Protection for high amperage connections

Abstract

The present invention relates to passive restraint devices that are designed to reduce the ability of an operator to gain access to a cable or battery connection before disconnecting the cable from a power supply while simultaneously informing the operator of the inherent dangers present at the cable connection.

Claims

1. A method of reducing arc flash comprising a) sandwiching an electrical connector between a front piece and a back piece of a passive restraint device, wherein the front piece has a handle section having one or more first openings and two second openings and a protector section; the back piece has a handle section having one or more first openings and two second openings and a protector section; and b) attaching the front piece to the back piece by one or more fasteners inserted through the first openings and by the tie strap inserted through the second openings in the respective handle sections such that the passive restraint device is held firmly against the exterior of the electrical connector and its associated cables, and the junction area between two joined connectors is covered over by the respective protector sections of the front and back pieces, and the junction area cannot be accessed without moving one of the protective sections of either the front piece or the back piece of the restraint device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.

(2) FIG. 1 shows a disassembled embodiment of the invention for covering a connector.

(3) FIG. 2 shows one half of an unconnected connector (a 350 Grey) that is commonly used for high or medium amperage cables.

(4) FIG. 3 shows a front view of the embodiment of FIG. 1 installed onto an unconnected half of a connector (a 350 Grey) for high to medium amperage.

(5) FIG. 4 shows a side view of the embodiment of FIG. 1 installed onto an assembled connector for high to medium amperage.

(6) FIG. 5 illustrates a top perspective view of a front piece of a second embodiment of the invention for covering a connector.

(7) FIG. 6 is a bottom perspective view of a bottom piece of the embodiment illustrated in FIG. 5.

(8) FIG. 7 illustrates a top perspective view of a front piece of a third embodiment of the invention for covering a connector.

(9) FIG. 8 is a bottom perspective view of a bottom piece of the embodiment illustrated in FIG. 7.

(10) FIG. 9 illustrates the embodiment of FIG. 5 in an assembled configuration without the presence of a connector or cables.

(11) FIG. 10 illustrates a top perspective view of a front piece of an embodiment for covering a battery connector cable.

(12) FIG. 11 is a bottom perspective view of the bottom piece of the embodiment illustrated in FIG. 10.

(13) FIG. 12 illustrates a top perspective view of a front piece of another embodiment for covering a battery connector cable.

(14) FIG. 13 is a bottom perspective view of the bottom piece of the embodiment illustrated in FIG. 12.

DETAILED DESCRIPTION

(15) The invention provides simple and efficient restraint devices that reduce the ability of an operator to gain access unsafely to a heavy-duty cable connection before disconnecting the cable from a power supply. The invention also reduces the ability of a user to incorrectly connect compatible, or seemingly compatible, cable connections to each other or to incorrectly attach a cable to an electrical vehicle rather than to a battery charger. In addition, the invention can be used to simultaneously inform the operator of the inherent dangers present at the cable connection or provide other pertinent information.

(16) The invention is a passive restraint device that comprises a front piece and a back piece that are attached to one another by one or more fasteners. Suitable fasteners include screws, rivets, bolts, tacks, twists, clips, clasps, pins, nuts, bolts, or combinations thereof, and the like that are known in the art. Those of skill in the art will appreciate that the screws shown in the accompanying figures are for illustrative purposes and another type of fastener can be substituted for the illustrated screws. Preferred fasteners are those that are not readily removed without the use of a tool (e.g. screwdriver, wrench, etc.) or are not easily dislodged through impact or rough handling. For example, clips or clasps that can be readily removed by hand are less desirable because users may not reassemble the device such that it functionally covers a cable connector(s). Preferred fasteners are those that can be mounted to the the exterior of a connector without contacting the metal parts of the connector; contribute to the insulation properties of the invention; and contribute to providing a rigid connection of the restraint device to the connector.

