Housing formed from extruded panels

A joint for a housing for electrical components has a series of extruded panels connected edge to edge. The first edge includes a slot defined by an inner wall and an outer wall and the second edge includes a blade inserted into the slot, the blade and the flexible wall including cooperating shoulders. The blade and slot are at an angle to the outer surface where a rib engages into an outer recess to seal the outer surface at the joint. A bridging member spans the joint to prevent spreading, while locking the flexible wall and carrying internal components. The housing can form a post or a receptacle on top of the post. The bridging members connect to end plates by screws extending though the plates so as to form an internal structure for the housing. Some of the connected panels can include cooling fins forming a cooling duct.

This invention relates to a housing formed from connecting extruded panels edge to edge.

BACKGROUND OF THE INVENTION

In U.S. Pat. No. 5,521,838 issued May 28, 1996 of Glenn Rosendahl is disclosed a micro processor controlled system is provided for supplying electrical power to a plurality of electrical outlets for example for use in a parking lot. A central power supply communicates with a series of outlet receptacles each arranged to supply electrical power. Each receptacle has its own micro processor controlled control unit which is arranged to control the supply of power to the receptacle. A detector unit detects the insertion of a connector plug to the receptacle and actuates a comparator which compares the instantaneous current drawn by the load with a predetermined variable maximum current and allows that current to be drawn only if it is less than the maximum. In the event that the maximum is exceeded, the load is disconnected and is only allowed to be reconnected after the connector plug is removed. A thermostat can be used to control the supply of power depending upon the outside temperature. The microprocessors can select a part only of a cycle for supplying power so that the total power drawn by the central power supply is reduced.

In U.S. Pat. No. 7,642,670 issued Jan. 5, 2010, the present inventor provided additional features of an arrangement of the above type and disclosed a system for supplying electrical power to a plurality of vehicles from a central power supply through a plurality of electrical outlets includes an outlet control unit for each of the outlets and a vehicle control unit for each of the vehicles. The outlet microprocessor switches the supply of power to the outlet to communicate data to the vehicle. The vehicle microprocessor communicates data by switching a load across the power supply to provide interaction between the microprocessors to manage requirement and availability of power. The data includes whether the power plant of the vehicle is gasoline powered, diesel powered, hybrid or electric battery powered. The microprocessor of the vehicle control unit is arranged to control switches which supply power to selected loads in the vehicle and includes an interface which is arranged to connect to a Canbus communication system of the vehicle.

These arrangements require a suitable housing to locate the electrical components and to provide a support for the outlet receptacle by which the vehicle may be attached to the electrical supply. The housing should be resistant to environmental conditions and provide a suitable structure which can be readily mounted in place.

U.S. Pat. No. 6,032,432 (Patti) issued Mar. 7, 2000 discloses a modular panel for light fixtures. The modular panel includes elongated extruded panels of different shapes including a corner panel with a curved cross section and a flat side panel. The side edges of the corner panel include a pair of spaced-apart lips defining an elongated slot for accommodating a co-operating side edge of an adjacent side panel for a tongue-in-groove connection. The corner panel has evenly spaced fins along the surface to provide structural integrity as well as to scatter light passing through the panel. Multiple panels being assembled with adjacent intermediate adjoining panels forming a housing having a closed cross section

U.S. Pat. No. 4,858,088 (Agabekov) issued Aug. 15, 1989 discloses an elongated lighting device having a housing with a bottom, two lateral wings, a longitudinally elongated opening adapted to receive a transparent closure, and an electric supply bar mounted on the bottom in the interior of the housing, so as to be enclosed between the lateral wings and to be placed in front of the elongated opening, the electric supply bar having at least one insulating support element whereon a succeeding series of electric contact pairs is mounted and which pairs are each destined to receive the connection contacts at the ends of a current consuming element such as a tubular electric lamp. A top cover is snap fastened at side edges onto the bottom section.

