Abstract:
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.

Description:
PRIORITY 
       [0001]    This application is a continuation of U.S. Nonprovisional patent application Ser. No. 12/231,508, entitled Extension Cord Lock and In Line Tap, filed Sep. 3, 2008, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/967,337, entitled Extension Cord Lock and In Line Tap, filed Sep. 4, 2007. 
     
    
     FIELD OF INVENTION 
       [0002]    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 
       [0003]    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. 
         [0004]    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. 
         [0005]    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 
       [0006]    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. 
         [0007]    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. 
         [0008]    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 
       [0009]    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. 
         [0010]    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&#39;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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  presents a perspective view of an in-line tap embodying the present invention. 
           [0012]      FIG. 2  presents a top plan view of the in-line tap illustrated in  FIG. 1 . 
           [0013]      FIG. 3  presents a left side elevational view of the in-line tap shown in  FIG. 1 . 
           [0014]      FIG. 4  presents a bottom view of the line-tap illustrated in  FIG. 1 . 
           [0015]      FIG. 5  presents a rear elevational view of the line-tap illustrated in  FIG. 1 . 
           [0016]      FIG. 6  presents a front elevational view of the line-tap illustrated in  FIG. 1 . 
           [0017]      FIG. 7 through 9  presents a pictorial sequence of connecting two extension cords with the in-line tap illustrated in  FIG. 1 . 
           [0018]      FIG. 10  presents a top pictorial view of the electrical subassembly encapsulated within the in-line-tap illustrated in  FIG. 1 . 
           [0019]      FIG. 10A  presents an elevational view taken along line  10 A- 10 A in  FIG. 10 . 
           [0020]      FIG. 11  presents an exploded pictorial view of the electrical subassembly illustrated in  FIG. 10 . 
           [0021]      FIG. 12  presents a pictorial view of the electrical subassembly top and bottom shells assembled without the terminal connector assemblies. 
           [0022]      FIG. 13  presents an inside view of the top half shell of the electrical subassembly illustrated in  FIG. 12 . 
           [0023]      FIG. 14  presents an inside view of the bottom half shell of the electrical subassembly illustrated in  FIG. 12 . 
           [0024]      FIG. 15  presents a wiring diagram for the electrical connector assembly, positioned within the bottom half shell of the electrical subassembly and the separate electrical connector assemblies illustrated in  FIG. 10 . 
           [0025]      FIG. 15A  presents an electrical schematic of the electrical subassembly illustrated in  FIG. 10 . 
           [0026]      FIG. 16  presents an alternate embodiment of the bottom half shell of the electrical subassembly illustrated in  FIG. 10  wherein stamped metal, electrical busbars replace the distribution wiring illustrated in  FIG. 15 . 
           [0027]      FIGS. 17-19  presents the configuration of the stamped metal, electrical busbars of  FIG. 16 . 
           [0028]      FIG. 20  presents a wiring diagram for the stamped metal, electrical busbars and the separate electrical connector assemblies positioned within the bottom half shell of the electrical subassembly illustrated in  FIG. 10 . 
           [0029]      FIG. 21  presents an isolated pictorial view of the circuit breaker incorporated within the line-tap wiring. 
           [0030]      FIG. 22  presents an isolated pictorial view of one electrical outlet connector assembly. 
           [0031]      FIG. 23  presents an exploded pictorial of the component parts of one electrical outlet connector assembly as illustrated in  FIG. 22 . 
           [0032]      FIG. 24  presents an inverse exploded pictorial of the outlet connector assembly illustrated in  FIG. 22 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0033]    Referring to  FIGS. 1 through 9 , in-line tap  10  comprises a main body assembly  12  having a typical male electrical input connector  20 , at its proximal end, typically comprising a grounding pin  14 , a common electrical spade connector  16  and a live, or hot, electrical spade connector  18 . A typical female electrical output connector  25  is provided at the distal end of main body  12  for receipt therein of the male electrical spade connectors of the add on electrical extension cord  50  as illustrated in  FIGS. 7 ,  8  and  9 . 
         [0034]    Integral with main body assembly  12  are four auxiliary female electrical output connectors  26 A,  26 B,  26 C, and  26 D for connecting additional add-on electrical extension cords. An integrated and guarded circuit breaker  28 B is provided to prevent an electrical overload on the electrical supply extension cord  31 . A vertically extending guard  36  is preferably provided to protect the circuit breaker reset button  23 . The internal structure of main body  12  and the electrical connections are further described below. 
         [0035]    Integrally molded into the top of main body  12  are two angular hooks, or eyelets,  32 A at its proximal end and  32 B. at its distal end. Each eyelet includes a hinged closure flap  34 A and  34 B hinged to its associated eyelet by a “living hinge”  35 A and  35 B as best illustrated in  FIG. 7 . Hinge  34 A and  34 B are secured, when closed by upwardly protruding locking lip  39  and  37  respectively. Preferably the inside surface of back wall  42 A and  42 B is provided with vertical ribs  44  to grippingly secure the extension cord when locked within eyelets  32 . 
       In Operation 
       [0036]    Referring now to  FIGS. 7 ,  8 , and  9 , hinged closure flap  34 B is first opened, as illustrated in  FIG. 7 . The male electrical input connector prongs (not shown) of add-on extension cord  50  are inserted into the appropriate electrical output apertures of output connector  25  as illustrated in  FIG. 7 . Add-on extension cord is looped about back wall  42  of distal eyelet  32 B, as illustrated in  FIG. 7 , and closure flap  34 B is then snapped shut, as illustrated in  FIG. 8  thereby securing add-on extension cord  50  therein. 
