Extension cord lock and in line tap

An electrical, circuit breaker protected, extension cord in-line tap, securement device for securing tandemly connected electrical extension cords. The securement device includes opposing proximal and distal open-ended eyelets each having a hinged locking flap for receiving therein a looped end of the associated extension cord thereby preventing unintended separation of the extension cords. The in-line tap further includes a pair of circuit breaker protected auxiliary electrical outlets on opposing sides for powering additional extension cords.

FIELD OF THE INVENTION

The present invention generally relates to an electrical extension cord accessory. More particularly the present invention teaches an improved extension cord coupling device for tandemly connecting two separate extension cords together in a manner to prevent the extension cords from being uncoupled by application of an unintentionally applied tensile force.

BACKGROUND

Hand held electrically powered tools generally have a relatively short power cord that severely limits the range within which such tools may be used. It is generally the practice to employ an electrical extension cord to increase the distance from a power source to the power tool being used. However, the typical male/female connectors, when coupled together, often, unintentionally, pull apart thereby interrupting the electrical power supply to the tool in use. Often the tool user will tie the two cords together, in some manner, thereby preventing unintentional separation of the cord coupling. However, such a practice many times will place an undesired stress, and/or strain upon the cord in the knotted area.

Further, it is many times desired to attach an additional electrical accessory to the power supplying electrical extension cord such as a light, for night work, to illuminate the work area.

Thus there is a need for an easy to use extension cord coupling device that prevents the unintentional separation of a first extension cord from a second extension cord that does not place undue stress and/or strain upon the cord material and that also provides additional auxiliary receptacles for the receipt of additional extension cords.

PRIOR ART

Heretofore many devices have been proposed for connecting two electrical cords together in a manner to relieve undue stress and/or strain upon the extension cord material.

One such device is taught in U.S. Pat. No. 5,582,524 issued to Sanner et al., entitled “Cord Loc,” on Dec. 10, 1996. Although the Sanner et al. device may relieve the stress and/or strain from two tandemly connected electrical extension cords it is relatively complex to use. The Sanner et al. device requires the user to first form a loop of the extension cord, pass the looped portion of the extension cord through an elongated eyelet and hook the looped portion of the extension cord upon a hook member.

A similar device is taught in U.S. Pat. No. 5,931,702 issued to Phil Fladung, entitled “Electrical Outlet In Line Tap,” on Aug. 3, 1999. Although the Fladung device may also relieve the stress and/or strain from two tandemly connected electrical extension cords it is also relatively complex to use. The Fladung device also requires first forming a loop of the extension cord, inserting the looped portion of the extension cord through an elongated eyelet. A rotating post like assembly, hingedly attached to the top of the eyelet, must then be rotated downward through the looped portion of the extension cord that protrudes through the eyelet.

BRIEF SUMMARY OF THE PRESENT INVENTION

The present invention teaches a simplified and improved in-line tap coupling for tandemly connecting a pair of electrical extension cords that prevents unintentional separation of the male/female extension cord connectors.

The improved in-line tap coupling comprises a main body having an electrical input connector comprising a typical male type pin and spade connector means at the main body's proximal end for receiving the female connector of a first extension cord. A female connector means for receiving the male connector of a second extension cord is provided at its distal end. Extending laterally from the opposing sides of the main body are multiple female outlet connectors for receiving therein the male connectors of additional extension cords. A resetable circuit breaker is electrically placed between the input male connector and the female outlet connectors.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIGS. 1 through 9, in-line tap10comprises a main body assembly12having a typical male electrical input connector20, at its proximal end, typically comprising a grounding pin14, a common electrical spade connector16and a live, or hot, electrical spade connector18. A typical female electrical output connector25is provided at the distal end of main body12for receipt therein of the male electrical spade connectors of the add on electrical extension cord50as illustrated inFIGS. 7,8and9.

Integral with main body assembly12are four auxiliary female electrical output connectors26A,26B,26C, and26D for connecting additional add-on electrical extension cords. An integrated and guarded circuit breaker28B is provided to prevent an electrical overload on the electrical supply extension cord31. A vertically extending guard36is preferably provided to protect the circuit breaker reset button23. The internal structure of main body12and the electrical connections are further described below.

Integrally molded into the top of main body12are two angular hooks, or eyelets,32A at its proximal end and32B. at its distal end. Each eyelet includes a hinged closure flap34A and34B hinged to its associated eyelet by a “living hinge”35A and35B as best illustrated inFIG. 7. Hinge34A and34B are secured, when closed by upwardly protruding locking lip39and37respectively. Preferably the inside surface of back wall42A and42B is provided with vertical ribs44to grippingly secure the extension cord when locked within eyelets32.

