Electrical cord cap with a housing part that is easy to connect

Abstract

An electrical connector body is provided that includes first and second housing portions formed from molded plastic. The housing portions include first and second interface surfaces configured to abut one another to define a housing, and one or more electrical components are disposed within the housing. The one or more electrical components may include male or female cord caps, in-line surge suppression circuitry, and / or a compact automatic transfer switch. In one embodiment, the first and second connector body portions may each include a strain relief projection for engaging an electrical cord, and a compression member (3691) may be disposed on the strain relief projection to secure the first and second connector body portions together. The compression member may be selected from a set of compression members based on the size of the electrical cord.

Description

Technical Field

[0001] Cross - References to Related Applications This application is a regular application of U.S. Patent Application No. 62 / 821,893, entitled "ELECTRICAL CORD CAP WITH EASY CONNECT HOUSING PORTIONS", filed on March 21, 2019. This application also claims priority to U.S. Patent Application No. 16 / 817,504 (surge suppression case), entitled "RELAY CONDITIONING AND POWER SURGE CONTROL", filed on March 12, 2020, and U.S. Patent Application No. 16 / 824,554, entitled "INTELLIGENT AUTOMATIC TRANSFER SWITCH MODULE", filed on March 19, 2020. The content of the above applications (collectively "parent applications") is hereby incorporated by reference as if fully set forth herein, and the priority to these applications is claimed to the maximum extent permitted under U.S. laws and regulations.

[0002] Incorporation by Reference The following cases are hereby incorporated by reference into this specification. 1. A provisional application of U.S. Patent Application No. 61 / 799,971, entitled "SECURE ELECTRICAL RECEPTACLE", filed on March 15, 2013, claiming the benefit of U.S. Patent Application No. 61 / 944,506, entitled "FRICTIONAL LOCKING RECEPTACLE WITH PROGRAMMABLE RELEASE", filed on February 25, 2014, and U.S. Patent Application No. 14 / 217,278, entitled "FRICTIONAL LOCKING RECEPTACLE WITH PROGRAMMABLE RELEASE", filed on March 17, 2014. 2. A continuation-in-part of U.S. Patent Application No. 12 / 531,235, filed September 14, 2009, which is the U.S. national stage of PCT Application No. US2008 / 57149, filed March 14, 2008, claiming priority to U.S. Provisional Application No. 60 / 894,849, filed March 14, 2007, entitled "LOCKING ELECTRICAL RECEPTACLE", and a continuation-in-part of U.S. Patent Application No. 12 / 568,444, filed September 28, 2009, claiming priority to the same application, and claiming priority to U.S. Patent Application No. 13 / 228,331, filed September 8, 2011, entitled "LOCKING ELECTRICAL RECEPTACLE WITH ELONGATE CLAMPING SURFACES". 3. U.S. Patent Application No. 13 / 088,234, filed April 15, 2011, entitled "LOCKING ELECTRICAL RECEPTACLE", claiming priority to U.S. Provisional Application No. 61 / 324,557, filed April 15, 2010, entitled "LOCKING ELECTRICAL RECEPTACLE SECURE LOCKING MECHANISM". The entire contents of the above applications are hereby incorporated by reference as if fully set forth herein.

BACKGROUND OF THE INVENTION

[0003] A variety of electrical connectors are known for providing electrical contact between a power source and an electrical device. The connector typically includes a prong-type terminal generally called a plug, and a female connector that receives the prong-type terminal, often called an electrical outlet, or simply an outlet, generally called a receptacle. The most common type of outlet includes a pair of terminal contacts that receive the prongs of a plug connected to a "hot" and a "neutral" conductor. Additionally, the outlet may include a terminal contact for receiving the mounting prong of the plug. Various standards for outlets have been established in various regions of the world.

[0004] Regardless of the standards at the time of issue, the most common plug and receptacle systems described above generally incorporate a friction mechanism only between the metal contact means that fix these two to the mating position. Without being limited to this, the coefficient of friction value varies depending on various conditions including the manufacturing process, foreign matter acting as a lubricant, and wear and distortion of the assembly. Due to this characteristic, the means for interconnecting power between two devices is uncertain. This is almost certainly the weakest link in the power delivery system to electrical or electronic devices that utilize the system. However, this is adopted worldwide as a standard and is mainly used because of the low manufacturing cost, ease of quality control during manufacturing, and efficient use of the space for the intended power delivery.

[0005] The main limitation of this connection technique is, in fact, the friction fit components. In some fields such as the data or medical fields, a technique for ensuring a mating connection is desirable for improving reliability due to the need for power continuity. This is particularly applicable when there is vibration or when the cord attached to the plug and receptacle may be mechanically bent or distorted in some way by an external force.

[0006] The above background exists for the development of the safe receptacle of the present invention.

Summary of the Invention

[0007] The present invention relates to an electrical connector body and a method of manufacturing such a body. The electrical connector body includes a housing for terminating or intervening electrical components on an electrical cord. A common example is a cord cap that forms a male plug or female receptacle for connecting a cord to a wall outlet, power strip, another cord, electrical equipment, or another connector. The present invention discloses embodiments that implement a locking cord cap to prevent unintended disconnection of such connections. The present invention also includes, among other things, an in-line surge suppression circuit and a miniaturized automatic transfer switch embodied in a connector body mounted on an electrical power cord (usually at least two input power cords and an output connectable to the cord, or an output directly connectable to one device). The present invention simplifies manufacturing by reducing or eliminating the need for a PVC overmold and enabling the formation of an electrical connector body by joining injection molded housing portions. In one variation, the housing portions can be joined by sliding a compression cone over a strain relief protrusion of the housing to simultaneously join the housing portions and compress and engage the electrical cord. This significantly simplifies manufacturing and allows for sharing of manufacturing and assembly methods among multiple manufacturers and regions, facilitating various business and distribution strategies.

[0008] According to one aspect of the present invention, a method of assembling an electrical cord connector body is provided. The method includes providing first and second connector body housing portions formed from injection molded plastic. The first and second connector body housing portions include first and second interface surfaces configured to abut each other to define an interface surface of the housing. The method further includes placing one or more electrical components in the first connector body housing portion and positioning the second connector body housing portion over the first connector body housing portion such that the first and second interface surfaces are in an aligned abutting relationship. The first and second connector body housing portions are then fixed together to form the electrical cord connector body.

[0009] As described above, the electrical cord connector body can embody a number of different types of electrical components. In this regard, the electrical component may include connection contacts that form an electrical connection between an electrical plug and an electrical outlet. For example, the electrical cord connector body may form a cord cap for a male plug or a female outlet. The cord cap may be a locking cord cap. As an alternative or in addition, the electrical component can include a surge suppression circuit disposed on an electrical cord and / or a small automatic transfer switch mounted on the electrical cord. In one embodiment, the first and second housing portions are provided as a single molded piece. In this regard, the molded piece can be bent such that the second connector body housing portion is located above the first connector body housing portion. The housing portion may include alignment elements or mating connectors.

[0010] The housing portions can be fixed together by various techniques including adhesives, welding, and / or snap fitting together. In one embodiment, each of the housing portions includes strain relief protrusions that engage an electrical cord. The strain relief portion can fix the strain relief protrusions and the connector body portion together and can be captured by a compression element that compressionally engages the electrical cord. In this regard, a set of compression elements may be provided to accommodate different sizes of electrical cords. For example, the compression element may have a generally conical shape such that it progressively presses the housing portions together as it slides over the strain relief protrusion. The strain relief protrusion and the compression element may be configured such that the compression element snaps onto the desired position on the strain relief protrusion.

[0011] According to another aspect of the present invention, an electrical connector body is provided. The connector body includes first and second housing portions formed from molded plastic. The housing portions include first and second interface surfaces configured to abut against each other to define a housing interface surface. One or more alignment features are disposed on the housing interface surface to assist in aligning the first and second connector body housing portions and securing each housing portion together to form the housing. Further, one or more electrical components are disposed within the housing.

[0012] As described above, the one or more electrical components may comprise male or female cord caps, in-line surge suppression circuits, and / or connectors for miniature automatic transfer switches. The alignment features can include mating structures formed on opposing surfaces of the first and second housing portions, or structures for snap-fitting the housing portions together. In one embodiment, the housing portions are formed from a single injection molded plastic including a fold line for folding the injection molded plastic such that the first and second housing portions are in an aligned abutting relationship. Further, each of the first and second connector body portions may include strain relief protrusions for locking an electrical cord. In this regard, the connector body may further include a compression member disposed over the strain relief protrusions for securing the first and second connector body portions together. The compression member can be selected from a set of compression members based on the size of the electrical cord.

[0013] Thus, the present invention provides an electrical connector body that can be easily configured by fixing together housing portions formed from injection molded plastic. The housing portions can be fixed together using compression elements, thereby reducing or eliminating the need for plastic welding or other techniques that complicate assembly. The present invention also reduces or eliminates the need for PVC overmolding so that manufacturing and assembly can be carried out using inexpensive and readily available tools. In this way, the manufacturing and assembly methods can be shared among multiple manufacturers and regions, facilitating various business and distribution strategies.

[0014] For a more complete understanding of the present invention and its further advantages, a detailed description will be given below with reference to the following drawings.

Brief Description of the Drawings

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Embodiments for Carrying Out the Invention

[0016] In the present invention, various modifications and alternative forms are possible. However, specific embodiments are illustrated in the drawings and detailed in this specification. Nevertheless, the present invention is not intended to be limited to the specific forms disclosed, and the present invention can include any modifications, equivalents, and alternative forms that do not depart from the scope and spirit of the present invention described in the claims.

[0017] As described above, the present invention relates to various electrical connector bodies that can be formed in a plastic portion in which a connector body housing is injection molded. The portion can be fixed together with internal electrical components to form an electrical connector body. Such fixation can be achieved by sliding a compression element over a strain relief protrusion. This method can be used, inter alia, to form various types of components including a cord cap, an in-line surge suppression circuit, and a small automatic transfer switch mounted on a cord. The following description describes a plurality of embodiments of a locking cord cap and other locking connectors, and then describes embodiments and methods related to an electrical connector body formed from injection molded plastic.

[0018] Figures 1A - 1C show the operation of an embodiment of a fastening mechanism for securing a mating electrical connection that may be included in a locking receptacle of the present invention. In each of Figures 1A - 1C, the bottom represents a side view of the prong 16 and the fastening mechanism 12, and the top represents a perspective view. First, referring to Figure 1A, the prong 16 of a plug inserted into the receptacle 10 is shown. The prong 16 may be the ground prong of a standard plug (e.g., an IEC 320 plug, a NEMA 5 - 15 or the like), and may be of various sizes and shapes. Further, the receptacle 10 may be a standard outlet (e.g., a NEMA standard cord cap, an IEC320 cord cap, or the like) that operates to receive a standard plug. Also, the receptacle 10 includes a fastening mechanism 12 coupled to a pivot 14. The fastening mechanism 12 includes an opening that is slightly larger in size than the prong 16 such that the prong 16 passes through the opening only when the longitudinal direction of the fastening mechanism is substantially perpendicular to the longitudinal direction of the prong 16. That is, the design of the fastening mechanism 12 utilizes simple slide-on and capture techniques.

[0019] Figure 1B shows the prong 16 at the time of insertion into the receptacle 10. As shown, the prong 16 is inserted into the receptacle 10 through the opening of the fastening mechanism 12, and as a result, the corresponding plug and outlet are in the mating position. The fastening mechanism 12 may further include a stopper (not shown) that prevents the fastening mechanism 12 from pivoting during the insertion of the prong 16. In this regard, during the insertion of the prong 16, the longitudinal direction of the fastening mechanism 12 is maintained substantially perpendicular to the longitudinal direction of the prong 16, whereby the prong can pass through the opening of the fastening mechanism 12.

[0020] Figure 1C shows the gripping function of the fastening mechanism 12 in response to the force applied to the prong 16 when attempting to withdraw the prong 16 from the receptacle 10. In response to the withdrawal of the prong 16, the fastening mechanism 12 deflects (i.e., rotates) at an angle about the spring pivot 14, and the opening of the fastening mechanism 12 grips the prong 16. Thus, the force itself attempting to withdraw the prong 16 from the receptacle actuates the fastening mechanism 12 to engage the prong 16, thereby preventing the withdrawal of the prong 16 and serving to maintain the electrical connection of the mating assembly. The fastening mechanism 12 can be manufactured from any suitable material including a high-strength dielectric with embedded metal gripping teeth. If the prong 16 is a ground prong, a all-metal fastening mechanism can also be used. In this regard, an all-metal fastening mechanism may be used, for example, for other prongs, but may need to be modified to obtain approval from the insurance carrier.

[0021] Figures 1D - 1F and 1H - 1J illustrate the operation of another embodiment of a fastening mechanism for securing a mating electrical connection that may be included in the latching receptacle of the present invention. In each of the illustrations 500 - 505 of Figure 1D, the top row of the figure represents an end view of the fastening mechanism, the bottom row represents a side view of the fastening mechanism, and the electrical contact prongs are in the following states: 1) separated 500, 2) in the process of insertion 501, 3) fully inserted 502, 4) fully inserted under tension 503, 5) fully released 504, 6) during contact removal 505. The exemplary fastening mechanism shown in Figure 1E has two channels 606 that grip both sides of the contact and a cross - link spring 603 that connects the channels. Note that the fastening mechanism can act as both the electrical contact and the fastening mechanism or can be only a fastening mechanism integrated with a separate electrical contact. Figures 1H - 1J show a fastening mechanism that acts as both the electrical contact and the fastening mechanism, and Figure 1F shows a fastening mechanism suitable for use with a separate electrical contact. The details of Figure 1H include gripping channels 902, cross - link spring 901, integral electrical conductor crimp portion 903, release shaft 904, and release shaft contact nub 905. To optimize the functionality, electrical and mechanical properties, ease of manufacture, and cost of the fastening mechanism, it is possible to embody it with one suitable material or several materials (e.g., steel and copper). The above materials are joined together or fixed to function together by any suitable means such as mechanical interlocks, fasteners, adhesives, etc. that are necessary to optimize their function and minimize cost.

[0022] This possible example is a fastening mechanism that is also an electrical contact made of annealed brass or phosphor bronze or other suitable materials. Due to the expansion characteristics of the selected material, the expansion associated with the heating of the retainer contact (receptacle), more specifically, the expansion of the cross-link spring, leads to a progressive tightening of the gripping function from any resistance in the connection to the inserted electrical prong (the prong may have different shapes, for example, it may be a pin). Even if the receptacle is "not latched" to the prong at the initial insertion, for example, no pulling force is applied to tighten the gripping mechanism and only the bearing force applied to the contact surface is due to the action of the cross-link spring, when current is applied, the resistance at the junction of the socket and the prong heats up to some extent. If the resistance value is large enough, for example, if the size of the prong is insufficient or damaged and does not contact the channel uniformly, the temperature of the assembly starts to rise. Further, the electrical connection between the channels, the electrical connection between the channel directly connected to the incoming wire and the opposite channel connected via the cross-link spring, can obtain additional heating at a higher current level by operating in cross-section so that higher heating occurs within the cross-link spring than at other locations. In any case, the heating of the cross-link spring causes expansion. The heat sink occurs mainly through the inserted prong and then through the associated connecting wire, so the temperature of the cross-link spring becomes higher than the average of the prong temperature. Therefore, the expansion of the prong becomes slightly smaller. In some way, due to this difference, the socket receptacle in the rack under the load of the spring can overcome the molecular lock (static friction) between the channel and the prong edge from its original tendency. The channel moves slightly with respect to the prong and a new engagement is established. At this point, the electrical resistance decreases due to the newly established, slightly tighter connection between the channel and the prong, and everything starts to cool. Here, the cross-link spring shortens and a tangential force is applied as in the case of the force applied when a pulling force is applied, and the electrical connection is re-established much more effectively, so the force exerted on the bearing point between the channel and the prong increases dramatically.As a result, the resistance is further reduced, the receptacle is effectively "locked" onto the prong, and excellent electrical connection is ensured even if the mating surface is incomplete. This is a regenerative condition that responds to a poor connection and attempts to resolve the electrical connection problem itself.

