LOW COST, COMPACT, SIDE ENTRY CABLE SEALING FOR IP66 LED OUTDOOR MODULES

Abstract

The invention provides a cable grommet element (1) for sealed entry of an electricity cable (100) into a housing (1000), wherein the grommet element (1) comprises a body (200), an engagement element (50), a flexible projection (26), and a cable transit (300), wherein (i) the body (200) comprises a first wall (10), a second wall (20), and a side wall (30) connecting the first wall (10) to the second wall (20); (ii) the engagement element (50) protrudes from the first wall (10) of the body (200), wherein the engagement element (50) comprises an engagement element side wall (51) and an engagement element top part (55), wherein the engagement element side wall (51) comprises a flexible rim (52) configured along a perimeter (59) of the engagement element side wall (51); wherein the engagement element (50) further comprises an alignment portion (56) protruding from the engagement element side wall (51); (iii) the flexible projection (26) protrudes from the second wall (20) of the body (200); and (iv) the cable transit (300) is configured for transit of the electricity cable (100) from the side wall (30) of the body (200) to the engagement element top part (55).

Claims

1. A cable grommet element for sealed entry of an electricity cable into an housing, wherein the grommet element is configured to be physically and/or chemically bound to the electricity cable, wherein the grommet element comprises a body, an engagement element, a flexible projection, and a cable transit, wherein: the body comprises a first wall, a second wall, and a side wall connecting the first wall to the second wall; the engagement element protrudes from the first wall of the body, wherein the engagement element comprises an engagement element side wall and an engagement element top part, wherein the engagement element side wall comprises a flexible rim configured along a perimeter of the engagement element side wall; wherein the engagement element further comprises an alignment portion protruding from the engagement element side wall; the flexible projection protrudes from the second wall of the body; and the cable transit is configured for transit of the electricity cable from the side wall of the body to the engagement element top part.

2. The cable grommet element according to claim 1, wherein the cable transit comprises the electricity cable, wherein a first cable end extends from the engagement element top part and the second cable end extends from the side wall of the body.

3. The cable grommet element according to claim 2, wherein the cable grommet element comprises a thermoplastic vulcanized material and wherein the electricity cable comprises a thermoplastic vulcanized material, and wherein the electricity cable is physically and/or chemically bound to the grommet element.

4. The cable grommet element according to claim 1, wherein the cable transit over a length from the side wall of the body to the engagement element top part has a cable transit axis, wherein a first part of the cable transit axis at the engagement element top part and a second part of the cable transit axis at the side wall define a mutual angle () selected from the range of 45-135.

5. The cable grommet element according to claim 1, wherein the side wall of the body comprises a flexible protrusion to allow a compression of the body.

6. The cable grommet element according to claim 1, wherein (i) a part of the body comprising the cable transit, (ii) the engagement element, and (iii) the alignment portion together define a hook configuration.

7. The cable grommet element according to claim 1, wherein at least part of the alignment portion comprises a slanted surface, wherein a first shortest distance (d1) between a first location of the slanted surface and the first wall of the body is larger than a second shortest distance (d2) between a second location of the slanted surface and the first wall of the body, wherein the second location protrudes further from the engagement element side wall than the first location.

8. The cable grommet element according to claim 1, wherein the cable grommet element comprises a plurality of flexible projections extending transverse with respect to a second part of the cable transit axis at the side wall and protruding from the second wall of the body, wherein the body comprises a first end of the body and a second end of the body defining a length (L) of the body, and wherein the cable grommet element further comprises a water ingress shield extending transverse to the second part of the cable transit axis and configured at the second end of the body and protruding from the side wall.

9. A housing comprising (i) a cable grommet element according to claim 1 configured in at least part of the housing, wherein the cable transit comprises the electricity cable, (ii) a base top and (iii) a receptor unit, wherein the base top comprises a base top opening; the body is arranged in the receptor unit, wherein the engagement element is configured through the base top opening.

10. The housing according to claim 9, further comprising a fixating element, wherein the receptor unit and the fixating element define a first receptor unit opening, wherein the second cable end extends from the first receptor unit opening, wherein the flexible projection resiliently contacts the fixating element and wherein the flexible rim resiliently seals the base top opening.

11. The housing according to claim 10, wherein the cable grommet element comprises the water ingress shield according to claim 8, and wherein the water ingress shield is arranged at a side of the first receptor unit opening.

12. The housing (1000) according to claim 9, further comprising an electrical power consuming or generating element functionally coupled to the first cable end, and a lock-up element sealingly connected to the base top, wherein a sealed space comprising the power consuming or generating element is defined by the base top and lock-up element.

