Water barrier system for an electrical panel

A water barrier system for use in conjunction with an electrical panel to control water intrusion into and within the electrical panel is disclosed. In use, the water barrier system provides one or more barriers to prevent, or at least inhibit, water from entering the electrical panel, and/or to direct water, which has entered the electrical panel. The water barrier system may include one or more barriers extending from an interior surface of the electrical panel to block the migration of water, one or more weep holes in fluid communication with one or more channels to direct water that encounters or comes into contact with a top surface of the electrical panel, and/or one or more troughs to direct water that encounters or comes into contact with the top surface of the electrical panel.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to electrical panels, and more particularly to a water barrier system for directing (e.g., preventing, inhibiting, controlling, etc.) water migration relative to an electrical panel.

BACKGROUND OF THE DISCLOSURE

Electrical panels such as, for example, circuit breaker panels, relay panels, or the like, are well known. In a conventional power distribution system, power from a utility may be fed to an electrical panel which, in turn, may feed a series of branch circuits. To provide protection for the branch circuits, the electrical panel may include a main breaker to control the supply of power from the primary power supply to the branch circuits. To protect the individual branch circuits, the electrical panel may include an individual circuit breaker for each branch circuit. Additionally, within a standard electrical panel, electrical components such as circuit breakers, relays, control circuitry, wiring (such as some low voltage, communication wiring, etc.) or the like can be located.

In certain geographic areas, electrical panels may be located externally and thus subject to environmental elements (e.g., moisture, rain, snow, etc.). As a result, it is important that the electrical components within an electrical panel be protected from the environmental elements. Moreover, in some installations, the electrical panel may be mounted in a semi-flush manner such that a rear portion of the panel may be located within a cavity of the structure or wall while a front portion of the panel may extend exteriorly of the wall or structure.

Additionally, improper installation of the electrical panel and surrounding structure or wall may lead to water intrusion into the structure or wall in which the panel is mounted. That is, in various installations, the electrical panel may be mounted to one or more studs of a structure or wall. Thereafter, one or more layers of material such as, for example, plywood, stucco, sheetrock, etc., may be mounted to the studs. The one or more layers may be cut to allow at least the front portion of the electrical panel to extend therethrough. As a result, gaps may be formed between the one or more layers of material and the electrical panel. Additionally, gaps may be formed between the various layers of material. During use, water may be able to contact and penetrate the electrical panel as a result of incorrect or inadequate sealing of these various gaps. Thus, electrical panels located indoors may also be subject to unintended water exposure or leakage.

It is with respect to these and other considerations that the present improvements may be useful.

SUMMARY OF THE DISCLOSURE

Disclosed herein is an electrical panel including, in one example embodiment, a back surface, a front surface, a top surface, a bottom surface, and first and second side surfaces defining an interior portion to house one or more electrical components. The electrical panel further including one or more flanges extending from the surfaces of the electrical panel to couple the electrical panel to a structure, the flanges dividing the electrical panel into front and rear portions. The electrical panel further including a barrier extending from an interior surface of the electrical panel, the barrier being adapted and configured to inhibit migration of water from the front portion of the electrical panel to the rear portion of the electrical panel, wherein the barrier is located between the one or more flanges and the front surface of the electrical panel.

The barrier may extend from the interior surface of the bottom surface of the electrical panel, the barrier being adapted and configured to inhibit water from migrating towards the rear portion of the electrical panel along the bottom surface of the panel.

In another example embodiment, an electrical panel may include a back surface, a front surface, a top surface, a bottom surface, and first and second side surfaces defining an interior portion to house one or more electrical components. The electrical panel further including one or more flanges extending from the surfaces of the electrical panel to couple the electrical panel to a structure, the flanges dividing the electrical panel into front and rear portions. The electrical panel further including a cover to at least partially cover a portion of the top surface of the electrical panel, the cover including a top surface, a front surface, first and second side surfaces, and first and second weep holes, the first and second weep holes being adapted and configured to enable water to pass through the top surface of the cover. The first and second weep holes may be positioned adjacent to first and second side surfaces, respectively, of the cover. The cover may further include first and second channels in fluid communication with the first and second weep holes, respectively.