[0023] Figure 1E shows the mechanical characteristics of the fastening mechanism. An electrical contact 600 (or other plug structure) is inserted into the fastening mechanism 601. The dimensions of the fastening mechanism are set such that the contact opens the fastening mechanism. In this regard, the front end of the fastening mechanism (the end where the electrical contact first makes contact) may be flanged outwardly to capture the contact and facilitate the expansion of the fastening mechanism. This expansion action is shown in Figure 1D 511. The transverse cross-link spring 603 acts to resist the expanding opening of the fastening mechanism. This ensures that the edge of the electrical contact 600 is deflected reliably to contact the channel at the contact 609 defined by the edge. Electrical contacts and / or fastening mechanisms of different shapes have different contacts and / or surfaces. In the illustrated embodiment, the contacts / surfaces where fastening occurs are mainly or exclusively on the upper and bottom surfaces of the prong, rather than on the side surfaces where electrical connections are normally made. This is only desirable to avoid concerns regarding any potential degradation of the electrical contact surface, but it should be noted that such degradation is unlikely as the fastening force spreads over a significant length. Once the electrical contact prong 600 is inserted into the fastening mechanism 601, any tensile force F (pull) 604 acting to pull the prong 600 out of the fastening mechanism 601 generates a fastening force F (grip) 605 exerted on both sides of the prong 600. The fastening force is generated by the action of the transverse cross-link spring pulled in the channel 606 on each side of the fastening mechanism such that each channel is biased towards each other. The relationship of the multiple forces is generally F (grip) = F (pull) / tangent (angle θ). Therefore, the fastening force F (grip) increases at a faster rate than the force F (pull) attempting to pull the prong 600 out of the fastening mechanism 601. Therefore, the gripping force of the fastening mechanism 601 on the prong 600 becomes more secure as the force attempting to pull out the prong 600 increases. When the gripping mechanism is actuated by the tensile force 604, the gripping mechanism attempts to maintain a tightly engaged state by friction. When releasing the gripping mechanism, the release rod 607 is pushed, generating a force F (release) 608. This force decreases the angle θ, biases each channel away from each other, rapidly decreases the gripping force (grip) 605, and allows the prong 600 to be easily removed from the gripping mechanism 601.Thereby, the release force 608 required for release can be made very small.

[0024] In one possible embodiment associated with a standard NEMA C-13 receptacle, the cross-link spring may be formed from copper or a copper alloy and may have a thickness of about 50 / 1000 to 75 / 1000 inches (about 0.127 to 0.1905 cm). In such a case, the curve 602 is of a generally circular shape and has a radius of curvature of about 75 / 1000 inches (about 0.1905 cm). The curve 602 may extend into the cross-link spring 603 such that a neck constricted by a radius ratio is formed within the cross-link spring 603. Such a curve 602, in addition to appropriately affecting the operating characteristics of the gripping mechanism, avoids acute angles that would be a starting point for cracks or accelerate metal fatigue. The constricted neck also serves to better define, as appropriate, the pivot point of the cross-link spring 603 with respect to the channel. It will be understood that certain operating characteristics, such as the amount of slight movement allowed prior to latching, the total amount and location of the fastening force exerted on the prong, the level of force (if any) at which the fastening mechanism releases, and the durability of the fastening mechanism for frequent cycles, are application specific and can be varied as appropriate (without limitation). A number of other configuration changes and manufacturing techniques are possible to vary the above operating characteristics. For example, the cross-link spring (or a portion thereof) may be twisted, as appropriate, to affect the pivot point and bending characteristics of the spring (e.g., at an angle of 90° with respect to the stamping plane of the material).

[0025] The selection of the material, thickness, geometry, and shape of the device affects the operating characteristics of the gripping mechanism 601. The transverse cross-link spring can have a spring constant that is affected by all of these variables. For example, the radius, position, and shape of the curve 602, as well as the thickness of the neck of the cross-link spring 603, can be varied to achieve various values of the spring constant. This is desirable for optimizing the pre-tension gripping force exerted by the spring on the contacts inserted into the holding mechanism, or the range of contact sizes for which the gripping mechanism can function. Note that the pre-tension gripping force is defined as the gripping force exerted on the contact 600 by the action of the transverse cross-link spring 603 before any tensile force 604 is applied on the contact.

[0026] Referring to FIG. 1G, another possible embodiment is shown. In this embodiment, the operation of the mechanism is similar to the operation described in FIGS. 1D - 1F. When tension is applied to the assembly between the force pull 710 and the reaction pull 711 on the prong 706, the bearing forces at the contacts (703, 707) of the channels (704, 705) and the inserted contact prong 706 (note that the prong may have different shapes, for example, it may be a pin) increase exponentially, and the prong is immediately captured by the channels. As the F pull 710 increases, the tension in the cross - link spring 701 also continues to increase. The cross - link spring, in this embodiment, is crescent - shaped as opposed to the linear springs described in FIGS. 1D - 1F and FIGS. 1H - 1J. Due to the crescent shape, the cross - link spring can now have two types of actions. First, the cross - link spring has a spring action at the connection points with the channels (704, 705), and second, the cross - link spring has a spring action along the major axis of the cross - link spring (701). With the spring action along the major axis applied, the cross - link spring has a predictable ability to extend or stretch. As the F pull 710 continues to increase, the tension in the cross - link spring 701 continues to increase until the point where the cross - link spring begins to elongate along the major axis. At this point, the relationship between the applied F pull 710 and the resulting gripping force at the contacts (703, 707) of the channels (704, 705) and the inserted contact prong 706 stops increasing. Here, due to the increasing force pull 710, overcoming the friction at the contacts 703, 704, the contact pin 706 moves relative to the channels (704, 705), i.e., the gripping mechanism 700. When the force pull 710 is maintained, the contact prong 706 is completely withdrawn from the channels (704, 705). In this state, the assembly 700 can have a predictable point in the tensile relationship where the plug and the receptacle can be separated without damaging any of the major components, the prong, or the gripping mechanism (the gripping mechanism may be, as described above, a gripping mechanism that is also an electrical contact or a gripping mechanism with an integrated electrical contact).

[0027] Referring again to FIG. 1D, the prong 530 of the plug in a state before being inserted into a receptacle having an electrical contact represented by 510 is shown. The prong 530 may be a ground prong or other prong of a standard plug (e.g., an IEC320 plug, NEMA 5-15, or the like) and may be of various sizes and shapes. Further, the receptacle including the electrical contact 510 may be a ground receptacle or other receptacle of a standard outlet (e.g., a NEMA standard cord cap, an IEC320 cord cap, or the like) that operates by inserting a standard plug. This receptacle includes a fastening mechanism 520, and multiple fastening mechanisms can be utilized in one receptacle. The design of the fastening mechanism 520 utilizes simple slide-on and capture techniques.

[0028] According to the present invention, other fastening mechanisms are also possible. For example, a wire mesh formed to accommodate contacts, prongs, or other plug structures (collectively "contacts") and having such dimensions can be utilized to provide a fastening mechanism. The wire mesh has dimensions such that when plugged in, it frictionally engages at least one surface of the contact. Then, when a force is exerted to pull the contact out of the receptacle, the wire mesh stretches and at the same time its cross-section contracts to fasten onto the contact. A Kellem-type release mechanism can be used to relax the weave of the mesh so that the contact can be released. Such a gripping mechanism may be useful, for example, when gripping a cylindrical contact.

[0029] Figure 2C is a cross-sectional view of one possible embodiment of the locking electrical receptacle 820. The receptacle 820 is an IEC type 320 cord cap receptacle that includes one or more gripping mechanisms 828. The receptacle 820 includes an internal contact carrier module 824 that includes the gripping mechanism and electrical contacts 826, 828. Wires 836 and 838 that protrude from the receptacle 820 via a cord 834 are attached to the gripping mechanism and the electrical contact sockets. The carrier module 824 may be attached to a cord strain relief 832 that functions to prevent the cord from separating from the cord cap or from damaging the assembly when force is applied to the cord 834. Figure 2C shows one possible method of actuating the release mechanism. Specifically, the receptacle 820 is formed in a nested fashion with a housing 822 that slides over the carrier module 824 and the strain relief 832. A protrusion 850 on the housing 822 engages a release portion 851 of the mechanism 828 so as to slide the housing 822 and engage the mechanism 828 in a release configuration. The fastening mechanisms described in FIGS. 1D - 1J can combine many of the other release mechanisms described in the incorporated applications.

[0030] Figures 2A - 2B are cross-sectional views of one embodiment of the locking electrical receptacle 20. The receptacle 20 is an IEC type 320 cord cap receptacle that includes a locking mechanism. The receptacle 20 includes an internal contact carrier module 24 that houses contact sockets 26 and 28. Wires 36 and 38 that extend from the receptacle 20 through a cord 34 are attached to the contact sockets. The carrier module 24 may be attached to a cord strain relief 32 that functions to prevent the cord from separating from the cord cap or from damaging the assembly when force is applied to the cord 34. A spring prong retainer 40 is disposed adjacent to a face of the carrier module 24 and extends across a prong receiving portion 44 of the receptacle 20. One end of the spring prong retainer 40 is bent around an end of the internal contact carrier module 24 and secured within the assembly (under the overmolded material 32).

[0031] Alternatively, the spring prong retainer 40 may be fixed to the internal contact carrier module 24 by a screw or other fastener and / or may be embedded within the module 24. A portion of the spring prong retainer 40 that is embedded within the module 24 or alternatively fixed within the cord cap via an overmolded material may be configured (e.g., by drilling holes in the embedded portion and / or serrating the edges or otherwise machining to increase the fixing strength at the embedded portion). The other end of the spring prong retainer 40 is in contact with the nested release grip 22. Similar to the fastening mechanism 12 shown in FIGS. 1A - 1C, the spring prong retainer 40 includes an opening sized to pass the ground prong of the plug into the socket 26. The opening of the spring prong retainer 40 can be sized slightly larger than one prong (e.g., the ground prong) within a standard plug so as to function as a fastening mechanism for the locking receptacle 20. Prongs with different cross - sectional shapes, such as circular prongs, can use the retaining mechanisms described herein and the opening shape and geometry of the spring prong retainer can be suitably modified. Such modifications may be specific to the various shapes of the cross - sections of the various prong types. Such variations function in substantially the same manner as the retaining mechanisms described herein. The spring prong retainer 40 may be shaped and manufactured to prevent contact with other prongs and provide a desired release tension, as detailed below. Further, the retainer 40 may be held within a recessed channel formed within the module 24 to further prevent transitional or lateral displacement of the retainer 40. The operation of the fastening features of the spring prong retainer 40 is detailed below.

[0032] Figure 2A shows the locking receptacle 20 when there is little or no strain in the cord 34. As shown, the portion of the spring prong retainer 40 disposed within the prong receiver 44 of the receptacle 20 is not in a substantially vertical position. Similar to the operation of the fastening mechanism 12 shown in FIGS. 1A - 1C, the opening of the spring prong retainer 40 of this configuration allows the prong of the plug to freely pass through the socket 26 when the prong is inserted. This is because when the prong of the plug acts, the position of the spring prong retainer 40 is not restricted to a substantially vertical position.

[0033] Figure 2B shows the locking receptacle 20 when a force is applied to the cord 34 of the receptacle 20 in the direction opposite to the release handle 30. This is the "release position" of the receptacle 20, and the mating prong is omitted for clarity of the operation. The actions starting from this position are shown in FIGS. 3A and 3B.

[0034] Figure 3A shows the operation of the locking electrical receptacle 20 shown in FIGS. 2A - 2B. When the prong 54 of the plug 50 first enters the receptacle 20 through the opening of the release grip 22, it reaches the spring prong retainer 40 which is not in a vertical orientation at this point. With further insertion, the spring prong retainer 40 deflects to a vertical position under the force applied by the prong 54. Then, the prong 54 passes through the opening of the spring prong retainer 40 and enters the contact socket 26 to establish an electrical connection as appropriate. When the insertion force is released, the spring prong retainer 40 is displaced only partially from the vertical axis when no axial strain is applied to the mating plug 50 and the receptacle 20. In this connection configuration, it should be noted that there is little separation between the frontmost face of the plug 50 and the end of the receptacle of the carrier module 24 adjacent to the plug 50, i.e., the prong extends into the receptacle to approximately the conventional extent.

[0035] FIG. 3B exaggerates the state in which an axial tension is applied to the code 34 of the receptacle 20. A slight backward movement pulls the spring prong retainer 40, thereby increasing the gripping angle of the offset angle of the spring prong retainer 40 and the prong 54, and then the offset angle thereof decreases. The receptacle 20 and the plug 50 are fully locked in this state. When an axial tension is applied between the release handle 30 and the plug 50, the position of the spring prong retainer 40 returns to a substantially vertical position as shown in FIG. 3A, thereby releasing the spring prong retainer 40 from the prong 54. When released, the receptacle 20 is easily separated from the plug 50. The release handle 30 is mounted so as to slide telescopically with respect to the carrier module 24, and by gripping, it becomes possible to release the prong from the top or side surface, so that even in a crowded or limited space environment such as a data center, the locking mechanism can be easily released.

[0036] FIGS. 13A-13C show an alternative spring prong retainer. In the above-described embodiment and the embodiment shown in FIGS. 1A-3B, the gripping points for retention are along the flat or semi-flat surface of the narrow axis of the prong. The opening is rectangular in shape, and the top and bottom of the rectangle have contact positions on the prong. The force applied to those contacts is limited by the relationship between the accuracy of the prong dimensions and the dimensions of the hole. In the embodiment of FIG. 13A, the opening has a rectangular top and a lower half that narrows downward, i.e., is tapered. In this opening design, the prong contacts the prong at three locations 1100, 1101, 1104 (see exaggerated view of FIG. 13A) on each side of the top and bottom of the prong.

