ELECTRICAL GROUND ROD CAP

Abstract

A ground rod cap is provided. The cap includes a body that fits around a ground rod, ground rod clamp and ground wire at their point of connection. The body retains a filler material within an internal cavity. In some embodiments, a portion of the body acts as a barrier to retain the filler material. In some such embodiments, the filler material is positioned within the body prior to installation of the cap on the ground rod connection components. In some embodiments, the filler material is located in an airtight cavity until installation. In some such embodiments, a shrink-wrap material is placed around the body to make the cavity airtight. In other embodiments, the filler material is retained within at least a portion of the cap by an internal barrier that breaks as the cap is installed to allow the filler material to flow around the components.

Claims

1. A protective cap comprising a body, the body defining: an inner cavity; and a first opening in communication with said inner cavity, said first opening being configured for selectively receiving a first portion of a first elongate member, wherein said inner cavity includes a diameter substantially greater than 1 inch to accommodate a connection component coupled to the first elongate member, and wherein said first opening is sized so as to prevent the connection component from passing through said first opening when the connection component is coupled to the first elongate member.

2. The protective cap of claim 1, further comprising: a filler material located within said inner cavity of said body, wherein said filler material changes from a generally liquid state to a generally solid or semi-solid state within said cavity; and a breakable barrier configured to break and expose said filler material to the connection component as the connection component is positioned within said inner cavity.

3. The protective cap of claim 1, wherein the first elongate member is a ground rod having a diameter of at least 0.5 inches and the connection component is a ground rod clamp that includes a main section for surrounding the ground rod and a bolt for electrically securing a ground wire to the ground rod.

4. The protective cap of claim 1, further comprising a lid coupled to said body and moveable between an open configuration and a closed configuration, wherein said body defines a second opening opposed to said first opening, said lid being in communication with said second opening when said lid is in the closed configuration such that said lid prevents air from entering or exiting said inner cavity through said second opening when said lid is in the closed configuration.

5. The protective cap of claim 4, wherein said lid is hingedly connected to said body.

6. The protective cap of claim 1, wherein said body includes a first body portion and a second body portion that mates with said first body portion.

7. The protective cap of claim 6, wherein said body portions are connected together via a hinge that is located in a plane that is spaced apart from a vertical axis of the first elongate member; and wherein said first opening is located generally at a bottom of the protective cap and said hinge is located generally along a side of the protective cap at a location generally higher than said first opening.

8. The protective cap of claim 6, wherein said cavity is at least partially located in said first body portion, and wherein said second body portion is moveable between an open configuration and a closed configuration such that the connection component may be placed within said cavity when said second body portion is in the open configuration and retained within said cavity when said second body portion is in the closed configuration.

9. The protective cap of claim 1, wherein said first opening defines a hole extending into said cavity for placement of the first elongate member.

10. The protective cap of claim 9, wherein said first opening further defines a channel extending into said cavity for placement of a second elongate member.

11. The protective cap of claim 10, wherein the first elongate member is a ground rod having a diameter of at least 0.5 inches, the connection component is a ground rod clamp, and the second elongate member is a ground wire, and wherein the connection component includes a main section for surrounding the ground rod and a bolt for electrically securing the ground wire to the ground rod.

12. The protective cap of claim 1, further including a barrier that creates an airtight state within said cavity.

13. The protective cap of claim 12, wherein said barrier comprises a shrink-wrap around said body.

14. The protective cap of claim 12, wherein a filler material is maintained in a fluid state within said cavity while said barrier is airtight, and wherein said filler material changes to a generally solid or semi-solid state after said airtight state of said barrier is broken.

15. The protective cap of claim 1, further including a barrier, and wherein a filler material is maintained in a fluid state within said cavity while said barrier is closed, and wherein said filler material changes to a generally solid or semi-solid state when said barrier is open.

16. The protective cap of claim 15, wherein said change from a fluid state results from exposure of said filler material to air.