In another example embodiment, an electrical panel may include a back surface, a front surface, a top surface, a bottom surface, and first and second side surfaces defining an interior portion to house one or more electrical components. The electrical panel further including one or more flanges extending from the surfaces of the electrical panel to couple the electrical panel to a structure, the flanges dividing the electrical panel into front and rear portions. The electrical panel may further include a trough formed in the top surface of the electrical panel, the trough extending a width of the electrical panel.

The trough may be positioned adjacent to a portion of the flanges extending from the top surface of the electrical panel, the trough extending beneath the portion of the flanges so that the trough is in fluid communication with the rear portion of the top surface of the electrical panel. Additionally, the electrical panel may further include one or more vertically extending channels formed in one of the first and second side surfaces of the electrical panel, the trough formed in the top surface of the electrical panel being in fluid communication with the one or more vertically extending channels.

DETAILED DESCRIPTION

Numerous embodiments of a water barrier system for use with an electrical panel in accordance with the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the present disclosure are presented. The water barrier system of the present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will convey certain example aspects of the water barrier system to those skilled in the art. In the drawings, like numbers refer to like elements throughout unless otherwise noted.

As will be described in greater detail below, in various embodiments, the water barrier system of the present disclosure is used in conjunction with an electrical panel to direct (e.g., prevent, inhibit, control, etc.) water intrusion into and within the electrical panel (the terms direct, directing, prevent, preventing, inhibit, inhibiting, control, and controlling are used interchangeably herein without the intent to limit). That is, in some embodiments, the water barrier system of the present disclosure provides one or more barriers to prevent, or at least inhibit, water from entering the electrical panel, and/or to keep water, which has entered the electrical panel, from entering a specific portion of an interior portion of the electrical panel, and/or to direct the flow or drainage of the water out of the electrical panel and away from the electrical components located within the electrical panel (e.g., the water barrier system directs the flow or drainage of water out of the electrical panel, away from the electrical components located within the electrical panel, and/or away from the interior wall cavity of the structure in which the panel is mounted).

Thus, in contrast with known, conventional electrical panels that primarily utilize flat top and bottom surfaces, which do not provide any barrier to water entering a specific portion of the interior portion of the panel, and do not direct the drainage of water out of the panel (e.g., water is free to flow to any area inside the panel and drain out any opening located in the electrical panel), the electrical panel according to the present disclosure prevents, or at least inhibits, the migration of water into the electrical panel, the free flow of water to any area inside the panel, and/or directs drainage of the water out of the panel.

Referring now toFIGS. 1 and 2, an exemplary electrical panel100according to the present disclosure is shown. In use, as will be described in greater detail herein, the electrical panel100may include one or more water barrier features to control the movement of water relative to the electrical panel100.

As illustrated, the electrical panel100may include a back surface104, a top surface106(FIG. 9), a bottom surface108(FIG. 2), first and second side surfaces110,112, and a front surface114. In use, the front surface114may be adapted and configured as one or more doors. That is, as shown, in one embodiment, the front surface114may be pivotably coupled to the first side surface110so that an interior portion120(FIG. 2) of the electrical panel100may be accessed.

The electrical panel100may also include a top cover130for operably covering and/or coupling to at least a portion of the top surface106of the electrical panel100(e.g., front portion106A of the top surface106, as will be described in greater detail below). Referring toFIGS. 3-7, the top cover130may include a top surface132, a front surface134, and first and second side surfaces136,138. In one embodiment, as illustrated, the front surface134and the first and second side surfaces136,138may be in the form of ledges descending from the top surface132. In use, the top cover130is coupled to the panel100and acts to at least partially overlap and/or project beyond the top surface106, the front surface114, and the first and second side surfaces110,112of the electrical panel100.