U.S. Pat. No. 5,031,083 (Claesson) issued Jul. 9, 1991 discloses an arrangement for open profile lengths intended to permit them to be connected together to produce a channel structure which is closed around its periphery. Two profile lengths of identical execution are connected together to produce a closed channel structure, each of which has its own flange with the desired external form and a number of connecting elements projecting from a common base are so arranged, with their channel-shaped spaces facing towards one another, as to be connected together through the interaction between the flanges and connecting elements in a tongue and groove connection.

U.S. Pat. No. 4,338,653 (Marrero) issued Jul. 6, 1982 discloses a fluorescent lighting fixture having a housing which will flush mount in either a corner or on a wall or ceiling surface, there being a recessed track in the back into which mounting plates slide. The front of the housing is adapted to accept either a translucent shield for direct lighting or an opaque reflector apparatus spaced somewhat from the housing for indirect lighting. The front reflector is snap fastened in place by a center snap and two edge tongue and groove connectors.

U.S. Pat. No. 4,551,792 (Hoke) issued Nov. 5, 1985 discloses an exterior post top mounted lighting fixture with a housing formed by four extruded right-angled aluminum members interlocked together, the housing providing means for aligning an electrical assembly and the components thereof in a predetermined position.

U.S. Pat. No. 3,596,427 (Bayamon) issued Aug. 3, 1971 discloses channel-shaped posts portions connected together by flanges interfitting with each other and joined by a plug wedge forced into the ends of the posts between the webs and flanged thereof and concealed inside. The plug wedges are designed to co-act with the webs and flanges of the posts in such manner that interlocking tongue and groove connections between the flanges of one channel-shaped post and the flanges of the other channel-shaped post so co-act with each other that the two posts form a single substantially rectangular post.

SUMMARY OF THE INVENTION

It is one object of the invention to provides a housing formed from connected extruded panels.

According to one aspect of the invention there is provided a housing comprising:

a plurality of extruded panels arranged side by side for connection at side edges;

each of the panels having a male connection member along a first side edge and a female connection member along a second side edge;

the male connection member being a snap fastening into the female connection member by insertion in a direction at right angles to the edges to form a joint therebetween;

the panels cooperating to form an enclosure defined by the panels for surrounding the electrical components.

The housing described herein is primarily designed for housing electrical components where protection from the environment is required, particularly where the components are to be mounted externally such as on a post or other ground support. This arrangement is particularly suitable where the electrical components provide a controlled electrical outlet for supplying current to a load such as a vehicle. However the device can also be used, not only for the automotive industries, but also the Recreational Vehicle (RV) and Marine industries, which are known to include hook-up for a water connection, telephone, cable and Internet, and even perhaps natural gas. Thus the housing may contain components for supplying any one or more of these utilities.

Preferably the housing includes panels of different cross section. This is particularly useful where the housing forms part of a system including different types of panes which can be selected for connection edge to edge to form different shape housings for different locations and for containing different components. Thus the system may include the panels themselves together with further components which cooperate with the panels to form the different structures.

Thus some of the panels may be generally straight in cross section and some of the panels may be generally curved in cross section. Some may include flat outer surface positions. Some may include cooling fins. Some may include corners both external and internal. These can be selected and joined to make the different arrangements of housing as required.

Preferably, in order to allow this selection and connection, the male connection members of each of the panels are of identical cross section and the female connection members of each of the panels are of identical cross section.

Preferably the panels are formed of an extruded metal to provide a suitable level of strength and resistance to the environment, such as mid steel, stainless steel or aluminum. However other plastics materials can be used.

Preferably there is provided a plurality of bridging members each bridging the panels at a respective one of the joints between panels and the panels each include a receptacle for receiving insert portions of the bridging member such that the bridging member bridges the joint inside an inside surface of the housing to hold the joint against spreading.

Preferably the bridging member extends substantially along the full length of the panels. However it can be shorter and used typically at the ends only.

Preferably the bridging member slides into place along the panels in the form of a zip lock.

Preferably the bridging member forms a support for components located inside the panels.

