120VAC to 240VAC power converter, adapter and methods of use

Abstract

The present invention is directed, in part, to electrical components and methods of use associated with such components. In particular, the invention relates to an electrical device and methods of converting the use of 120 VAC electrical power into 240 VAC electrical power in order to power 240 VAC-requiring equipment and appliances. The electrical system includes at least two 120 VAC electrical cords and plugs, at least one 240 VAC outlet, a plurality of electrical switches and coils managed by a plurality of electrical relays within a central housing unit. The housing unit includes hot side, neutral side and ground wiring that transfer 120 VAC electrical power through the plurality of switches so that the power is safely routed to a 240 VAC outlet for use in powering 240 VAC-requiring equipment and appliances. As a safety feature, the invention further includes a plug circuit breaker that will break the electrical circuit within either a 120 VAC or 240 VAC plug.

Claims

1. An electrical power adapter configured to combine two electrical inputs to produce an electrical output at a voltage substantially equal to a sum of voltages of the two electrical inputs, the adapter comprising: a first normally open relay operably connected to a first electrical input and comprising a coil of the first normally open relay and two contacts of the first normally open relay, and the two contacts of the first normally open relay closing only when the coil of the first normally open relay is energized at a first voltage from the first electrical input provided at a first phase; a second normally open relay operably connected to a second electrical input and comprising a coil of the second normally open relay and two contacts of the second normally open relay, and the two contacts of the second normally open relay closing only when the coil of the second normally open relay is energized at a second voltage from the second electrical input provided at a second phase; and a third normally open relay operably connected to both the first and second normally open relays and comprising a coil of the third normally open relay and four contacts of the third normally open relay, and the four contacts of the third normally open relay closing when the coil of the third normally open relay is energized at a third voltage, the third voltage being the sum of the first voltage and the second voltage.

2. The adapter of claim 1, wherein the first and second electrical inputs are configured with a plug circuit breaker.

3. The adapter of claim 2 wherein the plug circuit breaker includes a reset button, wherein the reset button, when pushed, closes electrical contacts to establish an electrical connection and the plug circuit breaker breaks an established electrical circuit during instances in which excessive heat is generated, the excessive heat being in excess of safe operating levels.

4. The adapter of claim 1, wherein the first and second electrical inputs comprise electrical cords with a length to span a distance within a home or establishment so that the electrical cords can be plugged into two 120 VAC electrical outlets that operate on different electrical phases.

5. The adapter of claim 1, wherein the adapter comprises an electrical outlet, the electrical outlet comprising a ground line, a neutral line, a hot line at the first voltage and the first phase, and a hot line at the second voltage and the second phase.

6. The adapter of claim 5, wherein the electrical outlet is configured to fit a standard 240 VAC plug.

7. The adapter of claim 5, wherein the electrical outlet is configured to fit any 240 VAC plug.

8. The adapter of claim 1, wherein the two contacts of the first normally open relay close only when the coil of the first normally open relay is energized at a first voltage value equal to or greater than 120 VAC, and wherein the two contacts of the second normally open relay close only when the coil of the second normally open relay is energized at a second voltage value equal to or greater than 120 VAC.

9. The adapter of claim 8, wherein the four contacts of the third normally open relay close only when the coil of the third normally open relay is energized at a third voltage value equal to or greater than 240 VAC.

10. The adapter of claim 1, wherein closing the two contacts of the first normally open relay allows the coil of the third normally open relay to be energized by the second voltage, and wherein closing the two contacts of the second normally open relay allows the coil of the third normally open relay to be energized by the first voltage.

11. The adapter of claim 1, wherein the adapter comprises an electrical outlet, the electrical outlet comprising a hot line at the first voltage and the first phase, and a hot line at the second voltage and the second phase.

12. The adapter of claim 1, wherein the adapter comprises a first cord comprising the first electrical input and a second cord comprising the second electrical input.

13. The adapter of claim 1, wherein the adapter comprises a central housing, the first electrical input comprising a first outlet located in the central housing and the second electrical input comprising a second outlet located in the central housing.

14. The adapter of claim 13, wherein the adapter comprises a third outlet located in the central housing.

15. The adapter of claim 13, wherein the adapter does not include an external cord extending between the first electrical input and the central housing.

16. The adapter of claim 1, wherein when one of the first electrical input or second electrical input is connected to an outlet, no voltage appears on contacts of the other of the first electrical input or second electrical input.