[0037] Not only the angular displacement of the spring prong, but also the wedge action at two adjacent contacts 1100, 1101 at each corner of the narrow shaft of the fitting prong 1103 enables a significant increase in gripping force by amplification of the tensile torque. When a tensile force is exerted on the hook tab 1106 of the spring retainer 1110, the initial action described for the spring prong retainer of FIGS. 1A - 1C occurs. After initial contact is made at points 1100, 1101, 1104 when attempting to withdraw the fitting prong 1103, the force applied to the fitting prong 1103 is amplified by the inclined surfaces at the bottoms of the slots 1100, 1001. The tension formed at the initial stage of gripping due to the axial displacement of the spring prong retainer 1110 around the fulcrum 1105 is greatly amplified, applying a compressive force to the contacts between the fitting prong 1103 and the contacts 1100 and 1101 at the bottom of the spring prong retainer. This force is multiplied at a ratio of approximately 10 to 1 for the amplification of the tension of the spring prong retainer 1110 around the fulcrum 1105. By this method, an overall force amplification of approximately 80 times can be achieved. It should be understood that the force can be amplified in various ways by adjusting the angles of the inclined surfaces 1100 and 1101 and the geometry of the metal 1104 forming the fulcrum 1105. It should also be understood that by varying the amplified force, the spring prong retainer can be tuned to optimally engage with various fitting prong materials and finishes.

[0038] This amplification, along with the relatively small contact area between the spring prong retainer, the inclined surfaces 1112 (FIG. 13C) 1110, 1101, and the fitting prong 1103, enables a force of about 30,000 pounds (about 13,608 kg) of psi (30 Kpsi), thereby ensuring secure gripping of the fitting prong 1103. It should also be understood that the use of this alternative method of fitting prong capture also allows for more tolerance of manufacturing variations within the prong.

[0039] Figure 13B shows the method for releasing this alternative spring prong retainer. This is the same as the method for releasing the spring prong retainer described above. When a release force is applied to the end of the spring prong retainer 1111 by the surface of the outer shell 1116, the surface of the spring prong retainer 1110 approaches more perpendicular to the fitting prong 1103. Then, the contact point of the fulcrum 1105 is released, and as described regarding the spring prong retainer 40 of each of the above embodiments, the fitting prong can, of course, be freely pulled out. However, at this point, the lower contacts (shown in Figure 13A) 1100, 1101 capture the fitting prong 1103 between them, and a small deflection of the metal of the fitting prong 1103 is likely to occur at those points. Therefore, the fitting prong 1103 is probably not yet released. When the outer shell 1116 compresses the surface of the spring prong retainer 1110, the formed lamp inside the outer shell 115 starts to push the spring prong retainer downward, and then pushes down the lower contacts 1100 and 1101 (shown in Figure 13A) to disengage them from the fitting prong 1103. And the whole assembly disengages from the fitting prong 1103.

[0040] It should be understood that the shape of the spring prong retainer (shown in Figure 13A) also contributes to the release characteristics. The shoulder of the spring prong retainer 1107 is in a position such that when the force applied to the spring prong retainer is released, the shoulder contacts the inner surface of the outer shell 1116. When the surface of the spring prong retainer continues to rotate almost perpendicular to the fitting prong 1103), the entire surface of the spring prong retainer 1111 is pushed down. This action, combined with the action of the lamp formed in the outer shell 1115), surely applies a downward force to the spring prong retainer to disengage the lower contacts 1100 and 1101 (shown in Figure 13A) from the fitting prong 1103.

[0041] Figures 14A - 15B show an alternative capture mechanism. Figure 14C shows the main mechanical parts of the capture mechanism. The saddle and strain relief part 1401 are placed within an injection - molded receptacle's plastic connector carrier. The capture toggle 1402 is inserted into two holes at the end of the saddle 1401. The opposite end of the saddle and strain relief part 1401 is a crimp ring that fastens around the end of the cord just beyond the start position of the outer jacket or other suitable position, depending on the cord design. For example, if designed to manufacture the strain relief and fastening mechanism from a different material such as a metal with different properties than the carrier or other cord attachment mechanisms, this can be easily done by a cord attachment - separation method, for example, separating the crimp ring from the strain relief piece and then mechanically connecting the two. It should be understood that the strain relief mechanism described herein can be used with the two additional holding mechanisms described above.

[0042] Figure 14A shows the assembly of the saddle 1401 and the cord assemblies 1400, 1407. The cord assembly includes the main cord 1400, the electrical interface surface terminal 1406, and the internal conductor 1407 of the cord that connects to the terminal 1406. The terminal 1406 is at the closed end of the saddle, and the strain relief part 1401 and the two parts are aligned along the major axis by a relief path within an external contact carrier (not shown). If desired or necessary, the terminal 1406 can be mechanically attached or joined to the saddle and strain relief part 1401 to facilitate assembly, increase strength, or for other purposes. The capture toggle 1402 is placed between two holes in the saddle 1401 during manufacturing. The pre - compression spring 1403 is pressed onto the capture toggle 1402 while the release actuating rod 1404 is seated on the opposite side of the toggle.

[0043] Figure 14B is a side view of this assembly. The external contact component carrier 1409 houses each of the components and prevents the injection molded plastic from entering the interior of the carrier during the final overmolding process. Also, Figure 14B is helpful for understanding the basic operation of the capture assembly. When the prong of the inserted plug 1405 is inserted into the receptacle, it enters the plastic carrier 1409, then enters the terminal 1406, and passes under the toggle 1402 until it is fully inserted and reaches the position shown. When tension is applied to the power cord in an attempt to pull out the mated plug, that force is transmitted through the cord to the prong 1405, i.e., through the electrical terminal 1406, by the pressure of the saddle 1401 at the bottom of the prong 1405 to the toggle 1402 that is pressed against the top of the prong 1405 (via the strain relief component and the saddle 1401). The toggle is preloaded by the spring 1403 against the top of the inserted prong of the plug connector 1405. As will be understood, the shape of the toggle that is depressed onto the prong can be a shape that controls the application of the fastening force to the prong. For example, the toggle can have grooves that control the force on the prong so as not to twist the prong. This can also be done with respect to the saddle and the base of the mating terminal, as desired or necessary. A suitable shaped insert between the saddle / strain relief 1401 and the terminal of a shape that mates with the insert can achieve this function. When the force applied to the cord 1407 creates a small movement along the long axis of the assembly, the mated prong also begins to try to retract, causing the toggle to begin to rotate so as to push down on the top of the inserted mated prong of the plug connector 1405, further screwing the mated prong deeper into the terminal 1406, and thus the terminal is screwed into the saddle 1401. The friction between the terminal 1406, the mated prong of the plug connector 1405, and the saddle 1401 rapidly increases until the movement stops. The depression of the mated prong 1405 onto the electrical terminal 1406 further improves the quality of the electrical connection. The prong of the plug connector 1405 is functionally locked to the saddle and strain relief component 1401, i.e., the cord 1407.Figure 1SA is an end view of the relationship of all components involved in the locking of components. The prong of the inserted plug 1405 is disposed within the terminal 1406, and the terminal 1406 is sandwiched between the prong 1405 and the saddle 1401.

[0044] Figure 14B shows a mechanism for releasing the connection between the toggle 1402 and the prong of the plug connector 1405. The opposite end of the release rod 1404 extends through the entire receptacle and can protrude from the back of the connector or assembly accessible to the user. The release rod 1404 can also be actuated by other means as shown in Figure 14D. The nested portion of the cord cap 1412 including the mechanical linkage 1408 can press the release rod 1404 against the toggle 1402 when the nested portion 1412 is pulled back by the user and the plug assembly separates from the receptacle assembly (line 1413 indicates the full insertion depth of the front of the plug). In this regard, the range of movement of the nested portion 1412 is controlled by the elements 1410 and 1411. The pressure at the opposite end of the rod 1404 is transmitted to the back side of the toggle 1402, slightly compressing the spring 1403. This action rotates the bottom of the toggle 1402 upward from the prong of the inserted plug connector 1405, reducing or eliminating the contact force between the toggle 1402 and the mating prong 1405 and allowing the mating prong to move in the retracting direction. Thus, the receptacle can be separated from the plug. The system can be designed such that when the user releases the nested portion 1412, the spring 1403 functions to return the nested portion 1412 to the locked configuration.

[0045] FIG. 15A is an end view of the main parts of the prong of the plug connector 1405 inserted and the locking parts of the receptacle in cross section. As described above, the toggle 1402 has been rotated to a position where it is pressed against the prong of the inserted plug connector 1405. The prong 1405 is pressed onto the terminal 1406, and then the terminal 1406 is pressed against the bottom of the saddle 1401. It should be understood that as the axial tension on the cord increases, the downward force exerted by the toggle 1402 also increases. With a suitable angle selected and suitable dimensions of the parts, the force amplification can be about 10 to 1. In other words, a 10-pound (about 4.536 kg) strain force on the cord results in a force of about 100 pounds (about 45.36 kg) exerted on the prong.

[0046] It should be understood that the bottom of the saddle and the strain relief component 1401 can be manufactured in a crown shape as shown. This crown shape enables the bottom of the saddle and the strain relief component 1401 to act like a leaf spring when pushed down by the prong. The spring at the bottom of the saddle, in combination with the toggle pressed onto the prong and the spring that resists the force transmitted by the prong and the terminal, can apply a very controllable and predictable force to the prong 1405. The maximum fastening force of the toggle on the prong is controlled by the resistance and movement of the spring. This feature can be used as follows. When strain is applied to the cord to release the connection, the toggle increases the force on the prong, and the spring at the bottom of the saddle and the strain relief component 1401 (or, as described in the alternative embodiment below, the lower spring) begins to be compressed. This action increases the distance between the saddle, the base of the strain relief component 1401, and the tip of the toggle 1402, allowing the toggle 1402 to rotate. As the tension on the cord continues to increase, the distance between the saddle, the strain relief component 1401, and the toggle 1402 reaches a point where it is large enough for the toggle 1402 to rotate and become perpendicular to the prong. At this point, the tab on the toggle 1402 cannot apply additional pressure to the prong 1405, and the prong 1405 moves under the tension applied to the cord 1407 that separates the plug and the receptacle. It should also be understood that the generation of the tension at which release occurs can be reliably predicted and that this tension can be varied by the strength and movement of the spring. This design tolerates some manufacturing variations in both the inserted connector prong and the mechanical parts of the locking mechanism. It should also be understood that the tension at which the mating connection is released under strain can be reliably preset.

[0047] In this design, Figure 15A is an end view of the saddle and the strain relief component 1401 with the wire crimping end away from the observer. The crown spring shown in the front view 1521 has the function of controlling the release point of the connected assembly under strain conditions. Figure 15B shows a crown spring with holes 1541 used to change the strength and movement of the crown spring. However, other means such as the thickness or type or temper of the material used can be selected to control the spring function. Considering that the position of the holes 1541 is located directly below the saddle part of the saddle and the strain relief component 1401, it should be understood that the strength of the crown spring action has been changed. Without holes, the resistance to compression of the spring crown is maximized, and if the holes are large, the strength of the spring is significantly reduced. By reducing the strength of the spring, the release point of the fitted connector component subsequently decreases. Therefore, the holding capacity of the locking receptacle can be reliably set to a specific release tension. It will be understood that this design further accelerates the ease of manufacture and cost reduction. The die for stamping the strain relief can have a changeable insert to change the size of the holes 1541 in the leaf spring due to the change in the value of the release tension. Other means of setting the strength and movement of the spring, such as using the thickness and shape of the material or other means, can be used. Also, other means can be used, such as using a spring of uniform or variable strength of a suitable type (hairpin, leaf, elastomer, etc.) that can be pressed at the bottom of the saddle 1401 directly below the toggle 1402. In this case, since the saddle does not need to incorporate a spring, the spring is separate from the saddle. This allows for the addition of a spring force adjustment mechanism in the factory, such as a screw, and / or by the end user. Using this mechanism, as described above, the strength and movement of the spring pressed on the saddle, that is, the release tension of the gripping mechanism, can be controlled. The adjustment range can be controlled to meet any required requirements. It will be understood that being able to reliably set the release tension is extremely useful. This allows for the manufacture of a locking code that does not require another release mechanism. The release is performed by the locking mechanism at the desired tension level.

[0048] Figure 14C is an orthogonal view of the saddle and the strain relief component 1401. The gripping ring 1408 at the end of the saddle and the strain relief component 1401 is shown as an essential part of the saddle and the strain relief component 1401. This ring may be a separate compression ring inserted at the end of the saddle and the strain relief component 1401, and the ends of the saddle and the strain relief component 1402 can be appropriately shaped so as to be sandwiched between the compression ring and the end of the cord attached to the compression ring. Due to potential difficulties in the composite heat treatment in the longitudinal direction of the saddle and the strain relief component 1401, an alternative method of attaching the saddle and the strain relief component 1401 to the cord is discussed. The saddle end of the saddle and the strain relief component 1401 are generally heat-treated, while on the other hand, the crimp ring ends must maintain malleability. It is possible to manufacture the saddle and the strain relief component 1401 with these characteristics, but it is more economical to manufacture a saddle and a strain relief component 1401 of an alternative shape and assemble it to the cord with another compression ring. It will be understood that the above holding mechanism cooperates well with prongs of shapes other than the illustrated flat blade type prong. For example, the holding mechanism cooperates well with the circular prongs used in NEMA 5-15 and other plugs. Only minor modifications such as shaping the end of this toggle so that it has a suitable mating shape and thickness for contacting the circular prong and optimizing the application of force to the prong material are required. This is desirable because many circular prongs are formed of materials that are not solid tubes, and excessive force may be applied to their too small area, causing deformation or crushing. Similarly, the bottom of the saddle and / or the electrical contact can be shaped to spread the fastening force more evenly over the circular prong, and / or an insert between the saddle and the terminal can be used for this purpose. Although the embodiments of FIGS. 14A-15B have been illustrated and described with respect to conventional cord caps, it will be understood that a similar structure can be incorporated into other types of receptacle devices including the structure described in PCT application PCT / US 2008 / 57140 entitled "AUTOMATIC TRANSFER SWITCH MODULE", which is incorporated herein by reference.

[0049] By using a fastening mechanism (e.g., spring prong retainer 40) that captures only the grounding prong of the plug 50, the safety of the receptacle 20 can be significantly improved. In this regard, the influence of the application of various potentials to the fastening mechanism of the assembly is avoided, the manufacture of the receptacle is simplified, and its overall safety is improved.

[0050] Figures 4A - 4C show a locking device 60 that provides a locking feature for a standard cord cap receptacle. As shown in Figure 4A, the locking device 60 includes a top retaining member 62 and a bottom retaining member 64 that position the locking device 60 on the standard receptacle. The locking device 60 also includes a portion 66 that couples the retaining members 62, 64 to each other to provide a secure attachment to the receptacle. The locking device 60 also includes a fastening mechanism 68 coupled to a pivot 70. The operation of the fastening mechanism 68 is similar to the operation of the fastening mechanism 12 shown in Figures 1A - 1C. It should be understood that other fastening mechanisms described above can also be used. As described above, some of these eliminate the need for separate release and, optionally, can provide release tension characteristics adjustable by the factory and / or the user. The locking device 60 may also include a release mechanism 72 that operates to allow the user to remove the fastening mechanism 68 when it is desired to remove the receptacle from the plug.

[0051] Figure 4B shows the locking device 60 positioned on the standard receptacle 80. To facilitate the attachment of the locking device 60, the retaining members 62, 64 may be formed of an elastic material so that the user can bend them outward and position the device 60 on the receptacle 80. For example, the retaining members 62, 64 may be made of plastic. Further, as shown, once attached to the receptacle 80, the retaining members 62, 64 are shaped such that the user cannot easily remove the device 60 without deforming the retaining members 62, 64. That is, the retaining members 62, 64 may be formed to conform to the standard receptacle so that normal movement does not disengage the device 60 from the plug 80.