(17) Preferably, the front piece (see FIGS. 5, 7, 10, and 12) and back piece (see FIGS. 6, 8, 11, and 13) of an embodiment comprise comparatively similar dimensions. Each piece comprises two sections. A handle or first section, i.e. a neck, can be narrowed as compared to the other protector or second section, i.e. restraint cover or cover, that is wider (FIGS. 5-9). Alternatively, the handle sections and protector sections can be of similar widths throughout their lengths (FIGS. 10-13). The neck can include one or more, preferably at least two, first openings (1) of suitable dimensions so that one or more fasteners (2) can be inserted into either a front or back piece and then into or through the corresponding piece of the device such that the front and back pieces are connected to each other. Preferably, the fastening means allows the front and back pieces to be securely attached to each other when an electrical connector or coupler is sandwiched between them. Herein, sandwiched refers to the arrangement of an assembled device around a connector such that the connector fits snugly between the front and back pieces of the device and the connector cannot be removed from the assembled device without using force sufficient to damage the connector or its associated cables.

(18) The second or protector section of a front or back piece, i.e. the covers, are of sufficient width and length (when viewed from above as in FIG. 1) such that when the device is assembled on or around a coupler (see FIGS. 3 and 4), the coupler cannot be accessed to physically connect or disconnect it from a power cable, charger, battery, or other power source without moving the restraint device. (For comparison, a disconnected coupler without a restraint device is shown in FIG. 2.)

(19) Passive restraint devices comprise a front piece that has a handle section having one or more first openings (1) and two second openings (11) and a protector section that is able to cover a junction formed between two joined electrical connectors; a back piece that has a handle section having one or more first openings (1) and two second openings (11) and a protector section that is able to cover a junction formed between two joined electrical connectors; one or more fasteners (2) that can be a screw, rivet, bolt, tack, twist, clip, clasp, pin, nut, bolt, or combination thereof; and a tie strap, cable strap, or strap (10).

(20) The front piece is attached to the back piece by the one or more fasteners (2) through the first openings (1) in the front and back pieces and by the tie strap (1) through the second openings (11) such that, when an electrical connector is sandwiched between the front piece and the back piece, the assembled device is held firmly against the exterior of the electrical connector and its attached heavy-duty cables such that the junction formed between two joined connectors is covered over by the assembled device and cannot be accessed without moving a cover section of either a front piece or a back piece (see FIGS. 4 and 9).

(21) In an assembled device, a tie strap (10) is inserted through second openings (11) in the respective front and back pieces such that the front and back pieces are attached to each other at the distal end of the handle sections of the front and back pieces (See FIG. 9). Note that in FIG. 9 the tie strap (10) is illustrated as being inserted through a single hole (11) in the front and back pieces. Those of skill in the art will appreciate that in use, the tie strap (10) would be inserted through both holes (11) (i.e second openings) in the front piece as well as the back piece so that the tie strap (10) surrounded the cables extending from a connector attached to the assembled device. When an electrical connector is sandwiched between the front piece and the back piece and the tie strap (1) is tightened, the handle section of the assembled device is held firmly against the cables that extend from the connector.

(22) Preferably, the upper, lateral edges (3) of the handle sections of both front and back pieces are rolled and slightly thicker than the remainders of the respective handle sections. Similarly, the upper, front edges (4) of the protective sections of both front and back pieces are rolled and slightly thicker than the remainders of the respective protective sections.

(23) Preferably, the ventral surface of the back piece includes one or more mounting spacers (5) that protrude from the surface of the back piece and through which one or more fasteners (2) can be inserted. When assembled, these mounting spacers (5) or protuberances nestle into cavities or indentions on a connector that are designed to seat nuts or fasteners that are inserted between the cables that are attached to the connector. These mounting spacers (5) assist in holding a device of the invention firmly in place when attached to a connector and help the device to remain in place even when the assembly is subjected to impact or jarring forces. Each mounting spacer includes a hole through which a fastener (2) can be inserted.

(24) So that safety precautions or other information can be provided to users, the exterior surface of a front or back piece includes at least one recessed area (6) suitable for placing a label containing such precautions or information. The recessed area reduces the wear to the labels that is caused by repeated handling and lengthens the useful life of the device.