17. The adapter of claim 1, wherein each of the first electrical input and the second electrical input comprises a plug having prongs, and wherein when one of the first or second electrical input is inserted into an outlet, no voltage appears on the prongs of the other of the first electrical input or second electrical input.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts the overall configuration of the present invention. In particular, the illustration provides the electrical schematic associated with transfer of electrical power from two 120 VAC cord and plug connections to a 240 VAC outlet. As shown, switches controlled by electrical relays are in an open position.

(2) FIG. 2 depicts the overall configuration of the present invention. In particular, the illustration provides the electrical schematic associated with transfer of electrical power from two 120 VAC cord and plug connections to a 240 VAC outlet. As shown, switches controlled by the 240 VAC relay and the lower right 120 VAC relay are open and switches controlled by the lower left 120 VAC relay are closed.

(3) FIG. 3 depicts the overall configuration of the present invention. In particular, the illustration provides the electrical schematic associated with transfer of electrical power from two 120 VAC cord and plug connections to a 240 VAC outlet. As shown, switches controlled by the 240 VAC relay are open and switches controlled by the lower 120 VAC relays are closed.

(4) FIG. 4 depicts the overall configuration of the present invention. In particular, the illustration provides the electrical schematic associated with transfer of electrical power from two 120 VAC cord and plug connections to a 240 VAC outlet. As shown, switches controlled by the 240 VAC relay and the two 120 VAC relays are closed.

(5) FIG. 5 depicts a side view of a plug circuit breaker wherein the breaker button is shown one side of an electrical plug.

(6) FIG. 6 depicts a second side view perspective of a plug circuit breaker of the invention where the breaker button is shown on the opposite side of an electrical plug illustrating that the plug circuit breaker can be configured to any one of the wires within the plug.

(7) FIG. 7A illustrates a through view of an electrical plug including its wiring thereof wherein the plug circuit breaker is electrically configured into one of the existing wires of the plug. The illustration depicts the three electric wires typically configured within a electric plug wherein one electrical wire is further configured with an electrical breaker. As shown, bimetallic electrical contacts of the breaker are not closed.

(8) FIG. 7B is a close up illustration of the electrical circuit breaker of FIG. 7A. In particular, the illustration shows the bimetallic contacts in an open position indicating that a circuit cannot be established.

(9) FIG. 8A illustrates a through view perspective of the electrical plug of FIGS. 7A and B and includes the typical wiring a traditional plug wherein a plug circuit breaker is electrically configured into one of the wires of the plug. The plug circuit breaker is shown on the side of the plug.

(10) FIG. 8B illustrates a close up view of the plug circuit breaker wherein the contacts of the bimetallic wire are closed, having been closed by the reset button on the side of the plug. Accordingly, electricity is allowed to transfer to the plug elements.

DETAILED DESCRIPTION OF THE INVENTION

(11) The present invention is directed to a novel device and methods of providing 240 VAC power in situations in which only 120 VAC power outlets are available for use. In particular, the invention is an electrical system that allows the use of 120 VAC power in a home, building or other structure, to be converted into 240 VAC power for use in powering 240 VAC-requiring equipment, appliances or otherwise.

(12) The electrical system includes a central unit that houses at least two 120 VAC cords and plugs and a 240 VAC cord configured with a 240 VAC outlet. The electrical system further includes a plurality of coils, electrical relays and switches that allow the conversion and transfer of 120 VAC power so that it can be used as 240 VAC power for higher power requiring equipment and appliances. In particular, the invention includes at least two 120 VAC relays that manage the power of 120 VAC entering the central housing unit via at least two 120 VAC electrical outlets and plugs. A first 120 VAC relay manages the power routed from a first 120 VAC cord and plug wherein the plug is plugged into a 120 VAC outlet in a home or other structure. A second 120 VAC relay manages power routed from a second 120 VAC cord and plug wherein the plug is plugged into a second 120 VAC outlet which is powered on a different supply phase than the outlet of the first 120 VAC plug and cord. As an additional safety measure, the invention further includes a circuit breaker that is configured within the electrical plug of either or both of the 120 VAC plugs employed in converting 120 VAC power for use in a 240 VAC capacity.

