Power plug adapter

An adapter for connecting a welding-type power source to various different input voltage signals is disclosed. The adapter comprises a body with a receptacle at one end which is connectable to a power cord of a welding-type power source and a plug at another end which is connectable with a number of different electrical outlet configurations. The body of the adapter is shaped to allow both the plug and a grounding prong of a connected power cord to engage the same outlet.

BACKGROUND OF THE INVENTION

The present invention relates generally to welding, and more particularly, to power cords for welding-type power sources. The present invention includes a power cord and adapter assembly capable of providing a plurality of different input voltage signals to a welding-type power source.

Standard input voltage signals provided by power utilities usually have approximate voltage values of 110/115V, 200/208V, 230/240V, 380/415V, 460/480V, 500V, or 575V. The actual line input voltage signals available at particular locations vary, and the voltage signals could be either single-phase or three-phase, could have different current ratings, and could be 50 or 60 Hz power signals. However, these values are merely exemplary and are not intended to limit the invention, only to provide actual values for ease of understanding. Additionally, whenever two input power signals are hereinafter described as “different” from each other, it is implied that at least one of the electrical parameters described above is not the same between the two signals.

Some welding-type power sources are able to convert several different line input voltage signals into power signals suitable for welding-type applications. For example, such a power source could receive one of several different input voltage signals and internally convert it to a different voltage AC signal or a different voltage DC signal to provide a welding-type power signal. The different high voltage AC input signals usable by such a power source are typically a subset of various line input voltage signals provided by a power utility. Some of these power sources require an operator to perform a manual adjustment to the power source to accommodate a particular input voltage signal, while other power sources can automatically sense and adjust to particular input voltage signals.

However, some drawbacks arise due to the fact that different standardized electrical interface configurations, wall outlets, and/or plug and socket configurations are employed for each standard input voltage signal. Thus, a power source must be able to interface with multiple standardized electrical interface configurations or the usefulness of converting various types of input voltage signals into welding-type output is reduced. For example, if a welding-type power source was capable of converting both a 60 Hz signal-phase 115 volt line input signal rated at 20 amps and a 60 Hz single-phase 230 volt line input signal rated at 20 amps, an operator would be required to change the power cord in order to allow connectivity of the welding-type device with multiple outlets having different plug and socket configurations or have some form of adapter.

Alternatively, connecting a power source to various standardized electrical interfaces could be achieved by cutting off the plug end of the power cord of a power source and replacing it with a new plug that is properly configured to receive a different line input voltage signal. Regardless of whether the entire cord is replaced or whether the plug is physically severed from the cord, such methods are time consuming, wasteful, and impractical. Additionally, such practices also present an undesirable opportunity for the operator to improperly connect the welding-type device to the electrical supply. That is, an operator may inadvertently connect the leads of the power cord to the wrong terminals of the welding-type device or the wrong prongs of the associated plug, respectively. Misuse of the plug or cord could result in improper operation of the welding-type device or damage to the electrical components thereof.

Other known methods for connecting power cords to various outlet configurations utilize adapters or power cord ends which have removable, repositionable, or interchangeable plug prongs. Notwithstanding the fact that such systems are not necessarily configured for use with welding-type systems, they are nonetheless undesirable for such applications. A power cord adapter or power cord end with removable plug prongs creates risks that prongs may be lost, damaged, corroded, or made otherwise unusable. In general, adapters and power cord ends using removable, repositionable, or interchangeable plug prongs do not ensure the same expectations of durability derived from similar, fixed-prong adapters and power cord ends.

Thus, although some welding-type power sources have the capability to convert one of a plurality of different input voltage signals into a welding-type output signal, such power sources must also be physically manipulated to connect to multiple electrical interface configurations. Several known methods of changing the plug orientation of the welding-type device are time-consuming to implement, add to the number of required parts, and increase the overall complexity of a welding-type device. It would therefore be desirable to have a power cord that is capable of quickly and conveniently providing a plurality of different input power signals to a welding-type power source. Furthermore, such a system should be efficiently connectable and removable, and able to receive various different line input voltage signals without the need for modifications to the power cord or power plug.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides an adapter useable in a system and method for connecting a welding-type power source to various standard electrical outlets having different interfaces therebetween that overcomes the aforementioned drawbacks. Specifically, the invention includes an adapter capable of connecting to more than one electrical interface configuration. The adapter connects to a power cord having one end that is attached to a welding-type power source and another end that is connectable with the adapter in a plurality of positions. The adapter is connectable to the power cord and a number of different electrical outlet configurations.