[0052] Figure 4C shows the operation of the locking device 60 when the receptacle 80 is mated with the standard plug 84. The ground prong 86 of the plug 84 passes through the opening of the fastening mechanism 68 and enters into the receptacle 80. When a withdrawal force is applied to either the cord of the standard plug 84 or the cord of the receptacle 80 to terminate the mating connection, the fastening mechanism 68 rotates and grips the ground to the prong of the standard plug 84, thereby maintaining the electrical connection. If the user wishes to terminate the connection, the user engages the release element 72 and the fastening mechanism 68 is maintained in a position substantially perpendicular to the ground prong 86, thereby allowing the prong 86 of the standard plug 84 to be withdrawn from the receptacle 80. Although a particular embodiment of the locking device 60 is shown, it should be understood that there may be various ways to implement a locking device that can be retrofitted to a standard receptacle using the techniques of the present invention.

[0053] FIG. 5 shows an embodiment of a standard two-port locking receptacle 100. In this embodiment, the fastening mechanisms 112 and 114 are integrated with the receptacle 100. The top of the receptacle 100 includes sockets 102 and 104 that receive the prongs 128 and 130 of the standard plug 126, respectively. Similarly, the bottom of the receptacle 100 includes sockets 106 and 108 that receive a second standard plug. The fastening mechanisms 112 and 114 are rotatable about pivots 116 and 118, respectively. Further, the receptacle 100 also includes release elements 120 and 122 that operate so that the user can terminate the connection when desired. The operation of the fastening mechanisms 112 and 114 is the same as in the previously described embodiments. That is, in response to a force to pull the plug 126 out of the receptacle 100, the fastening mechanism 112 rotates in the direction of the plug 126, engages the ground prong 130, and prevents the mating connection from being terminated. If the user attempts to intentionally remove the plug 126 from the receptacle 100, the release mechanism 120 can be actuated to pull out the plug 126. It should be understood that the other fastening mechanisms described above can be used for a standard two-port locking receptacle. As described above, some of these eliminate the need to provide a separate release mechanism and, optionally, can provide a release tension feature that can be adjusted by the factory and / or the user.

[0054] FIGS. 6A-6B are side views of a receptacle 150 including a cam locking portion 152 that locks the prong 162 of the plug 160 to maintain a mating connection between the receptacle 150 and the plug 160. FIG. 6A shows the receptacle before the plug 160 is inserted, and the cam locking portion 152 may be freely suspended from the pivot 153. In this regard, the end of the cam locking portion 152 is disposed within an opening of the receptacle 150 configured to receive the prong 162 of the plug 160.

[0055] FIG. 6B shows the mating connection between the plug 160 and the receptacle 150. As shown, in the mating position, the prong 162 deflects the cam latch 152 around the pivot 153, tilting the cam latch 152 away from the plug 160 and abutting against the prong 162. Thus, when an axial strain is exerted on the plug 160 or the receptacle 150, the friction between the cam latch 152 and the prong 162 functions to bias the cam latch 152 downward toward the prong 162 and hold the plug 160 in its mating position. If the user attempts to intentionally remove the plug 160 from the receptacle 150, the user may press the actuating mechanism 154, which operates to disengage and rotate the cam latch 152 away from the prong 162, whereby the user can freely withdraw the plug 160 from the receptacle 150. It should be understood that the cam latch 152 and the actuating mechanism may be manufactured from any suitable material. In one embodiment, the cam latch 152 is manufactured from metal and the actuating mechanism 154 is manufactured from an insulating material such as plastic.

[0056] FIGS. 7A-7D show a device 170 that can be used to ensure a mating connection between a plug and a receptacle. As shown, the device 170 includes a top surface 173, a bottom surface 175, and a front surface 171. The three surfaces 171, 173, 175 generally have a size and orientation that conforms to the outer periphery of a standard receptacle 178 at the end of a cord (i.e., a cord cap). The top surface 173 and the bottom surface 175 each include hooks 174 and 176, respectively, that are used to secure the device 170 to the receptacle 178 (shown in FIG. 7D). The operation of the hooks 174 and 176 will be described herein with reference to FIG. 7D, which is a side view of the device 170 when installed on the outer periphery of the receptacle 178. The hooks 174, 176 may be bent inwardly toward each other and wrapped around an end 179 of the receptacle 178 to secure the device 170 to the receptacle 178. The other end of the receptacle 178 (i.e., the end having the opening 181 for receiving the prong of the plug) may abut against the surface 171 of the device 170.

[0057] The device further includes tabs 172 that are used to fix the prongs in the plug-in position. The operation of the tabs 172 is shown for the device 170 when placed on the prongs 182, 184 of the plug 180. It is best shown in FIG. 7B. The plug 180 may be any plug including prongs that includes a normal plug arranged on the back of an electrical data processing device. As shown in the figure, when the device 170 is installed by sliding axially towards the plug 180, the tabs 172 deflect slightly towards the ends of the prongs 182, 184. In this regard, when an axial force is applied to pull the device 170 out of the plug 180, the tabs 172 apply a downward force to the prongs 182, 184. Since the openings of the device 170 are slightly larger than the prongs 182, 184, this downward force holds the prongs 182, 184 in their position relative to the device 170. Further, the device 170 may be fixed to a standard receptacle as shown in FIG. 7C, so that the tabs 172 prevent the connection between the receptacle 178 and the plug 180 from being terminated. The device 170 can be manufactured from any suitable non-conductive material. In one embodiment, the device 170 is manufactured from semi-rigid plastic. In this regard, the device 170 may be a disposable device where the user must forcibly pull the device 170 installed from the prongs 182, 184 of the plug 180, resulting in the plastic deforming and / or the tabs 172 being damaged. If the user wishes to remove the plug from the receptacle 178, it should be understood that the user only needs to peel the hooks 174, 176 from the end 179, release the mating connection, and leave the device 170 installed on the plug.

[0058] FIG. 8A shows a plug 190 including a locking mechanism before insertion into a receptacle 210. As shown in a simplified manner, the receptacle 210 includes recesses 212 and 214, and most standard receptacles include recesses or shoulders inside an opening configured to receive the prongs of the plug. This recess may exist due to manufacturing requirements such as the molding process used to manufacture the receptacle. Further, when there is a need to include various components (e.g., electrical wiring, screws, etc.) within the receptacle, small recesses may be required. If the recess does not originally exist, it can be designed into the receptacle.

[0059] The plug 190 aids in manufacturing the locking mechanism using the recess 214. As shown, the hollow prong 194 (e.g., a ground prong) of the plug 190 includes a toggle 196 pivotally attached to an inner portion 193 of the prong 194. A spring 198, a piston 199, and an actuating mechanism 200 function together to enable the toggle 196 to be oriented in a locked configuration (shown in FIG. 8B) and an unlocked configuration (shown in FIG. 8C). In one embodiment, the spring 198 acts to bias the tab 198 to an unlocked position that may be substantially aligned horizontally within the prong 194. Further, the actuating mechanism 200 may be operable to rotate the toggle 196 to an unlocked position (shown in FIG. 8C) where it retracts within the prong 194 at an angle substantially parallel to the body of the plug 190. The user may control the actuating mechanism 200 via a control switch 202 that may be disposed on the front face of the plug 190.

[0060] FIG. 8B shows the plug 190 when in the mating position with the receptacle 210. As shown, the tab 196 is positioned in the locking position by the pressure applied by the spring 198 and the piston 199. In this configuration, the tab 196 resists any axial force that attempts to pull the plug 190 out of the receptacle 210. This is because the recess 214 acts as a stop for the tab 196. Thus, the plug 190 can be firmly fastened to the receptacle 210. FIG. 8C shows that when the user attempts to remove the plug 190 from the receptacle 210, the control switch 202 on the front surface of the plug 190 may be depressed, whereby the actuating mechanism 200 and the spring 198 rotate the tab 196 to the release position.

[0061] FIGS. 9A - 9B show another embodiment of a plug 220 including a different spring tip locking mechanism before being inserted into the receptacle 240. Similar to the plug 190 shown in FIGS. 8A - 8B, the plug 220 may be configured to cooperate with a standard receptacle 240 including recesses 242 and 244. The plug 220 may include a hairpin spring 226 disposed inside a hollow prong 224 (e.g., a ground prong). In the release position, the end 227 of the spring 226 is disposed inside the prong 224 adjacent to the opening of the prong 224. The plug 220 may further include an actuating mechanism 228 coupled to a control switch 230 on the front surface of the plug 220 for biasing the spring 226 to the locking position, and the end 227 of the spring 226 projects outside the opening of the prong 224 (see FIG. 9B).

[0062] FIG. 9B shows the plug 220 when attached to the standard plug 240. As shown, the actuating mechanism 228 moves axially into the standard receptacle 240 towards the spring 226, and the end 227 separates from and spreads outside the opening in the prong 224. The opening of the prong 224 is aligned with the recesses 242 and 244 such that the end of the spring 226 is disposed within the recesses 242 and 244 when in the locked position. Thus, as understood, when an axial force is applied to pull the plug 220 out of the receptacle 240, the end 227 of the spring 226 is pressed against the recesses 242 and 244, thereby making it impossible to remove the prong 224 from the receptacle 240. If the user attempts to remove the plug 220 from the receptacle 240, the actuating mechanism can be axially withdrawn from the spring 226 by operating the control switch 230. Then, the end 227 of the spring 226 retracts into the prong 224 and the user can easily remove the plug 220 from the receptacle 240.

[0063] FIGS. 10A and 10B show a locking electrical receptacle 1000 according to another embodiment of the present invention. The receptacle 1000 is generally configured in a similar manner to the structure of FIGS. 2A - 2B. In this regard, the illustrated receptacle 1000 includes an end cap formed from an external release grip 1002 slidably mounted on an internal contact carrier module 1004. The internal contact carrier module carries a plurality of sockets or receptacles generally identified by reference numeral 1006. The illustrated receptacle 1000 further includes a cord strain relief 1010 and a spring prong retainer 1008.

[0064] Figure 10B is a perspective view of the spring prong retainer 1008. As shown, the retainer 1008 includes a plurality of gripping tabs 1012 that grip the contact carrier module 1004. In this regard, the gripping tabs 1012 may be embedded within the molded contact carrier module 1004 so as to more firmly secure the retainer 1008 to the carrier module 1004. Alternatively, the tabs 1012 may be press-fitted into the carrier module 1004 or may be attached to the module 1004 by an adhesive or the like. In this way, the tabs 1012 fix the spring prong retainer 1008 to the contact carrier module 1004 and assist in maintaining the relative positioning between the spring prong retainer 1008 and the contact carrier module 1004. From the above description, it will be understood that this relative positioning is important in ensuring the proper functioning of the locking mechanism and in controlling the release tension. The locking electrical receptacle 1000 functions differently as described above in connection with FIGS. 2A-3B.

[0065] FIGS. 11A and 11B show another embodiment of the locking electrical receptacle 1100. Again, the receptacle 1100 is generally similar in structure to that described above in connection with FIGS. 2A and 2B and includes an external release grip 1102 and an internal contact carrier module 1104 that includes a plurality of receptacles 1106 and a cord strain relief structure 1110. The illustrated embodiment further includes a spring prong retainer 1108 incorporating a strain relief structure. In the locking mechanism of the present invention, it will be understood that when a large tensile force is applied to the plug relative to the locking mechanism, a large strain force is applied to the end cap. Such forces can damage the end cap and pose potential risks associated with exposed wires if such forces are not considered in the design of the end cap.

[0066] Therefore, in the illustrated embodiment, the spring prong retainer 1108 includes a strain relief structure that directly transfers such strain forces to the power cord. Specifically, the illustrated spring prong retainer 1108 is elongated and includes a cord gripping structure 1114 at its rear end. The cord attachment gripping structure 1114 is either attached to the power cord or, alternatively, is connected to a crimp band 1112 that can be fixed to the power cord via crimping and / or welding, or the like, or the like. In this way, the strain forces associated with the operation of the spring prong retainer 1108 that grips the prong of the plug are directly transferred to the power cord.

[0067] Various characteristics of the latching electrical receptacle of the present invention can be modified to control the release stress of the latching electrical receptacle. In this regard, the release tension of the latching mechanism can be controlled using the geometric shape, thickness, material quality, and detailed shape of the gripping component. As an example, increasing the thickness and / or rigidity of the material of the gripping component increases the release tension of the latching mechanism.

[0068] The geometric shape of these spring prong retainers can also be varied to improve safety and performance. FIG. 12 shows an example in this regard. For example, the illustrated spring prong retainer 1200, which can be incorporated into the embodiments of FIGS. 2A-2B, 10A-10B, or 11A-11B, includes a constricted neck portion 1202 between the bend point 1204 of the spring prong retainer and the prong engagement opening. This neck portion can provide a plurality of desirable functions. For example, the neck portion 1202 may be positioned to provide a greater gap between the spring prong retainer 1200 and the other prongs of the plug. Further, the narrow portion 1202 may be designed to provide a defined break point in the event of a structural defect. That is, in the event of breakage due to stress or material fatigue, the neck portion 1202 provides a safe failure point that does not result in electrical hazards or malfunctions of the electrical connection.

[0069] It should be understood that all of the retention mechanisms described herein that can vary their release tension by varying design parameters are capable of having a release tension that is compatible with the receptacle design or standard or specification, to ensure that the cord cap or receptacle does not break and cause a potentially dangerous exposure of the wire. Thus, for example, based on analysis of end cap or receptacle structure, regulatory requirements, or design specifications, it may be desirable to provide a peel strength of 40 pounds (about 18.144 kg). The latching mechanism may be implemented, for example, by a spring prong retainer as shown in FIGS. 2A-2B, FIGS. 10A-10B, and FIGS. 11A-11B. Next, the material and thickness of the spring prong retainer and the specific geometry of the spring prong retainer can be selected to provide a release stress of 40 pounds (about 18.144 kg). The latching mechanism with a release stress of 40 pounds (about 18.144 kg) can also be implemented, for example, by the toggle and saddle mechanisms shown in FIGS. 14A-14D and 15A-15B. The values of these various design parameters can be determined theoretically or empirically to provide the desired release point.

[0070] FIGS. 16A-16B show an embodiment of a retention mechanism for securing a mating electrical connection included in a secure connection of the present invention. In FIGS. 16A-16B, the top represents a top view of the mating plug, receptacle 100, and retention mechanism 1020, and the bottom represents a perspective view. The electrical prongs 1030 may be plural (e.g., IEC320 plugs, NEMA 5-15, or the like) and of various sizes and shapes. Further, the plug and receptacle 1000 may be plugs and receptacles of a standard outlet (e.g., an IEC320 cord cap, or the like). The plug further includes a retention mechanism 1020. The design of the secure retention mechanism 1020 is such that a simple slide-in is performed, after which a secure connection technique is utilized. Referring now to FIG. 17A, a state is shown before the connection is fixed although the plug and receptacle are mated. This embodiment is one that the user must manually select to fix, as described above.