(13) The two 120 VAC cords are plugged into 120 VAC outlets in the walls of a home or structure that are of different electrical supply phases otherwise, there is no actual conversion of the power to 240 VAC power. Once a user plugs the two 120 VAC cords and plugs into 120 VAC outlets that are out of phase with one another, the power supplied is transferred through at least two electrical relays, the relays managing a plurality of coils and electrical switches that route the power to a 240 VAC relay. The 240 VAC relay includes a plurality of coils and switches that manage the power incoming from the 120 VAC relays and routes the power to a 240 VAC outlet for use in powering 240 VAC-requiring equipment or appliances.

(14) The invention described herein employs one or more electrical relays. As known in the electrical arts, a relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.

(15) It will be understood by those of ordinary skill in the art that there exists numerous types of relays and coils all of which are encompassed within the scope of the present invention and patent claims including those described herein. As a preferred embodiment of the present invention, relays employed herein include for example, 110, 120 VAC relays with 20 ampere contacts as well as 220, 240 VAC relays with 20 amp contacts. The invention can also be used in Europe, and around the world to provide a doubling of amperage (versus doubling of voltage in the U.S.). With regard to amperage in Europe, and other parts of the world, voltage is sufficient however amperage is not. Therefore, in these cases the invention employs two separate electrical outlets to double the amperage, not the voltage. By way of example, in Europe the voltage is 220/240 and the amperage is 10 amps. In such a case, the invention is employed to combine two separate outlets to make 20 amps @220/240 volt. In the U.S. using the invention, a user combines two 110/120 volt 20 amp outlets to make one circuit of 20 amps @220/240, so those of pertinent skill in the art will understand that the outcome is essentially the same.

(16) Further, the invention can also be employed in a three phase application. By way of example: In a commercial application one can employ use of the invention for three separate outlets of 110/120 VAC in order to make a 208/220/240 volt three phase plug. As described above as well as below, the invention can also be employed in order to power traditional plug and play technology.

(17) The installation methods, including use with a Plug and Play as well as in fast charging of vehicle electrical batteries further allow a user to employ the device in any number of household and automobile applications. The invention further includes a safety measure and device in the form of an electrical plug circuit breaker that includes a bimetallic strip and a reset button that establishes the connection of cord wiring with a plurality of electrical contacts configured near the reset button. The plug circuit breaker establishes an in-line connection within one of the cord wires that routes power to an appliance or piece of equipment. In instances in which the plug wiring gets dangerously hot, or is at risk of causing a fire, the plug circuit breaker breaks the connection in the cord wiring thus, interrupting the electrical connection being routed through the plug. When the plug circuit breaker is reset, the contacts of the plug wiring are closed and electrical power is again routed through the wiring to provide power to an appliance requiring energy.

(18) Installation of the electrical system invention is simple and requires no instructions other than basic details for use since to use the invention, a user only needs to be plug the two 120 VAC cords and plugs into two separate 120 VAC outlets that are supplied by two different electrical phases.

(19) It is therefore, a primary object of the present invention to provide an electrical system device and method of employing the claimed invention in a variety of applications including but not limited to charging of vehicle electrical batteries such as those installed in plug-in and all-electrical vehicles, Plug and Play devices, solar and other alternative energy generators and other technologies as are known in the art.

(20) The electrical system device and method further includes a system that lacks the two 120 VAC plugs and cords and merely provides 120 VAC outlets allowing a user to supply his own cords to connect to the central housing unit of the invention. In other words, with regard to this particular embodiment, the invention is configured with three outlets in total, two for 120 VAC power and one 240 VAC outlet, all the outlets available to be fitted with electrical cords by a user. The system and methods of the invention also include use of the device with so-called Plug and Play devices to provide, for example, electrical power generated from a solar panel or solar cell.

(21) As used herein, the term connected refers to the general and known understanding of the term as it relates to the electrical field. For example, understanding of the term includes an electrical connection between two electrical components wherein either an electrical circuit is created when power is present or alternatively, a circuit is interrupted under certain circumstances wherein the electrical components no longer connected to form a circuit to carry power.

(22) As used herein, the term structure refers to any building, or manufactured facility that possesses and electrical system that includes 120 VAC power. For example, a home provides outlets that deliver 120 VAC power when an appliance is plugged into the outlet. The structure in this example includes a home, a commercial building or any other structure that is wired to deliver 120 VAC power to an appliance or equipment.

(23) Turning now to the substance of FIGS. 1 to 8 and the preferred embodiments of the invention.

