Corrosion resistant multiple tap connectors

A multi-tap enclosure for an electrical cable includes a housing including a first wall and an opposite second wall and a third wall extending between the first and second wall. A first opening is in the first wall of the housing. The first opening defines a main cable axis for the multi-tap enclosure. A second opening is in the second wall of the housing. The second opening is located on the main cable axis. A main cable access opening is in the third wall of the housing. The main cable access opening has a frangible wall therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis. The first opening and the second opening have frangible covers therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis to allow the electrical cable to extend along the main cable axis through the first and second openings when installed in the multi-tap enclosure.

BACKGROUND OF THE INVENTION

The present invention relates to environmentally protective enclosures and, more particularly, to enclosures for environmentally protecting cable connections and the like.

Partially sealant-filled environmentally protective enclosures are employed to protect cable connections. Such enclosures may be used to environmentally protect the connections between telecommunications signal transmission cables, the electrical power transmission cables, etc. For example, U.S. Pat. No. 5,763,835 to Huynh-Ba, et al. discloses a gel-filled enclosure including a pair of cavitied bodies that are hingedly connected and closable in clam shell fashion. When the enclosure is closed about the cables, gel is typically displaced and thereby elongated and seals about a cable splice or the like. However, such enclosures are typically adapted to suitably seal about a limited range of connection/cable sizes. Additionally, for relatively large connections and cables, the force required to close an enclosure about the connection/cables may be unduly large.

It is also known to provide overhead multi-tap (multiple tap) closures for use with electrical power transmission cables and the like. Most overhead multiple tap connectors only provide an empty plastic housing, separate from the connector (conductive component), which only provides touch protection for the energized connector with very limited corrosion protection of the connector or its tap screws. The connectors may corrode due to being exposed to the outside elements and the utility linesman may not be able to remove a tap cable from the connector due to corrosion of the tap screws to a point where they are no longer removable. This generally requires the tap cable to be cut or the connector must be cut off the line entirely.

Tyco Electronics (TE Connectivity) offers a product line, called Gelport™, which provides entry for multiple cables into a connector and a separate cap to allow access to the screws. In addition, Tyco Electronics (TE Connectivity) offers a product line, called GHFC, which seals a connector in a gel-filled plastic box after it is installed on the line.

SUMMARY OF THE INVENTION

According to some embodiments of the present invention, a multi-tap enclosure for an electrical cable includes a housing including a first wall and an opposite second wall and a third wall extending between the first and second wall. A first opening is in the first wall of the housing. The first opening defines a main cable axis for the multi-tap enclosure. A second opening is in the second wall of the housing. The second opening is located on the main cable axis. A main cable access opening is in the third wall of the housing. The main cable access opening has a frangible wall therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis. The first opening and the second opening have frangible covers therein configured to allow movement of the electrical cable horizontally therethrough towards the main cable axis to allow the electrical cable to extend along the main cable axis through the first and second openings when installed in the multi-tap enclosure.

In further embodiments, a multi-tap enclosure for an electrical cable includes a housing having a first main cable opening and a second main cable opening and a tap cable opening. An electrically conductive multi-tap connector in the housing has a main cable contact region positioned on a main cable axis extending between the first main cable opening and the second main cable opening and a tap cable contact region proximate the tap cable opening. Securing members are associated with each of the contact regions. The securing members are movable between an open position in which a cable can be inserted in the respective contact regions and a closed position securing a cable inserted in the respective contact regions. A sealant is disposed in the housing and contacts the multi-tap connector to provide environmental protection to the multi-tap connector and connections thereto. A main cable access opening is in the housing. The main cable access opening is configured to allow movement of the electrical cable therethrough into the main cable contact region on the main cable axis to allow the electrical cable to extend along the main cable axis through the first and second openings and be electrically connected to the multi-tap connector in the main cable contact region when installed in the multi-tap enclosure.