The electrical panel100may also include flanges116for securing the electrical panel100to the surrounding structure (e.g., studs) in a building. The flanges116may extend from one or more of the top, bottom and first and second side surfaces106,108,110,112of the electrical panel100. As illustrated, in one embodiment, the flanges116may be provided in multiple parts. That is, as illustrated, electrical panel100may include one or more flanges116A extending from the bottom and first and second side surfaces108,110,112of the electrical panel100for securing the electrical panel100to the surrounding structure (e.g., studs) in a building. In addition, the top cover130may include a flange116B for securing the top cover130of the electrical panel100to the surrounding structure (e.g., studs) in a building. In use, as will be described herein, the flanges116A,116B may provide a secondary function to act as flashing. Additionally, for purposes of the present disclosure, the flanges116may lie on a plane which divides the electrical panel100into front and rear portions, as will be described in greater detail below.

It should be appreciated that the illustrated electrical panel100is but one example and that the electrical panel may take any form, thus the present disclosure should not be limited to any one electrical panel unless especially claimed.

Referring toFIGS. 1-8, in one embodiment, the electrical panel100may include one or more features for inhibiting water from entering through the top surface106of the electrical panel100. In one embodiment, as illustrated, the top surface132of the top cover130may include one or more weep holes, such as first and second weep holes150A,150B (FIGS. 4-7) for enabling, for example, water to pass through the top cover130of the electrical panel100. As illustrated, the first and second weep holes150A,150B are positioned adjacent to the first and second side surfaces136,138of the top cover130, respectively, and adjacent to the flanges116B associated with the top cover130(e.g., weep holes150A,150B may be positioned adjacent to the intersection of the flange116B and the first and second side surfaces136,138).

Additionally, as illustrated inFIGS. 3, 5 and 7, the electrical panel100may include one or more channels170. In one embodiment, the electrical panel100may include first and second channels170positioned below the first and second weep holes150A,150B, respectively, to catch water passing therethrough. In one example embodiment, as illustrated, the top cover130includes first and second channels170formed in or attached to the first and second side surfaces136,138, respectively. The channels170may be formed by any mechanism now known or hereafter developed. As illustrated, the channel170may be formed by inwardly curving a bottom portion of the side surfaces136,138(e.g. a rolled edge) so that a channel is formed for collecting any water that passes through the weep holes150A,150B. In other words, any water that passes through weep holes150A,150B, is captured by the channels170since the channels170are located directly below the weep holes150A,150B. The channels170may extend from the flange116B associated with the top cover130to the front surface114of the electrical panel100(or a portion thereof). Additionally, each channel170may be inclined or angled downward from the flange116B to the front surface114of the electrical panel100to direct water outward towards the front of the electrical panel100. It should be noted that the channels170may be positioned anywhere on the electrical panel100so long as they are in fluid communication with the weep holes150A,150B. For example, the channels may be formed in the first and second side surfaces110,112of the electrical panel100.

In use, the weep holes150A,150B and channels170control (e.g., direct) water migration from the top surface132of the top cover130. That is, in use, the combination of weep holes150A,150B formed in the top surface132of the top cover130and channels170located on the side surfaces136,138of the top cover130enable water to pass through the top surface132of the top cover130into the channels170and eventually down and away from any of the components located therein. In this manner, the weep holes150A,150B and channels170control (e.g., direct) water that encounters or comes into contact with the exposed front portion106A of the top surface, which may be exposed to the environmental elements (e.g., portion of the top surface positioned in front of the flange116). In particular, the weep holes150A,150B and channels170control (e.g., direct) water that encounters or comes into contact with the electrical panel100along a front surface of the flange116due to, for example, improper installation of the panel (e.g., existence of gaps between, for example, the exterior surface of the panel100and the surrounding layers of material, as previously mentioned). In addition, any water that comes into contact with the top surface132of the top cover130that does not make its way into weep holes150A,150B, may be directed over the side surfaces136,138of the top cover130. When this water reaches the lower edge172of the channel170, it will be directed outward towards the front of the electrical panel100.

Additionally, and/or alternatively, the electrical panel100may include one or more features for controlling (e.g., directing) water that penetrates or otherwise encounters or comes into contact with the rear portion106B of the top surface106of the electrical panel100(e.g., portion of the top surface106positioned behind the flange116B). Referring toFIG. 9, the illustrated example embodiment of the electrical panel100may include one or more lateral troughs200formed in the top surface106of the electrical panel100. The lateral trough200can extend the entire width of the electrical panel100(e.g., from the first side surface110to the second side surface112), although it is envisioned that the lateral trough200may only extend a partial width thereof.