In accordance with one aspect of the present invention, an adapter is provided having an electrical outlet mating surface, a body having a distal end and a proximate end, a pair of electrical sockets at the distal end of the body, and a pair of flanges extending outwardly from the electrical outlet mating surface. The electrical outlet mating surface has a pair of electrical prongs extending outwardly therefrom. The body extends rearwardly from the electrical outlet mating surface and parallel to the electrical prongs. Each electrical socket at the distal end of the body is in electrical communication with a respective electrical prong of the electrical outlet mating surface. Each flange extends perpendicular to the electrical prongs and has an opening therein sized to allow passage of an electrical grounding prong therethrough.

In accordance with another aspect of the invention, an adapter for a power cord of a welding-type power source is provided. The adapter has a body having a first end and a second end. The first end is electrically connectable to a power cord connectable to a welding-type device. The second end has a pair of prongs fixedly attached to the body and constructed to operably connect the power cord to a first outlet and a second outlet, the second outlet being configured differently than the first outlet.

In accordance with another aspect of the invention, an adapter is provided for connecting a power cord to a plurality of outlet configurations. The adapter includes a body having a plug and a receptacle. The receptacle is constructed to removably engage a power cord, and the plug is constructed to be connectable with a first electrical outlet configuration and a second electrical outlet configuration different than the first electrical outlet configuration. The body is constructed to allow a prong of the power cord to engage one of the first and second electrical outlet configurations with the body positioned therebetween.

In accordance with another aspect of the present invention, a power cord for a welding-type device is provided. The power cord has one end connectable to a power source of a welding-type device and another end connectable to an adapter. The adapter has a pair of immovable prongs which are connectable to a first input voltage signal and a second input voltage signal wherein the first input voltage signal has a power characteristic different than a power characteristic of the first input voltage signal.

In accordance with yet another aspect of the present invention, a welding-type apparatus is provided, having a power source, a power cord, and an adapter. The power source is configured to generate a welding-type power. The power cord has a first end connectable with the power source and a second end. The second end of the power cord has an adapter interface and an electrical contact configured to engage electrical outlets. The adapter is configured to engage a number of different electrical outlet configurations.

In accordance with a further aspect of the present invention, a method is disclosed for providing a power cord and adapter useable with multiple electrical interface configurations. The method includes the steps of forming an adapter interface on a power cord having a pair of power prongs extending therefrom and a grounding prong extending significantly past the pair of power prongs, and molding an adapter to couple to the adapter interface of the power cord and having a pair of openings which allow the grounding prong to pass through one of the openings when the adapter is engaged with the power cord in one orientation and through another of the openings when in another orientation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring toFIG. 1, a welding system10includes a power source12, constructed to generate an electrical signal suitable for welding-type applications. Power source12is configured to receive any one of a number of different input power signals. Some exemplary input power signal values include 110/115V, 200/208V, 230/240V, 380/415V, 460/480V, 500V, or 575V, which could be single-phase, three-phase, different current ratings, or frequencies such as 50 or 60 Hz signals. It is recognized that other power signals may be suitable or desirable. Regardless of the characteristics of the power signal, power source12is able to automatically detect the values of the input power signal and convert the signal into one suitable for welding-type applications. Alternatively, power source12may require a user to manually select a setting before receiving and converting a respective power input. In any event, power source12is supplied with an input power signal from an outlet14via a power cord16and an adapter18.

Preferably, power cord16is removably attached at one end17to power source12and is electrically interconnected at another end19to adapter18and outlet14. Alternatively, power cord16may be permanently attached to power source12. Power cord16is configured to conduct a plurality of different power signals to power source12. Adapter18has one end21electrically interconnected with power cord16at end19of power cord16, and is electrically connected with outlet14at another end23. As will be discussed further below, power cord16and adapter18allow for different power signals to be supplied from outlet14. Outlet14is one of several having different electrical interface configurations that can supply an input signal to power source12.

A torch20is operably connected to power source12via weld cable22. Ground cable24is also attached to power source12at one end25, and has a clamping member26attached at a second end27. Clamping member26is constructed to removably secure cable24to workpiece28so that a desired welding application may be performed. Although the present invention will be described in terms of a welding application, one skilled in the art will appreciate that the present invention is equally applicable to other similar high power output operations, such as induction heating and plasma cutting.