In other embodiments, a method of inserting an uncut electrical cable in a multi-tap enclosure includes removing an outer insulating cover of the electrical cable from a section of the electrical cable. The section of the electrical cable is passed horizontally through a frangible wall of a main cable access opening into a main cable contact region of a multiple tap connector in a chamber of a multi-tap enclosure housing having a sealant disposed therein. The electrical cable then extends along a main cable axis from a first opening of the housing to an opposite second opening of the housing. The section of the electrical cable is passed vertically through frangible covers in the first opening and the second opening to seat the section of the electrical cable in the main cable contact region after passing the section of the electrical cable horizontally through the frangible wall of the main cable access opening. Passing the section of the electrical cable horizontally includes passing the section of the electrical cable horizontally through the frangible covers in the first and second openings. The section of the electrical cable is secured in the main cable contact region. The main cable access opening is plugged with a plug of the multi-tap enclosure housing.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

With reference toFIGS. 1-6, a partially sealant-filled multiple tap enclosure101suitable for use on overhead power cables according to some embodiments of the present invention is shown therein. The enclosure101is adapted to form a sealed enclosure about and including a multiple tap connector102(FIG. 5) and the connection of cables138,140(FIG. 2) or the like thereto. In some embodiments, the enclosure housing defines a chamber that is completely filled with a sealant to provide corrosion protection.

The enclosure101includes a housing100having a first member105and a second member110that define a chamber therein. The members105,110each have a cover112,114hingedly connected thereto, which may be a separate part. In the illustrated embodiments, the enclosure101is configured to electrically couple up to four tap cables140to a main cable138. In addition to the housing100, the enclosure101includes a plug including plug members116,118coupled to each of the housings members105,110by respective flexible tethers120,122, which may be separate parts. The enclosure101further includes a multiple tap connector102(FIGS. 2,5) in the chamber defined by the housing100with securing members, shown as a main screw136and four connector tap screws134(two of which are visible inFIGS. 2 and 5), therein. The members105,110may be snapped together to form a unified housing with the connector102therein using the four mating connector plastic housing tabs149(including tongues149aand mating grooves149bon respective ones of the members105,110) in the illustrated embodiments. In the illustrated embodiments, the members105,110are configured to maintain the connector102in a fixed position, in the illustrated embodiments, by using internal ribs192each include that maintain the connector102in position in the housing100. The second member110is illustrated as including four tap cable openings144for receiving respective tap cables140and a main cable opening146for receiving the main cable138. A frangible cover144a,146ais positioned in each opening144,146. The first member105likewise includes a main cable opening146with a frangible cover146ato allow the main cable138to extend longitudinally through the enclosure101. In some embodiments, however, no tap cable openings144are provided in the first member105as the tap cables140need not extend through the enclosure101. Other embodiments may have more or less than the 4 tap cable openings shown in the illustrated embodiment.

The connector102has a main cable contact region170and four tap cable contact regions172(FIG. 5). With reference toFIG. 1, the member110includes a first wall10within which a first main cable opening (i.e. , the opening146of the member110) is defined. The member105includes a second wall20(opposite the wall10) within which a second main cable opening (i.e. , the opening146of the member105) is defined. A side wall32of the member110and a side wall34of the member105collectively form a third wall30extending axially between the first wall10and the second wall20. A main cable access opening40is defined in the third wall30and a securing member access opening44is defined in the top of the enclosure101by the members105,110, collectively.

As best seen inFIG. 2(open position of covers112,114) andFIG. 3(closed position of covers), the cover112allows access to the tap screws134and main screw136in the open position and covers the tap screws134, main screw136and connector102in the closed position. Similarly, the cover114provides access to and coverage for the two additional tap screws134that are not visible in the figures. When the covers112,114are closed, they may be releasably latched in the closed position by tabs151on the latch members150,152of the covers112,114.

While the tap cables140will generally be provided as an end of a cable with a specified tap length of the covering thereof removed that may be inserted longitudinally into the enclosure101, the main cable138may be a longitudinally extending cable that does not have an end thereof available for insertion into the enclosure101. As such, a method of inserting the main cable138into the enclosure101and the features of the enclosure101related thereto will now be described with reference toFIGS. 3 and 4.FIG. 3illustrates the main cable138inserted in the enclosure101with the plug members116,118installed.FIG. 4illustrates the enclosure101with the main cable138prepared to be inserted therein. As will be more fully described later herein, before insertion, the main cable138has the outer insulating cover thereof removed from a section138awhere an electrical connection will be formed in the enclosure101. A sealant material, such as a gel wrap strip160, may be positioned over the section138aas in the illustrated embodiments ofFIG. 4. In the following description, references to a horizontal and vertical direction will be used herein, which directions are relative to the housing as seen by the axes inFIG. 2for the vertical direction v and the horizontal direction h, both of which are with reference to a cross-sectional plane of the longitudinal axis defined by the main cable138. It will be understood that, for the relative positioning of the openings shown in the figures, the defined main cable axis would be straight, however, in some embodiments the openings may not be positioned in such a relationship and the main cable axis may be curved.