17. The protective cap of claim 15, wherein said filler material is a particulate.

18. A method of reducing the risk of corrosion at a point of connection between a connection component and a first elongate member, the method comprising: moving a second body member of a protective cap away from a first body member of the protective cap such that the protective cap is in an open configuration; positioning the protective cap around the connection component; and moving the second body member of the protective cap towards the first body member of the protective cap until the protective cap is in a closed configuration such that the connection component is positioned entirely within an inner cavity of the protective cap, wherein a first portion of the first elongate member extends into the inner cavity of the protective cap through a first opening of the protective cap; wherein said cavity includes a diameter substantially greater than 1 inches to accommodate said connection component, and wherein the first opening is sized so as to prevent the connection component from passing through the first opening when the connection component is coupled to the first elongate member.

19. The method of claim 18, further comprising: holding a filler material within the cavity with a breakable barrier; and breaking the breakable barrier during the positioning step to expose the filler material within the cavity to the point of connection.

20. The method of claim 18, wherein the two body members are connected together via a hinge that is located in a plane that is spaced apart from a vertical axis of the first elongate member; and wherein the first opening is located generally at a bottom of the protective cap and the hinge is located generally along a side of the protective cap at a location generally higher than the first opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] A preferred embodiment of the invention, illustrative of the best mode in which the applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

[0020] FIGS. 1a, b, c and d are top, side, end and bottom views, respectively, of a ground rod cap of a first embodiment of the instant invention.

[0021] FIGS. 2a, b, c are top, side and bottom views, respectively, of a ground rod cap of a second embodiment of the instant invention.

[0022] FIG. 2d is a partial detail view of the top of the ground rod cap of FIG. 2a.

[0023] FIGS. 3a, b, c are top, side and bottom views, respectively, of a ground rod cap of a third embodiment of the instant invention.

[0024] FIG. 3d is a partial detail view of the top of the ground rod cap of FIG. 3a.

[0025] FIGS. 4a, b, c are side, front and bottom views, respectively, of a ground rod cap of a fourth embodiment of the instant invention.

[0026] FIG. 4d is a sectional view taken along line A-A of FIG. 4b.

[0027] FIG. 4e is a sectional view taken along line B-B of FIG. 4b.

[0028] FIG. 4f is a detail view of a hinge connecting to halves of the cap body taken from FIG. 4e.

[0029] FIG. 4g is a detail view of a clamp releasably connecting two halves of the cap body taken from FIG. 4d.

[0030] FIG. 4h is a detail view of the clamp taken from FIG. 4e.

[0031] FIGS. 5a and 5b are side and front views, respectively, of a ground rod cap of a fifth embodiment of the instant invention.

[0032] FIGS. 5c and 5d are sectional views taken along lines A-A and B-B of FIG. 5b, respectively.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0033] As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

[0034] FIG. 1 shows top, side and bottom views of a ground rod cap 10 of a first embodiment of the instant invention. The cap 10 in the embodiment shown includes a body 12 and a removable lid 14 connected to the body 12. In the embodiment shown, the body 12 and lid 14 are made of a plastic material; notwithstanding, it will be appreciated that other suitable materials will be apparent to those of ordinary skill in the art. In the embodiment shown in FIG. 1, the lid 14 is connected via a living hinge 16. It will be appreciated that alternative connections may be utilized without departing from the spirit and scope of the instant invention, including but not limited to alternative hinge connections or separable connections such as through the use of external threads on the body 12 and internal thread on the lid 14. The hinge connection in the embodiment shown allows for the inclusion of the wire channel 18, which allows a ground wire 60 (see FIG. 5) to easily extend out of the cap 10.

[0035] The cap 10 of FIG. 1 further includes a punch out hole 20 at the bottom end of the body 12, opposing the lid 14. The punch out 20 shown includes perforated or weakened portions of material of diameters ranging from inch to inch. It will be appreciated that punch outs 20 of other diameters may be utilized, as well as alternative structural arrangements for providing holes of various diameters (including but not limited to an x shaped cutout similar to a straw hole in a drinking cup lid). In addition, it will be appreciated that a fixed diameter hole may also be utilized without departing from the spirit and scope of the instant invention.