13. The housing according to claim 12, comprising a lighting outdoor module, wherein the electrical power consuming or generating element comprises a lighting device, wherein the lock-up element comprises a light transmissive optical element, and optionally a closure element, and wherein a sealing element sealingly connects the lock-up element and the top base.

14. A method for providing a sealed housing, the method comprising: providing a cable grommet element according to claim 1, wherein the cable transit comprises the electricity cable; providing a base top comprising a base top opening and a receptor unit, wherein the base top is configured for holding at least part of the of the grommet element; and arranging at least part of the engagement element comprising the alignment element through the base top opening, wherein at least part of the body is configured in the receptor unit.

15. A mold for providing a cable grommet element according to claim 1, wherein the mold comprises a cavity configured to receive (i) a part of the electricity cable and (ii) a polymer to be injection molded over the part of the electricity cable, and wherein the cavity comprises a shape that corresponds to the body, the engagement element, and the flexible projection.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0076] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

[0077] FIG. 1 schematically depicts some general aspects of the grommet element;

[0078] FIG. 2 schematically depicts a cross section of a grommet element in an electronic housing.

[0079] FIGS. 3-4 schematically depict some aspects of electronic housing;

[0080] FIG. 5 schematically depicts a mold of the invention.

[0081] The schematic drawings are not necessarily to scale.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0082] FIG. 1 schematically depicts an embodiment of a grommet element 1, comprising. The grommet element 1 comprises a body 200, an engagement element 50 and a cable transit 300. The body 200 comprises a first (or top) wall 10, a second (or bottom) wall 20 and a side wall 30 connecting the first wall 10 to the second wall 20. The grommet further comprises a (flexible) projection (such as rib) 26 protruding from the second wall 20 of the body 200. In the figures, the projection 26 is embodied by a rib 26

[0083] The grommet element 1 especially comprises at least one projection 26 configured at the second wall 20 and protruding in a direction away from the engagement element 50. Yet, embodiments may comprise a plurality of said projections (ribs) 26. The embodiment depicted in FIG. 1, e.g., comprises five 26 configured at the second wall 20 and protruding away from the engagement element 50. The height h1 of the grommet element 1 may especially be defined by a shortest distance between an extreme of the projection 26 and the first wall 10.

[0084] The engagement element comprises an engagement element side wall 51, an engagement element top part 55 and an alignment portion 56 protruding from the engagement element side wall 51. Said wall 51 further comprises a (flexible) rim 52 configured along a perimeter 59 of the engagement element side wall 51

[0085] The cable transit 300 is configured for transit of the electricity cable 100 from the side wall 30 to the engagement element top part 55 and is depicted by a dotted line because the embodiment of FIG. 1 comprises, especially encompassing (a part of) the cable 100. A first cable end 110, comprising two wires 101, extends from the engagement element top part 55 and the second cable end 120 extends from the side wall 30 of the body 200.

[0086] Herein, these wires 101 are also referred to as cable 100, and no discrimination is made between a cable 100 not showing the wires 101, and a cable 100 only represented by the wires 101. Especially, the cable transit 300 sealingly encloses the cable 100.

[0087] The cable transit 300 has a cable transit axis 310 over a length from the side wall 30 of the body 200 to the engagement element top part 55. The cable transit axis 310 is over its entire length especially no straight line. A mutual a may be defined between a first part 311 of the cable transit axis 310 arranged at the engagement element top part 55 and a second part 312 of the cable transit axis 310 arranged at the side wall 30. Said angle may especially be selected from the range of 45-135. In the depicted embodiment, the angle is substantially a right angle. It is noted that in FIG. 1 the projections (ribs) 26 extend transverse with respect to the second part 312 of the cable transit axis 310.

[0088] In the figure, a first end 210 of the body 200 and a second end 220 of the body 200 (comprising the second cable transit opening 320) are depicted. Especially the first end 210 and the second end 220 define a length L of the body 200.

[0089] The embodiment, further comprises flexible protrusions 31 comprised by the side wall 30 to allow a compression of the body 200. The protrusions are arranged near the first and second wall 10,20 providing a concave shape, especially providing a V-shape 32. In further embodiments, one or more protrusion(s) 31 may be configured remote from the first and second wall 10,20, e.g. providing a convex shape.