Referring now toFIG. 2, power cord16is shown with adapter18connected in a first position29thereto. End17of power cord16is depicted having three electrical connectors30. The electrical connectors30are constructed to engage the power source12,FIG. 1, and electrically connect power cord16thereto. It is recognized that the shape, configuration, and number of connectors necessary to connect power cord16to the power source12may differ between various types of power sources. Alternatively, power cord16may be permanently attached to the power source such that a different configuration of electrical connectors is required.

Referring again toFIG. 2, power cord16has an adapter interface32at end19thereof. Adapter interface32is permanently affixed and integrally formed with power cord16. Additionally, it is understood that adapter interface32may be formed of any suitable material or may be removable from power cord16so that other adapter interfaces could be attached thereto. Adapter interface32is formed having two snap lock arms34which extend from adapter interface32of power cord16to engage about adapter18when adapter18is attached thereto. It is understood that adapter interface32could be formed having more or fewer snap lock arms34thereon. A connector, or ground pin38, of power cord16protrudes through adapter18such that ground pin38of power cord16electrically engages an inlet (not shown) of outlet14,FIG. 1, when the power cord16is connected thereto.

Adapter18,FIG. 2, is formed having an elongated body40and a plug or front face42. It is recognized that other suitable variations in the appearance and shape of adapter18are possible, so long as adapter18is able to simultaneously interface with power cord16and an outlet, such as that shown inFIG. 1. The plane of front face42,FIG. 2, is generally perpendicular to a longitudinal axis43of adapter body40. Front face42includes two flanges, or tabs44, that extend therefrom and are coplanar with front face42. Tabs44extend in directions generally opposite one another and beyond adapter body40. Each tab44has a hole, or opening46, formed therein to allow ground pin38of power cord16to pass therethrough. Front face42also has two electrical prongs50which are preferably molded into front face42. However, it is equally recognized that electrical prongs50may be otherwise fixedly secured to front face42. Prongs50extend generally perpendicular to front face42, are generally parallel to longitudinal axis43of adapter body40, and are preferably not removable from adapter18. Therefore, it can be seen that front face42is the surface of adapter18which can mate with electrical outlets. In this embodiment, prongs50are orientated 90 degrees apart, as will be further explained below.

Referring now toFIG. 3, adapter18is attached to power cord16in a second position51, wherein adapter18is rotated 180 degrees from the first position shown inFIG. 2. ComparingFIG. 2andFIG. 3, adapter18has been removed, rotated approximately 180 degrees about longitudinal axis43relative to cord16, and reinserted and connected thereto in second position51. Prongs50extending from front face42of adapter18are generally planar, rectangular metal protrusions common to many electrical prongs constructed to engage electrical outlets. Each prong50has an elongated planar side48,52. In one embodiment, the planes of the elongated sides48,52of the two prongs50are perpendicular to one another, or in other words, one prong50with sides48is rotated 90 degrees with respect to the other prong50with sides52. As such, the position of prongs50shown inFIG. 3allows for engagement of power cord16, with adapter18connected thereto, to a standard electrical interface configuration for a single-phase, 60 Hz, approximately 230V, 20 ampere line input voltage signal in the United States. Referring back toFIG. 2, when adapter18is positioned in first position29, the power cord and adapter are configured to engage a standard electrical interface for receiving a single-phase, 60 Hz, approximately 115 volt, 20 ampere line input signal in the United States. Thus, it can be seen that when adapter18is rotated 180 degrees about a longitudinal axis of the body40, the prongs50become oppositely oriented relative to power cord16. Adapter18is therefore able to electrically interconnect with different outlet configurations.

Specifically, inFIG. 3, adapter18is shown in the second position51wherein the elongated side48of one prong50is horizontally oriented with respect to an axis49of front face42passing through openings46, and the elongated side52of the other prong50is vertically oriented with respect to axis49. Conversely, inFIG. 2, position29is shown wherein the prong50with elongated side48is vertically oriented and the prong50with elongated side52is horizontally oriented. However, adapter18is equally attachable to power cord16when prongs50are in either of the two aforementioned positions29,51.

