is improved, but water can still penetrate between the cover and wallbox structure
Solution Approach 1:
The patent employs a flexible gasket material that conforms to the interface between the weatherproof cover and wallbox, creating a compliant seal that accommodates surface irregularities and prevents water infiltration along the junction
Solution Approach 2:
The gasket is pre-installed on the weatherproof cover before attachment to the wallbox, ensuring the sealing surface is prepared in advance to prevent water penetration paths at the interface
3Ease of manufacture
If openings are provided in the device for wire access, then ease of manufacture is improved, but reliability deteriorates due to moisture ingress through openings
Solution Approach 1:
The grommet is nested within the opening structure, creating a multi-layer protection system where the sealing element is positioned inside the opening to block moisture while maintaining wire access functionality
Solution Approach 2:
The flexible grommet material creates a conformal seal around the wire opening, providing moisture protection while maintaining the necessary access pathway for electrical conductors
Data Source
AI summary
A sealed device with integral weatherproof cover includes a device integral with a weatherproof cover to prevent the introduction of moisture into the device. A portion of the device is positioned within the weatherproof cover housing. The device includes wires extending out through one or more openings along or near the back of the device. The openings are environmentally sealed around the wires to prevent moisture from passing therethrough. The weatherproof cover housing includes a pair of openings. A portion of the device is positioned next to, and sometimes through, one of the openings. A door is coupled to the weatherproof cover housing and positioned adjacent the other opening. The door can be moved about an axis along an edge of the weatherproof cover housing such that the door can be adjusted between an open position and a closed position about the second opening.