Preferably the bridging member is connected at one end to a support member such as a base plate or end plate extending generally at right angles to the panels so as to provide a connection between the panels and the plate. There can also be provided two end plates so that the two end plates and the bridging members form a supporting structure inside the panels.

Preferably the bridging member is fastened to the end plate by a screw through the support member engaging into a channel extending longitudinally of the bridging member.

Where cooling of the electrical components in a hot environment is desirable, at least one of the panels can carry a plurality of cooling fins extending generally outwardly therefrom, either to an inwardly facing side or to an outwardly facing side depending on the require construction.

Preferably the panels are arranged connected edge to edge such that the cooling fins form part of a cooling duct extending along the housing.

For example, two or more of the panels may form a cooling duct located inside an outer housing with the housing being formed by respective ones of the panels.

In one example the panels are connected to form an upstanding elongate post.

In one example the panels are connected to form a receptacle on top of a post. In this case the post may also be formed from the panels or may be of a conventional construction.

In another example some of panels may have exterior slots to receive edges of a slidable face panel. In this case some of panels may be shaped so that they are generally concave so as to form an interior recess.

In another example at least one of the panels has an opening for receiving an electrical outlet receptacle.

According to a second aspect of the invention there is provided a housing for electrical components comprising:

a plurality of extruded panels arranged side by side for connection at side edges;

the panels being connected by longitudinal joints at the side edges to form an enclosure defined by the panels for surrounding the electrical components;

wherein there is provided a plurality of bridging members each bridging the panels at a respective one of the joints between panels such that the bridging member bridges the joint inside an inside surface of the housing to hold the joint against spreading;

and wherein the bridging member is connected at one end to a support member extending generally at right angles to the panels so as to provide a connection between the panels and the support member.

According to a third aspect of the invention there is provided a housing for electrical components comprising:

a plurality of extruded panels arranged side by side for connection at side edges;

the panels being connected by longitudinal joints at the side edges to form an enclosure defined by the panels for surrounding the electrical components;

wherein at least one of the panels carries a plurality of cooling fins extending generally outwardly therefrom;

and wherein the panels are arranged such that the cooling fins form a cooling duct.

According to a fourth aspect of the invention there is provided a housing for electrical components comprising:

a plurality of extruded panels arranged side by side for connection at side edges;

the panels being connected by longitudinal joints at the side edges to form an enclosure defined by the panels for surrounding the electrical components;

wherein some of panels have exterior slots to receive edges of a slidable face panel.

DETAILED DESCRIPTION

The embodiments of the housing shown inFIGS. 4 to 18are described in more detail hereinafter. These arrangements of housing use the joint according to the present invention which is shown inFIGS. 1 to 3. This is formed between a first extruded member10having an outside surface10A, an inside surface10B and a first side edge10C and a second extruded member11having an outside surface11A, an inside surface11B and a second side edge11C. The first side edge10C and second side edge11C are arranged to provide cooperating connections for connecting the side edges of the members together to form a connected structure.

The extruded members can be of any construction and typically include a second side edge10D on the member10and a first side edge11D on the member11for connection to a next extruded member so that each includes male and female side connectors at respective side edges. In this way the members can be used to form a complete housing or other structure of connected members with male and female connections as required.

The members10and11are in the embodiment curved so as to be part cylindrical but other shapes can be used as described hereinafter. The members10and11have the outer surface10A,11A corrugated to form an attractive appearance but this is of course not an essential requirement.

The members10and11are extruded so that they have a constant cross section along their length. The material from which they are formed can vary depending on requirements but typically is of sufficient strength and stiffness to form a structural member such as a housing, post or the like. In such a case the use of metal such as aluminum, mild coated steel or stainless steel is preferred. Thicknesses and dimensions of the walls and the snap fastening components to accommodate their functions as described hereinafter can be selected by persons skilled in the art using conventional knowledge.

The first edge10C thus has a first cooperating connection member20and the second edge11C thus has a second cooperating connection member30with each extending along the first and second edges respectively. The members20and30form cooperating male and female connections by which the first edge10C is fastened to the second edge11C along the length of the edges.

