Molded case circuit interrupter having circuit components positioned adjacent to rear exterior surface

Abstract

The present invention is entitled "MOLDED CASING CIRCUIT INTERRUPTER HAVING CIRCUIT COMPONENTS POSITIONED ADJACENT TO REAR EXTERIOR SURFACE". The present invention provides a molded case circuit interrupter. The molded case circuit interrupter advantageously employs circuit components positioned adjacent to the rear exterior surface of the molded case of the molded case circuit interrupter. Prior circuit interrupters sometimes employed a non-conductive back plate having a nominal thickness of 0.62 inches adhered to the rear surface of the molded case circuit interrupter to electrically isolate screws, posts, etc. mounted to and exposed on the rear of its molded case. The concepts disclosed and claimed herein provide a circuit component that replaces or supplements the back plate, wherein the circuit component includes a flexible strip having an electrical conductor that extends through a hole formed in the molded case and is electrically connected to an electronic component located inside the molded case.

Description

Technical Field

[0001] The disclosed and claimed concepts relate generally to circuit interrupters and, more particularly, to molded case circuit interrupters having circuit components positioned adjacent a rear exterior surface of the molded case. Background Art

[0002] Many types of circuit interrupting devices are known in the related art. It is known to use a thermal magnetic trip system on other molded case circuit interrupters to trigger a set of separable contacts of the circuit interrupter to move between a closed state and an open state, such as in the event of an overcurrent condition or other such condition. However, it should also be understood that newer circuit interrupters sometimes employ electronically controlled tripping mechanisms rather than conventional thermal magnetic tripping systems. Although such newer systems are more accurate and provide better results, they may require a large amount of data processing power, which requires processor equipment that takes up space. The space within the interior area of ​​the circuit interrupter is typically occupied by the circuit interrupter mechanism itself, which may include, without limitation, accessories such as shunt trip devices, auxiliary switches, undervoltage relays, alarm bells, etc. Therefore, the space inside the circuit interrupter is generally insufficient, and therefore the data processing power to operate such electronic components is also generally insufficient. Therefore, improvements are desired. Summary of the invention

[0003] Thus, an improved molded case circuit interrupter advantageously employs a circuit component positioned adjacent to the rear exterior surface of the molded case circuit interrupter. Prior circuit interrupters sometimes employed a non-conductive back plate having a nominal thickness of 0.62 inches adhered to the rear surface of the molded case circuit interrupter to electrically isolate screws, posts, etc. mounted to and exposed on the rear of its molded case. The disclosed and claimed concepts provide a circuit component that replaces or supplements the back plate, wherein the circuit component includes a flexible strip having an electrical conductor that extends through an aperture formed in the molded case and electrically connects to an electronic component located within the interior of the molded case.

[0004]

[0011] Accordingly, one aspect of the presently disclosed and claimed concept provides a molded case circuit interrupter having circuit components positioned adjacent an exterior surface of a molded case of the molded case circuit interrupter.

[0005] Another aspect of the disclosed and claimed concept provides such a molded case circuit interrupter having circuit components positioned adjacent an exterior surface of the circuit interrupter that are electrically connected to a plurality of electronic components located within an interior region of the circuit interrupter.

[0006] Another aspect of the presently disclosed and claimed concept provides such a circuit interrupter having circuit components that are located external to the circuit interrupter and that provide additional data processing capabilities that can be used by components located internal to the circuit interrupter.

[0007] These and other aspects of the concepts disclosed and claimed herein provide an improved molded case circuit interrupter, the general substance of which may be described as comprising: a molded case, the molded case generally described as comprising a first case portion and a second case portion, the molded case having an interior region formed therein and located between the first case portion and the second case portion; an electrical device located on the molded case, the electrical device generally described as comprising a set of separable electrical contacts located within the interior region, a handle structured to at least initiate movement of the set of separable contacts between an open state and a closed state, and a circuit component, the molded case having an exterior surface opposite the interior region, the exterior surface generally described as comprising a front exterior surface and a rear exterior surface facing away from each other in opposite directions, the handle being located adjacent the front exterior surface, the circuit component generally described as comprising a substrate located adjacent the rear exterior surface and may also be generally described as comprising a plurality of electronic components located on the substrate, and the substrate may be generally described as comprising a plurality of electrical conductors and a support, the plurality of electrical conductors being located on the support, the support being formed of an electrically insulating material, at least some of the plurality of electronic components being electrically connected to at least some of the plurality of electrical conductors. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A further understanding of the concepts disclosed and claimed herein may be obtained from the following description when read in conjunction with the accompanying drawings, in which:

