Protective shell for cable connection module

A protective shell for a splice closure or the like has a flange base member and a flange cover member. A triangularly shaped ridge extends along each flange which hold triangularly shaped clamps in place against displacement, yet, in conjunction with the clamps, create room for the insertion of mounting hardware in the clamps. The closure is supported within the shell so that it is surrounded by space for an encapsulant. The supports for the closure are configured to permit passage of liquid encapsulant into the space between the-bottom of the closure and the base member.

FIELD OF INVENTION 
This invention relates to protective covers for use with splice closures 
and the like, and, more particularly, to a shell that encloses a closure 
and protects it from moisture, dust and corrosive atmosphere, for example. 
BACKGROUND OF THE INVENTION 
In a signal transmission system, whether the signal transmission medium be 
wire or optical fibers, there are, of necessity, interruptions such as 
splices, for example. In general, in the prior art, such splices are 
enclosed in a splice closure module for protection, wherein large numbers 
of splices are housed and, to a large extent, protected from the 
environment and from other damaging factors, such as from lightning or 
from various gnawing animals. Where conditions are likely to be extreme, 
it has been the practice to enclose a splice closure within a protective 
shell and, often, to fill the empty volume within the shell with 
encapsulant. 
In the area of fiber optics, the splice closure module preferably comprises 
a metallic body having entrances at each end for the ingress and egress of 
optical fiber cables to be spliced together. Within the closure, the 
cables are stripped to the individual fibers for splicing, and the splices 
are generally organized and protected by means of a splice tray. One such 
closure is the AT&T UCB1, which, with the proper component parts, anchors 
and seals the cables, routes the cable fibers to the splice tray, and 
supports the splice tray itself. Sealant is used around the periphery and 
in the opening to seal the closure so that the splices are protected from 
mechanical shock, displacement, or breakage, as well as from moisture and 
the like. In U.S. patent application Ser. No. 08/263,645, filed Jun. 22, 
1994, of Denis E. Burek, Marc D. Jones, Wesley W. Jones and Phillip M. 
Thomas, the UCB1 closure is shown, along with the several components for 
achieving the ends discussed heretofore. Another type of splice closure is 
shown in U.S. Pat. No. 5,185,845 of Wesley W. Jones. In both types of 
closures, as well as in most other types, it is a necessary feature that 
the closure be re-entrant. That is, it must be amenable to being entered 
so that work may be performed on the splices themselves, or so that 
damaged or malfunctioning parts may be replaced. As a consequence of the 
need for re-entry, the splice closure itself cannot be filled with an 
encapsulant which would insure substantially complete protection. It has 
been the practice, as pointed out in the foregoing, to enclose the splice 
closure within a shell which can then be filled with a protective 
material. 
In prior art arrangements, the outer protective shell which encloses the 
splice closure or other type of assembly is filled with an insulating 
liquid curable encapsulant. The shell must, of course, be substantially 
leak tight so that the encapsulant, in its liquid phase, does not leak out 
prior to hardening. The liquid encapsulant is generally poured into the 
shell and it flows to fill the voids within the shell so as to surround 
the closure. However, even in its liquid phase the encapsulant is not free 
flowing because of its high viscosity. As a consequence, air pockets and 
other voids often remain after the encapsulant hardens, and thus 
insufficient protection of the closure results. Often such voids occur 
around the cables entering and leaving the shell and thus water, for 
example, has almost a clear pathway along the cables themselves directly 
to the region that is most in need of protection. In U.S. Pat. No. 
4,875,952 of Mullin et al., there is shown an encapsulating arrangement 
that overcomes the problems of the prior art, in which the encapsulant is 
introduced under pressure into an elastic bladder surrounding the splice 
tray, and then an additional amount of encapsulant is forced into the 
surrounding protective shell. Such an arrangement effectively protects the 
splices or other connectors, but re-entry is made difficult by the splices 
and wires being embedded in the encapsulant. In U.S. Pat. No. 4,692,564 of 
Campbell, et al. there is shown an arrangement that is somewhat similar to 
the arrangement of the Mullin et al. arrangement, but where the 
encapsulant can be either gravity fed or fed under pressure. The outer 
cover or shell of the Campbell et al. arrangement comprises two 
substantially identical members having flanges along their edges and which 
are fastened together by means of C-clamps. 