As best shown in the enlarged view ofFIG. 3, the first connection member20includes a slot201defined by an outer wall202and an inner wall203. The second connection member30includes a blade member301to be inserted into the slot201in a snap fastening action.

The blade member301is relatively stiff and is not intended to flex. The blade member301has a ramp surface303leading to a shoulder302on the side thereof adjacent the outer wall203. The inner wall203includes a cooperating shoulder204so that when seated the shoulders sit in engagement at an angle generally at right angles to a direction D of insertion of the blade into the slot so as to hold the blade inserted into the slot against movement opposite to the direction D. In order to allow the insertion, the wall203is flexible to allow the shoulders302and204to pass by the wall203flexing away from the blade when pressed inwardly by the ramp surface303sliding over an inlet surface205of the wall203.

In order to allow the flexing of the inner wall203, the inner wall203has a thinner portion206at a base end207of the slot201and a wider portion208at the outer end of the slot201at the surface205with the wider portion defining the shoulder204.

The slot201and the blade301are inclined at an angle A to a plane P at the outer surface of the first and second extruded members at the joint. The angle A is of the order of 30 degrees but can be larger and as much as 45 degrees.

The second connection member30includes a second slot304parallel to the slot201in the first connection member and arranged to receive the outer wall202of the first connection member. As the slot304is parallel to the slot201, these slots define the direction D of insertion at the angle A to the plane P.

The first connection member20includes an overlapping rib portion209at the outer surface10A which engages onto the outer surface11A of the second of the extruded members. In order to receive this rib portion and still provide a flush or contiguous outer surface at the junction between the surfaces10A and11A, the surface11A includes a recess305which matches the rib. Both the recess305and the rib209include a side surface210which is parallel to the plane P so that the insertion of the overlapping rib portion209into the recess305is parallel to the plane P and the outer surfaces at the joint.

The use of the inclination angle A as opposed to being just a straight tongue and groove is that:

a) In order for the joint to fail and come apart it requires the extruded members move apart one form the other in two directions, not just movement one apart from the other, but also one moving up as the other moves down.

b) As well the idea of the angle increases surface area of the joint therefore creating a stronger joint.

c) The increased surface area of the connecting joint increases the water resistance of the joint due to the increased distance, and opposing angle, of the likely flow the water would have to travel in order to compromise the joint.

d) Also in assembly of the joint the visual clue to a tight joint is easier to ascertain as one extrusion is set higher than the other if the joint is not properly connected.

As the snap action of connecting the connection members20and30is based on the flexing of the thinner portion206of the wall203, this can be locked by providing a retention member401of a bridging member40. The retention member401is a set screw with a head402and a front face403for contacting the outer wall203to hold the outer wall against flexing so that compression of the outer wall203acts to squeeze the blade member301in the slot201and prevent the blade from being pulled out of the slot due to the engagement of the shoulders204and302. For this purpose, the outer wall203at the wider portion208includes a surface211which is parallel to the plane P and thus to the outer wall and thus butts flush against the front face403of the screw401.

The bridging member40spans the joint and is supported by the first and second extruded members at its respective ends. Thus the first and second extruded members10,11each include a receptacle10E,11E for receiving insert portions404,405of the bridging member such that the bridging member bridges the joint inside the inside surface to hold the joint against spreading. Each receptacle10E,11E forms a part cylindrical slot with a part cylindrical inner wall10F and an open mouth10G narrower than the wall. The insert portions include a neck407and a compressible bead408which can be snapped into the receptacle by compression of the bead so that the outside surface of the bead matches the cylindrical surface10F. The bridging member can extend substantially along the full length of the first and second extruded members and can slide into place along the first and second extruded members. The necks407extend generally at right angles to the surface or to the plane P so that tension tending to allow the joint to part is communicated at right angles to the neck and through the bridging member itself so that the bridging member resists the movement of the joint apart and thus acts as a lock. The bridging member extends across the joint close to the inner surface of the joint at the wall203and thus provides a support for the joint without significantly interfering with the area inside the structure. The bridging member includes a longitudinal slot409with a mouth410and a part cylindrical receptacle411for attaching components inside the structure.