[0009] Figure 1 is an illustration of an improved circuit interrupter in accordance with a first embodiment of the concept disclosed and claimed herein and wherein a set of separable contacts of the circuit interrupter are in a closed state;

[0010] Figure 2 is similar to Figure 1 , except that the set of separable contacts is depicted in an open state;

[0011] Figure 3 yes Figure 2 A perspective view of a circuit breaker;

[0012] Figure 4 yes Figure 3 An exploded view of a front housing portion, a rear housing portion, and a portion of an electrical device of a circuit interrupter;

[0013] Figure 5 yes Figure 3 circuit components of a circuit breaker;

[0014] Figure 6 yes Figure 3 A rear view of a circuit interrupter with circuit components exploded away from a molded housing of the circuit interrupter;

[0015] Figure 7 yes Figure 6 Assembly drawing of the circuit breaker;

[0016] Figure 8 is a partially exploded view of a circuit interrupter in accordance with a second embodiment of the concept disclosed and claimed herein; and

[0017] Fig. 9 is an exploded view of a circuit interrupter in accordance with a third embodiment of the concept disclosed and claimed herein.

[0018] Like numbers refer to like parts throughout the specification. DETAILED DESCRIPTION

[0019] exist Figures 1 to 3 and Figure 6 to Figure 7 1 and 2, an improved circuit interrupter 4 according to a first embodiment of the concepts disclosed and claimed herein is generally described. The circuit interrupter 4 in the exemplary embodiment shown is a molded case circuit interrupter, which may be referred to as including a molded case 6 and an electrical device 8 located on the molded case 6. As will be explained in more detail below, the electrical device 8 advantageously provides data processing capabilities that are located and executed outside of the molded case 6 and provide such data processing capabilities to components located inside the molded case 6.

[0020] from Figure 3 and Figure 4 It will be appreciated that the molded housing 6 may be referred to as including a front housing portion 12 and a rear housing portion 16, both of which are molded from an insulating plastic material or other suitable material. The molded housing 6 may be referred to as having an outer surface 28, which includes a front outer surface 32 located on the front housing portion 12 and a rear outer surface 36 located on the rear housing portion 16 ( Figure 6 ). In the exemplary embodiment shown, the front outer surface 32 and the rear outer surface 36 face away from each other in opposite directions.

[0021] The molded housing 6 also includes an interior region 40, at least a portion of which is located between the front housing portion 12 and the rear housing portion 16. More specifically, the interior region 40 includes a main interior cavity 42 located between the front housing portion 12 and the rear housing portion 16. The front housing portion 12 also has a first accessory cavity 42 and a second accessory cavity 46 formed therein, which may or may not be in communication with the main interior cavity 42. In the exemplary embodiment shown, the first accessory cavity 44 and the second accessory cavity 46 are separate from and not in communication with the main interior cavity 42, but are still within the front housing portion 12. The first accessory cavity 44 and the second accessory cavity 46 can be considered part of the interior region 40, but need not be considered so.

[0022] The electrical device 8 may be said to include a set of separable contacts 48 located within the main interior cavity 42 of the interior region 40. The set of separable contacts 48 may be connected to line and load conductors and may be used in applications such as Figure 1 The closed state in Figure 2 It will be appreciated that the electrical device 8 further includes an operating mechanism connected to a handle 54 that moves the set of separable contacts 48 between the closed state and the open state. The handle 54 protrudes from the front outer surface 32 and is operable to at least initiate movement of the set of separable contacts 48 between the closed state and the open state.