In use, it is often desirable or where necessary that the entire assembly 
of cables, closure and protective shell be suspended from an overhead 
support strand, wire rope or for interior mounting, a support bar. This 
can be, and most often is, accomplished by the use of straps surrounding 
the shell and attached to the support stand. Such lashing of the assembly 
produces the desired suspension, but can be both awkward and time 
consuming which, in turn, can be costly. 
SUMMARY OF THE INVENTION 
The present invention, in a preferred embodiment thereof, is intended for 
use with the AT&T UCB1 or UCB2 splice enclosure, although it is to be 
understood that the principles and features thereof are applicable for use 
with other types of closures, both rigid and non-rigid. 
The shell of the invention comprises a top or cover portion and a separate 
bottom or base portion, both having longitudinally extending mating 
flanges, with the flanges on the bottom portion each having a plastic foam 
strip extending therealong, which functions as a resilient grommet when 
the flanges are mated. The ends of both the top and bottom portions are 
U-shaped to form cable openings when the two are assembled to form the 
cover. Plastic foam inserts with cable receiving holes are provided at 
each end through which the cables pass into the splice closure. The 
inserts are shaped to fill completely the cable openings, and are slit to 
receive and hold the cables. 
First and second closure support members of styrofoam or other suitable 
material are adapted to be positioned within the shell and to rest on flat 
surfaces in the bottom portion. Each of support members has a U-shaped top 
portion adapted to receive the bottom portion of the splice closure, and a 
U-shaped bottom portion forming first and second legs or feet with a gap 
therebetween, thereby forming a passageway through which liquid 
encapsulant can flow. The bottom portion of the shell is contoured to 
receive the splice closure, thus facilitating centering of the splice 
closure thereon. 
The top portion of the shell is also contoured to conform to the shape of 
the top portion of the splice closure, and is spaced therefrom. This 
contouring of both the top and bottom portions of the shell to the general 
shape of the splice closure makes possible a complete encapsulation of the 
splice closure while requiring less encapsulant than is needed for a shell 
such as is shown in the aforementioned Mullin eta. patent. 
The upper or exterior surface of each flange on the cover has, extending 
longitudinally, a wedge or triangularly shaped ridge, with one side of the 
triangle facing the body of the cover to form a shoulder and sloping 
downward toward the outer edge of the flange. In like manner, the bottom 
or exterior surface of each of the flanges on the base has a triangularly 
shaped ridge oriented the same as the ridges on the flanges of the cover. 
When the cover and base are assembled together, with the interior surfaces 
of the flanges in mating relationship, triangularly shaped C-type steel 
clamps are slid along the flanges, with the lips of the C-clamps bearing 
against the sides of the triangular wedge shaped ridges that face the body 
of the cover and of the base and firmly clamping the cover and base 
together. Each of the triangular C-type clamps thus presents a sloping 
side in which are formed keyhole-shaped mounting holes for insertion of 
mounting hardware, and additional slots for lashing the shell to a support 
member, if desired. In prior art C-clamp arrangements, as shown in the 
Mullin et al. patent and in U.S. Pat. No. 5,189,725 of Bensel, III, et 
al., the clamps fit tightly against the flanges, and thus cannot receive 
any mounting hardware. With the triangularly shaped clamp of the 
invention, only a portion of the clamp fits firmly against the flanges, 
thereby creating a space for the insertion of mounting hardware through 
the keyhole shaped holes. 
In the assembly of the shell about the splice closure, the plastic foam 
inserts are slit from an outer edge to the holes therein, and the holes 
and slits are coated with a suitable sealant, as are the cables. The 
cables are then inserted in the foam inserts and the assembled splice 
closure is placed within the base, resting on the closure support members. 
