Abstract:
An enclosure for a buried-cable splice. The enclosure has two parts: (i) a container having a closed end, an open end, and sealant inside, sealant inside, and (ii) splice-supporting member that is received through the open end of the container. Once inserted into the container, the splice-supporting member immerses the splice within the sealant so that the splice will be protected from its underground environment. A locking mechanism is provided which prevents withdrawal of the member from the container after assembly. The mechanism has a number of wave-shaped annular protrusions located on the inner surface of the open end of the container, and a reciprocating number of accommodating channels located on an outside engaging surface of the splice-supporting member. These channels accept the wave-shaped protrusions and thus prevent the member from being removed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     None. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     None. 
     BACKGROUND OF THE INVENTION 
     The present invention relates to underground cable splice enclosures. More specifically, the invention relates to the kind of buried splice enclosures which protect the splice by immersing it into a sealant and securing it within a shell which contains the sealant 
     Telecommunications lines are oftentimes buried beneath the ground. It is oftentimes necessary to connect or reconnect wires using a splice. A splice is a way of electrically connecting two wires. The end of each wire is connected to the other. When such a splice is completed, it is necessary to protect it from the underground environment. This is because moisture intrusion can cause corrosion and other degradation of the wires and other associated equipment. While it is important to prevent against moisture intrusion, it is also desirable to create a splice that holds the wires securely together so that they may not be pulled apart. This is important as cable may be unintentionally snared once placed in service. 
     The prior art has dealt with these problems by creating an enclosure having a plug and a sleeve. In such a system, the cables are first assembled and attached on the plug, and then the plug is inserted into a sealant-containing enclosing sleeve. This causes the splice to become buried in the sealant. The sealant completely encapsulates the unjacketed portions of cable so that it will not be exposed to the underground elements when it is used in the field. 
     One example of a conventional encapsulating device is shown in prior art FIG.  1 . Referring to the figure, the prior-art assembly  100  has two parts. The first part is a splice-supporting plug  102 . The second part is a tubular sleeve  104 . 
     Plug  102  has an encapsulating end  113  and a cable driver end  114 . Cable driving end  114  is used to receive and secure the spliced portions of the cables (not pictured) in a forked collar  118 . Driver end  114  is stabilized using cross members  116 . Intermediate the driver end  114  and encapsulating end  113  is an arm portion  110 . Arm  110  is the thinnest portion of the plug  102 . On arm  110  is a plate receiving snap-lock  112 . Snap-lock  112  is used in conjunction with an aperture (not shown) bored through arm portion  110 . Snap-lock  112  and the aperture are used to secure two plates which are meshed together around the wires used in the splice in a manner known to those skilled in the art. 
     Encapsulating end  113  comprises a pair of arms  106  each having female threads  120  on an inside surface thereof. Also on encapsulating end  113  is an outer plug surface  108 . 
     Tubular sleeve  104  comprises a closed end  124  and an open end  126 . On the sleeve  104  is generally cylindrical at the open end  126  to the left of an annular rib  128  (see smooth surface  132 ). To the right of the annular rib  128 , however, a handle portion  134  has a hexagonal cross section. 
     The two spliced wires are admitted into sleeve  104  via passageways which are formed by a plurality of proposed wire conforming jaws  136  as can be seen on the plug  102  in FIG.  1 . Throughout, one side view showing conforming jaws  136  is shown in FIG. 1, it should be understood that the other side his identical structure. When the device  100  is used to bury a splice, the two cables to be spliced are attached to plug  102 . This is done by inserting a first wire in the passageway created by opposing jaws  136  and then the arm portion  110 . This is done by clamping the wire to the plug using clamping plates (not. pictured) which are secured to plate receiving snap-lock members  112 . On the other side of plug  102 , the identical set of clamping members on the other side create a passageway for a second wire which is then held to the arm portion  110  by an opposing plate on the opposite side of the plug, said opposing plate being held by another snap-lock (all not pictured). The forked collar  118  is what receives the actual spliced cable and supports it. This collar  118  is what is used to drive the splice into the sealant. The sealant (not pictured) is contained in the shell  104 . 
     In order to create a water seal and protect the splice in its buried environment, plug  102  is screwed into sleeve  104 . This is done by taking the plug  102  with the splice already installed on it and inserting it into forked collar end  118  first. When the splice held within forked collar  118  is pushed deeper into shell  104 , the bare wire (unjacketed) is driven into the sealant (not pictured) within shell  104 . Once plug  102  has penetrated a significant depth into shell  104 , female threads  120  on plug  102  will engage male threads  122  on shell  104  by twisting plug  102  in a clockwise manner. This will cause the splice to be driven deep within shell  104 . As plug  102  is screwed in, projection  130  will pass through the female threads  120  on each of the arms  106 , and will, at least partially, prevent the plug  102  from later being unscrewed. This design, however, has proved inadequate for preventing removal of the plug because the user can easily manipulate the arms or simply unscrew with force to defeat the projection  130 , and remove the plug. 