Each of the receptacles10E,11E and409is of the type which can receive a screw fastener engaged into the end of the part cylindrical wall inserted longitudinally into one end of the slot.

The bridging member40can also be used, as shown inFIG. 1, to form a support415for components located inside the panels using mounting pins416carried on the member40or by other mounting elements using for example the receptacle409.

Turning now to the construction of housing for electrical components formed using the panels and joint construction described above and shown in the further figures, inFIG. 14particularly is shown a construction for mounting a housing for the electrical components (not shown). The construction comprises a concrete base52defined by a footing portion50and a cylindrical upstanding portion51. These are typically mounted in or on the ground as a structural base for the housing construction and can be of any shape or arrangement dependent on the number of housings to be mounted and the terrain on which they are to be mounted.

The housing construction includes a post60attached to the portion51and a top receptacle section70. The electrical components can be mounted in one or both of the post and receptacle depending on the construction and size of the components. Typically an electrical supply and optionally communication cables will pass through the base52into the post for supplying the electrical components.

The post60comprises a plurality of extruded panels10,11connected by joints at edges10C and11C. A bridging member40spans the joint. All these components are of the construction described above so that it is not necessary to repeat that description here. Thus each of the panels has a male connection member30along a first side edge and a female connection member20along a second side edge for connection of the male members with the female members as previously described. Thus the male connection member provide a snap fastening into the female connection member by insertion in a direction of the blade301into the slot201at right angles to the edges to form a joint therebetween. Thus the panels10and11cooperate to form a cylindrical enclosure forming a post defined by the panels for surrounding the electrical components.

At each joint is provided a respective one of the plurality of bridging members40each bridging the panels at a respective one of the joints between panels. Each of the panels includes the receptacle10E,11E for receiving the insert portions404,405of the bridging member40such that the bridging member bridges the joint inside an inside surface of the housing to hold the joint against spreading. The bridging members40extend along the full length of the panels10,11and slide into place along the panels.

The post60further includes, as best shown inFIG. 17, a bottom end plate601and a top end plate602at right angles to the panels. Each bridging member is connected at one end to a support member or plate601and at the other end to the plate602extending generally at right angles to the panels so as to provide a connection between the panels and the support members or plates601,602. Thus the plates and the bridging members form a structural member for holding the panels10,11in place.

Each plate601,602includes a recess603indented onto the face receiving the bridging member and shaped to match the inner face of the bridging member40at the receptacle409therein. Thus the end face of the bridging member sits in the recess603and is prevented from movement relative to the end plate by this recess. The bridging member is fastened to the plate by a screw604engaged though holes605in the end plate at the recess603which screws engage into the end of the part cylindrical receptacle409as a screw fit to tighten the bridging member against the end plate.

Thus the bridging members are connected at each end to a respective one of two end support member extending generally at right angles to the panels so that the two end support members and the bridging members form a supporting structure inside the panels. The panels are then connected on the outside of this structure by engaging their joints and by attaching the bridging members, by sliding the connected panels along the supporting structure. The end plates601and602have a central hole606allowing the insertion of the electrical components and/or the connection leads.

The bottom plate601is fastened to the portion51by suitable fasteners (not shown). The top plate forms a support for a base701of the receptacle70.

InFIG. 14, the receptacle70is relatively small and is formed by two panels702and703connected by edge connection joints20and30as previously described. Additional panels in the manner ofFIG. 4can also be provided depending on the size of the receptacle required. The bottom plate701is formed in two sections706and706with a hole707which is connected by edge connectors20and30as previously described. The bottom plate is fastened to the panels702and703by screws extending through the plate into the ends of the receptacles10E and11E (FIG. 3). A top plate704forms a closed top formed in one piece and fastened to the panels702and703by screws (not shown). Each of the panels702and703includes a hole709through the wall thereof to access the interior so that an electrical outlet of a conventional construction can be mounted in the wall to allow connection of a plug from a vehicle or the like, with the electrical connection to the internal electrical components passing through the wall to the interior. In this embodiment most of the electrical components are housed in the pose and the top receptacle is primarily merely a support for the electrical outlets.