[0071] Figures 17A - 17B show the plug 2010 when inserted into the receptacle 2020. As shown, the plug and receptacle are in a mated but not yet fixed position. The manually - operated nut 2030 is twisted by the user to secure and release the connection. The nut can have the optional ratchet mechanism described above, but this is not shown. The outer shell 2040 is press - fitted into the elastomer 2050 by the action of the nut 2030 when the nut is tightened. The outer shell compresses the elastomer when tightened and is pushed back by the expansion of the elastomer when the nut is loosened. Optionally, a suitable mechanism (such as a mushroom - shaped end pin passing through a semi - circular slot in the nut, etc.) can be used to securely attach the shell to the nut to ensure that it reliably retracts when the nut is loosened. This is an optional configuration not shown. The enlarged portions of Figures 2100 and 2200 show two different possible embodiments of this part of the mechanism. Detailed Figure 2030 shows the shape of the region of the mechanism where the elastomer is compressed to be approximately rectangular. Detailed Figure 2040 shows the shape of the region of the mechanism where the elastomer is compressed using an inclined ramp for compressing the elastomer. It will be understood that the materials and detailed geometric shapes of both 2100 and 2200 can be changed to optimize their function as described above.

[0072] Figures 18A - 18B show the plug 3010 when inserted into the receptacle 3020. As shown, the plug and receptacle are in a mated and fixed position. The manual - operation nut 3030 is twisted by the user to secure the connection. The outer shell 304 is press - fitted into the elastomer 3050 by the action of the nut 3030 tightened downward. The outer shell compresses the elastomer, and the elastomer is firmly pressed against the wall 3060 of the contacting receptacle 3020. This is shown in more detail in the enlarged portions of FIGS. 3100 and 3200. The outer shell 3040 is pushed back by the expansion of the elastomer when the nut 3030 is loosened. Optionally, the outer shell 3040 can be securely attached to the nut using a suitable mechanism (e.g., a mushroom - type end pin passing through a semi - circular slot in the nut, etc.) to ensure that it will surely retreat when the nut is loosened. This is an optional configuration not shown. Detail FIG. 3100 shows the shape of the region of the mechanism where the elastomer is compressed in a substantially rectangular shape. Detail FIG. 3200 shows the shape of the region of the mechanism where the elastomer is compressed in a form that utilizes an inclined ramp to compress the elastomer. It will be understood that the materials and detailed geometric shapes of both 3100 and 3200 can be changed to optimize their functions as described above.

[0073] Figure 18C is an enlarged view of another possible embodiment of the present invention. The tab 3300 disposed on the outer shell 3310 is driven axially forward by the action of the nut 3340 when the nut 3340 is tightened. The tab 3300 pushes forward over the lamp 3320 of the portion of the assembly inserted into the mating receptacle. The example shown in Figure 18C is male type C13, but as shown in Figure 18D, the same concept and mechanism also apply to female type C13. The only substantial difference in configuration between the male type C13 shown in Figure 18C and the female type C13 shown in Figure 18D is the way the electrical contacts are arranged. In the female type, the contact carrier 3480 (usually a part approved by the safety authority) is molded into the cord cap. The outer shell 3470 can be overmolded onto the contact carrier, but can be manufactured as another part snap-fitted onto the contact carrier having the structure shown in Figure 3D. Other manufacturing methods are also possible. By changing the geometric shape, material, position, number, and mechanical action of the tabs 3300, 3400 and the lamps 3320, 3420, it can be ensured that the area of the maximum force exerted by the lamps contacting the mating receptacle is appropriately arranged. This can be important to maximize the holding force and ensure that the receptacle can withstand the force applied by the tabs 3300, 3400 without damage. The tabs 3300, 3400 can be one or more and can be arranged to maximize the holding force of the mechanism. The tabs may or may not be arranged opposite each other, but with this configuration, it can be ensured that the force applied to the receptacle maximizes the holding force. As shown, the tabs 3300, 3400 attempt to apply a force to the receptacle, and the walls of the receptacle are stressed with a desirable tension depending on the material of the receptacle. The surfaces of the tabs 3350, 3450 contacting the walls of the mating receptacle can be made from one or more materials having suitable mechanical and friction properties. An example of a possible embodiment is to form the outer shells 3310, 3410 from a harder, mechanically stronger material and then coat the tab surfaces 3350, 3450 with a high coefficient of friction elastomer. This can be done economically, for example, via a co-injection (“sandwich”) molding process.In response to the withdrawal forces 3385, 3485 applied to the cords 3380, 3480, the retaining mechanisms shown in FIGS. 18C and 18D are understood to transmit a force to the ends of the cord caps 3390, 3490 via the cords 3380, 3480. As a result, the elastomeric injection molding material commonly used to manufacture electrical cords is compressed, and as a result, the ends of the cord caps move slightly closer to the outer shells 3310, 3410, moving the tabs 3300, 3400 further upward over the lamps 3340, 3440. Thereby, the contact areas of the tabs 3350, 3450 contact the walls of the receptacle more tightly, increasing the frictional interlock between the plug and the receptacle. Thus, the forces 3385, 3485 themselves that attempt to withdraw the plug from the receptacle engage the retaining mechanism and frictionally engage the walls of the receptacle, preventing the plug from being withdrawn and serving to maintain the electrical connection of the mating assembly. Also, the geometry, material, and mechanical action of the tabs 3300, 3400 and the lamps 3320, 3420 can be changed to provide a programmable release mechanism by limiting the force applied to the walls of the mating receptacle, i.e., the frictional interlock between the contact surfaces of the tabs 3350, 3450 and the walls of the mating receptacle. Limiting the frictional interlock is limiting the maximum force that the fixed connection can withstand. When that level of force is applied, the plug and receptacle separate. As described above, the level of the maximum force can be specified to satisfy the applicable standards and / or the range of values of the holding force adjustable by the user via the action of the nuts 3340, 3440, as described above, to prevent damage to the plug and receptacle.

[0074] Figures 18E - 18K illustrate another possible embodiment of the present invention and represent an alternative latching method for an IEC - 13 receptacle that utilizes a novel retention mechanism. This embodiment primarily comprises three main components associated with the gripping of this connector, for example, IEC - 14. Note that this mechanism is not limited to IEC series connectors and can be configured for various connector mating applications, including those that utilize a shield barrier outer shell on the receptacle. In the case of such a shield barrier receptacle, gripping can be achieved by using the shield barrier as a friction element against the wall of the mating receptacle and does not depend on the electrical conduction method utilized within the connector itself.

[0075] Referring to Figure 18E, the inner core of connector 1 comprises a molded assembly that is very similar to a conventional IEC - 13 (or other standard) cord cap receptacle (female end) with respect to dimensions and electrical interface components. This molded assembly differs in that it has two rectangular holes 3551 that penetrate through an outer shell where a dielectric overmold penetrates into the interior of the shell. Further, a latching tab shuttle 2 made of a suitable material provides a latching tab 3553 and structure that transmits the force received from the latching nut 3 into the interior of the shell region of the inner core 1 through the holes 3551.

[0076] Locking to the mating connector is achieved by the tab 3553 being driven by the nut, thereby wedging between the upper and lower outer surfaces of the mating connector and the upper and lower inner surfaces of the inner core shell 1. When attempting to release the connection, the nut 3 is loosened and the tab 3353 reliably retracts. This movement is achieved by an engagement collar 3555 on the nut 3 that rotates within a slot 3554 of the locking tab shuttle 2 that pulls out the tab 3553. Other methods can also be used to attach the nut 3 to the locking tab shuttle 2, and an example is shown in FIG. 25. This locking method provides good gripping using a programmable release force. By carefully selecting the shapes, geometries, and materials used, the maximum holding force can be limited to a desirable range of values. Additionally, an overmold (e.g., an outer surface directly formed on the locking tab 3553) can optionally be coated, finished, or otherwise designed to increase the frictional force between the outer shell 3551 and the mating wall of the receptacle. The ability to control the release force to a selected range of values is desirable to prevent the possibility of excessive tensile forces damaging the plug and cord cap in the mating connection. It is also useful for meeting the approvals of certain agencies. Further, this method is simple to manufacture and has a minimum number of moving parts.

[0077] Referring to FIG. 18F, cross-sections of two main parts are shown, including a top view of a conventional cord cap plug (male connector) 1 and a top view of a mating cord cap connector (female receptacle) 2. The plug 1 is described as part of an explanation of a method for securing an electrical connection, but the important point is that the plug may be a standard unmodified plug. Only the mating receptacle 2 is different from the conventional standard and is unique. This means that the present invention is applicable to an environment where a large number of standard plugs are installed, such as for use in a plug strip in a data center. The IEC C14 plug strip is extremely popular in the distribution of 200V+ electrical services worldwide. The conventional plug includes three main parts shown in FIG. 18F, namely, an overmolded dielectric 3561, a connection cord including the necessary conductors 3562, and electrical mating connector pins 3563. This example is a conventional IEC-14 type plug, but other types that utilize an external pin dielectric barrier 3569 may also be used. This external pin barrier 3569 is generally concentric around the pin 3563 and, when installed, becomes the object of gripping by the mating receptacle.

[0078] The focus of the present application is the receptacle assembly 2 that includes a core with an outer shell 3564 and a shuttle 3565 that includes a locking tab 3567 as part of it. Since this is a top view, the outline of the tab can be seen. There are two tabs, one at the top of the connector and one at the bottom, and each tab is an integral part of the molded shuttle part in the figure. The illustrated tabs are a preferred embodiment, but the described method is effective even if the number, shape, and position of the tabs change. The core 3564 also has some type of thread 3570 cut that engages with a locking nut 3566. This threaded nut acts against the threads of the core 3564, applies a force to the movable shuttle 3565, and transmits the axial force to the tab 3567.

[0079] Figure 18G is a cross-sectional side view of the above-described component of Figure 18F. This figure more clearly shows the relationship of the upper and lower locking tabs 3567 and shows that both tabs are part of the shuttle 3565. In Figure 18G, the receptacle assembly 2 is shown with the locking nut 3570 rotated to the locking position, the shuttle 3565 pushed forward, and the locking tab 3567 fully inserted into the shell and core 3564. Figure 18H is an enlarged cross-sectional side view of the receptacle assembly 2. This figure more clearly shows that the tab 3567 passes through the hole 3551 in the core and shell 3564. The hole 3551 has a tapered inlet 3571 within the cavity of the core and shell 3564, and this inlet 3571 pushes the tab 3567 towards the centerline as the shuttle 3565 moves from right to left in this example. This example has the shuttle 3565, i.e., the tab 3567 in the release position in the figure. The tab 3567 is significantly retracted from the cavity, leaving within the cavity an area available for inserting the shell of the mating plug. For the purpose of explaining the focus of this application, no further mention will be made of parts not applicable to both the plug and the receptacle. Those parts include electrical components such as pins and sockets and the cord.

[0080] Figure 18I shows the receptacle assembly of Figure 18F, where the locking nut 206 rotates to apply an axial force to the shuttle 3565, pushing the tab 3567 into the cavity of the core and shell 3564. It is important to note the relationship between the tab 3567 and the tapered inlet 3571. The combination of the taper on the tab 3567 and the tapered inlet 3571 is configured such that the tab 3567 bends inward towards the centerline of the assembly. Figure 18J represents the mating of the receptacle 2 in the unlocked position including the standard mating plug 1. A detailed enlarged view is shown in the lower right to more clearly show the non-interference between the locking tab 3551 and the mating plug barrier shell 3569. As shown in the illustration, when the shuttle 3565 is retracted, there is little or no contact between the tab 3551, the inner wall ramp of the core and shell 3571, and the outer surface of the barrier shell 3569 of the mating plug.

[0081] Figure 18K shows the mating and locking state of the combination of plug 1 and receptacle 2. Nut 3566 forces shuttle 3565 to rotate forward. The detailed enlarged view shown in the lower right more clearly shows the new relationship between tab 3567 and mating plug barrier shell 3569. As shown in the illustration, when shuttle 3565 is pushed forward, there is significant contact between tab 3551, the inner wall ramp of core and shell 3571, and the outer surface of the barrier shell 3569 of the mating plug. As locking nut 3566 is further tightened, the radial force between tab 151, the inner wall ramp of core and shell 3571, and the outer surface of the barrier shell 3569 of the mating plug increases very rapidly due to the amplification of the progressive taper force between tab 3567 and the inner wall ramp of core and shell 3571. The same action occurs on the opposite side of the plug's barrier shell in the opposite direction on that side. These opposing forces help maintain the centering of plug 1 within receptacle 2.

[0082] Figures 18K2, 18K2b and 18K3 show some other embodiments of the present invention incorporating different ergonomic ways of actuating and releasing the locking function. These variations are very suitable for plugs with dielectric insulation shells or barriers such as IEC C14, C20 and other models.

[0083] The first design shown in FIG. 18K2 uses no nut to move shuttle 3580. Instead, the user pushes or pulls the shuttle to lock and unlock the plug into the receptacle connection. The geometry of the shuttle tab can be changed so that this process functions as desired. Details of the engagement method between the modified dielectric shell 3581 and the modified shuttle tab shape are shown in cross-section C-C. This cross-section shows the plug and receptacle in the locked position of FIG. 18K2 and the released position in FIG. 18K2b. The user first pushes the plug through the shuttle and seats it in the receptacle, then continues to push the shuttle and also feels by hand that the shuttle holding feature 3582 has seated on the mating feature on the dielectric shell. This is useful to indicate that the connection is now in the locked state. Conversely, when releasing the connection, the user pulls the shuttle and then feels by hand that the shuttle holding feature has become unseated from the mating feature on the dielectric shell when removed. This allows the user to remove the plug from the receptacle. Cross-section E-E shows additional details 3583. This feature shows a method of attaching a single dielectric shell component to the rear cross-section incorporating a contact carrier that can have an access mechanism for inserting contacts during manufacture. This method is useful for providing the user with a cable with few or no visible connecting wires, i.e., providing an impression of robustness and reliability.

[0084] The shuttle locking tab (FIG. 18K2) 3580 described above has been modified as shown in section C-C of FIG. 18K2, and the tab 3584 of the shuttle 3580 incorporates a profile 3582 which, in combination with features of the pair of modified outer shells 3581, seeks to increase the frictional force maintaining the connection between the plug and the receptacle when more force is applied to separate the plug and the receptacle. This is because the force attempting to separate the plug and the receptacle acts to move the outer barrier shell rather than the shuttle tab prong. As a result, the locking connection will be made more secure when more force is applied to pull the locking connection apart. An ergonomic push / pull release mechanism is a valuable feature in some applications. The ability of the locking mechanism to be more secure when a separating force is applied to the locked plug and receptacle can also be a desirable characteristic in some applications. This characteristic can optionally include the provisions for programmable release described above within this application and other incorporated applications.

[0085] Figure 18K3 shows another embodiment of the present invention incorporating different ergonomic methods for actuating and releasing the locking function. This design shown in Figure 18K3 does not use a nut to move the shuttle 3590. Instead, the user presses or pulls the dielectric shell 3591 via the rear protrusion to lock and unlock the plug into the receptacle connection. The shuttle in this case is not a user interface. The geometry of the shuttle tab can be changed to enable this configuration to function as desired. Details of the engagement method between the modified dielectric shell 3590 and the geometry 3592 of the modified shuttle tab are shown. The mating engagement features are on the shuttle 3592 and the dielectric shell 3594. The user first presses the rear protrusion of the dielectric shell, inserts it, and manually checks that the retaining feature has seated on the mating feature on the shuttle. This is useful now to indicate that the connection is in the locked state. Conversely, when releasing the connection, the user pulls the rear protrusion of the dielectric shell and then manually checks that the retaining feature has become unseated from the mating feature on the shuttle when removed. This allows the user to remove the plug from the receptacle. In other respects, this embodiment functions in a similar manner to the embodiment described in Figure 18K2.