During insertion, the main cable138is moved horizontally towards the enclosure101until it contacts the frangible walls148,148′. In particular, the main cable138may be vertically aligned to make contact along a gap162extending longitudinally along a middle region of the frangible walls148,148′. As best seen inFIG. 6, the frangible walls148,148′ are configured to preferentially bend along a line parallel to the longitudinal axis of the main cable138when the cable138is pressed horizontally into the enclosure101due to the orientation of the ribs180(FIG. 6). Other embodiments may have only thin walls at148&148′ hingedly connected without ribs. In addition, the frangible covers146ain the main cable openings146of the respective members105,110are configured to be horizontally frangible when contacted by the main cable138to allow the main cable138to move horizontally there through to be received in a main line contact interface170of the connector102(FIG. 5).

After the cable138is fully inserted horizontally in the enclosure101, the frangible walls148,148′ will rotate at least partially back to their original orientation, in part due to loading from a sealant material in the enclosure101as will be further described later herein. The main cable138is then moved down vertically to be seated in the main line contact interface170, shown as a J-shaped interface in the illustrated embodiments. The frangible covers146ain the main cable openings146of the respective members105,110are also configured to be vertically frangible when contacted by the main cable138to allow the main cable140to move vertically there through. In addition, in the illustrated embodiments, an opening190(FIG. 5) is provided in each of the members105,110to allow independent flexing of the frangible walls148,148′ and the frangible cover(s)146a. Thus, the enclosure101in the illustrated embodiments is configured to allow movement along two distinct axes to allow insertion of a longitudinally unbroken section of the main cable138therein. As such, the connector102may be connected to an overhead main cable138after it has already been enclosed in the housing100, in contrast with the prior art approach of attaching the connector to the main line before snapping an electrically insulated housing around the connector.

After the main cable138is inserted and secured in the connector102using the main screw136, the plug members116,118are attached to the housing100as seen inFIG. 3. The plug members116,118include a first wall116a,118aand a second wall116b,118b. The plug members116,118are coupled together when installed by a mating tab119and channel117on the respective plug members116,118. In the attached position, the first wall116a,118aof the respective members105,110substantially cover the openings146in each member105,110while the second wall116b,118bcover the frangible walls148,148′ to provide improved closure of the connector102within the housing100. In addition, in some embodiments as illustrated inFIG. 6, at least one of the plug members116,118includes a tongue188. The tongue(s)188in some embodiments are tapered to provide a wider opening displaced from the wall118bthan proximate the wall118b. In some embodiments, when the plug members116,118is mounted to the housing100it is slid longitudinally onto the housing, during which motion the frangible walls148,148′ are engaged by the tongue188to rotate the frangible walls148,148′ more fully towards their original orientation.

In the embodiments shown in the Figures, the plug members116,118are tethered to the respective members105,110by the flexible tethers120,122. The flexible tethers120,122may remain attached in the closed position of the plug members116,118shown inFIG. 3. As such, the members105,110and plug members116,118may be conveniently provided as coupled parts both as provided initially and for later use if the enclosure101needs to be removed from the cable138and subsequently re-installed (although they may be separate parts in other embodiments).

As noted above, in some embodiments, the enclosure101is a sealant filled enclosure, which may provide improved corrosion control for the connector102. As best seen with reference toFIG. 6, masses of sealant184′,186′ are disposed in regions184,186defined by the respective members105,110, including ribs192for the region184(member110is shown inFIG. 6, but member105may be substantially similarly configured for purposes of this discussion, albeit the frangible covers144amay not be frangible in member105as discussed above). According to some embodiments, and as discussed in more detail below, the sealant184′,186′ in the regions184,186may be a gel. By providing a sealant in both regions184,186in both members105,110, each of the corresponding faces173,175,177,179of the connector102may be contacted by the sealant. Faces177,179are contacted by sealant in regions184on coupling of the members105,110while faces173,175are contacted by sealant in regions186on closing of the covers112,114as the connector102protrudes above the interior plastic walls defining the regions186when the covers112,114are closed. In addition, sealant may be moved into the contact regions170,172of the connector102by insertion of the cables138,140, each of which passes through sealant when inserted into the housing100. Additional sealant contact to the region170may be provided by placement of the sealant160on the main cable138before insertion as discussed with reference toFIG. 4. Thus, corrosion protection may be provided for not only the coupling between the cables138,140and the connector102but also for the tap screws134,136. As such, enclosure101according to some embodiments may provide for improved reliability for re-use, including removal of installed tap cables140or the main cable138.