     The removability of the plugs in conventional devices has proved problematic. This is because such spliced devices are not designed to be reused. It has been the experience that-technicians in the field will oftentimes attempt to make a quick fix of a faulty cable splice by simply removing the plug  102 , reconnecting the wires, and then reinserting the same plug into the same shell  104  rather than make a replacement of the splice using a new enclosure with fresh sealant. This temporary shortcut, however, on the whole has proved to be very costly. This is because, though the technician may save minutes by reusing an enclosure, the reused enclosure will never be as protective as would a new enclosure with fresh sealant. Significant cost is tied into making repeat calls to fix failed splices that are due to such “quick fix” repairs in which the technicians simply reuse the old device intended for replacement. Though these devices are very inexpensive to replace, the cost of a repeated call of a technician is much more expensive. Therefore, there is a need in the art for a buried splice enclosure with the sealing properties of device  100 , however, with a closure system that is not easily defeated. 
     SUMMARY OF THE INVENTION 
     The present invention provides an enclosure having a cap that is nearly impossible to remove. This is accomplished by providing a container having a closed end at one end and an opening at the other end. The container has protect sealant exposed inside of it. A splice-supporting member is received through the open end of the container. Once inserted into the container, the splice-supporting member immerses the splice within the sealant so that the splice will be protected from its underground environment. More specifically, this invention provides a locking mechanism is provided which prevents withdrawal of the member from the container. The mechanism comprises a number of wave-shaped annular protrusions located on the inner surface of the container, and a reciprocating number of accommodating channels located on an outside engaging surface of the splice-supporting member. These channels accept the wave-shaped protrusions and thus prevent the member from being removed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     The present invention is described in detail below with reference to the attached drawing figures, wherein: 
     FIG. 1 shows a conventional buried-splice arrangement. 
     FIG. 2 discloses the buried splice cap and container arrangement of the resent invention. 
     FIG. 3A shows a side view of the container of the present invention. 
     FIG. 3B shows the container of the present invention as viewed from the pen end. 
     FIG. 3C is also of the container, but shows it as viewed from the closed end. 
     FIG. 3D is a sectional view of the container of the present invention, said view taken in a plane inserting the center axis of said container. 
     FIG. 3E is a detailed view-showing the protrusions from the inside surface of the container of the present invention. 
     FIG. 4A shows the member of the present invention from its side. 
     FIG. 4B shows the member of the present invention from above (or below, as the two views are identical). 
     FIG. 4C shows the member of the present invention as viewed from the end with the collar. 
     FIG. 4D shows a cross-sectional view of the member, said section taken down the center axis of the member. 
     FIG. 4E is a detailed view of a channel of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is a tamper-proof buried splice enclosure. Its features prevent reuse of the enclosure by technicians in the field. Some technicians in the field are compelled to reuse existing enclosures for convenience sake. Reuse, however, has its cost. This is because, when old enclosures are reused, they will not seal as well as would a newly manufactured one. This will likely cause the reused splice enclosure to fail early—allowing the splice to degrade—eventually causing a break in continuity. Premature splice failure will necessitate a service call much earlier than would be required if a fresh enclosure had been used in the first place. Reuse, therefore, though possibly affording immediate time-savings, will ultimately cost the company. This is because the cost of providing a new enclosure is insignificant when compared to the cost of a technician making a maintenance call. Thus, by preventing technicians from reusing old enclosures, the tamper-proof enclosure of the present invention saves the user (business) money. 
     An enclosure  6  of the present invention is shown first in FIG.  2 . FIG. 2 shows both cable driving member  40  and a tubular container  10  of enclosure  6 . Container  10  has a receiving end  12  and a closed end  14 . Closed end  14  is substantially flat, except it is rounded at its peripheral edge  18  where it meets up with tubular housing of container  10 . 
     Container  10  defines an outwardly extending bulbous portion  20 . Portion  20  is used during insertion of member  40  into container  10 , as will be described hereinafter. 
     Receiving end  12  of container  10  defines an opening or mouth  16 . It also has a peripheral flange  77  having an abutment surface  24 . Surface  24  presses against an abutment surface  78  on a head  42  of member  40  as will be described hereinafter. 