[0086] Figures 18L - X show another embodiment of the present invention incorporating another tab shape incorporating a locking function with different characteristics. This example is a conventional IEC - 14 or IEC - 20 type plug, although other types utilizing an external pin dielectric barrier (Figure 18K) 3569 may be used. In Figure 18L, the external pin barrier is generally concentric around the pin and becomes the object of gripping by the mating receptacle when installed.

[0087] The shuttle locking tab (Figure 18K) 3567 described above has been modified as shown in Figures 18L - O, and the tab 3609 of the shuttle 3603 includes an inclined profile 3608 that, in combination with the mirror lamp feature 3607 of the modified outer shell 3602, attempts to increase the frictional force that maintains the connection between the plug and the receptacle when more force is applied. This is to make the locking connection more secure when more force is applied, which can be a desirable characteristic in some applications. This characteristic can optionally include the provisions for programmable release described above within this application and other incorporated applications.

[0088] To properly function this new tip design feature, the locking nut (Figure 18K) 3566 is modified so that the insertion and locking sequence of operations is as follows: 1) The user rotates the nut so that the tip is at the maximum insertion depth or reaches the maximum insertion depth. 2) The user inserts the cord cap into the mating receptacle. 3) The user rotates the nut, causing the prong tip to be withdrawn and then gradually frictionally locked via the action of the mirror lamp to secure the connection. Notes regarding this embodiment are described below: 1) To make the user interface easier to use, the threads of the nut 3566 can be reversed so that the user rotates the nut clockwise to secure the connection and counterclockwise to release it. However, the tab retracts when the nut is rotated clockwise and inserts when the nut is rotated counterclockwise. 2) Optionally, the threads of the nut can be manufactured with a much coarser pitch that requires fewer rotations in either direction to lock or release the plug to the receptacle connection. This is desirable because it is quicker and easier for the user to operate. In a preferred embodiment, the nut does not need to be rotated more than 1 - 3 / 4 turns to secure and release the connection.

[0089] As described initially in FIG. 18L, FIG. 18M details the basic functionality of the above-described alternative embodiment. In this figure, the plug and receptacle are fully mated. The plug assembly components involved in friction locking consist of the plug barrier outer shell 3602 and the shuttle 3603. Only the cross-sections of the barrier and the shell are shown for clarity. Also, the mating receptacle 3605 is shown as a simplified cross-section. The simplified cross-section shows the essential components of this locking alternative embodiment.

[0090] As described initially in FIG. 18L, FIG. 18N details the basic functionality of the above-described alternative embodiment. In the release position, the mating pair 3610 has four insertion tabs as in many other preferred embodiments, three of which are shown in FIG. 3610. The fourth tab is essentially hidden by the central tab 3609 shown. The enlarged cross-section 3611 shown in the release position shows the interaction of the components of the assembly. The locking tip 3608 of the shuttle 3603 is shown with a plastic tip having an exemplary inclined surface that mates with a similar mirror-image inclined surface 3607 of the outer shell 3602. The outer shell 3602 is shown being pushed towards the mating receptacle 3605, and the shuttle 3603 is also shown in the moved-to-release position, where the shuttle 3603 is pushed as far as possible towards the mating receptacle. Thus, the lamp face is in the minimum engagement position.

[0091] A schematic view of the locked position of the mating pair 3612 shows that the shuttle 3603 has been moved relative to the barrier outer shell 3602 so as to pull the shuttle 3603 away from (to the left) the mating receptacle 3605. At the same time, the outer shell 3602 has not moved away from the mating receptacle 3605. The movement of the shuttle 3603 relative to the barrier shell 3602 is achieved by any of the above-described actuation means. A screw assembly with a manually rotated nut has been described above. The movement of the shuttle can also be achieved by the action of a cam lever or other means suitable for pulling the shuttle 3602 and the outer shell 3503 together in the manner shown by the arrow in FIG. 3612.

[0092] The forces applied to the barrier shell and the shuttle are symmetric but opposite and only interact with each other, so the force is not directly applied to the mating receptacle 3605 that is not perpendicular to the insertion / extraction axis. Therefore, when the locking mechanism is engaged, there is little or no tendency to remove the plug from the optimal electrically connected position within the receptacle.

[0093] The enlarged portion for the locking position 3613 is shown in detail regarding the relationship between the inclined surface at the tip of the shuttle 3603 and the mating inclined surface of the outer shell 3602. At the locking position, the relationship of the shuttle inclined surface 3608 is away from the mating receptacle 3605, and the reversing tip 3606 of the shuttle 3603 slides along the inclined surface and presses the tip 3606 into the inner surface of the core of the mating receptacle 3605. The interference point indicated by 3606 is the result of the shuttle operation when the shuttle moves away from the mating receptacle 3605. This is important because the action of "locking" the plug within the receptacle attempts to draw the plug and the receptacle together. This ensures a complete engagement relationship between the plug and the receptacle, and thus a good electrical and mechanical connection is guaranteed.

[0094] At the same time, when the heel of the shuttle tip inclined surface 3608 moves away (to the left) from the mating receptacle 3605, the heel slides along the tip of the inclined surface 3607 of the outer shell 3602, causing interference between the tip of the outer shell inclined surface 3607 and the inner surface of the plastic outer shell of the mating receptacle 3605. The tip half is basically formed in a wedge shape within the slot in the mating receptacle. There is a tip half on each of the four flat surfaces of the barrier shell that engage the four flat surfaces of the slot within the mating receptacle that receives the outer shell when engaged (four from the outer shell, four from the shuttle prong, for a total of eight).

[0095] Briefly stated, an alternative method of securing (locking) two mating connectors using only friction is shown. The description of the mechanical properties of the receptacle shows a mechanism for securing (locking) the receptacle to a standard and unmodified mating plug of the same specification. This method of ensuring electrical connection can be easily configured to meet the various release tension ranges required by the application or regulatory agencies. Minor changes in the shape, arrangement, and geometry of the tabs, the tapered openings, and the thread pitch can all have various effects on the fixing force and type of force required to release the "locked" mating of the plug and receptacle. The simplicity of this design is robust and easy to manufacture. The reduced number of parts and use of all injection-moldable materials reduce manufacturing costs.

[0096] Most of the conventional power cords currently manufactured use a manufacturing technique known as polyvinyl chloride (PVC) overmolding as the generally preferred manufacturing method. This is a mature manufacturing technique where precision-molded metal parts and assemblies, such as contact carriers, wires, etc., are either non-existent or few in number, and are overmolded with a PVC plastic material inside an injection molding machine to give them their final shape and dimensions, and they are mechanically connected into one assembly and guaranteed to be robust. PVC overmolding is commonly used in many cord caps to form elements such as the outer cover and strain relief. The overmolding may or may not cover some or all of the precision-molded parts, such as those made of nylon or other plastics suitable for the intended application. The precision-molded parts may also be designed to be joined by adhesives, ultrasonic welding, or other techniques commonly used to join parts of such materials. This joining operation may usually be done beforehand, but it may also be done after the PVC overmolding process.

[0097] The manufacturing of PVC overmolds became dominant in the power cord manufacturing technique from the late 1960s to the early 1970s. This technique is more labor-intensive and requires greater investment and expertise by using injection molding machines. Appropriate tooling for the injection mold is a requirement of this manufacturing technique, which involves expensive and long lead times to introduce new designs to the market. The economic significance of this technique is that by the early 2000s, almost all manufacturing of this type of cord had shifted to Asian manufacturers in Taiwan and China. Also, this manufacturing method is optimal for large manufacturing runs per SKU because the setup time required each time a different SKU is run can generate additional costs. Since shipping via ocean was a reasonable cost option for products such as power cords that can be heavy and bulky, the lead time for product delivery became long. As a result, there was a longer supply chain for value-added, unique power cord designs such as Zonit zLock (trademark) required for data centers and other mission-critical applications by clients who thought "it's just a power cord" and did not understand the complexity and constraints of the supply chain for these unique products. Also, specialty designs such as zLock usually have far fewer quantities per manufacturing run, so both time and cost are increased. Furthermore, long-term competition for global resources and the resulting transaction disputes are making the choice of manufacturing location even more important. By both reducing the lead time of zLock and minimizing the time and cost required to change the SKU model on the production line, sales will increase and profits will improve.

[0098] Changing the manufacturing technique of the zLock power cord, which consists entirely or mostly of high-precision metal and plastic components that can be snap-fitted or pressed to produce the final assembly, has the following major advantages. 1) The manufacturing of components can be completely separated from the final assembly process. Further, the manufacturing of components can be easily transferred from one plastic injection manufacturer to another, and the final customer only needs to move the molds that they usually own. This ensures that there is no single point of failure at this step of the manufacturing process. 2) The resources required for final assembly are very simple, such as manual labor, jigs, and extremely simple assembly machines like mechanical presses (if necessary), which can be operated manually or by power. These are widely available. 3) The setup costs for implementing various models of power cords are minimal, but the main setup cost is to switch the rolls of wire, which may be the reels of contacts on an automatic stripping / clamping device that can be implemented quickly. Also, the machine is not a large investment, and many wire harness shops own them. The final assembly operation of assembling components and connecting them to form a power cord has a nearly constant cost per cord and can be automated for further economic benefits. 4) The location of final assembly can be the location required for the best transportation logistics, low labor costs, and tax / regulation / tariff benefits. This method also ensures that there is no single point of failure at this step of the manufacturing process. If one contract manufacturer fails to meet the required deadlines, cost points, or quality requirements, it is very easy to transfer the final manufacturing program to another contract manufacturer if possible. This serves as an incentive for more competitive bidding by contract manufacturers to win contracts, and attention is focused on the details when executing and maintaining the program.

[0099] Examples of zLock using the new manufacturing techniques discussed below can use various design techniques. Some relatively obvious examples will be touched upon. Many of them are described in other zLock applications, including various manufacturing methods, which are incorporated herein by reference. 1. Component joining methods included in or usable in these designs. One or more methods can be combined as needed. a. Spiked post and mating opening b. Mushroom-shaped plastic post riveting c. Aligning post and adhesion to holes d. Adhesion of part edges with / without alignment grooves e. Ultrasonic welding f. Other suitable methods 2. Parts that can use these methods in a design set a. Half-shell inner housing contact carrier b. Optional separate contact carrier c. Concentric ring or sleeve on the back side of the inner housing d. Other parts or assemblies described in this application. The inner housing contact carrier joins the halves 3. The strain relief options, inner housing, and any other necessary parts are modified to fit the selected method. See FIGS. 18Q - T. a. Labyrinth path with / without additional bushings for power cord b. Contact / prong crimp with flange etc. for pull - through prevention c. Gripping ring on power cord for pull - through prevention d. Adhesion of power cord to strain relief e. Concentric ring or sleeve for firmly fastening the inner housing halves together. Passing over the inner housing halves f. Concentric barbs g. Optional strain relief cord radius control sleeve and additional element that can be placed on the cord and fastened by the rear half of the inner housing where the cord exits. If desired, it can be made of a material different from the inner housing halves, probably more flexible. This can be done in various ways. One simple way is to have a flange on the cord radius control sleeve captured by the alignment groove inside the inner housing half. Another way is to have ribs inside the cord radius sleeve captured by the alignment groove outside the rear of the inner housing half. 4. Structure of the inner shell - One of the illustrated inner shells is designed as a single piece that folds and self-aligns when joined. The inner shells are joined together using barbed posts and alignment openings. It can also be designed as one bent piece or two separate pieces joined by any of the joining methods described above. Selecting one or more of these methods of use is motivated by cost and the capabilities and machinery of the manufacturer. The illustrated design incorporates the contact carrier, but can be implemented as a separate part held by the inner shell if required for reasons of structure and / or safety compliance. The inner shell can incorporate a strain relief function or perform its function in combination with an external concentric ring or sleeve having some of the advantages described below. This can also incorporate an optional strain relief radius control sleeve, as described above. 5. Structure of the shuttle and nut - The shuttle and nut are designed to be a single part if possible and are preferably formed within a single action mold. This is a preferred embodiment, but other embodiments are possible. 6. Outer shell structure - The outer shell is designed to be a single piece that is preferably formed within a single action mold if possible. This is a preferred embodiment, and other embodiments, such as two parts, etc., are possible. 7. Strain Relief Structure - There are several ways that can be used to form a suitable strain relief. This operation can be carried out entirely by the inner shell or in combination with an external ring or sleeve concentric with the inner shell. The method selected in one of the zLock embodiments described below is described below. Figures 18P - T show various possible ways. Figure 18Q shows a method of transmitting the force attempting to pull the plug and mating receptacle away from the power cord side using a ground contact protrusion. This force is transmitted from a spring retainer (see Figure 18U) to a flange on the ground carrier and thus to the power cord via the crimp of the extended ground contact to the power cord. This crimp has a flange that prevents it from being pulled through the inner shell assembly when joined and closed, as shown in Figures 18Q) and 18Q). The advantage of this method is that the strong and potentially brittle material of the retaining spring does not need to be crimped onto the power cord (a possible design modification using a suitable material), and the crimping is done using a more malleable metal for the contacts.

[0100] Another strain relief method that can be used is to insert a labyrinth or serpentine path feature on the back side of the inner shell assembly that grips the cord when closed. This is shown in Figure 18R.

[0101] Another strain relief method that can be used is to insert a concentric barbed feature on the back side of the inner shell assembly that grips the cord when closed. This is shown in Figure 18S.

[0102] The function of the labyrinth passage strain relief can be improved by shaping the back side of the inner shell assembly into a suitable shape such as a cylinder or a slightly tapered cone and using a concentric retaining ring or groove of a metal or plastic sleeve with a concentric groove or ring aligned on the outer surface of the inner shell assembly. The external ring or sleeve is pressed onto the assembled halves of the inner shell to ensure that good compression of the power cord is achieved by the labyrinth passage inside the inner shell halves.

[0103] Also, the concentric compression component can be changed to be a short sleeve (often molded into a frustum of a cone of a suitable shape) that is the outer surface of the assembly as seen from the rear of the cord cap into which the power cord enters. It can be made to fit exactly to the size of the power cord diameter and have holes that are visible to the end user when looking at the exit of the power cord from the side of the cord cap. In this case, one possible variation is to make the concentric ring into the form of a longer sleeve and then press it onto the tapered wall of the inner shell assembly that ensures that the alignment retaining ring and the grooves on both parts are firmly joined. The tapered sleeve can also be attached via barbed posts and alignment openings, adhesion or ultrasonic welding, or any of the aforementioned joining methods. Some of these variations are shown in Figure 18P. The strain relief radius control sleeve can be integrated within the concentric sleeve, inserted through the large end of the sleeve, and then held in place by the retaining flange and the alignment grooves on the inner surface of the sleeve. Alternatively, as described above, it may be held by the inner shell half. This technique can also be used to provide threads for nuts used in types of locking male plugs as shown in Figures 18W and 18X. In that case, the material used can be selected to be optimal for use as threads. The advantage of this design variation is that the joint between the concentric ring sleeve and the inner shell assembly is covered by the outer shell overhang within the female variant (e.g., IEC C13 / 15 / 19) and by the nut in some male locking models (e.g., IEC C14 / 20), so that there is little or no pigtail. This is desirable for forming an impression of robustness and reliability in the mind of the end user.

