Electrical connectors – With coupling separator – Nonconducting pusher
Reexamination Certificate
2000-12-06
2002-04-02
Ta, Tho D. (Department: 2833)
Electrical connectors
With coupling separator
Nonconducting pusher
C439S348000
Reexamination Certificate
active
06364675
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to an electrical connector having two mating assemblies that eject from one another as a result of a tug on a power cord connected to at least one of the connector assemblies.
BACKGROUND OF THE INVENTION
Appliance cords present safety hazards when accidentally subjected to pull forces. Often users will manually pull on a typical 6-foot or 8-foot cord extending from an appliance resulting in abnormal forces at the wall outlet and/or damage to the cord, the outlet, or the appliance itself. It has been reported that on many occasions children have been injured by pulling a hot coffee pot or other similar electrical appliance down on themselves. In other instances, one tripping over a cord may pull the appliance from the shelf.
U.S. Pat. No. 5,480,313 describes an automatic disconnect mechanism for an electrical terminal fitting including a single assembly that springs from electrical engagement with a mating fitting, such as an existing fixed wall socket or the like, in response to a pull on an associated electrical cord. The single assembly includes both the spring to cause separation of the two mated terminal fittings and a trigger mechanism that is actuated by pull forces on the cord to trigger the separation. The mechanism requires the user to pre-set the trigger release which is not automatic. The mechanism does not have a self-locking mechanism actuated upon initial engagement of the terminal fittings. The mechanism generally requires a firm wall socket or other base from which to push-off when disconnecting. The disclosure includes a description of a dangerous situation that can arise with one embodiment in an application to a vehicle under battery charge, where one end would necessarily be left dangling with exposed electrical terminals. In the described situation, although the fitting containing the spring assembly actuates as the vehicle moves off, the electrical prongs of the mating plug fitting are left protruding and electrically exposed.
U.S. Pat. No. 4,114,969 discloses a plug release mechanism designed for use at the plug end of an electrical cord to interact with the structure surrounding a wall outlet in which the plug end is engaged. The device requires manual setting a cam-like actuation rod before use. The device relies on a wall socket-to-plug release in an axial force direction during a tug on the cord. The device does not provide a positive locking mechanism. The device is not designed for application at the appliance, or in-line on a cord.
What is needed is a device that would allow breakaway at an appliance during a tug on the cord. What is also needed is a device with the ability to have a positive locking mechanism while in place. What is also needed is a device that would not present a safety exposure situation when disconnected. What is also needed is a device that would have flexibility of design to allow interfacing to various types of outlets, appliances and yet be simple to manufacture.
SUMMARY OF THE INVENTION
The present invention resolves these problems and satisfies these needs. The present invention provides a quick release breakaway mechanism. The present invention also provides a design that leaves neither end with protruding terminals after disconnecting or when it is in a disconnect state. The present invention also provides a locking mechanism which provides the user with a positive feedback as to when the locking mechanism is engaged. The present invention also can be easily manufactured and is adaptable to many types of appliances, wall outlets and other uses.
The main aspect of the present invention is to provide a breakaway electric cord mechanism that can be used in connection with the base of an appliance. The term appliance as used herein is not limited to those kitchen appliances that might be easily supported by a counter top, but is also intended to refer broadly to other objects that are typically connected to a conventional wall plug by a length of electric cord, which cord presents the potential for injury or damage to property. The major components are a plug assembly, and engagement mechanism, and a base assembly. The term plug assembly is used here to refer in the most general sense to an assembly attached to or integral with one end of an electrical cord, the electrical cord having a plug for insertion into a conventional wall socket to provide a source of power. The term base assembly is used here to refer in the most general sense to an assembly designed to mate with a corresponding plug assembly in conjunction with the engagement mechanism of the present invention. The base assembly will generally be directly electrically connected to an electrical power consumption unit of an electrical appliance. These assemblies act in conjunction to provide a spring release of the assemblies from each other in the event of a tension, for example a tug, being applied to the cord greater than a preset minimum level sufficient to allow disengagement of the engagement mechanism. Since the plug assembly is separable from the base assembly, the separate assemblies can be color coordinated with each other. The plug assembly can be manufactured in a variety of color options to allow the consumer to match each portion of the assembly with the expected decorative environment in which the electrical appliance is to be employed.
In the most general case, the invention can be viewed as an electrical connector comprising a first assembly including a housing defining a cavity containing prongs suitable for connection to one portion of an electrical power delivery system, and an ejection plunger; a second assembly including a case containing electrical contacts for electrical connection with the prongs, the contacts being suitable for connection to another portion of the electrical power delivery system; and an engagement mechanism coupled to one of the first and second assemblies and engaging another of the first and second assemblies during a connection between the first and second assemblies, the engagement mechanism being releasable in the event of a tug on either assembly thereby enabling the ejection plunger to separate the first assembly from the second assembly.
More particularly, the invention can be viewed as an electrical connector comprising a first assembly including a housing defining a cavity containing prongs suitable for connection to one portion of an electrical power delivery system, and an ejection plunger; a second assembly including a case containing electrical contacts for electrical connection with the prongs, the contacts being suitable for connection to another portion of the electrical power delivery system; and a holder coupled to the second assembly and containing slidable receptacles for engaging the prongs of the first assembly and the electrical contacts of the second assembly, the holder carrying an engagement mechanism for engaging the cavity of the first assembly during a connection between the first and second assemblies, the second assembly being movable over a predetermined range relative to the holder in the event of a tug on either assembly thereby allowing disengagement of the engagement mechanism and enabling the ejection plunger to separate the first assembly from the holder and second assembly.
The first or base assembly includes a housing including a plug-receiving cavity. A set of prongs are situated wholly within the plug-receiving cavity of the housing so as not to project outward from the housing. The prongs can be electrically connected to the electrical power consumption unit of an electrical appliance by way of retention screws provided at a rear end of the base assembly. The ejection plunger or thrust mechanism consisting generally of a thrust spring and thrust spring plunger is located centrally within the base assembly. The thrust spring and thrust spring plunger are respectively contained within the base assembly housing via a slot or opening into which a plunger spring retention plate is fastened with two screws. The thrust spring plung
Brauer Bonnie
Russell Robert A.
Brinks Hofer Gilson & Lione
Nguyen Phuong
Ta Tho D.
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