         [0037]    With add-on extension cord  50  locked in place the male electrical input connector prongs  14 ,  16 , and  18  of main body  12  are plugged into the female end  30  of electrical supply extension cord  31  as illustrated in  FIG. 9 . Electrical supply extension cord  31  is then similarly secured to the proximal eyelet  32 A. Extension cords  31  and  45  are now secured one to the other so as not to pull apart. 
       Electrical Sub Assembly Structure 
       [0038]      FIGS. 10 through 15  illustrate details of the internal, electrical subassembly  50  of the in-line tap illustrated and described in  FIGS. 1 through 9  above. 
         [0039]      FIG. 10  shows a top view of subassembly  50 . Subassembly  50  once completed is fully encapsulated by an elastomeric covering thereby producing the final in-line tap configuration as illustrated in  FIGS. 1 through 9 . 
         [0040]    Referring to  FIG. 11 , subassembly  50  generally comprises a top shell  52  and a bottom shell  54 . Spaced between top shell  52  and bottom shell  54  is the electric power distribution circuitry  55 . 
         [0041]    Referring to  FIGS. 11 and 15 , electric power distribution circuitry  55  comprises an active, or hot, busbar wire  56  attached to active spade connector  18 , a common busbar wire  58  attached to common spade connector  16  and a grounding wire  57  attached to grounding pin  14 . 
         [0042]    Terminal connector assemblies  130  A,  130 B,  130 C,  130 D, and  130 E, having their appropriate terminals connected to the active, common and ground wires, are positioned within molded saddles  60 A,  60 B,  60 C,  60 D, and  60 E respectively as illustrated in  FIG. 15 . 
         [0043]    As illustrated in  FIGS. 11 and 14 , bottom shell  54  is further provided with integrally molded wiring guide channel  62  for ground busbar wire  57  therein. 
         [0044]    Busbar wires  56 ,  57 , and  58  are preferably made of braided copper strands thereby producing a flexible electrical conducting wire. Ground busbar wire  14  is preferably placed within channel  62  generally circumscribing shell  54  as best illustrated in  FIG. 15 . common busbar wire  58  is wrapped about the outside periphery of channel  62  and active busbar wire  56  is wrapped about the inside periphery of channel  62  each being held in place by appropriately positioned guide lugs. Connecting wires from the appropriate terminals of each connector assembly  130  are attached to each appropriate busbar wire  56 ,  57 , or  58 . In this way busbar wires  56 ,  57 , and  58  need not have an insulator covering and may be installed as bare wires separated from one another by the walls of channel  62 . However, it is preferred to insulate the wires from the connectors  130  to the busbar wires.  FIG. 15A  presents a circuit diagram of the subassembly wiring 
         [0045]    After having positioned circuit breaker  28 A, terminal connector assemblies  130  and wiring  56 ,  57  and  58 , within bottom shell  54 , top shell  52  is placed atop the assembly thereby completing sub assembly  50 . as illustrated in  FIG. 10 . Integrally molded dome covers  64 A,  64 B  64 C  64 D, and  64 E and saddles  60 A,  60 B,  60 C,  60 D, and  60 E closingly encase terminal connector assemblies  130 A,  130 B,  130 C,  130 D and  130 E therebetween. Similarly dome  65  acts to encase circuit breaker  28 A. 
         [0046]    The top shell  52  and bottom shell  54  are typically snapped together as illustrated in  FIG. 10A . However, the two shells may be assembled using a suitable adhesive, electron beam welding or any other convenient means. 
         [0047]    Turning now to  FIGS. 16 ,  17 ,  18 ,  19 , and  20 , an alternate embodiment of the bottom shell assembly  54 ′ is illustrated. Braided wire busbars  56 ,  57 , and  58  may be replaced by flat fabricated brass or copper busbars  66 ,  67  and  68  respectively. The ground busbar is divided into two elements  66 A and  66 B with circuit breaker  28 A interconnecting the two 
         [0048]    The appropriate connecting wires to each connector assembly are soldered to its appropriate busbar as illustrated in  FIG. 20 . All active connecting wires are soldered to element  66   b  thereby providing circuit breaker overload protection for all connector assemblies  130 A,  130 B,  130 C,  130 D, and  130 E. 
         [0049]    Once subassembly  50  is complete, it is encapsulated within a one piece molded, elastomeric covering as illustrated in  FIGS. 1 through 6 . 
         [0050]    Referring now to  FIGS. 22 through 24  terminal connector assembly  130  basically comprises a unitary, molded upper component  132  and a unitary molded lower component  134 . Upper component  132  includes two open ended cavities  136   a , receiving therein spade electrodes  116   a , and cavity  136   b , receiving therein spade electrode  116   b . Appropriately positioned between cavities  136   a  and  136   b  is open ended cavity  136   c  receiving therein pin electrode  116   c.    
         [0051]    Lower component  134 , of assembly  130 , completes the assembly by receiving therein upper component  132  having electrodes  116   a ,  116   b ,  1   16   c  Upper and lower components,  132  and  134 , 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. 
         [0052]    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.