[0104] In yet another aspect of the present invention, a novel strain relief that can be used in many applications is shown in FIGS. 18AA through NN. In this embodiment of the invention, the concentric compression part (3691) can be made in a size range that covers the range of power cord diameters and can function effectively as a strain relief mechanism. The advantage of this design is that the concentric compression element 3691 is a simple and inexpensive part to manufacture and does not require any other changes to the other elements of the assembly. Examples of cord caps that comply with various international standards (e.g., C13, C14, C15, etc.) using the strain relief protrusions captured by the compression part 3691 are shown in FIGS. 18EE - 18NN. An example of an in-line surge suppression circuit using the strain relief protrusions captured by the compression element 3691 is shown in FIGS. 18AA through 18DD. Various embodiments and details of the surge suppression circuit are described in the surge suppression cases incorporated herein by reference.

[0105] FIGS. 18U through X show some possible embodiments of the present invention. These embodiments can function in any of the ways of the other embodiments described in the present invention and can use any of the described features, but their manufacturing methods are different, so the aforementioned advantages can be realized.

[0106] Figures 18U through X illustrate several embodiments of examples of zLock designs that can use the manufacturing techniques described above. The designs shown lock IEC C13 / 15 / 19 and C14 / 20 cord caps, but the methods described can be used for both locking and non-locking cord cap designs and standards. Here, for purposes of illustration, the details of an IEC 13 / 15 assembly using the new manufacturing method (C13 and C15 assemblies are the same except for the recess in the outer shell C15 as shown in Figure 18U) will be described (see Figure 18U). The C19 assembly, Figure 18V, shares the new manufacturing method and functions basically the same, with the contacts and retaining springs rotated 90 degrees. The assembly consists of a power cord 3800 inserted into an internal housing 3900 and electrical contacts 3810, 3830 crimped to the preferably stripped internal wires 3801 of the power cord. Contact carrier slots 3920 are integrated into the inner housing 3900. The internal housing also incorporates a strain relief function, which in this example is accomplished via a stop 3930 that prevents the ground crimp 3830 on the power cord through an opening formed when the two halves of the inner shell 3900 are closed. A flange or other feature (see Figure 18Q) may be included as part of the ground crimp and helps prevent it from being pulled through the opening in the closed inner shell half. An optional external strain relief cord radius control sleeve (not shown) that slides over the power cord and is captured via a lip or other suitable means when the two halves of the internal housing are joined can also be used as needed for compliance with UL or other regulatory agencies. The electrical contact, in this case a spring retainer 3840 that grips the ground prong of the mating cord cap, transmits the force trying to pull the plug and receptacle apart to the ground contact 3830 via the flange 3831 on the ground contact and thus to the ground crimp 3832 on the power cord 3800. The outer shell 3950 is pressed onto the closed half of the inner shell assembly and is held by one or more formed pegs 3901 on the side of the inner shell assembly that fit into one or more formed openings 3951 in the outer shell.One or more elastic rings 3960 that fit into one or more grooves 3952 in the rear half of the outer shell provide both assistance in gripping the outer shell and a means of identification that can be useful to a data center operator for marking certain characteristics of the power cord connection, such as power, phase, or priority or other characteristics important to the data center operator. This design is released from the locked position by a pull-back on the outer shell, as described in past applications incorporated herein by reference. Here, for purposes of illustration, the details of one possible embodiment of an IEC C14 assembly using a new manufacturing method will be described (see FIG. 18W). The C20 assembly (FIG. 18X) shares the new manufacturing method and functions in basically the same way with the contacts rotated 90 degrees. This assembly consists of a power cord 4100 and an inner shell 4200 incorporating a dielectric shield around which the power cord 4100 is inserted. The inner shell surrounds, positions, and supports the electrical prong 4102. The electrical prong 4102 is crimped to the suitably stripped internal wire 4101 of the power cord. The electrical prong carrier 4203 is integrated into the inner shell housing. The shuttle 4210 has one or more prongs 4211 with tips 4212 shaped to pass through slots 4250 in the inner shell housing 4200. The shuttle is moved back and forth via a nut 4215 having one or more flanges 4216 captured by one or more slots 4217 in the shuttle, whereby the shuttle and the nut remain attached and both move together when the nut is rotated.

[0107] In this embodiment, strain relief is provided via a stop that prevents crimping of the ground prong on the power cord that is pulled through a support feature formed when the two halves of the inner shell are closed. Other strain relief methods described above can also be used.

[0108] As shown in the figure, the inner shell can incorporate a combination nut screw and a strain relief function, or can be another component 4110. In this design option, it can be formed by a threaded sleeve connected to the inner shell 4200. The inner shell can be connected by being pressed on the rear protrusion of the inner shell housing and held by a concentric retaining ring or groove that aligns by aligning with a concentric groove or ring on the outer surface of the inner shell assembly. Also, the inner shell can have a retaining groove for capturing the flange on the concentric sleeve, or can be held by any other joining method detailed above. The inner shell can ensure that it does not rotate once pressed by incorporating a retaining pin or other features. The sleeve can also be manufactured to be wire-free, thus providing a smooth nut rotation function.

[0109] The prong 4211 of the shuttle 4210 is moved and retained between the wall of the mating receptacle and a dielectric shell that secures the connection between the plug and the receptacle. This can be done in several of the ways described above. The assembly of the inner shell, outer shell, and nut - equipped shuttle acts to transfer the force attempting to separate the plug and receptacle to the power cord 4100 via a crimped ground prong or any other strain relief feature used to secure the power cord within the inner shell assembly. The illustrated shuttle 4210 is mounted on the inner shell assembly and held by the nut behind it as described above. One or more elastic rings can be provided that enter one or more grooves 4218 in the rear half of the shuttle, providing both an aid in gripping the shuttle and a color - identification method for marking certain characteristics of the power - cord connection, such as power, phase, or priority or other characteristics important to the data - center operator. This design releases from the locked position by rotating the nut to release the locked connection, as described in past applications incorporated herein and in this application.

[0110] The new features created for the problems of a specific device are described below. Some models of the power cord receptacle are sold with a shroud that prevents the end user from easily removing the locked power cord. For a photo example, see Figure 18Y.

[0111] A simple solution is to provide a way to expand the outer housing through a tool that allows the user to pull out the outer shell and release the locked plug. The tool can be designed to be used in the following ways. 1. It is inserted, used, and then removed. In this case, a simple sheet metal tool shown in Figure 18Z acts. This is pushed into the receptacle shroud, where it catches the split rib on the outer shell where two elastic rings are seated, allowing the user to pull back the outer shell and remove the plug. 2. It is inserted, used, and left in place. In this case, the inner and outer shells of the plug are slightly modified. One or more channels are formed on the outer surface of the inner shell. The recesses are formed on one or more surfaces of the outer shell, with the walls closest vertically at the back and the front wall inclined at 45 degrees. The recesses are aligned with the channels of the inner shell. This tool has one or more prongs with hooks at the tip that are inserted into the channels of the inner shell and pushed in until the hook tips expand and catch on the vertical wall of the outer shell. The user can then pull back the tool and release the locked plug. If desired, the tool can be left attached. When removing the tool, the user pushes the tool in slightly, causing the tool to disengage and the hook tips to come into close contact. Since the user can then slightly grip the tool and it will come off, the prongs can be pulled out of the channels of the inner shell to remove the tool.

[0112] Figures 19 to 22 show the operation of another embodiment of a mechanism for fixing a mating electrical connection included in a secure connection of the present invention. This embodiment automatically fixes itself in response to a force 6070 attempting to disconnect the connection. Figures 20 to 22 are top views of the retaining mechanism in each of the states of 1) fully inserted 5000, 2) fully inserted under tension 6000, and 3) released 7000. Figure 19 shows the elements of the plug, receptacle, and retaining mechanism. Figure 20 shows a connection where the plug is inserted into the receptacle but no force is applied to attempt to disconnect the connection. Figure 21 shows the operation of the retaining mechanism 6000 in response to a force on the plug 6010 attempting to pull the plug 6010 out of the receptacle 6020. In response to the pulling of the plug 6010, the retaining mechanism shown in the detailed enlarged portion 6100 causes the elastomer 6050 to adhere more closely to the wall of the receptacle 6060 through the action of the inclined ramp 6040, increasing the frictional interlock between the plug 6010 and the receptacle 6020. In this way, the force 6070 itself attempting to pull the plug 6010 out of the receptacle 6020 engages with the retaining mechanism 6000 and frictionally engages with the wall of the receptacle 6060, thereby preventing the pulling out of the plug 6010 and acting to maintain the electrical connection of the mating assembly. The retaining mechanism 6000 can be manufactured from any of the suitable materials described above. Figure 22 shows the operation of the retaining mechanism during the release of a secure connection. When the user attempts to release the connection, by gripping and pulling the outer shell 7030, the outer shell 7030 pulls 7070 and, through the protrusion of the outer shell 7060, retracts the elastomer 7040 along the ramp 7050, relieving the compression of the elastomer 7040 and releasing the connection.

[0113] Figures 23 - 24 illustrate the operation of another embodiment of a mechanism for securing a mating electrical connection included in a secure connection of the present invention. This embodiment automatically secures itself in response to a force attempting to pull the connection apart. Figure 23 is a side top view of a plug 8000 incorporating a safety mechanism, and side view 8010 and perspective view 8020 of a normal standard receptacle. The receptacle has fingers 8030 used to secure the receptacle 8020 when snap - fitted into a panel. These fingers 8030 are typically provided on individually molded snap - fit receptacles 8020 and are typically provided within a molded model of a receptacle that provides two, three, or more receptacles within one molded unit for snap - fit insertion onto a plug strip. The fingers 8030 spread widely when the receptacle 8020 is inserted, leaving an opening in the body of the receptacle 8020. In the absence of fingers, the manufacturer can modify the molded part so that fingers, or similarly molded and positioned slots or holes, can be provided at low cost to any model of individual or multiple receptacles with little or no impact on regulatory approval and can be provided easily and inexpensively. The plug 8000 has tabs 8040 (optionally moldable as hooks) that expand and insert into the openings in the body of the receptacle 8020 when the plug 8000 is inserted into the receptacle 8020. The ends of the tabs 8040 are inserted into the walls of the receptacle 8020 and are positioned and molded such that they transmit a force attempting to pull the connection to the walls of the receptacle but do not pass through the openings in the walls of the receptacle 8020. Thereby, the tabs 8020 cannot be tethered by the walls of the receptacle in response to a force attempting to pull the connection apart, ensuring that the plug 8000 and the receptacle 8020 are separated. By molding the tabs 8020 in this way, a secure connection functions properly and is always releasable as required. When releasing the connection, the user grips the outer shell 805 and pulls it back to withdraw the plug 8000 from the receptacle 8020.

[0114] Figures 24A - 24E are top views of a retaining mechanism with electrical contact prongs in each of the following states: 1) partially inserted (Figure 24A), 2) inserted but not yet fixed (Figure 24B), 3) fully inserted and fixed, 9020 (Figure 24C), 4) fully inserted but released, 9030 (Figure 24D), 5) removed and connection completed, 9040 (Figure 24E). As previously described, as shown in 24A - 24E, the plug 8000 has a tab 8040 (which can be shaped as a hook as an option) that expands and inserts into the opening of the body of the receptacle 8020 when the plug is inserted into the receptacle 8020. When disconnecting the connection, as shown in Figures 24D and 24E, the user grips the outer shell 8050 and pulls it back (8060) to withdraw the plug 8000 from the receptacle 8020. The outer shell 8050 has a generally rectangular opening suitably shaped for the tab 8040 to extend, and when the outer shell 8050 is pulled by the user (8060), the edge 8070 of the rectangular opening closest to the front of the male plug presses down the tab 8040, releasing the plug 8000 and disengaging it from the receptacle 8020. The retaining mechanism can be manufactured from any of the suitable materials described above. Note that this embodiment of the mechanism can be easily combined with the previous version that uses a manually actuated retaining mechanism actuated by the user. This example uses the aforementioned actuating nut to control the position and movement of the outer shell. The release position of the actuating nut positions the outer shell to press down the tab and prevent engagement with the receptacle, but does not prevent the plug from being inserted into or removed from the receptacle. The secure position of the actuating nut enables the tab to engage with the receptacle to secure the connection. This version may be useful in several situations.

[0115] Figures 26A - I show other possible ways of fixing cords to a plug strip. Since the locking mechanism is incorporated into the plug strip, all cords can be locked at once and all cords can be released at once. Figure 26I shows a multi - outlet electrical outlet assembly 4040 with 12, for example, National Electrical Manufacturers Association (NEMA) type 5 - 15 receptacles (other receptacle types can also be used, with the 5 - 15 type being used as an example) assembled in a narrow - profile, long "strip" oriented in a row. This configuration is commonly used in electronic equipment racks and is often called a plug strip, and this name will be used hereinafter in this specification. Using this method, any number of receptacles from one to any practical limit can be manufactured. The plug strip, which is an object of the present invention, is unique in that it incorporates a locking feature for fixing the plugs of electrical cords attached to the plug strip. Locking or releasing the receptacle to the attached electrical plug is achieved by rotating the hex socket screw 4021 on the front of the panel with a small tool. This does not necessarily have to be a hex socket; it could be a knob or handle integrated into the assembly, or any other means of actuating the internal mechanism. This could also be a uniquely - designed connector with a mating tool, knob, or lever, etc., that restricts the ability to release and re - lock the plug strip to qualified personnel. The tool could be a motor or solenoid - driven locking mechanism controlled by either a locally - controlled (by a button or switch or secure key - operated switch or secure digital authentication data fob or automotive door, or for example, a digital passkey, ID card, or any other suitable physical access control mechanism) or remotely - controlled motor - driven device. Remote control can be achieved, if necessary, via any suitable communication mechanism, with or without security features, for example, over the Internet, on an in - house data network, via a wireless network (any of which can be implemented as a secure connection using encryption, authentication, tokens, etc.), or via any other suitable means, using encryption, authentication, tokens, etc.

[0116] The unique concept of the present invention is the ability to lock or unlock all receptacles from an attached plug with a single simple operation. Further, this design allows for a predictable withdrawal force (programmable release) to pull out the attached plug when the assembly is in the locked position. This may be necessary to meet the requirements of an agency such as Underwriters Laboratories (UL) in the United States. This design allows for a wide variation in the manufacturing tolerances of the attached plug. Further, the design of this assembly allows for a reduction in manufacturing cost and an improvement in reliability due to the simplicity of the design. This design can be configured to fit various plug types and is not limited to the example of a NEMA type 5-15 plug.

