Abstract:
A cylindrical guard is used for protecting the electrical junction between connectors. The guard is essentially two split cylindrical sections oriented end-to-end with breakaway tabs therebetween. The split cylindrical pieces are hinged, and substantially irreversibly lock together in a “clamshell” like fashion. The resulting guarded junction is less likely to be accidentally disengaged, thereby protecting both property and life. The guard can be removed by cutting, or broken and moved to expose the underlying junction by severing the breakaway tabs.

Description:
BACKGROUND 
     (1) Field 
     The present invention relates generally to devices that protect wiring assemblies and, more particularly, to a hinged, split, tubular structure that irreversibly snaps onto the connection point of two adjoined wire connectors. 
     (2) Related Art 
     The invention discussed herein can be used with connectors disclosed in U.S. patent application Ser. No. 12/502,395, pertaining to “Low Leakage Electrical Joints and Wire Harnesses, and Method of Making the Same”, filed on Jul. 14, 2009, which is hereby incorporated by reference. 
     Solar power has long been considered a niche utility. It is considered desirable from an environmental and political standpoint, but perhaps not economically feasible for generating enough power to make a meaningful contribution to the grid. However, as the problems associated with our dependence on fossil fuels have become better understood, more attention has been paid to so-called alternative energy such as solar power. This attention has led to significant technological and policy advances, such that solar power is now quite prevalent, and more economically feasible. 
     Technological advances in the generation of solar energy have occurred in multiple areas, including collector material and structure, and wiring infrastructure. In particular, certain advances in devices used in the electrical infrastructure have increased safety and reliability, while decreasing labor and cost. One example is the use of wire harnesses, male and female connectors, and low-leakage T, cross and Y joints. These devices facilitate correctly wiring a solar energy system using plug-and-play components, versus hard-wiring using conventional methods and materials such as wire, crimps, cutting, welding, testing, etc. This technology is explained in more detail in patent application Ser. No. 12/502,395. 
     It is advantageous if connectors, such as male and female connectors, can be easily engaged and disengaged because this facilitates on-the-fly wiring without having to measure, cut, weld, etc. However, this unfortunately also creates the possibility of inadvertent disengagement, especially when wiring architecture is above ground, as it commonly is, where people can trip on the wires. Such a disconnection may simply temporarily cut off one solar panel in an array, or may be catastrophic with respect to widespread damage to the system, or even risk of electrocution. 
     In addition, it is desirable that electrical standards are met to ensure compliance with code, as well as safety. 
     Thus, there remains a need for a new and improved device for guarding the connection point of two adjoined connectors. Preferably the device is inexpensive to manufacture and transport, and is quick and easy to use. Preferably this device locks into place and is difficult to accidentally remove. Most preferably the device is a hinged cylindrical structure constructed of plastic, that irreversibly engages to firmly grasp an electrical junction within the interior channel. Finally, preferably the device meets or exceeds the recommendations of the 2008 National Electrical Code, section 690.32(c). 
     SUMMARY OF THE INVENTIONS 
     The present invention is directed to a guard that quickly fits around the junction of joined connectors. The guard is essentially two cylinders which are joined in an end-to-end orientation with a tabbed gap there between, to form one discontinuous cylinder. The resulting longitudinally split, discontinuous cylinder has a hinge joining two halves of the cylinder longitudinally, and spaced irreversibly locking mechanisms joining the other halves of the cylinder when the cylinder is in the closed position. The tabs connecting the two cylinders can be intentionally broken, but are strong enough to prevent accidental exposure of the surrounded junction. 
     Accordingly, one aspect of the present inventions is to provide a connector guard that is easy to use and prevents accidental disengagement of connectors. It is also an aspect of the present inventions to provide a device that can be quickly and easily removed when desired, by using common electrical tools. Another aspect is to be able to expose the underlying connector without actually removing the invention, by twisting the device. Another aspect is providing frictional grips within the device to prevent the connection from slipping around. 
     These and other aspects of the present inventions will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a perspective view of the exterior of a preferred embodiment of the invention shown in the open position; 
         FIG. 2  is a perspective view of the interior of a preferred embodiment of the invention shown in the open position; 
         FIG. 3  is a perspective view of a preferred embodiment of the invention shown in the closed position; 
         FIG. 4  is a plan view of the interior of a preferred embodiment of the invention shown in the open position; 
         FIG. 5  is a side view of the invention shown in the open position; 
         FIG. 6  schematically shows disengaged connectors positioned in the channel of the invention in the open position; 
         FIG. 7  is a perspective view of the invention with connectors guarded inside; 
         FIG. 8  is a perspective view of the exterior of an alternative embodiment of the invention shown in the open position; 
         FIG. 9  is a perspective view of the interior of an alternative embodiment of the invention shown in the open position; and 
         FIG. 10  is a plan view of the interior of an alternative embodiment of the invention shown in the open position. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following description, like reference characters designate like or corresponding parts throughout the several views. It should be understood that the illustrations are for the purpose of describing a preferred embodiment of the inventions and are not intended to limit the inventions thereto. 