[0090] The figure, further shows an embodiment wherein a part of the body 200 (comprising the cable transit 300) and the engagement element 50 with the alignment portion 56 together define a U-shape or a hook configuration. This hooked configuration may be used when arranging the grommet element in the electric housing 1000 (see FIG. 3)

[0091] The embodiment further comprises a water ingress shield 36 configured at the second end 220 of the body 200 and protruding from the side wall 30. The water ingress shield 36 has a width that is larger than a width of the remainder of the grommet element 1. The water ingress shield 36 extends beyond a perimeter of the top wall 10 and beyond a perimeter of the bottom wall 20. After installing the grommet element in an electronic housing 1000, the shield 36 may prevent any water entering the receptor unit 1050 of the electronic housing. In the depicted embodiment, the shield is configured at an end of the sleeve 36, especially between the sleeve 36 and the body 200.

[0092] The cable 100 is especially physically and/or chemically bound to the grommet element 1, such as to the cable transit 300, and the sleeve 35. In specific embodiments, the grommet element 1 comprises a thermoplastic vulcanized material, such as Santoprene, and the cable 100 comprises the same thermoplastic vulcanized material. Especially, in such combination a bond between the cable 100 and the grommet element may be substantially complete. Such embodiment may also advantageously be provided by molding the grommet element 1 over the cable 100.

[0093] In FIG. 2 is schematically a cross section of a grommet element 1 in an electronic housing 1000 depicted. Herein the side wall 30 is completely enclosed in the receptor unit 1050 of the electronic housing 1000, and the engagement element 50 is protrudes from the base top 1200 and is configured through the base top opening 1255. This way the cable 100, especially comprising two wires 101, is provided to the electronic housing 1000 for connecting to a power consuming or generating element 300 (not shown). For introducing the grommet element in the electronic housing 1000, it may be advantageous to have a flexible grommet element 1. In the depicted embodiment, the side wall 30 of the grommet element 1 comprises a protrusion 31 to allow a deformation of the body 200, especially a deformation of the side wall 30. The figure further shows that the fixating element 1100 is associated with the receptor unit 1050. Because the rib 26 resiliently contacts the fixating element 1100, the rim 52 resiliently seals the base top opening 1255. Herein this is also indicated with phrases like the rim 52 in combination with the projection (rib) 26 especially provide the sealed cable entry interface.

[0094] FIG. 2 also depicts the receptor unit height h2. Essentially, the receptor unit height h2 is especially smaller than the height h1 of the grommet element 1. To provides the sealed cable entry interface.

[0095] FIG. 3 depicts some further elements of the electronic housing 1000. The housing comprises the cable grommet element 1. The housing further comprises a fixating element 1100, a base top 1200 and a receptor unit 1050. The receptor unit 1050 comprises (at least part of) the first receptor unit opening 1155 through which the grommet element 1 is arranged. Especially the receptor unit 1050 and the fixating element 1100 define the first receptor unit opening 1155. The grommet element 1 is also arranged through the second receptor unit opening 1160, in this case comprising the base top opening 1255. The grommet element 1 is especially arranged such that the engagement element 50 is configured through the base top opening 1255 and especially, the second cable end 120 protrudes from the first receptor unit opening 1155. In the given embodiment a part of the alignment portion 56 is configured tilted in a direction towards the first wall 10 of the body 200. Such a configuration may further facilitate arranging the grommet element through the base top opening 1255.

[0096] In the embodiment, the alignment portion 56 comprises a slanted surface 57 (see also FIG. 1.). The slanted surface 57 comprises a first location 53 and a second location 54 protruding further from the engagement element side wall 51 than the first location 53. In FIG. 3 the extend of protruding is schematically depicted by a shortest distance d11 between the first location 53 of the slanted surface 57 and a shortest distance d21 between the second location 54 of the slanted surface 57. Because of the slanted surface 57, especially a first shortest distance d1 between the first location 53 of the slanted surface 57 and the first wall 10 of the body 200 is larger than a second shortest distance d2 between the second location 54 of the slanted surface 57 and the first wall 10 of the body 200. Especially because above described distances d1, d2, d11, d21 comprise shortest distances, the distances may be measured along lines (see the depicted arrows) that are arranged mutually perpendicular to each other.

[0097] When the grommet element 1 is configured in the electronic housing 1000 (comprising the fixating element 1100) the alignment portion 56 is arranged at a first side of the base top 1200 and the rim 52 is arranged at another side of the base top 1200. Because at least one projection (rib) 26 (in the figure all five projections are ribs 26) resiliently contacts the fixating element 1100, the rim 52 resiliently seals the base top opening 1255 and provides the sealed cable entry interface. FIG. 3 further depicts an embodiment comprising the water ingress shield 36 arranged at a side of the first receptor unit opening 1155. The water ingress shield 36 especially extends transverse to (the second part 312 of) the cable transit axis 310. In the figure an electrical power consuming or generating element 80 is functionally coupled to the first cable end 110, especially to two wires 11.