The regions of the base, and of the cover, adjacent the openings formed by 
them are also coated with a sealant, and the cover is placed over the base 
with their flanges mating. The triangular clamps, two to a side, are then 
slid into place thereby clamping the base and cover together. The cover is 
provided with access holes for the introduction of liquid encapsulant 
which flows throughout the interior of the shell, including the passages 
formed by the closure support members. The material of the support members 
which preferably, but not necessarily, is styrofoam, absorbs liquid 
encapsulant so that the support members actually become part of the 
encapsulant. Similarly, the plastic foam inserts, which prevent the liquid 
encapsulant from leaking out of the ends of the shell, absorb some of the 
encapsulant to form a moisture block to prevent outside moisture from 
entering the shell. After the encapsulant has set, i.e., hardened, the 
completed assembly may then be mounted from a bar or cable strand, for 
example, by means of suitable mounting brackets having headed members 
which fit within the keyhole shaped openings. 
Inasmuch as the encapsulant completely surrounds the splice closure, but 
does not enter it (the material viscosity of the liquid encapsulant 
preventing it from entering any small openings), the splice closure can be 
re-entered by simply removing the shell and the encapsulant which does not 
disturb the interior of the splice closure.

DETAILED DESCRIPTION 
In FIG. 1 there is shown the complete assembly 10 of a splice closure 11 
and the base 12 and cover 13 of the protective shell of the invention with 
its component parts, to be described hereinafter. 
Splice closure 11, as shown, is, in this embodiment of the invention, a 
UCB1 or UCB2 closure as shown and described in detail the aforementioned 
in U.S. patent application Ser. No. 08/263,645, filed Jun. 22, 1994 in the 
names of Denis E. Burek, Marc D. Jones, Wesley W. Jones and Phillip M. 
Thomas. Basically, the closure 11 comprises a base portion 14 and a cover 
portion 16 and first and second protective clamp members 17 and 18 which, 
in conjunction with base portion 14, define openings 19 and 21 (only 
opening 19 being shown) through which the cables entering the closure 11 
pass. Clamp members 17 and 18 bear against, and compress, grommets (not 
shown) which surround the cables, and also cover and protect grip block 
assemblies (not shown) which anchor the cables in the closure 11. 
Base 12 comprises a U-shaped member having longitudinally extending flanges 
22 and 23 on the top or interior surfaces of which are affixed plastic 
foam strips 24 and 26, respectively, which function as sealing gaskets 
when the shell is assembled. Base 12 also has formed therein first and 
second flat surfaces 27 and 28 and a depressed central section 29 for 
accommodating base portion 14 of closure 11, as will be discussed more 
fully hereinafter. Cover 13 is, as will be discussed in conjunction with 
FIG. 7 is contoured to accommodate top or cover portion 16 of closure 11 
and, at each end, is substantially U-shaped, with a retaining shoulder 31 
at the edge of the U-shaped openings. In like manner, base 12 has shoulder 
portions 32 and 33 at its extreme ends. Cover 13 also has a pair of 
longitudinally extending flanges 34 and 36 which, when their interior 
surfaces are mated with the interior surfaces of flanges 22 and 23 
respectively result in the U-shaped ends of both base 12 and cover 13 
forming openings for the cables passing through the shell to the closure 
11. 
Closure 11, more particularly base portion 14 thereof, is supported on base 
12 by means of closure support members 37 and 38 which are shaped to 
receive that portion of base portion 12 directly under the clamp members 
17 and 18, and are adapted to rest upon flat surfaces 27 and 28. The 
support members will be discussed more fully in connection with FIG. 3. 
First and second plastic foam insert members 39 and 41 have apertures 42,42 
and 43,43 respectively for receiving the cables, as shown. In order that 
the inserts 39 and 41 may be attached to the cables, slits 44,44 and 46,46 
leading from an outer edge of inserts 39 and 41 to the apertures 42 and 43 
are provided. Usually, such slits will be cut into the inserts 39 and 41 
in the field during the assembly and installation process. Both inserts 39 
and 41 also have slits 47,47 and 48,48, formed therein for receiving 
grounding straps, where necessary, as shown. During the assembly process, 
apertures 42,42 and 43,43, slits 44,44 and 46,46, and slits 47,47 and 
48,48, where necessary, are filled with a suitable sealing gel, as are the 
cables and ground strips, in the region thereof where the inserts 39 and 
41 surround them. 