[0036] A filler or sealant material (not shown) is included in the cap 10. In a preferred embodiment, the filler or sealant is included in the cap 10 prior to placement on a ground rod 28 (see FIG. 4). In some embodiments, the filler or sealant is included during manufacturing of the cap 10. In some such embodiments, the filler or sealant is designed to harden when it is exposed to air. In some such embodiments, a plastic or other suitable barrier 22 is included to keep the sealant air tight. In other such embodiments, the lid 14 may be sealed to the body 12 to keep the sealant air tight.

[0037] In the embodiment shown in FIG. 1, the barrier 22 extends across the top of restraint flanges 24. In addition, another barrier 22 is included on the opposing end below the lid 14. The barrier 22 is easily breakable during installation.

[0038] In operation, the ground rod 28 (see FIG. 4) is punched through the knock-out hole 20. This can be done either before or after the ground rod 28 is driven into the ground (if the rod is driven into the ground). If done before the rod 28 is driven into the ground, a ground rod clamp 26 and the ground wire 60 can be attached to the ground rod 28 before the cap 10 is installed. If done after the ground rod 28 is driven into the ground, the cap 10 is placed on the ground rod 28, and the ground rod clamp 26 and the ground wire 60 are installed in the sealing material. Then the lid 14 is closed to seal the assembly.

[0039] FIG. 2 shows top, side and bottom views of a ground rod cap 30 of a second embodiment of the instant invention. The cap 30 shown in FIG. 2 is generally spherical in shape and includes two halves that are connectable together. In the embodiment shown, the two halves are connected together via a hinge 32; however, it will be appreciated that alternative connections (including but not limited to no hinge) may be utilized without departing from the spirit and scope of the instant invention. In the embodiment shown, one half includes a continuous clip edge or channel 34, similar to a Tupperware or other container lid connection. The other half includes a generally flat edge (not shown) that fits within the channel 34. This allows a secure connection of the two halves. It will be appreciated that alternative connections may be utilized without departing from the spirit and scope of the instant invention.

[0040] In the embodiment shown in FIG. 2, a 1 inch diameter hole 36 is included on the bottom of the cap to accommodate a ground rod 28 (see FIG. 4) up to 1 inch in diameter. Nevertheless, it will be appreciated that other diameter holes may be utilized without departing from the spirit and scope of the instant invention. In addition, it will be appreciated that knockouts or other structures may be utilized as well.

[0041] The embodiment shown in FIG. 2 also includes a wire channel 38 located at the top of the ground rod cap 30. Nevertheless, the channel 38 may be located at other positions without departing from the spirit and scope of the instant invention. In addition, it will be appreciated that the hole 36 for the ground rod 28 may also accommodate a ground wire 60 (see FIG. 5), either through a larger diameter for the hole, or through a separate channel incorporated into the hole. The cap 30 of this embodiment allows for the cap 30 to be easily installed onto the ground rod 28 after the clamp 26 and wire 60 are installed and after the rod 28 is driven into the ground. The two halves are placed around the rod 28 and closed together. A sealant material (not shown) is located within the two halves and contained by a barrier (not shown). The barrier is made from breakable plastic or other breakable sealing material. As the halves are closed around the rod 28 and clamp 26, the barrier is broken to expose the sealant.

[0042] In one embodiment of a no hinge connection cap 30 similar to that shown in FIG. 2, one half is sized to fit telescopically within the other half. In such an embodiment, the size of the cap 30 can be selectively increased and decreased by either lessening or increasing, respectively, the amount the one half is inserted into the other half In such an embodiment, increasing or decreasing the size of the cap 30 will simultaneously increase and decrease the size of the hole 36 for the ground rod 28. In some embodiments, the hole 36 within the cap 30 tapers outward toward the edge of each half to better accommodate varying rod diameters.