InFIG. 15is provided a similar arrangement in which there is provided a base52, a post60and a receptacle80. In this case the receptacle is much larger and is intended to contain all of the electrical components. In this case the receptacle is formed of panels801and802and a top plate803all forming a generally rectangular construction with vertical sides. The panels801are curved to form corners of the receptacle. The panels802are flat and include holes804,805for electrical outlets. In this arrangement the bridging members40are omitted from the receptacle and the fastening of the panels to the top and bottom plates is effected solely by the insertion of screws806into the receptacles10E,11E.

Turning now toFIG. 16, there is shown a further arrangement of receptacle90which can be mounted on a post or directly in a ground base. A base plate901and a top plate904is connected to flat panels902, with holes913, and corner panels903in the manner previously described.

In this embodiment there is provided a cover plate905mounted on top of the top plate904and held spaced from it by spacer panels906and907around the edge. The panels906and907match in shape the panels902and903and attach in similar manner. A cooling duct915extends through the receptacle90from a bottom hole912in the plate901to a top hole914in the plate904. The cooling duct is formed of two connected panels909and909using joints916and receptacles911as previously described. The surface of the panels908and909carries cooling fins910. These extend outwardly from the surface of the respective panel and can project to the interior or the exterior of the duct915, but preferably extend to the interior so as to engage air passing though the duct. The air flow is caused by convection and thus enters the duct through the bottom hole912and escapes the duct through the top hole914into the area between the top late904and the cover plate905. The panels906have holes to allow the escape of the air. Thus the panels can be used to effect cooling of the electrical components in locations where significant ambient heat can cause overheating. Thus in this embodiment, the panels908and909are arranged such that the cooling fins form a cooling duct on an inside of the housing.

As shown inFIG. 10, at least one of the panels carries a plurality of cooling fins120on the exterior extending generally outwardly therefrom.

As shown inFIGS. 12 and 13some of panels130and140are shaped so that they are generally concave so as to form an interior corner defining a recess141which has a hole142for the mounting of an outlet. Thus the hole142is protected in a recess and is not presented merely on the outside as previously described. This allows some protection for the hole by way of a cover143and a sliding front panel144. Both the cover143and the panel144have edge beads145mounted in receptacles146on the panels130and140thus defining exterior slots to receive edges of the slidable face panel.

As shown inFIGS. 4 to 12, the housing includes panels of different cross section. Thus as shown inFIG. 4, some of the panels190are generally straight or flat in cross section and some191form corners. A short connector panel192can also be provided.

Thus as shown inFIG. 5, some of the panels193define a flat plate194with the connectors20and30extending at right angles to the rear face of the flat panel.

InFIG. 6, a T-shaped cross section is formed using flat panels190, part cylindrical panels197and inverted corner panels198.

InFIG. 7, a hexagonal cross section is formed using flat panels190, and short 60 degree connector panels198.

InFIG. 8, a circular cross section is formed using four part cylindrical panels197.

InFIG. 9, a D-shaped cross section is formed using part cylindrical panels197and flat plate panels193.

InFIG. 10, an oval cross section is formed using part cylindrical panels197and short connector panels198.

InFIG. 11, a triangular cross section is formed using straight panels190and short connector panels198.

This construction to form different cross sections is obtained since the male connection members of each of the panels are of identical cross section and the female connection members of each of the panels are of identical cross section.

FIG. 18shows a modification of the arrangement ofFIG. 17where the recesses621for the end of the bridging members40are spaced inwardly from an outer edge624of the plate620so that the panels10and11(not shown in this figure) sit on the outer periphery of the plate rather than being located outside the plates as inFIG. 17. Thus the plate620fully closes the end of the housing.