After inserts 39 and 41 have been positioned on the cables, and the closure 
11 placed on base 12, supported by supports 37 and 38, cover 13 is lowered 
onto base 12, with the interior surfaces of flanges 34 and 36 mating with 
the interior surfaces of flanges 22 and 23, and with insert members 
bearing against the shoulders 31 and 32, as best seen in FIG. 8, the base 
12 and cover 13 are clamped together by means of a plurality of clamping 
members 49,49. The top surface of each of flanges 34 and 36, and the 
bottom surfaces of each of flanges 22 and 23 is provided with a 
longitudinally extending wedge shaped ridge 51, only one of which is 
visible in FIG. 1, for enabling each of the clamping members 49,49 to grip 
firmly both base 12 and cover 13 without the possibility of lateral 
slippage or displacement. The arrangement of clamping members 49,49 and 
ridges 51,51 will be fully discussed in conjunction with FIGS. 4, 5 and 6. 
After the assembly 10 has been completed, liquid encapsulant is introduced 
into the interior of the shell through one or more holes 52,53 by any 
suitable means, such as a funnel 54. As will be discussed more fully 
hereinafter, the liquid encapsulant flows freely throughout the interior 
of the shell, substantially completely filling it. After the encapsulant 
has set, funnel 54 is removed and holes 52 and 53 are plugged by plugs 56 
and 57 respectively. 
In FIG. 2 there is shown the plastic foam insert 41, which is identical to 
insert 39, and which has holes or apertures 43,43 for receiving the 
cables, and slits 46,46 for affording cable access to the holes 43,43. As 
pointed out heretofore, slits 46,46 may be cut by the installer in the 
field, or they may be formed during the manufacture of the insert. Insert 
41 also has slits 48,48 therein for receiving ground straps or wires, 
where necessary. Insert 41 is shaped to conform to the openings formed by 
the base 12 and cover 13 and is slightly larger than such opening so that 
it rests against the interior surface of shoulder 32 (or shoulder 33, as 
the case may be). Insert 41 has first and second projecting tabs 58 and 59 
which are adapted to fit between the mating flanges 22,34 and 23,36 
respectively. Thus, when base 12 and cover 13 are clamped together, insert 
41 is firmly held against both lateral and longitudinal displacement by 
the flanges and the shoulders. The material of insert 41 is such that it 
absorbs some of the encapsulant, thereby forming a moisture impervious 
seal for interior of the shell of the invention. 
FIG. 3 is an elevation view of the closure support member 37 which is 
identical to support member 38, both of which rest upon flat surfaces 27 
and 28 respectively of the base 12 as indicated by the dashed line 60, and 
which hold and support the base portion 14 of the closure member 11, as 
indicated by the dashed lines 65. Member 37, which is preferably made of 
an encapsulant absorbing material such as styrofoam is substantially 
U-shaped in cross-section, having first and second upstanding legs 61 and 
62 defining a central area 63 in which base portion 14 of closure 11 
rests. The lower portion of member 37 is recessed, as shown, to define 
first and second feet 63 and 64 with a passageway 66 extending 
therebetween. As pointed out hereinbefore, passageway 66 permits free flow 
of liquid encapsulant under the bottom portion of base portion 14 of the 
enclosure after the assembly 10 is completed. 