[0043] In other embodiments of the invention, a single piece ground cap 30 is utilized. In one such embodiment, a semi-spherical cap 30 similar to one half of the cap shown in FIG. 2 is utilized. In that embodiment, the cap 30 includes a notch (not shown) for the rod 28 and a breakable plastic to hold a sealing material within the cap 30. In operation, the cap 30 is turned sideways, with the opening facing the ground rod 28 and clamp 26, and the rod 28 and clamp 26 are slid into the notch pressing against the breakable plastic. The cap 30 is rotated about the rod 28 and clamp 26 with the opening facing approximately 90 degrees to the starting orientation. The pressing of the clamp 26 against the breakable plastic as the rod 28 is slid into the notch, along with increased pressure as the cap 30 is rotated, results in the plastic breaking and exposing the sealant material, and results in the sealant material flowing around the clamp 26 and rod 28.

[0044] FIG. 3 shows top, side and bottom views of a ground rod cap 40 of another embodiment of the instant invention similar to that of FIG. 2. The cap 40 shown in FIG. 3 is generally cylindrical in shape and includes two halves that are connectable together. In the embodiment shown, the two halves are connected together via a hinge 42 (such as a living hinge); however, it will be appreciated that alternative connections (including but not limited to no hinge) may be utilized without departing from the spirit and scope of the instant invention. In the embodiment shown, one half includes a continuous clip edge or channel 44, similar to a Tupperware or other container lid connection. The other half includes a generally flat edge (not shown) that fits within the channel. This allows a secure connection of the two halves. It will be appreciated that alternative connections may be utilized without departing from the spirit and scope of the instant invention.

[0045] In the embodiment shown in FIG. 3, a 1 inch diameter hole 46 is included on the bottom of the cap to accommodate a ground rod 28 (see FIG. 4) up to 1 inch in diameter. Nevertheless, it will be appreciated that other diameter holes may be utilized without departing from the spirit and scope of the instant invention. In addition, it will be appreciated that knockouts or other structures may be utilized as well.

[0046] The embodiment shown in FIG. 3 also includes a wire channel 48 located at the top of the ground rod cap 30. Nevertheless, the channel 48 may be located at other positions without departing from the spirit and scope of the instant invention. In addition, it will be appreciated that the hole for the ground rod 28 may also accommodate a ground wire 60 (see FIG. 5), either through a larger diameter for the hole, or through a separate channel incorporated into the hole. The cap 40 of this embodiment allows for the cap 40 to be easily installed onto the ground rod 28 after the clamp 26 and wire 60 are installed and after the rod 28 is driven into the ground. The two halves are placed around the rod 28 and closed together. A sealant material (not shown) is located within the two halves and contained by a barrier (not shown). The barrier is made from breakable plastic or other breakable sealing material. As the halves are closed around the rod 28 and clamp 26, the barrier is broken to expose the sealant.

[0047] FIG. 4 shows front, side and bottom views of a ground rod cap 50 of another embodiment of the instant invention similar to that of FIG. 3. The primary difference between the embodiment of FIG. 3 and FIG. 4 is that the cap 50 of FIG. 4 does not include a separate wire channel (the rod hole functions as the wire channel), and the cap 50 of FIG. 4 utilizes several clip/clamp features 52 to hold the two halves of the cap 50 together.

[0048] Each half of the cap 50 defines a primary opening. The edge of each primary opening includes a continuous lip that mates together with the lip of the opposing half of the cap 50. Neither lip includes a channel. Instead, one or more clamps 52, combined with the hinge 54, hold the two halves together.

[0049] In the embodiment shown in FIG. 4, the clamp 52 includes a tongue 56 that extends generally along the outer surface of one half of the cap body away from the opening, and towards the other half of the cap body. The opposing half of the cap body includes a ridge 58 protruding generally transverse to the surface of the cap body for frictional engagement with the tongue 56. The tongue 56 snap-fits over the ridge 58 for tight engagement.