     FIG. 2 shows the orientation of driving member  40  relative to container  10  before insertion of said member  40 . As can be seen from the figure, a forked end  43  of member  40  is inserted within container  10 . Upon insertion, forked end  43  will penetrate a sealant (not pictured) which is predisposed in container  10 . The splice is securely held in a collaring surface  44  of the forked end  43 . The splice along with forked end  43  will be pushed deep within the sealant almost to the extent of the closed end  14 . There, the splice will be held protectively within the sealant in a manner that is known to those skilled in the art, and will be protected from the elements. 
     Member  40  has outside surfaces  32  and  34  that are received within the open end  12  of container  10 . Because outside diameters of surfaces  32  and  34  are substantially equal to the inside diameter of open end  12 , member  40  is able to slide in to open end  12 . Upon this occurring, the open end  12  will be substantially plugged by member  40 . The member will penetrate the container until the abutment surface  78  engages abutment surface  24 . Long channels with wave-shaped cross sections  70 ,  71 , and  72  are used to secure member  40  within container  10  such that it may not be removed. These channels  70 ,  71 , and  72  on member  40 , and their reciprocating internal ribs  26 ,  28 , and  30  (respectively, See FIG. 3D) serve to lock member  40  within container  10 . 
     FIG. 3B shows the opening  16  in the receiving end  12 . The interior of the container  32  is where the sealing-material is located, as will be known to those skilled in the art. FIG. 3C is looking at the container  10  from its closed end  14 . In this figure, the flat circular wall  22  with its rounded edge  18  may be seen. Additionally, the peripherally outwardmost parts of bulbous portion  20  may be seen as well. 
     FIGS. 3D and 3E show the details of the innards of container  10 , including shallow interlocking rib  26 , a middle inner rib  24  and a deep inner rib  30  each of said ribs having a wave-shaped cross sections. FIG. 3E shows the configurations of each of ribs  26 ,  28 , and  30  in more detail. Each of these ribs has a sloped face  62 , an annular crest  64  and a barrier face  66 . These features are uniquely configured to, in conjunction with each of channels  70 ,  71 , and  72  to lock the member  40  securely within container  10  such that it is virtually unremovable once the member is secured within said container. 
     The specifics regarding the cable driving member  40  are disclosed in FIGS. 4A through 4E. Referring first to FIG. 4A, it may be seen that a number of mass reduction cross apertures  48 ,  49 ,  50 ,  51 ,  52  and  53  are defined by member  40 . These apertures are large enough to reduce the overall material required during manufacture, yet still small enough that structural integrity is not compromised. 
     FIGS. 4A and 4C show the cable permitting mechanisms of member  40 . Referring first to FIG. 4C we see that cable passageways  58  and  60  are formed through the member longitudinally. Thus, passageways  58  and  60  each receive a separate cable. Each cable runs alongside the stem  36  of said member  40 . The unjacketed wire to be spliced is received in the forked end of the member. FIG. 4A reveals that passageways are formed by a number of opposing faces  98  on each side of said member  40 . Even though only one side of member  40  is shown in FIG. 4A, it is to be understood that the opposite not-pictured side has identical structure. 
     As may also be seen in FIG. 4A, four gaps  68 ,  69 ,  73 , and  75  are formed in said member to remove unnecessary mass while maintaining structural integrity. These gaps may also be seen in FIG. 4D which shows a section of the member of the present invention taken down the middle of the member shown in FIG.  4 A. 
     FIG. 4C is a forked-end view of member  40 . From this view, longitudinal scoops  92  may be seen. These, like gaps  68 ,  69 ,  73 , and  75  also serve mass-reduction purposes while still enabling structural integrity. 
     Similarly, as may be seen in FIG. 4B, cross-sectional scoops  90  in rim  42  also serve mass-reduction purposes. Another feature shown in FIG. 4B is the bi-directional locking peg  46  and a corresponding bolt receiving square hole  54 . These features are known in the prior art. Pegs  46  is used to poke through one hole in a metal plate (not pictured), and hole  54  is used to receive a bolt that is used to secure the plate to stem  36 . This arrangement is known to those skilled in the art, and thus, not a part of the present invention. A second plate (also not pictured) is secured to the opposite side of stem  36  is the same manner. Together, these plates are used to clamp down one cable on each side of stem  36  (also not pictured) such that they may not be pulled out of passageways  58  and  60 . Thus, the cable will be held snuggly within the plug. 