The plug members116,118may be integrated (molded-in or tethered) components of the plastic members105,110, respectively; and may provide additional electrical and/or corrosion protection to any remaining open areas around the main cable138. The plug members116,118may or may not have a sealant, such as a gel, therein. They may mechanically cover any remaining open areas in the plastic enclosure members105,110that might exist around the main cable138after the connector102with its sealant filled enclosure101is installed on the line as discussed above. They may also work in conjunction with the sealant (gel strip)160ofFIG. 4by displacing sealant/gel within the enclosure101to further seal around the main cable138and the main screw136. As also noted above, at least one of the plug members116,118may contain the tongue188, which may displace the frangible walls148,148′ at the main line opening of the plastic enclosure101, pushing these walls148,148′ back to their flat condition, hence closing up an open area after installation. Additionally, when the plug members116,118are installed, they may perform an insulation function by mechanically covering an open area in the enclosure101as well as covering any bare conductor of the main line138. In some embodiments, plug members116,118are not included.

The housing100may be formed of any suitable material. According to some embodiments, the housing100is formed of an electrically insulative material. In some embodiments, the housing100is formed of a molded polymeric material. The housing100may be formed of polypropylene, flame retardant polypropylene, polyethylene and/or any suitable thermoplastic or thermoset material. The housing100may be formed of a flame retardant material. The plug members116,118may be separate parts as mentioned above and formed of a different material than members105,110. The connector102may be an aluminum connector, which may be tin plated. The connector and/or its screws may also be formed of a copper alloy material or combination of copper and aluminum thereof.

As best seen inFIG. 6, all of the described features of the enclosure101may be molded into the respective members105,110, except for the connector102and tap screws134,136therein. In the illustrated embodiments, a sealant material, such as a gel, that is placed in the regions184,186in a liquid form and then cured is used. As seen in the most clearly inFIG. 6, molded in features define enclosed regions where the gel is received before curing except for the opening190and the slot162(FIG. 5). As shown inFIG. 6, a tape182may be applied to the member105,110to cover the opening190and to cover the slot162up to a desired fill height of the gel. The tape182may then be removed after curing of the gel. In some embodiments, the tape may be left in place. In some embodiments, a gasket/fixture may be used to cover the opening rather than using a tape.

As described above, in some embodiments of the present invention, an overhead multiple tap (multi-tap) connector may be pre-installed into a silicone gel filled box with hinged screw covers and an auxiliary tethered main plug. Such connector assemblies may provide access to the connector tap or main screws without having to remove the gel filled box. The connector tap screws may be accessed via, for example, molded hinged screw covers that snap over the tap screw areas. These screw covers may also be filled with silicone gel. The tap connector may first be installed into the gel filled box as a completed product, which is then installed by the customer onto the overhead main line and used as with their non-covered multi-tap connectors. In addition, for even further environmental protection, additional gel sealant could be added, for example, through the openings190, after installation of the enclosure101on the main cable138. In some embodiments, the housing100may be supplied to a user/customer in two halves. The user/customer may then install the housing100around the connector102, either before or after installation of the connector102on a main cable.

In some embodiments of the present invention, as described above, corrosion protection may be provided for the exposed main cable. The exposed bare conductor area of the main cable may be wrapped with a strip of silicone gel product prior to the installation of the multi-tap connector. The main screw of the multi-tap connector may then displace this gel strip at the connector/main line and main screw/main line interfaces when the screw is torqued onto the main cable. This approach may provide superior corrosion resistance immediately outside the main screw, while still enabling good electrical contact at the interfaces between the connector and the main line.

In some embodiments of the present invention, as described above, a gel filled plastic enclosure may be pre-assembled around a multi-tap connector, allowing the connector to be installed onto the line after it is installed into the gel filled plastic enclosure.

In some embodiments of the present invention, an auxiliary (molded-in or tethered) “plug” is included in the design of the plastic enclosure to provide additional corrosion protection to any remaining open areas around the main cable. This plug may or may not have gel in it. The plug may mechanically cover any remaining open areas in the plastic enclosure that might exist around the main cable after the connector with its gel filled enclosure is installed on the main line. The plug may also work in conjunction with the gel strip on the main cable by displacing gel within the enclosure to further seal around the main cable and the main screw.