[0117] Detailed Description The main design feature of the engagement assembly is a unique prong capture mechanism that can be assembled in any length at any number of capture points corresponding to the number of receptacles supplied by the plug strip. Figures 26A and 26A2 schematically show the three basic components of each prong capture assembly. These assemblies are arranged in each receptacle in at least one assembly combination per receptacle, but are likely to apply to all prong capture positions of any one receptacle and to all receptacles. These assemblies must be maintained separately for each electrical conductor for electrical isolation. The components shown in Figures 26A and 26A2 are all essentially metallic and can be manufactured from a good conductive metal such as brass, beryllium copper, or other reasonable tensile strength materials, but are not limited to these materials. The primary electrical prong receptacle 4001 is shown on the left side of the figure. This comprises a machine-stamped and die-formed part. The prong wipe 4010 is formed from a base-stamped metal and is rolled inward as is commonly practiced in the art so that the mating prong can reasonably easily enter and exit, but the electrical connection with the mating prong is extremely reliable. The hole in the stamping 4012 is located behind the electrical wipe 4010 and allows the prong of the mating connector to pass completely through the assembly. An additional hole is drilled in the metal 4011 directly above the first hole. This hole 4011 allows for the operating space for the spring of the additional parts of the completed assembly. The second part of the gripping assembly is the prong bearing stamping 4002 that performs the function of actually holding the inserted prong when actuated. It too is also a conductive metal and must have a certain degree of brittleness. This is necessary because there is an integral spring 4017 formed in the stamping. Referring to the side view of the part, it can be seen that the metal of the spring 4017 is deflected to the left within the arc. The purpose of this spring will be explained later when the assembled parts are described. Further, a hole is stamped in this part 4015, and this hole allows the prong of the mating plug to pass through this stamping without interference.The third part, the rear prong support 4003, is shown, and it is a simple stamping having a hole 4020 at the same relative position as on the prong receiver 4001 in the lower opening 4012.

[0118] Figures 26B and 26B2 are orthogonal view 4051 and side view 4052 of three parts 4001, 4002, 4003 with respect to the assembly. It is clear that the hole 4011 was necessary for the prong receiver part 4001, and the protrusion of the spring 4017 has a position where it does not receive interference. In this figure, it can also be understood that the three lower openings are aligned to allow penetration by the prongs engaging the plug to be installed.

[0119] Figures 26C and 26C2 show additional parts, the prongs. A partial view of a representative plug having a single prong 4013 is shown. The partial view is not part of the completed assembly of the present invention but is used to clarify the function of the parts in the process of locking two parts 4052, 4053 together. The assembly of the representative plug and prong 4053 includes a prong 4017 and an insulating carrier 4020. This assembly, generally, is part of a three - prong plug assembly, but it may be a member of any combination of prongs. This system acts on prongs of any shape by matching the shape of the openings of various sub - parts to the desired prongs to be captured. The prong receiver assembly 4052 is shown in the figure and includes a primary electrical prong receiver 4001, a prong bearing stamping 4002, and a rear prong support 4003. At this time, the electrical prong wipe 4010 is not yet engaged by the mating prong 4017.

[0120] Figure 26D shows the electrical plug 4053 fully inserted within the prong receptacle assembly 4052. The aligned openings of the three parts 4001, 4002, 4003 allow the prong 4017 to be inserted through those openings into the electrical wipe 4010. At this point, the three openings are basically aligned and the prong 4017 can pass through freely. The spring 4017 is shown in a relaxed state.

[0121] In Figure 26E, the prong bearing stamping 4002 is shown with a downward force applied. The top of the opening in this stamping is here pressed against the top of the prong 4017. At the same time, the bottom of the openings of the primary electrical prong receptacle 4001 and the prong bearing stamping 4002 apply a reaction force in the direction opposite to the prong 4017, creating a shearing action. Since the relative strength of the prong is great, the shearing force acts only to capture the prong and does not damage the prong. At this time, the spring 4017 is shown in a compressed state. In this configuration, a measurable range of motion for the prong bearing stamping 4002 is ensured after the first contact with the prong 4017. This is necessary because prong dimensions vary among manufacturers, and when multiple prong receptacles are placed in a line, a means of compensating for small manufacturing variations is needed. This spring 4017 also serves to apply a predetermined level of force to the prong 4017 for a given range of vertical deflection of the prong bearing stamping 4002. At this point, the prong is captured and "locked".

[0122] Figure 26F shows a plurality of the above-described prong receptacle assemblies 4052 arranged in a continuous linear configuration. The three whole parts of the part 4052 are replicated in a row on a single set of three stampings. The final plurality of prong capture assemblies 4054 each comprise three metal parts assembled together.

[0123] Figure 26G shows three multi-prong capture assemblies 4054 arranged adjacent to each other to generate the location of each opening to conform to the placement of the prongs of the mating plug. This configuration is not limited to three conductors, and a variant including only one capture plate and two electrical wipe plates is just one example of possible variants. At least one capture plate assembly is required to capture the plug. This assembly is the electrical conduction and capture sub-assembly 4055.

[0124] Figure 26H represents one possible way to provide force to the prong bearing stamping 4002. Note the hook end 4020 of the prong bearing stamping hung on the edge of the cam plate 4022. When force is applied to the bearing hole 4023 of the cam plate 4022, the force is transmitted to the three prong bearing stamping hooks 4020. The cam plate 4022 is shaped to allow a certain left-right movement of the plate relative to the prong bearing stamping hook 4020 to enable a transverse action associated with the cam operation. The cam 4024 is held in a predetermined position within the bearing 4025 and in this embodiment is actuated by the receiving hex socket 4027. When the cam 4024 is rotated via a tool inserted into the hex socket 4027, it rotates eccentrically about the axis of the bearing 4025. The eccentric movement is transmitted to the cam bearing 4002 and then to the cam bearing receiver 4023 and further transmitted to the movement within the cam plate 4022. Since only a small deflection is required, the force applied to the tool (knob or other means for rotating the said cam) is amplified many times, so the force required to lock all the plugs is maintained at a level that is easy to achieve.

[0125] FIG. 26I shows the subassembly parts of the assembled plug strip 4040 (FIG. 26I), the dielectric receptacle surface 4058, the conductive and capture subassembly 4055, the cam actuator 4056, the cam support C-frame 4057, the dielectric separator 4059, and the back housing 4050. End caps, cord assemblies, and electrical attachments are not shown but are included in the final assembly and are attached by conventional means.

[0126] The present invention has several novel features, in particular, it is possible to lock and unlock all receptacles simultaneously, manufacture a spring having the property of producing a predictable withdrawal force for the captured plug, any practical length and number of receptacles from one operating point are possible, the profile area behind the surface of the receptacle is an absolute minimum, simple stamping enables lower-cost assembly and manufacture, and a simple twist operation by any of the aforementioned tools or other means is all that is required to lock and unlock the assembly.

[0127] The foregoing description of the invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Accordingly, variations and modifications commensurate with the related art, the above teachings, and the skill and knowledge of the relevant art are within the scope of the invention. The above-described embodiments illustrate the best-known mode of carrying out the invention and are intended to enable others skilled in the art to utilize the invention in the above-described embodiments or other embodiments with various modifications as are required for particular applications or uses of the invention. The appended claims are intended to be construed to include alternative embodiments to the extent permitted by the prior art. The invention disclosed in this specification includes the following. [Aspect 1] A method of assembling an electrical cord connector body, providing first and second connector body housing portions formed from molded plastic, each including first and second interface surfaces configured to abut each other to define a housing interface. Placing one or more electrical components on the first connector body housing portion, positioning the second connector body housing portion on the first connector body housing body portion such that the first and second interface surfaces are in an aligned abutting relationship, and fixing the first and second connector body housing portions together, a method of assembling an electrical cord connector body. [Aspect 2] The method according to aspect 1, wherein the one or more electrical components include connection contacts for forming an electrical connection between an electrical plug and an electrical outlet. [Aspect 3] The method according to aspect 2, wherein the connection contacts comprise prongs of the electrical plug. [Aspect 4] The method according to aspect 2, wherein the connection contacts comprise receptacle contacts of the electrical outlet. [Aspect 5] The method according to aspect 1, wherein the one or more electrical components include a locking mechanism for selectively locking an electrical connection between a first electrical connector of the connector body and a second electrical connector of a mating connector device. [Aspect 6] The method according to aspect 1, wherein the one or more electrical components include a surge suppression circuit disposed on the electrical cord. [Aspect 7] The method according to aspect 1, wherein the one or more electrical components include an automatic transfer switch. [Aspect 8] The method according to aspect 1, wherein the first and second housing portions are provided as a single molded piece. [Aspect 9] The method according to aspect 8, wherein the positioning includes folding the molded piece such that the second connector body housing portion is positioned on top of the first connector body housing portion. [Aspect 10] The method according to aspect 1, wherein the positioning step aligns mating elements of the first and second connector body housing portions. [Aspect 11] The method according to aspect 1, wherein the fixing includes snap-fitting the first and second connector body housing portions together. [Aspect 12] The first and second connector body portions are provided with strain relief protrusions for engaging an electrical cord, and the fixing includes pressing the compression member onto the strain relief protrusions of the first and second connector body portions such that the compression member fixes the first and second connector body portions together, the method according to aspect 1. [Aspect 13] The method according to aspect 12, further comprising providing a set of compression members sized to align different electrical cords and selecting the compression members based on the size of the electrical cords. [Aspect 14] An electrical connector body, a first connector body housing portion formed from molded plastic, a second connector body housing portion formed from molded plastic, wherein the first and second connector body housing portions each include first and second interface surfaces configured to abut each other to define a housing interface, one or more alignment features disposed at the housing interface to assist in aligning the first and second connector body housing portions to fix the housing portions together to form a housing, and one or more electrical components disposed inside the housing. [Aspect 15] The electrical connector body according to aspect 14, wherein the one or more electrical components include a locking mechanism for selectively locking an electrical connection between a first electrical connector of the connector body and a second electrical connector of a mating connector device. [Aspect 16] The electrical connector body according to aspect 15, wherein the one or more electrical components include connection contacts for forming an electrical connection between an electrical plug and an electrical outlet. [Aspect 17] The electrical connector body according to aspect 16, wherein the connection contacts include prongs of the electrical plug. [Aspect 18] The electrical connector body according to aspect 16, wherein the connection contacts include receptacle contacts of the electrical outlet. [Aspect 19] The electrical connector body according to aspect 15, wherein the one or more electrical components include a locking mechanism for selectively locking an electrical connection between a first electrical connector of the connector body and a second electrical connector of a compatible connector device. [Aspect 20] The electrical connector body according to aspect 15, wherein the one or more electrical components include a surge suppression circuit disposed on the electrical cord. [Aspect 21] The electrical connector body according to aspect 15, wherein the one or more electrical components include an automatic transfer switch. [Aspect 22] The electrical connector body according to aspect 15, wherein the first and second housing portions are provided as a single molded piece. [Aspect 23] The electrical connector body according to aspect 20, wherein the formed piece is configured to facilitate folding such that the second connector body housing portion is positioned on the first connector body housing portion. [Aspect 24] The electrical connector body according to aspect 15, further comprising an alignment structure for aligning the first and second connector body housing portions. [Aspect 25] The electrical connector body according to aspect 15, further including a structure for snap-fitting the first and second connector body housing portions together. [Aspect 26] The electrical connector body according to aspect 15, wherein the first and second connector body portions include strain relief protrusions for engaging an electrical cord, and the electrical connector body further comprises the compression member disposed on the strain relief protrusions of the first and second connector body portions such that the compression member fixes the first and second connector body portions together. [Aspect 27] The electrical connector body according to aspect 26, wherein the compression member is selected from a set of compression members based on the size of the electrical cord.

Claims

1. A method of assembling an electrical cord connector body, comprising: providing first and second connector body housing portions formed from molded plastic, each including first and second interface surfaces configured to abut each other to define a housing interface and first and second strain relief protrusions for engaging an electrical cord; disposing one or more electrical components on the first connector body housing portion; positioning the second connector body housing portion on the first connector body housing portion such that the first and second interface surfaces are in an aligned abutting relationship; and securing the first and second connector body housing portions together, the securing including providing a compression member configured to extend over and press against the first and second strain relief protrusions for gripping the electrical cord.

2. The method of claim 1, wherein the one or more electrical components include connection contacts for forming an electrical connection between an electrical plug and an electrical outlet.

3. The method of claim 2, wherein the connection contacts comprise prongs of the electrical plug.

4. The method of claim 2, wherein the connection contacts comprise receptacle contacts of the electrical outlet.

5. The method of claim 1, wherein the one or more electrical components include a locking mechanism for selectively locking an electrical connection between a first electrical connector of the first and second connector body housing portions and a second electrical connector of a mating connector device.

6. The method of claim 1, wherein the one or more electrical components include a surge suppression circuit disposed on the electrical cord.

7. The method according to claim 1, wherein the one or more electrical components include an automatic transfer switch.

8. The method according to claim 1, wherein the first and second connector body housing portions are provided as a single molded piece.

9. The method according to claim 8, wherein positioning includes folding the molded piece such that the second connector body housing portion is positioned on top of the first connector body housing portion.

10. The method according to claim 1, wherein the step of positioning aligns mating elements of the first and second connector body housing portions.

11. The method according to claim 1, wherein securing includes snap - fitting the first and second connector body housing portions together.

12. The method according to claim 1, further comprising providing a set of compression members sized to align different electrical cords and selecting the compression members based on the size of the electrical cords.

13. An electrical connector body, A first connector body housing portion formed from molded plastic, A second connector body housing portion formed from molded plastic, the first and second connector body housing portions including first and second interface surfaces configured to abut each other to define a housing interface and first and second strain relief protrusions for engaging an electrical cord, respectively, One or more alignment features disposed on the housing interface to assist in aligning the first and second connector body housing portions to fix them together to form the housing, and one or more electrical components disposed inside the housing. An electrical connector body comprising a compression member that extends onto and presses against the first and second strain relief protrusions for gripping the electrical cord.

14. The electrical connector body according to claim 13, wherein the one or more electrical components include a locking mechanism for selectively locking an electrical connection between a first electrical connector of the first and second connector body housing portions and a second electrical connector of a mating connector device.

15. The electrical connector body according to claim 14, wherein the one or more electrical components include connection contacts for forming an electrical connection between an electrical plug and an electrical outlet.

16. The electrical connector body according to claim 15, wherein the connection contacts comprise prongs of the electrical plug.

17. The electrical connector body according to claim 15, wherein the connection contacts comprise receptacle contacts of the electrical outlet.

18. The electrical connector body according to claim 14, wherein the one or more electrical components include a locking mechanism for selectively locking an electrical connection between a first electrical connector of the first and second connector body housing portions and a second electrical connector of a compatible connector device.

19. The electrical connector body according to claim 14, wherein the one or more electrical components include a surge suppression circuit disposed on the electrical cord.

20. The electrical connector body according to claim 14, wherein the one or more electrical components include an automatic transfer switch.

21. The electrical connector body according to claim 14, wherein the first and second connector body housing portions are provided as a single molded piece.

22. The electrical connector body according to claim 21, wherein the formed piece is configured to facilitate folding such that the second connector body housing portion is positioned on the first connector body housing portion.

23. The electrical connector body according to claim 14, further comprising an alignment structure for aligning the first and second connector body housing portions.

24. The electrical connector body according to claim 14, further including a structure for snap-fitting the first and second connector body housing portions together.

25. The electrical connector body according to claim 14, wherein the compression member is selected from a set of compression members based on the size of the electrical cord.

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