Referring toFIG. 9, as illustrated, in use, the lateral trough200may be positioned adjacent to the flange116(e.g., flange116B associated with the top cover130when the top cover130is coupled to the electrical panel100). That is, in use, the lateral trough200is positioned adjacent to the flange116B extending from the top surface132of the top cover130, when the top cover130is coupled to the electrical panel100). The lateral trough200extends beneath the portion of the flange116B so that the lateral trough200is in fluid communication with the rear portion106B of the top surface106of the electrical panel100. That is, in use, the lateral trough200formed in the top surface106of the electrical panel100may collect and subsequent direct any water that penetrates or otherwise encounters or comes into contact with the rear portion106B of the top surface106of the electrical panel100(e.g., portion of the top surface106positioned behind the flange116B).

Additionally, as illustrated, the electrical panel100may include one or more vertical channels210(FIGS. 1, 2, 8, and 9) formed in the first and second side surfaces110,112, respectively. In use, upper ends of the vertical channels210are positioned in fluid communication with ends of the lateral trough200formed in the top surface106of the electrical panel100. In this manner, any water entering the lateral trough200from the top surface106of the electrical panel100is directed into the vertical channels210formed in the first and second side surfaces110,112.

In one example embodiment, the first and second vertical channels210formed in or attached to the first and second side surfaces110,112may extend the full height of the electrical panel100(e.g., extend from the top surface106to the bottom surface108), although it is envisioned that the vertical channels210may only extend a partial height thereof.

Additionally, referring toFIG. 10, the top cover130may also include a lateral trough202. As illustrated, the lateral trough202formed in the top cover130may be formed or otherwise positioned adjacent to the flange116B and the lateral trough202can extend the entire width of the top cover130(e.g., from the first side surface136to the second side surface138), although it is envisioned that the lateral trough202may only extend a partial width thereof. In use, the lateral trough202formed in the top surface132of the cover130may direct or control water mitigation that encounters or comes into contact with the top surface132of the top cover130.

As illustrated inFIGS. 5, 6, and 10, the top cover130may include a projection206extending therefrom. In use, the projection206is sized and configured to sit within the lateral trough200formed in the top surface106of the electrical panel100when the top cover130is coupled to the electrical panel100. By positioning the projection206into the lateral trough200, capillary action assists with directing water from the lateral trough200and into the vertical channels210. As illustrated inFIG. 10, in the illustrated example embodiment, the bottom surface204of the lateral trough202formed in the top cover130may extend below a bottom surface133of the top cover130thereby defining the projection206. Additionally, and/or alternatively, as will be appreciated by one of ordinary skill in the art, the lateral trough200formed in the top surface106of the electrical panel100may include a sloped surface for directing water into the vertical channels210formed in the first and second sides surfaces110,112, respectively.

In use, by positioning the lateral trough200formed in the top surface106of the electrical panel100adjacent to the flange116B, and by placing the lateral trough200formed in the top surface106of the electrical panel100into fluid communication with the vertical channels210formed in the first and second side surfaces110,112, respectively, of the electrical panel100, the lateral trough200and the vertical channels210direct water from the rear portion106B (e.g., portion of the top surface106positioned behind the flange116B) of the top surface106of the electrical panel100. That is, in use, the combination of the lateral trough200formed in the top surface106of the electrical panel100and the vertical channels210in the side surfaces110,112, respectively, of the electrical panel100enable any water which may enter, for example, along a rear surface of the flange116B, to pass from the rear portion106B of the top surface106of the electrical panel100into the lateral trough200and then into the vertical channels210and eventually down from the electrical panel100and away from any of the components located therein. In this manner, the lateral trough200and the vertical channels210control (e.g., direct) any water that may encounter or come into contact with the rear portion106B of the top surface106of the electrical panel100and thus prevent, or at least inhibit, migration of water towards the back side of the electrical panel100, which may be positioned within an interior wall portion of a building. As such, the combination of the lateral trough200and the vertical channels210prevent, or at least inhibit, water from draining into the interior wall portion or cavity of the building to which the panel100is mounted.