Referring back toFIG. 3, body40of adapter18includes a pair of bosses62extending outwardly therefrom. Bosses62form gripping surfaces to allow an operator to quickly and conveniently engage or disengage adapter18from power cord16. Bosses62include a plurality of ribs68which provide for improved gripping of the adapter18by an operator.

Also shown inFIG. 3, snap lock arms34secure adapter18to adapter interface32of power cord16when adapter18is orientated in second position51,FIG. 3, or first position29,FIG. 2. Referring back toFIG. 3, snap lock arms34engage ridges54formed on body40of adapter18. When adapter18is thus secured to adapter interface32and power cord16, any electrical contacts therebetween are kept generally free of dirt, moisture, or other contaminants and adapter18is substantially prevented from shifting or sliding with respect to adapter interface32of power cord16. To release the adapter18, snap lock arms34are deflected away from adapter body40so that adapter ridges54can slide past snap lock arms34and adapter18can disengage power cord16.

As shown inFIG. 4, adapter18is disengageable from power cord16. Ridges54of adapter18are formed on lateral sides56of the adapter body40. As shown, ridges54are generally triangular and protrude from adapter body40on opposing sides. Ridges54are tapered such that they gradually extend further outward from the adapter body40nearer the face42of adapter18to easily effectuate engagement upon insertion into adapter interface32. At one end60of lateral sides56of adapter body40, ridges54turn sharply back towards the body40, forming shoulders64over which snap lock arms34engage. Snap lock arms34have inwardly pointing tabs72which snap fit over shoulders64of ridges54of adapter body40.

Also shown inFIG. 4, power cord16has a pair of power contacts70and a ground pin38that extends from adapter interface32of power cord16past contacts70. Ground pin38extends beyond the snap lock arms34so that it can protrude through a respective opening46of adapter18when adapter18is attached to power cord16. Ground pin38extends from a ground pin collar74, which is shown having a generally semi-circular cross section and is preferably an insulating jacket that extends past contacts70. However, it is recognized that ground pin collar74may be of any shape suitable for interfacing with adapter18while allowing ground pin38to pass through one of the openings46of the adapter18. Ground pin collar74slides into either of two complementary-shaped grooves58, formed on opposing sides of adapter body40, so that ground pin38can be positioned properly for interfacing with standard electrical outlet configurations. Additionally, groove58formed in adapter body40provides for greater stability of the engagement between adapter18and power cord16when ground pin collar74is positioned therein.

Prongs50of adapter18shown inFIG. 4are arranged in first position29, similar to that ofFIG. 2and opposite that ofFIG. 3. Referring again toFIG. 4, adapter body40is formed such that a opening46is in position to allow ground pin38to protrude therethrough and a groove58is in position to fit about ground pin collar74when adapter body40is in either of first position29, shown inFIG. 2, or second position51, shown inFIG. 3. Furthermore, ridges54are engageable with snap lock arms34of power cord16in either of positions29and51. Thus, adapter18interfaces a first outlet configuration and attaches to power cord16when positioned in first position29and interfaces with a different outlet configuration and attaches in a similar manner to power cord16when positioned in second position51.

Still referring toFIG. 4, a slot66is formed between snap lock arms34into which adapter18slides when engaged with adapter interface32. Electrical contacts70extend parallel to ground pin38from adapter interface32of power cord16. Electrical contacts70electrically interface with receptacles or sockets76formed on a rear face78of adapter18. A voltage signal is conducted from an outlet14,FIG. 1, through adapter18,FIG. 4, to contacts70when adapter18is engaged with an outlet. From contacts70, a power signal passes through power cord16to a power source12,FIG. 1. It is equally recognized that electrical contacts70,FIG. 4, could be formed on the rear face78of adapter18and sockets76could be formed on adapter interface32. Ground pin38, however, passes through adapter18, interfaces with an outlet, and connects power cord16directly thereto.

When an operator wants to connect a power source to a first outlet configuration, adapter18is slidingly engaged with adapter interface32of power cord16. When the operator is required to connect the power source to a different outlet configuration, the operator, without the aid of tools, can simply and efficiently remove the adapter18from the adapter interface32of the power cord16, rotate the adapter approximately 180 degrees as indicated by arrow79, and reattach the adapter18to the adapter interface32of the power cord16. As such, the operator can quickly and efficiently change the type of power signal the power source12is configured to receive.