(25) To improve the gripping area of the assembled device, the back, lateral edge (7) of the handle sections of both front and back pieces is wider laterally than the remainder of the respective handle sections. This increased lateral width allows for the assembled device with the cable connector to approximate the base of the handle section of a baseball bat, that is, the area for gripping incorporates a ridge or lip that provides mechanical resistance when a pulling force is applied to the assembled device.

(26) Preferably, the front piece of a device includes at least one indicator (8) of electrical current flow on its exterior surface. These indicators (8) mirror those that are commonly found on the exterior of connectors and are intended to prevent a user from reversing an electrical current when making a junction between two connectors. In addition, either the front piece or the back piece can include a mounting hole (9) so that the assembled device and associated cables can be hung up and away from the floor or walking areas.

(27) The thickness of each front and back piece can be varied and depends, at least partially, on the type of material(s) used to construct the restraint device. The pieces should be of sufficient thickness and durability that when assembled the device can withstand multiple attempts by a user to move one of the covers to access a coupler, battery, or charger and then the cover will return to its original position over the coupler.

(28) At least one, and preferably both, of the front and back pieces is flexible. Preferably, the pieces are comprised of plastics, rubbers, composites, or combinations thereof that are non-conductive and of sufficient durability. An entire piece may be flexible or it may be mostly stiff and only flexible at, adjacent to, or near the area where the neck and cover sections meet. A piece has sufficient flexibility such that a user can move a cover to connect or disconnect a coupler without completely removing the restraint device.

(29) The attachment means is suitable for attaching the front and back portions to each other such that sufficient space or area is between the front and back portions so that a connector or coupler can occupy that space or area. The size and length of an attachment means can be varied as desired so that the space or area is larger, wider, or narrower and can be adapted to fit a desired coupler or connector. Preferably, the space is sufficiently large for a connector or coupler to occupy the space, but it is difficult for another object (e.g. a hand or fingers) to simultaneously occupy the space without moving the device.

(30) While not shown in the figures, other embodiments of the invention include additional elements that provide additional features and improvements.

(31) For example, other embodiments of the invention include at least one magnet, preferably an electromagnet, which is attached to the front and back pieces of the device. The magnet comprises two parts. A first magnet part is attached to the front piece of the device, and the second magnet part is attached to the back piece. When the device is attached to a connector, the two parts of the magnet interact with each other to prevent the device from being easily or unintentionally moved. Where the magnet is an electromagnet, the power for the magnet is preferably from the power cable attached to the coupler, and the power must be deactivated for the electromagnet to be released so that the restraint device can be moved to access the connector.

(32) In another embodiment, the device includes one or more audible or visual (e.g. flashing light) alarms that is triggered when a cover is moved. The alarm may be attached either to an inner side (i.e. the side facing the connector), outer side (i.e. the side not facing the connector), or inside a front or back piece of the device. Those of skill in the art will be familiar with the variety of types of alarms and their suitability for use in the invention.

(33) Some embodiments of the device include both a magnet, preferably an electromagnet, and one or more alarms. For example, a restraint device may include an electromagnet that is powered when a coupler is connected to a power cable and prevents the device from being moved until the power is disconnected. When the power is disconnected and the device is moved to disconnect the coupler then an audible, visual, or both audio and visual alarm is triggered. The alarm(s) continues until either the power is restored and the electromagnet functions, or the operator turns the alarm(s) to the OFF position. Those of skill in the art will understand that the power cannot be restored unless the device is put back in place on the coupler, as well as, that setting the alarm(s) to the OFF position can be overridden by restoring the power to the device.

(34) Unless defined otherwise, all technical terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs at the time of filing. The meaning and scope of terms should be clear; however, in the event of any latent ambiguity, definitions provided herein take precedent over any dictionary or extrinsic definition. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular. For example, the singular forms a, an and the include plural referents unless the content clearly dictates otherwise. Herein, the use of or means and/or unless stated otherwise. Furthermore, the use of the term including, as well as other forms such as includes and included is not limiting. Any patents and publications referred to herein are incorporated by reference.

(35) All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the following claims.