In some embodiments of the present invention, as described above, the plug may contain a “tongue” member, which displaces frangible walls at the main line opening of the plastic enclosure, pushing these walls back to their flat condition, hence closing up an open area after installation. Additionally, when this plug is installed, the tongue member may perform an insulation function by mechanically covering an open area in the box as well as covering any bare conductor of the main line.

According to some embodiments of the invention, the sealant used is a gel. As used herein, “gel” refers to the category of materials that are solids extended by a fluid extender. The gel may be a substantially dilute system that exhibits no steady state flow. As discussed in Ferry, “Viscoelastic Properties of Polymers,” 3rded. P. 529 (J. Wiley & Sons, New York 1980), a polymer gel may be a cross-linked solution whether linked by chemical bonds or crystallites or some other kind of junction. The absence of the steady state flow may be considered to be the key definition of the solid-like properties while the substantial dilution may be necessary to give the relatively low modulus of gels. The solid nature may be achieved by a continuous network structure formed in the material generally through crosslinking the polymer chains through some kind of junction or the creation of domains of associated substituents of various branch chains of the polymer. The crosslinking can be either physical or chemical as long as the crosslink sites may be sustained at the use conditions of the gel.

Gels for use in this invention may be silicone (organopolysiloxane) gels, such as the fluid-extended systems taught in U.S. Pat. No. 4,634,207 to Debbaut (hereinafter “Debbaut '207”); U.S. Pat. No. 4,680,233 to Camin et al.; U.S. Pat. No. 4,777,063 to Dubrow et al.; and U.S. Pat No. 5,079,300 to Dubrow et al. (hereinafter “Dubrow '300”), the disclosures of which are hereby incorporated herein by reference. These fluid-extended silicone gels may be created with nonreactive fluid extenders as in the previously recited patents or with an excess of a reactive liquid, e.g., a vinyl-rich silicone fluid, such that it acts like an extender, as exemplified by the Sylgard® 527 product commercially available from Dow-Corning of Midland, Mich. or as disclosed in U.S. Pat. No. 3,020,260 to Nelson. Because curing is generally involved in the preparation of these gels, they are sometimes referred to as thermosetting gels. The gel may be a silicone gel produced from a mixture of divinyl terminated polydimethylsiloxane, tetrakis(dimethylsiloxy)silane, a platinum divinyltetramethyldisiloxane complex, commercially available from United Chemical Technologies, Inc. of Bristol, Pa., polydimethylsiloxane, and 1,3,5,7-tetravinyltetra-methylcyclotetrasiloxane (reaction inhibitor for providing adequate pot life).

Other types of gels may be used, for example, polyurethane gels as taught in the aforementioned Debbaut '261 and U.S. Pat. No. 5,140,476 Debbaut (hereinafter “Debbaut '476”) and gels based on styrene-ethylene butylenestyrene (SEBS) or styrene-ethylene propylene-styrene (SEPSS) extended with an extender oil of naphthenic or nonaromatic or low aromatic content hydrocarbon oil, as described in U.S. Pat. No. 4,369,284 to Chen; U.S. Pat. No. 4,716,183 to Gamarra et al.; and U.S. Pat. No. 4,942,270 to Gamarra. The SEBS and SEPS gels comprise glassy styrenic microphases interconnected by a fluid-extended elastomeric phase. The microphase-separated styrenic domains serve as the junction points in the systems. The SEBS and SEPS gels are examples of thermoplastic systems.

Another class of gels which may be used is EPDM rubber based gels, as described in U.S. Pat. No. 5,177,143 to Chang et al.

Yet another class of gels which may be used is based on anhydride-containing polymers, as disclosed in WO 96/23007. These gels reportedly have good thermal resistance.

The gel may include a variety of additives, including stabilizers and antioxidants such as hindered phenols (e.g., Irganox™ 1076, commercially available from Ciba-Geigy Corp. of Tarrytown, N.Y.), phosphites (e.g., Irgafox™ 168, commercially available from Ciba-Geigy Corp. of Tarrytown, N.Y.), metal deactivators (e.g., Irganox™ D1024 from Ciba-Geigy Corp. of Tarrytown, N.Y.), and sulfides (e.g., Cyanox LTDP, commercially available from American Cyanamid Co. of Wayne, N.J.), light stabilizers (i.e., Cyasorb UV-531, commercially available from American Cyanamid Co. of Wayne, N.J.), and flame retardants such as halogenated paraffins (e.g., Bromoklor 50, commercially available from Ferro Corp. of Hammond, Ind.) and/or phosphorous containing organic compounds (e.g., Fyrol PCF and Phosflex 390, both commercially available from Akzo Nobel Chemicals Inc. of Dobbs Ferry, N.Y.) and acid scavengers (e.g., DHT-4A, commercially available from Kyowa Chemical Industry Co. Ltd through Mitsui & Co. of Cleveland, Ohio, and hydrotalcite). Other suitable additives include colorants, biocides, tackifiers and the like described in “Additives for Plastics, Edition 1” published by D.A.T.A., Inc. and The International Plastics Selector, Inc., San Diego, Calif.