Referring now toFIGS. 5A and 5B,FIG. 5Ashows an end view of adapter18taken along line5A—5A ofFIG. 4, andFIG. 5Bshows an end view of power cord16taken along line5B—5B ofFIG. 4. The rear face78of adapter18abuts adapter interface32of power cord16when adapter18is connected thereto. Whether adapter18is oriented as shown or rotated 180 degrees as indicated by arrow79, receptacles or sockets76are configured to receive and electrically connect with electrical contacts70. As shown inFIG. 5A, apertures, or openings46, are formed in tabs44of the front face42of adapter18, ridges54extend outwardly from adapter body40, and grooves58are formed on opposing sides of adapter body40such that ground pin collar74may slide therein. It can be seen that the shape of adapter18and configuration of its constituent parts are substantially mirrored on both sides of a horizontal axis75drawn between sockets76. Thus, adapter18attaches to power cord16with ground pin38extending through an opening46when adapter18is either oriented as shown or rotated 180 degrees as indicated by arrow79. While the preferred embodiment shows openings46as holes, it is understood that such need not be completely enclosed. A partial enclosure, “U”-shaped configuration, or any opening to allow the ground pin38to pass will suffice.

As shown inFIG. 5B, electrical contacts70extend outwardly from adapter interface32of power cord16and are generally aligned with ground pin38. Snap lock arms34extend from adapter interface32of power cord16on opposing sides of electrical contacts70. When adapter18is attached thereto, electrical contacts70of power cord16are inserted into sockets76, ground pin collar74is received in a groove58of adapter body40, and snap lock arms34snap fit about ridges54formed on adapter body40.

Thus, it can be seen that the present invention provides a power source the ability to easily connect to a number of different electrical interface configurations. A power supply system incorporating the present invention is desirable as requiring only a single adapter for connectivity with several outlet configurations. Additionally, due to the adapter18being snugly secured to adapter interface32of power cord16by snap lock arms34, prongs50being fixedly attached to front face42of adapter18, and ground pin38being securely formed in ground pin collar74of adapter interface32of power cord16, the electrical power cord and adapter system disclosed herein forms a generally rugged and durable electrical connector.

Therefore, an adapter is provided which has an electrical outlet mating surface having a pair of electrical prongs extending outwardly therefrom, a body having a distal end and a proximate end, the body extending rearwardly from the electrical outlet mating surface and parallel to the electrical prongs, a pair of electrical sockets at the distal end of the body, each electrical socket in electrical communication with a respective electrical prong, and a pair of flanges extending outwardly from the electrical outlet mating surface, perpendicular to the electrical prongs, each flange having an opening therein sized to allow passage of an electrical grounding prong through each opening in each flange.

An adapter for a power cord of a welding-type power source is also disclosed and has a body having a first end and a second end, wherein the first end is electrically connectable to a power cord connectable to a welding-type device and the second end has a pair of prongs fixedly attached to the body and constructed to operably connect the power cord to a first outlet and a second outlet, the second outlet being configured differently than the first outlet.

An adapter is also provided for connecting a power cord to a plurality of outlet configurations. The adapter has a body having a plug and a receptacle. The receptacle is constructed to removably engage a power cord, and the plug is constructed to be connectable with a first electrical outlet configuration and a second electrical outlet configuration different than the first electrical outlet configuration. The body is constructed to allow a prong of the power cord to engage one of the first and second electrical outlet configurations with the body positioned therebetween.

The invention also includes a power cord for a welding-type device that includes a power cord having one end connectable to a power source of a welding-type device and another end connectable to an adapter. The adapter has a pair of immovable prongs, which are connectable to a first input voltage signal and a second input voltage signal wherein the first input voltage signal has a power characteristic different than a power characteristic of the first input voltage signal.

A welding-type apparatus is presented and has a power source configured to generate a welding-type power, a power cord having a first end connectable with the power source and a second end having an adapter interface and an electrical contact configured to engage electrical outlets, and an adapter configured to engage a number of different electrical outlet configurations.

A method is disclosed for providing a power cord and adapter useable with multiple electrical interface configurations. The method includes the steps of forming an adapter interface on a power cord having a pair of power prongs extending therefrom and a grounding prong extending significantly past the pair of power prongs, and molding an adapter to couple to the adapter interface of the power cord and having a pair of openings which allow the grounding prong to pass through one of the openings when the adapter is engaged with the power cord in one orientation and through another of the openings when in another orientation.