(24) FIG. 1 represents the condition of the present invention in which both 120 VAC plugs are not connected to a supply. The two 120 VAC plugs are indicated at the bottom of the Figure 10, 12, the 240 VAC outlet, 14, is at the top. Each three-prong plug has a ground wire 40, a neutral wire 50 and a hot, or supply, wire 60, 70. Connection of these prongs to the corresponding wires in the 120 VAC outlets (not shown) is enforced by the physical configuration of the 120 VAC plugs. Neutral 50 and hot, or supply lines 60, 70 within the present invention indicates respectively circuits that may, under certain conditions-specifically the state of the relaysbe connected, but are not necessarily always connected. For example, not all supply lines on the diagram represent one continuously connected electrical circuit.

(25) Tracing through the circuit, the ground wires 50 of both 120 VAC plugs and the 240 VAC outlet 14 are always connected. This is correct and necessary to maintain a safe condition. The hot and neutral wires from both 120 VAC plugs are connected to a series of relay windings and coils. Aided by the symmetry in the figure, both 120 VAC plugs 10, 12 are treated exactly the same in the present invention and are functionally and operationally identical. As shown in the Figure, the switches are all open and in this unconnected condition, there is no voltage anywhere in the circuit.

(26) FIG. 2 represents the condition of the present invention wherein a first 120 VAC cord and plug 10 has been connected to its supply, but a second 120 VAC cord and plug 12 is not connected. The change from FIG. 1 is that the contacts of the relay closest to the first 120 VAC cord and plug 10 are shown in the closed or energized position. This occurs because the hot and neutral wires of the first 120 VAC plug are supplying power to the coil of that relay, closing its contacts. Following the first 120 VAC cord 10 hot wire through the contacts of the relay, the illustration provides that path ending at an unconnected contact of the relay nearest the second 120 VAC plug 12. Following a branch off the first 120 VAC plug neutral wire, the wire ends at an open contact of the relay near the top of the figure. There is no opportunity for either the hot or neutral wires of the first 120 VAC plug wire to be connected in this state to any of the prongs of the second 120 VAC plug wire or to the 240 VAC wire and outlet 14. A similar chain of reasoning would apply if the second 120 VAC plug was connected to its supply and the first 120 VAC plug was unconnected.

(27) FIG. 3 represents the condition of the present invention when both the first and second 120 VAC plugs have been connected to their respective supplies, with the supplies being of different phases. Under normal conditions, the situation in FIG. 3 exists only for an instant; the present invention is in a transient on its way to the fully connected condition that will be described with the help of FIG. 4. However, in FIG. 3, the two lower relays 16, 18 are energized, but the top relay is not yet energized. The neutrals from both the first and second 120 VAC plugs and cords help to energize their respective relays and also branch to contacts 30, 32, 34, 36 in the top relay that are still open. The first 120 VAC hot wire energizes its relay 16 and also continues through the closed contacts of that relay to a contact in the relay closest to the second 120 VAC plug and cord 18. Those contacts are now closed, so the first 120 VAC hot wire continues through that contact to one side of the coil for the top relay.

(28) The second 120 VAC plug hot wire 70 follows a corresponding course, first though the contacts of its own relay 20 then through the contacts of the first 120 VAC relay 16 and on to the other side of the winding for the top relay 20. Having the hot connections from two different phases connected to its winding is sufficient to activate the top relay, so FIG. 3 shows the state of the present invention in the instant before the contacts of the top relay close. In effect, the relays are wired to perform a logical and; the first 120 VAC plug and cord must be connected and the second 120 VAC plug and cord must be connected to supply power to the coil of the top relay. In this transient state, neither of the hots are connected to 240 VAC outlet, nor are the neutrals.

(29) There is a set of conditions under which the situation depicted in FIG. 3 is not a transient but endures indefinitely until connections at the first and second 120 VAC plugs and cords are changed. One of these conditions occurs when the first and second 120 VAC plugs have been connected to the same phase of the electrical supply. In this case, the contacts of the two lower relays 16, 18 close, but both ends of the coil of the upper relay 20 are connected to the same phase and therefore the same voltage; this will not energize the upper relay and its contacts remain open. The other conditions under which the situation in FIG. 3 will persist is if either or both of the outlets that the first and second 120 VAC plugs have been connected to are incorrectly wired. It is explicitly against electrical code, but it does occasionally happen that outlets are wired with the hot and neutral connections reversed. Suppose this has happened at one outlet but not the other.