In some embodiments, suitable gel materials include POWERGEL sealant gel available from Tyco Electronics (TE Connectivity) Energy Division of Fuquay-Varina, NC under the RAYCHEM brand. In some embodiments, a thicker (less flowing prior to curing) gel is used for the sealant160, such as a gel wrap strip of Thixo(tropic) gel, also available from Tyco Electronics.

Alternatively, the sealant may be a non-gel sealant. For example, the sealant may be silicone grease or a hydrocarbon-based grease.

The enclosure may be formed in the following manner. The members105,110and the hinged covers112,114may be integrally formed. According to some embodiments, the members105,110and the hinged covers112,114are unitarily molded. According to some embodiments, the plug members116,118and tethers120,122are also unitarily molded with the members105,110. The housing100may be injection molded.

If the sealant is a material, such as a curable gel, that requires curing, the sealant may be cured in situ. As will be apparent to those skilled in the art from the description herein, partially sealant-filled enclosures of the present invention may be formed by other methods.

The enclosure101may provide a number of advantages. The enclosure101may provide a reliable (and, in at least some embodiments, moisture-tight) seal about the connector102. The sealant, particularly gel sealant, may accommodate cables of different sizes within a prescribed range. For example, in some embodiments, the main cable138may range from 250 kcmil maximum, down to #2 AWG minimum with a maximum outside insulation diameter of 0.72″. The four tap cables140may range from 4/0 AWG maximum, down to #6 AWG minimum or 1/0 ACSR).

Various properties of the gel as described above may ensure that the gel sealant maintains a reliable and long lasting seal, between the housing100and the cables138,140. The elastic memory of and the retained or restoring force in the elongated, elastically deformed gel generally cause the gel to bear against the mating surfaces of the cables138,140and the interior surface of the housing100. Also, the tack of the gel may provide adhesion between the gel and these surfaces. The gel, even though it is cold-applied, is generally able to flow about the cables138,140and the housing100to accommodate their irregular geometries.

The sealant, particularly when formed of a gel as described herein, in addition to providing corrosion protection, may, in some embodiments, provide a reliable moisture barrier for the cables138,140and the connector102, even when the enclosure101is submerged or subjected to extreme temperatures and temperature changes, although in such embodiments the enclosure101may be at least more fully sealant-filled. The housing100may be made from an abrasion resistant material that resists being punctured by the abrasive forces.

The gel may also serve to reduce or prevent fire. The gel is typically a more efficient thermal conductor than air and, thereby, may conduct more heat from the connection. In this manner, the gel may reduce the tendency for overheating of the connector102that might otherwise tend to deteriorate the cable insulation and cause thermal runaway and ensuing electrical arcing at the connection. Moreover, the gel may be flame retardant.

As will be appreciated from the description herein, enclosures according to the present invention may be provided as pre-formed and fully assembled units, with pre-cured gel or other sealant therein as described above, that may be cold applied about a connection assembly to form an environmental seal.

While, in accordance with some embodiments, the housing100is integrally and unitarily formed, the housing may be otherwise formed in accordance with some aspects of invention. For example, the members105,100and their respective covers112,114and plug members116,118may be separate parts joined together in hinged fashion or otherwise. According to some embodiments, the covers112,114are not hinged, but are instead provided as two separate members that are secured to the members105,110by latch structures, ties, clamps or other suitable means allowing repeated access to the tap screws134,136.

The frangible walls148,148′ and covers144a,146amay be constructed as described in U.S. Pat. No. 5,763,863 to Huynh-Ba, et al., the disclosure of which is incorporated herein by reference. Additionally or alternatively, the covers144a,146amay be formed with pre-formed holes for receiving a cable or cables (in which case supplemental means may be provided for retaining uncured sealant in the regions184during manufacture.

It will be appreciated that enclosures in accordance with the present invention may have components (e.g., cover members, walls, etc.) and cavities or chambers having shapes, configurations and/or sizes different than those shown and described herein.