     The features on member  40  that make it unremovable are three wave-shaped channels  70 ,  71 , and  72 . These channels may also be seen in FIG. 4C as being present on a pair of portions having battle-axe-like cross sections  97  and also present on the ends of four cross-sectional-extending portions  99 . Channels  70 ,  71 , and  72  terminate at the openings created by passageways  58  and  60  and scoops  92 . FIG. 4E shows a close-up view of one of these channels. All of channels  70 ,  71 , and  72  have identical cross sections. Channel  70  has been selected to show the cross-section for each of channels  70 ,  71 , and  72  in more detail. In FIG. 4E, we see each channel cross-section has a gradual dropoff  82 , a trough  84  and a steep rise  86 . Comparing these cross-sectional features to those of corresponding ribs,  26 ,  28  and  30 , disclosed in FIG. 3D, we see that the two correspond inversely, one to the other. That is, that each (i) sloped face  62 , (ii) annular crest  64 , and (iii) barrier face  66  of each inner rib ( 26 ,  28 ,  30 ) of container  10  corresponds inversely to the cross-sectional profile of each (i) gradual dropoff  82 , (ii) trough  84 , and (iii) steep rise  86  of each channel ( 70 ,  71 , and  72 ) on member  40 . This causes the ribs to snap into the channels when the member  40  is inserted into the container  10 . 
     In operation, the member  40  of the enclosure  6  of the present invention is first prepared for insertion. This is done by installing the cables (not pictured) on the member. The cables are drawn up against each side of the member  40  through each of channels  58  and  60  between the opposing faces  98 . The exposed tip on each cable, where the jacket has been removed, is then spliced together with the unjacketed tip of the other. These spliced tips are then secured in the collar  44  of member  40 . Once the splice is secured in collar  44 , the cables are secured to stem  36  by mashing them between a pair of metal plates in a manner known to those skilled in the art. 
     Once the cables are secured, member  40  is ready to be inserted into container  10 . To do so, the collar end  44  of member  40  will first be inserted through container opening  16 . A user will typically do this by holding member  40  in one hand while gripping an exterior surface  95  near the closed end  14  of container  40  in the other. The container-gripping hand may be pressed against the outwardly extending bulbous portion in order that more insertion force may be obtained. 
     The inside of container  10  is typically about full of sealant. The sealant typically silicone grease; petroleum jelly or amphorous calcium carbonate is disposed from the closed end of the container to the open end (or close thereto). Because of this, the splice, contained within collar  44 , will be immersed into the sealant when the member is inserted. Once member  40  is over half way in, the plugging surface  34  will be received within opening  16 . Next, shallow rib  26  on the inside of container  10  will snap into the forward-most channel  72  on the member  40 . By maintaining insertion force, however, rib  26  will move out of channel  72 , and on to channel  71 . This further insertion is allowed because of the opposed surfaces of the ribs and channels. When insertion of member  40  is compelled, the gradually sloped face  62  of the rib is engaged with gradual dropoff  82  of the channel. The gradual pitch of the engaged sloping surfaces offers some, but nominal resistance to insertion. Once rib  26  is snapped into channel  71 , rib  28  will simultaneously snap into channel  71 . Upon further application of insertion force, rib  26  will make it to its final destination, and snap into channel  70 . Once this happens, ribs  28  and  30  will be similarly locked into channels  71  and  72 , respectively, and the member is permanently held within container  40 . 
     The installation is made permanent by the barrier faces  66  on each of the ribs and the steep rise surfaces  86  on each of the channels. This is because when any force is applied that would remove member  40  from container  10 , each of the barrier faces  66  would engage the steep rise surfaces  86 . Because these opposing surfaces ( 66  and  86 ) are nearly normal to the movement of the member and container relative to one another, the member is unremoveable once it is fully inserted. 
     It is important to note that although the locking mechanism of the invention is shown as having the wave-shaped channels  70 ,  71 ,and  72  on splice-support member  40 , and the protruding annular ribs  26 ,  28  and  30  on the inside surface of container  10 , that the ribs and channels could be reversed. In such a reverse arrangement, ribs  26 ,  28  and  30  could be defined by the outer surface  34  of member  40  and reciprocating channels defined by the inside surface of container  40 . 
     Also possible, is that more or less pairs of channels and corresponding ribs could be used. For example, though only three ribs arc shown here, but more could be used as well and still fall within the scope of the present invention. Fewer ribs could also be used. The same is true regarding channels. Three are used in the preferred embodiment. However, more or less than three could be used as well. 
     Thus, there has been shown and described a locking buried spice enclosure. Many changes, modifications, variations, and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification together with the accompanying figures and claims. The same device, together with ensuing benefits is also applicable to similar equipment in unrelated industries. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.