[0098] Further very schematically a lock-up element 800 is depicted that may sealingly be connected (see arrow) to the base top 1200 to define a sealed space 1800 comprising the power consuming or generating element 80 by the base top 1200 and lock-up element 800. It is noted that since the lock-up element is not connected to the base top 1200 the space indicated by the reference number 1800 is still open and not sealed.

[0099] In FIG. 4 schematically an exploded view of an electronic housing 1000, comprising a lighting outdoor module 2000 is depicted. The embodiment depicts an LED outdoor module 2005. In the embodiment the electrical power consuming or generating element 80 comprises a lighting device 85, especially an LED board 1300. The lock-up element 800 comprises a light transmissive optical element 1500, especially a lens 1550 and a closure element 1600. After assembling the elements, the sealing element 1400 will sealingly connects the lock-up element 800 and the top base 1200.

[0100] In embodiments, the fixating element 1100 may be comprised by the electronic housing 1000. In further embodiments a fixating element 1100 may be associated to the receptor unit 1050 at a later stage, e.g. when mounting the lighting outdoor module 2000 at a luminaire (not shown) which comprises a fixating element 1100.

[0101] In the embodiment a base plate 1001 comprises the top plate 1200. The base plate further comprises the receptor unit 1050. Especially, the base plate comprises a heat spreader 1002.

[0102] It is noted that for better understanding the different elements are not connected. The grommet element 1 is for instance also not configured through the top base opening 1255, and also the cable 100 is connected to the power consuming or generating element 80.

[0103] An oval cut-out 1255 on top of the heatsink 1002 allows the neck 50 of the grommet element 1 and thus the wires 101 to enter and reach the Light Emitting Surface 80. The alignment portion (a hook) 56 has been configured at the neck 50 of the grommet element 1 to align the grommet element 1 during assembly in the cut-out 1255 of the base plate 1001/heat spreader 1002 and keep it in place during handling and transportation. Two dents 31 configured at the side wall 30 reduce the force required to insert and assemble the grommet element 1 in the base plate 1001. The water ingress shield 36 may comprise two flaps. These two flaps at first receptor unit opening 1155 prevent direct exposure to waterjets.

[0104] The grommet element 1 is inserted from the bottom, first from an angled position the nose 56 is inserted through the cut-out 1255, then the grommet element 1 is slightly pulled outwards in a direction of the second cable end 120 to hook the nose 56 in the cut-out 1255, especially around an edge of the base top opening 1255, and successively the cable grommet 1 is pushed from the bottom, such that the rest of the grommet element neck 50 is inserted.

[0105] In FIG. 5 schematically a part of a mold 3 according to the invention is depicted. The mold may be used for providing a cable grommet element 1. The mold 3 comprises a cavity 5 configured to receive a part of the electricity cable 100 and a polymer to be injection molded over the part of the electricity cable 100. Especially, the cable 100 may first be introduced and successively the polymer. The polymer will further fill the cavity 5. The cavity 5 at least comprises a shape that corresponds to the body 200, the engagement element 50 and the (flexible) projection(s) 26 of the grommet element 1. It is noted that in the schematic figure the projection 26 is not visible.

[0106] The term plurality especially refers to two or more.

[0107] The term substantially herein, such as substantially consists, will be understood by the person skilled in the art. The term substantially may also include embodiments with entirely, completely, all, etc. Hence, in embodiments the adjective substantially may also be removed. Where applicable, the term substantially may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%. The term comprise includes also embodiments wherein the term comprises means consists of. The term and/or especially relates to one or more of the items mentioned before and after and/or. For instance, a phrase item 1 and/or item 2 and similar phrases may relate to one or more of item 1 and item 2. The term comprising may in an embodiment refer to consisting of but may in another embodiment also refer to containing at least the defined species and optionally one or more other species.

[0108] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0109] The devices herein are amongst others described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation or devices in operation.

[0110] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb to comprise and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article a or an preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

[0111] The invention further applies to a device comprising one or more of the characterizing features described in the description and/or shown in the attached drawings. The invention further pertains to a method or process comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.

[0112] The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined. Furthermore, some of the features can form the basis for one or more divisional applications.