Additionally, and/or alternatively, referring toFIG. 11, the illustrated example embodiment of the electrical panel100may include one or more features to prevent, or at least inhibit, migration of water that has entered the interior portion120of the electrical panel100. For example, if water accumulates on a flat surface such as, for example, the bottom surface108or the like of the electrical panel100, the one or more features prevent, or at least inhibit, water from migrating towards a rear portion of the electrical panel100.

In use, the one or more features may be any suitable feature now known or hereafter developed to prevent or inhibit water from moving from the front portion of the electrical panel100towards the rear portion of the electrical panel100. As illustrated inFIG. 11, in one embodiment, the one or more features may be in the form of one or more barriers, projections, raised lips, ridges, wall, or the like (used interchangeably herein without the intent to limit)250formed in or coupled to a flat surface such as, for example, the bottom surface108or the like of the electrical panel100. As illustrated, in one example embodiment, the barrier250is formed in or coupled to an interior portion109of the bottom surface108of the electrical panel100. The barrier250may extend the entire width of the electrical panel100(e.g., from the first side surface110to the second side surface112), although it is envisioned that the barrier250may only extend a partial width thereof. In one embodiment, the barrier250is positioned forward of the flange116(e.g., between the position of the flange116and the front surface114of the electrical panel100). In this manner, if any water enters the electrical panel100, the water is maintained in the front portion108A of the bottom surface108of the electrical panel100and thus is prevented from moving towards the rear portion108B of the bottom surface108and into contact with electrical components located within the electrical panel100and/or into the wall cavity of the structure in which the panel100is mounted.

The barriers250may be formed into the surfaces (e.g., bottom surface108) of the electrical panel100or coupled to the surfaces (e.g., bottom surface108) of the electrical panel100by any suitable mechanism now known or hereafter developed including, for example, stamping, welding, fastening, rolling, etc. Alternatively, the one or more features could be in the form of a channel or trough with a slope for directing water to a drainage hole.

As illustrated inFIG. 11, the electrical panel100may also include one or more ledges113. In use, one or more gaps260may be formed in between the side surfaces110,112of the electrical panel100and the ledges113to enable any water collected into the front portion108A to escape. Alternatively, it is envisioned, that other mechanisms may be incorporated for enabling water to escape including, for example, one or more drainage holes (e.g., weep holes or the like) formed in the bottom surface of the electrical panel. As will be appreciated by one of ordinary skill in the art, the front portion108A of the bottom surface108of the electrical panel100may include a sloped surface extending, for example, from the barrier250so that any water that encounters or comes into contact with the bottom surface108of the electrical panel100may be directed (e.g., funneled) through the gaps260or drainage holes and out of the electrical panel100.

While the present disclosure makes reference to certain embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present disclosure, as defined in the appended claim(s). Accordingly, it is intended that the present disclosure not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof. The discussion of any embodiment is meant only to be explanatory and is not intended to suggest that the scope of the disclosure, including the claims, is limited to these embodiments. In other words, while illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art.

The foregoing discussion has been presented for purposes of illustration and description and is not intended to limit the disclosure to the form or forms disclosed herein. For example, various features of the disclosure are grouped together in one or more aspects, embodiments, or configurations for the purpose of streamlining the disclosure. However, it should be understood that various features of the certain aspects, embodiments, or configurations of the disclosure may be combined in alternate aspects, embodiments, or configurations. Moreover, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.

The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. The terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, longitudinal, front, back, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of this disclosure. Connection references (e.g., engaged, attached, coupled, connected, and joined) are to be construed broadly and may include intermediate members between a collection of elements and relative to movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. All rotational references describe relative movement between the various elements. Identification references (e.g., primary, secondary, first, second, third, fourth, etc.) are not intended to connote importance or priority, but are used to distinguish one feature from another. The drawings are for purposes of illustration only and the dimensions, positions, order and relative to sizes reflected in the drawings attached hereto may vary.