(30) Then 120 VAC will appear at one end of the coil of the upper relay and neutral will appear at the other end. Though this was sufficient to energize the two lower relays, the upper relay is specified to close its contacts only if at least 240 VAC wire appears across its coil, so its contacts remain open and no voltages are connected to the 240 VAC outlet. Crucially, the neutral wires from both plugs are not connected to each other, which would otherwise trip a breaker at least and possibly cause damage or fire. There are even more ways that outlets can be mis-wired involving incorrect assignment of the ground, but none of these mistakes will allow sufficient voltage to energize the top relay either.

(31) FIG. 4 represents the steady-state, persistent condition when the first and second 120 VAC plugs and cords are connected to different phases of the electrical supply. The top relay has 240 VAC applied across its coil, its contacts are closed 30, 32, 34, 36, and this is the only condition under which voltages appear at the 240 VAC outlet. The hot from the first 120 VAC plug appears at one hot for the 240 VAC outlet, the hot from second 120 VAC plug and cord appears at the other hot on the 240 VAC outlet. The neutrals from the first and second 120 VAC plugs and cords are connected together through the contacts of the top relay, and on to the neutral of the 240 VAC outlet. As noted earlier, the grounds of all three plugs are permanently connected. If at any time the second 120 VAC plug and cord becomes disconnected from its supply, the present invention will immediately revert to the situation depicted in FIG. 2. If the first 120 VAC plug becomes disconnected while the second 120 VAC plug remains connected, a similar state will apply. In either partially disconnected situation, the top relay will de-energize, its contacts will open, and no voltages will appear at the 240 VAC outlet nor at any of the prongs of the disconnected plug.

(32) FIG. 5 illustrates a preferred embodiment of the 120 VAC plugs that provides a safety measure in practicing the electrical system of the invention. The Figure provides a plug 9 configured with an internal plug circuit breaker and reset button 5. As shown, the cord 1 is shown from a side view perspective and provides a neutral side electric probe 8 as well as a grounding probe 6 as is typically known in the art. The circuit breaker (not shown) is fitted with a reset button 5 configured on the side of the plug 9. FIG. 6 illustrates the opposite side view perspective of the plug circuit breaker. In particular, a cord 1, which can be 120 VAC or otherwise, leads to a plug 9 configured with a hot side electric probe 7 as well as a ground probe 6. The reset button 5 for the plug circuit breaker in this illustration is on the side of the plug 9.

(33) FIGS. 7A and 7B illustrate the internal configurations of a preferred embodiment of the plug circuit breaker of the invention. A cord 1 is connected to a plug 9, wherein the cord includes the typical 3-wire configuration for electrical conductance 2. The plug is shown from a top or bottom view perspective and includes a neutral side 8, hot side 7 and grounding electric probe 6. The plug circuit breaker is shown connected to one of the cord wires 2 wherein the reset button 5 is configured to close the contacts of the breaker. FIG. 7B is an expanded view of the plug circuit breaker wherein a bimetallic strip 4 creates a set of contacts between the two contact leads of the cord wire 2. Several contacts 3 form the ends of the bimetallic strip so that when closed, the contacts establish an electrical connection for transfer of electricity through the wire.

(34) FIGS. 8A and 8B illustrate a preferred embodiment of the plug circuit breaker wherein the contacts 3 of the breaker are closed. Again, the cord is configured with a hot side 7, neutral side 8 and ground probe 6 that are connected to wires 2 in the cord 1. The plug circuit breaker reset button 5 is configured on the side of the plug 9. FIG. 8B is an expanded view perspective of the plug circuit breaker and illustrates the bimetallic strip 4 with the contacts 3 closed by the reset button, allowing transfer of electrical power through the wire.

(35) To manufacture the electrical system of the present invention, traditional electrical manufacturing methods are employed. Electrical relays, switches and coils as are known in the art are manufactured and assembled according to the specification herein.

(36) Benefits of the present invention over the prior art include a user's ability to charge their electrical batteries with 240 VAC power routed from two 120 VAC power plugs and outlets. Accordingly, charge time is greatly decreased. Moreover, employing use of the electrical system in conjunction with plug and play technology allows a user to route power generated from alternative energy sources to a home in need of such power or alternatively, back to the electrical power grid, thus, lowering the user's energy bills.

(37) Although the invention has been described with reference to the above examples, it will be understood that modifications and variations are encompassed within the spirit and scope of the invention. Accordingly, the invention is limited only by the following claims.