     As best seen in  FIG. 1 , guard  10  generally includes two semi-cylindrical sections  15 ,  15 , that are joined together at hinge  40 . As used herein “semi-cylindrical” conceptually refers to approximately half, or approximately 180°, of a generally cylindrical or tubular structure that has been longitudinally divided. It should be understood that “semi-cylindrical” does not preclude breaks in symmetry such as planar sections or the addition of structures such as locking mechanisms, tabs and the like. Semi-cylindrical sections  15 ,  15  each include large section  20  and small section  25 , which are connected to each other by at least one tab  35 . Two tabs per section  15 , for a total of four tabs per guard  10 , is preferred. Large and small sections  20 ,  25  define gap  30  therebetween, with tabs  14  connecting sections  20 ,  25  across gap  30 . Tabs  35  are preferably breakaway tabs, which, as use herein, are tabs that provide suitable strength to maintain integrity with regular use, but are specifically designed to “breakaway”, or be broken, with the application of a minimum amount of human effort, either with or without standard electrical tools. In particular, when guard  10  is in situ, for example see  FIG. 7 , a user can grasp large section  20  in one hand, small section  25  in the other hand, and rotate the sections in opposite directions to sever tabs  35 , then pull the connectors away from each other, to expose the electrical junction underneath. 
     Referring to  FIG. 2 , semi-cylindrical sections  15 ,  15  each include proximal longitudinal edge  17 , which abut hinge  40 , and distal longitudinal edge  18 , away from hinge  40 . Hinge  40  is preferably constructed of the same material as the remainder of guard  10 , thereby lending the device to injection molding or other known methods of economical mass production. Distal longitudinal edges  18  include locking mechanisms that are aligned so that mating portions, for example locking tab  47  and locking aperture  48 , (collectively locking mechanism  45 ) connect upon closure of guard  10 . While locking tab and aperture  47 ,  48  are preferred, other locking mechanisms known in the art, such as latches, or ball and sockets, would also be suitable. Locking mechanism  45  is preferably capable of irreversible engagement. As used herein, “irreversible engagement” refers to engagement wherein a user would not be able to “unlock” the mechanism, or otherwise “undo” the engagement in regular use, without using unusual force or the assistance of tools. In the most preferred embodiment, large section  20  includes two locking mechanisms  45  and small section  25  includes one locking mechanism, with all locking mechanisms  45  identical. This orientation is shown in  FIG. 1 . However, as depicted in  FIG. 8 , alternative guard  110  could include elongated locking mechanism  146  on alternative small section  125 , and two identical locking mechanisms  45  on alternative large section  120 . 
     Referring back to  FIG. 2 , the interior portions of semi-circular sections  15  define at least one semi-circumferential rib  55 , with each large section  20  and each small section  25  preferably defining one rib  55 , for a total of four ribs  55 . Ribs  55  are oriented so that upon closure of guard along axis of hinge  40 , rib sections  55  align in end-to-end orientation, thereby forming “rings” within channel  12  of guard  10 . Ribs  55  exert additional frictional pressure on electrical connectors  60  within channel  12 , thereby maintaining the longitudinal position of the junction held within. This is generally shown in  FIG. 6 . Said another way, ribs  55  help prevent connector  60  from slipping within channel  12 , as shown in  FIG. 7 . In the preferred embodiment, rib  55  includes chamfer  57 , ( FIG. 2 ) but straight wall  157  is also possible, as shown in alternative guard  110  ( FIG. 9 ). 
     Referring now to  FIG. 6 , in use, one would connect female connector  61  to male connector  62 , then circumferentially surround the resulting connection, or junction, in guard  10  by rotating one semi-cylindrical section  15  around the axis of hinge  40 , thereby bringing distal longitudinal edges  18  together, and engaging locking tabs  47  with locking apertures  48 . The resulting orientation is depicted in  FIG. 7 . To remove the guard  10 , a user would preferably employ cutters to cut off guard  10 . As discussed above it is also possible to expose junction by twisting to sever breakaway tabs  35 . 
     Guard  10  is preferably constructed of Polypropylene using known techniques such as injection molding. 
     Guard  10  meets meet the recommendations of the 2008 National Electrical Code, section 690.32(c). More specifically, a preferred embodiment was tested according to IEC61646 Damp Heat and UL1703 Thermal Cycling Testing, 3 rd  Edition, dated Mar. 15, 2002 with revisions through and including Apr. 8, 2008. This protocol is hereby incorporated in its entirety. 
     Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, it is possible to vary the number of clips, the number of breakaway tabs, the width of the breakaway tabs, the length of the device, the profile of the inside surface of the device, the design of the hinge, the material of the device, and/or the thickness of the material. It is also possible to eliminate the hinges so the device is two halves that snap together. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.