Removable Weatherproof Seal for Wiring Device Shoulder
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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 inadequate sealing, and allow moisture to enter the device through wiring connections.
Innovation Solution
A sealed wiring device with a removable weatherproof cover that includes a shoulder with a sealing element to create a weatherproof seal between the wiring device and the cover, preventing moisture from entering, while allowing for easy replacement of the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a weatherproof cover with gasket material is used to protect the device, then protection against elements is improved, but water can still penetrate between the cover and structure leading to short circuits
Solution Approach 1:
The device is segmented into multiple sealing zones: a first sealing element at the interface between the weatherproof cover and wallbox, and a second sealing element at the interface between the device and wallbox. This segmentation ensures that if water penetrates one seal, it cannot reach the electrical components.
Solution Approach 2:
Sealing elements are pre-installed at both interfaces before the device is fully assembled and mounted. This preliminary sealing action prevents water from entering critical areas during installation and operation, addressing the short circuit risk before it can occur.
2Reliability
If the weatherproof cover is permanently sealed to prevent water entry, then reliability is improved, but the ability to remove and replace the cover is lost
Solution Approach 1:
The sealing system is designed with dynamic characteristics, allowing the weatherproof cover to be removably mounted while maintaining sealing integrity. The first sealing element enables repeated attachment and detachment cycles without compromising the weatherproof seal, combining reliability with operational flexibility.
3Ease of manufacture
If openings are provided for wiring connections, then ease of installation is improved, but water can enter through these openings and cause short circuits
Solution Approach 1:
The second sealing element acts as an intermediary barrier between the wiring openings and the electrical device. It allows wires to pass through the wallbox interface while preventing water from traveling along the wires into the device, thus protecting against moisture contamination while maintaining wiring accessibility.
Data Source
AI summary
An environmentally sealed wiring device with removable weather-resistant cover includes a wiring device with a device housing, a shoulder extending from the device housing and a sealing element disposed about the shoulder. The wiring device includes wires extending through one or more openings in the device housing. The openings are environmentally sealed around the wires to prevent moisture from entering the device. A weatherproof cover housing includes a pair of openings. The wiring device is positioned next to, and sometimes through, one of the openings. The sealing element is disposed between the weatherproof cover housing and the shoulder of the wiring device, providing a weatherproof seal therebetween, to prevent moisture from entering the device. A door is coupled to the weatherproof cover housing and can be rotated about an axis along an edge of the weatherproof cover housing between an open position and a closed position.