In Operation

Referring now toFIGS. 7,8, and9, hinged closure flap34B is first opened, as illustrated inFIG. 7. The male electrical input connector prongs (not shown) of add-on extension cord50are inserted into the appropriate electrical output apertures of output connector25as illustrated inFIG. 7. Add-on extension cord is looped about back wall42of distal eyelet32B, as illustrated inFIG. 7, and closure flap34B is then snapped shut, as illustrated inFIG. 8thereby securing add-on extension cord50therein.

With add-on extension cord50locked in place the male electrical input connector prongs14,16, and18of main body12are plugged into the female end30of electrical supply extension cord31as illustrated inFIG. 9. Electrical supply extension cord31is then similarly secured to the proximal eyelet32A. Extension cords31and45are now secured one to the other so as not to pull apart.

Electrical Sub Assembly Structure

FIGS. 10 through 15illustrate details of the internal, electrical subassembly50of the in-line tap illustrated and described inFIGS. 1 through 9above.

FIG. 10shows a top view of subassembly50. Subassembly50once completed is fully encapsulated by an elastomeric covering thereby producing the final in-line tap configuration as illustrated inFIGS. 1 through 9.

Referring toFIG. 11, subassembly50generally comprises a top shell52and a bottom shell54. Spaced between top shell52and bottom shell54is the electric power distribution circuitry55.

Referring toFIGS. 11 and 15, electric power distribution circuitry55comprises an active, or hot, busbar wire56attached to active spade connector18, a common busbar wire58attached to common spade connector16and a grounding wire57attached to grounding pin14.

Terminal connector assemblies130A,130B,130C,130D, and130E, having their appropriate terminals connected to the active, common and ground wires, are positioned within molded saddles60A,60B,60C,60D, and60E respectively as illustrated inFIG. 15.

As illustrated inFIGS. 11 and 14, bottom shell54is further provided with integrally molded wiring guide channel62for ground busbar wire57therein.

Busbar wires56,57, and58are preferably made of braided copper strands thereby producing a flexible electrical conducting wire. Ground busbar wire14is preferably placed within channel62generally circumscribing shell54as best illustrated inFIG. 15. common busbar wire58is wrapped about the outside periphery of channel62and active busbar wire56is wrapped about the inside periphery of channel62each being held in place by appropriately positioned guide lugs. Connecting wires from the appropriate terminals of each connector assembly130are attached to each appropriate busbar wire56,57, or58. In this way busbar wires56,57, and58need not have an insulator covering and may be installed as bare wires separated from one another by the walls of channel62. However, it is preferred to insulate the wires from the connectors130to the busbar wires.FIG. 15Apresents a circuit diagram of the subassembly wiring

The top shell52and bottom shell54are typically snapped together as illustrated inFIG. 10A. However, the two shells may be assembled using a suitable adhesive, electron beam welding or any other convenient means.

Turning now toFIGS. 16,17,18,19, and20, an alternate embodiment of the bottom shell assembly54′ is illustrated. Braided wire busbars56,57, and58may be replaced by flat fabricated brass or copper busbars66,67and68respectively. The ground busbar is divided into two elements66A and66B with circuit breaker28A interconnecting the two

The appropriate connecting wires to each connector assembly are soldered to its appropriate busbar as illustrated inFIG. 20. All active connecting wires are soldered to element66bthereby providing circuit breaker overload protection for all connector assemblies130A,130B,130C,130D, and130E.

Once subassembly50is complete, it is encapsulated within a one piece molded, elastomeric covering as illustrated inFIGS. 1 through 6.

Referring now toFIGS. 22 through 24terminal connector assembly130basically comprises a unitary, molded upper component132and a unitary molded lower component134. Upper component132includes two open ended cavities136a, receiving therein spade electrodes116a, and cavity136b, receiving therein spade electrode116b. Appropriately positioned between cavities136aand136bis open ended cavity136creceiving therein pin electrode116c.

Lower component134, of assembly130, completes the assembly by receiving therein upper component132having electrodes116a,116b,116cUpper and lower components,132and134, snap together and may be held together by a “snap together locking mechanism,” by a suitable adhesive, electron beam welding or any other convenient means.

While I have described above the principles of my invention in connection with specific embodiments, it is to be clearly understood that this description is made only by way of example and not as a limitation of the scope of my invention as set forth in the accompanying claims.