FIGS. 4 and 5 are an elevation view of the triangular clamping member 49 
and an end view thereof, respectively. Each clamping member is preferably 
of stainless steel or other material having a degree of elasticity or 
resiliency. As can be seen in FIG. 5, the cross-sectional form of member 
49 is that of a C-clamp modified to have a triangular shape having first 
and second sides 67 and 68 with a clamping opening 69 formed by base legs 
71 and 72. Because of the spring action of the material of member 49, 
opening 69 may be increased in size with a consequent increase in pressure 
of 71 and 72 toward the opening. As can be seen in FIG. 4, side 67 has a 
key-hole shaped opening 73 located approximately midway between the ends 
of clamp member 49, and spaced slots 74 and 76 aligned therewith. In like 
manner, side 68 has a keyhole shaped opening 77 approximately opposite 
opening 73, but oriented in the opposite direction, as shown, and spaced 
slots 78 and 79 aligned therewith. The opposite orientation of keyholes 33 
and 77 allows either end of clamp 49 to be inserted over the mating 
flanges 22, 34 and 23, 36. 
FIG. 6 is an end elevation view of the assembled shell of the invention, 
with the insert 41 in place, but for clarity, not depicting the cables and 
ground straps. As was disclosed hereinbefore, each of the flanges 22, 23, 
34 and 36 has a longitudinally extending wedge or triangularly shaped 
ridge 51 formed thereon. As can be seen in FIG. 6, one side of the 
triangular wedge shape 51 on each of flanges 22 and 23 faces the body of 
base 12 thereby forming a shoulder, and the wedge tapers down toward the 
outer edge of the flange. In like manner, one side 82 of the triangular 
wedge shape on each of flanges 34 and 36 faces the body of the cover 13 
forming a shoulder and the wedge tapers down toward the outer edge of the 
flange. The opening 69 in each of the clamps 49 has a width slightly less 
than the combined width of the mating flanges and the uncompressed foam 
strips 24 and 26 so that when clamps 49, which have a degree of 
elasticity, are slid into place along flanges 22, 34 and 23, 36, strips 24 
and 26 are tightly compressed, and the inside surfaces of legs 71 and 72 
bear against sides or shoulders 81 and 82 of the ridges 51,51, thereby 
tightly clamping base 12 and cover 13 together. In addition, the unique 
configuration of the clamps 49,49 and the ridges 51,51 prevent clamps 
49,49 from being laterally pulled off of the flanges. As can be seen in 
FIG. 6, there is room between the inner surfaces of legs 67 and 68 and the 
flanges to permit insertion of headed mounting members 83 and 84 in the 
keyholes 73 and 77. As can be seen in FIG. 7, which depicts the completed 
assembly 10 in an aerial mounting, hanging from strand 86, the clamps 
49,49 provide easy access for the mounting bolts 83 and 84 and, in turn, 
hanger clamps 87 and 88. The time necessary to hang the assembly 10 is 
thus greatly reduced and the process greatly simplified. The weight of the 
assembly 10 is borne by the top clamp members 49,49 which cannot be 
dislodged due to the legs of the clamps bearing against the sides of the 
wedge shaped ridges. 
In FIG. 8 the assembly 10 is shown in cross-section so as to depict the 
relationship of closure 11 to base 12 and cover 13 in the assembly 10, as 
well as depicting the flow paths of the liquid encapsulant. As can be seen 
in FIG. 8, closure 11, supported by supports 37 and 38, does not touch the 
inner surfaces of the shell of the invention, so that it may be completely 
surrounded by the encapsulant. In addition, with foam inserts 39 and 41 
bearing against the inner surfaces of shoulders 31, 32, and 33, as shown, 
liquid encapsulant is prevented from leaking out during the encapsulation 
process. As can also be seen in FIG. 8, base 12 and cover 13 are contoured 
to conform roughly to the shape of closure 11. With the base 12 and cover 
13 thus shaped, the amount of encapsulant necessary has been reduced by a 
factor of three over prior art requirements, from approximately ten 
thousand (10,000) grams of encapsulant to approximately thirty-two hundred 
(3,200) grams. 
The foregoing has been a discussion of the numerous unique features of the 
present invention in a preferred embodiment thereof. These features, as 
well as the principles of the present invention, are readily adaptable to 
other types of closures, for example, without departure from the spirit 
and scope of the invention.