[0050] FIG. 5 shows front and side views of a ground rod cap 50 of another embodiment of the instant invention similar to that of FIG. 4. The primary difference between the embodiment of FIG. 4 and FIG. 5 is that the cap 50 of FIG. 5 includes more than one punch out hole 20 (See FIG. 1) and more than one clip/clamp features 52. Specifically, the embodiment shown in FIG. 5 includes three punch out holes 20 and two clamps 52. A first punch out hole 20 is positioned at a bottom of the cap 10, a second punch out hole 20 is positioned on a side of the cap 10, and a third punch out hole 20 is positioned at a top of the cap 10. A first clamp 52 is positioned between the first and second punch out holes 20 and a second clamp 52 is positioned between the second and third punch out holes 20. Additionally, a hinge 54 is positioned between the first and third punch out holes 20 on a side of the cap 10 opposite the second punch out hole 20. In this way, the hinge 54 and the first and second clamps 52 are capable of retaining the cap 10 in a closed configuration when a first half of the cap 10 is coupled to a second half of the cap 10. It will be appreciated that in other embodiments alternative configurations will be utilized without departing from the spirit and scope of the instant invention.

[0051] In some embodiments, as shown in FIG. 5, the first and third punch out holes 20 are aligned such that a ground rod 28 is capable of being received simultaneously by both the first and third punch out holes 20 when the cap 10 is in a closed configuration. In this way, a ground rod clamp 26 need not be positioned at a top end of the ground rod 28 for the ground rod clamp 26 to be positioned in an interior area of the cap 10 when the cap 10 is in a closed configuration. In some such embodiments, the second punch out hole 20 is configured to receive a ground wire 60. In other such embodiments, the ground wire 60 and/or the ground rod 28 are capable of being received by any other punch out hole 20 and/or combination of punch out holes 20.

[0052] It will be appreciated that although the present invention is suited for providing superior protection for ground rod clamps, the present invention is also capable of providing superior protection for a variety of connections and connectors. For instance, in some embodiments the present invention is capable of being used to protect a guy wire connection. It will be appreciated that in still other embodiments the ground rod cap 10 will also be employed to protect still other structural and non-structural features, including other structural and non-structural connections, without departing from the spirit and scope of the instant invention.

[0053] It will be appreciated that a variety of different filler materials may be utilized in connection with the cap of the instant invention. In some embodiments, the filler material is a sealant. In some such embodiments a silicone is utilized. In some embodiments the silicone is an rtv silicone, such as GT-3100. In some embodiments the silicone includes dielectric properties. In some embodiments, a dielectric grease is utilized. In some preferred embodiments the filler material is a material that acts as a fluid. Such embodiments include filler materials such as liquids, semi-solids, particulates, gels, rubber, closed or open cell expandable or nonexpendable foams, and the like. In some embodiments, the filler material is in a fluid state prior to and during installation of the cap, and changes to a solid or semi-solid or hardened state after/during installation of the cap. In some embodiments the change from fluid to non-fluid state is the result of exposure of the filler material to air. In other embodiments, it is the result of a chemical, heat-activated, or other reaction. It will be appreciated that in some embodiments, the filler material will not change from a fluid to non-fluid state. In some embodiments, the filler material may remain in a single state at all times, such as in only a fluid state or only a non-fluid state.

[0054] In some embodiments, grooves are added to the inside surface of the body of the cap to increase the filler's (or in the case of sealant, the sealant's) adhesion to the plastic or other material of the body.

[0055] In some embodiments, the filler material of the instant invention provides water-resistant connection by sealing the connection (i.e. ground rod/clamp/wire connection) to make it water-resistant. In other embodiments, the connection is strengthened or stabilized by the filler material providing support for the connection. In some embodiments, particularly when dielectric material is utilized, the filler material electrically insulates the ground rod connection.

[0056] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described.

[0057] It will be appreciated that alternative embodiments of the instant invention include combinations of one or more features of one or more embodiments of the instant invention. For example, some embodiments of the instant invention may include the sealant material of one of the embodiments discussed herein and the barrier of another embodiment discussed herein. As another example, the material in which one embodiment is manufactured may be utilized in connection with manufacturing any of the other embodiments.

[0058] Although the foregoing detailed description of the present invention has been described by reference to exemplary embodiments, and the best mode contemplated for carrying out the present invention has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall with in the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0059] Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.

[0060] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.