[0023] In the exemplary embodiment shown, Figure 3 Schematically shown in FIG, the circuit interrupter 4 includes a first accessory 50 located in the first accessory cavity 44 and a second accessory 52 located in the second accessory cavity 46. As will be described in more detail below, the first accessory 50 and the second accessory 52 are electronic components or electromechanical components that are electrically connected to the electrical device 8 and provide data processing capabilities to the electronic components or electromechanical components remotely from a location adjacent to the rear outer surface 36. The first accessory 50 and the second accessory 52 are shown in a schematic manner in the drawings. The first accessory 50 and the second accessory 52 can each provide, for example, auxiliary functions such as a shunt trip device function, an auxiliary switch function, an undervoltage relay function, an alarm bell function, etc., without limitation. In addition or alternatively, either or both of the first accessory 50 and the second accessory 52 can include a user interface (which can include an LCD or other visual display), one or more physical or virtual buttons, a universal serial bus (USB) located on or adjacent to the front outer surface 32.

[0024] The electrical device 8 includes a circuit component 56, which is usually Figure 5, and is located on the molded housing 6 when the circuit interrupter 4 is fully assembled. The circuit component 56 includes a substrate 58 positioned adjacent to the rear outer surface 36, and also includes a plurality of electronic components 60 located on the substrate 58. As used herein, the expression "plurality" and its variations should be broadly referred to as any non-zero quantity, including the amount of "one". The substrate 58 can be referred to as including a support 64 formed of an insulating material, and also includes a plurality of electrical conductors 68 located on the support. The plurality of electrical conductors 68 are electrically connected to the plurality of electronic components 60. The plurality of electronic components 60 may include a processor, a memory, and other electronic components suitable for performing data processing operations. Generally speaking, the memory will store a plurality of instructions in the form of routines, which, when executed on the processor, perform various operations, which can be transmitted to the first accessory 50 and the second accessory 52 and together cause the circuit interrupter 4 to perform various operations.

[0025] like Figure 5 As best shown, the substrate 58 may be referred to as including a main portion 72 and a strip portion 76, wherein the strip portion 76 includes a plurality of strips indicated at numerals 80A, 80B, 80C, and 80D, and which may be referred to collectively or individually herein by the numeral 80. The strips 80 and the main portion 72 are formed of a flexible insulating material and are formed together as a single piece of insulating material. In the exemplary embodiment shown, at least some of the plurality of electrical conductors 68 extend along the strips 80 of the strip portion 76 to transmit data signals between the plurality of electronic components 60 located on the main portion 72 and the first accessory 50 and the second accessory 52. Figure 5 It will be appreciated that the exemplary ribbons 80 each have a length 84, a width 88, and a thickness 92, wherein the length 84 and the width 88 are each substantially greater than the thickness 92, and the length 84 is substantially greater than the width 88. Thus, the ribbons 80 each have a thin, flexible, ribbon-like form factor. However, it will be appreciated that the exemplary ribbons 80 may be replaced with cables, interconnecting printed circuit boards, or other conductive structures without departing from the spirit of the present disclosure.

[0026] from Figure 3 to Figure 4 and Figure 6 to Figure 7 It will be appreciated that the molded housing 6 has a plurality of front apertures 86 formed in the front housing portion 12 and a plurality of rear apertures 90 formed in the rear housing portion 16, such as Figure 7In the exemplary embodiment shown, straps 80A and 80B extend from the main portion 72 of the support member 64 through a pair of rear holes 90 and then through a pair of front holes 86 to terminate at the first accessory cavity 44. In a similar manner, straps 80C and 80D extend from the main portion 72 through another pair of rear holes 90 and then through another pair of front holes 86 to terminate in the second accessory cavity 46. In the exemplary embodiment shown, at least one of the straps 80A and 80B is electrically connected to the first accessory 50 and at least one of the straps 80C and 80D is electrically connected to the second accessory 52. ​​However, it should be understood that other electrical connections may exist between the straps 80 and the various accessories that may be located in the first accessory cavity 44 and the second accessory cavity 46.

[0027] from Figure 5 It will be appreciated that the electrical device 8 includes a quantity of adhesive 96 applied to the substrate 58 in order to adhere and thereby attach the circuit components 56 to the molded housing 6. For example, Figure 7 The substrate 58 is shown adhered to and attached to the rear housing portion 16 adjacent the rear exterior surface 36. In this case, the strap 80 extends through the rear aperture 90 and through the front aperture 86 and terminates in the first accessory cavity 44 and the second accessory cavity 46 as described above. In this case, the circuit components 56 and more specifically the plurality of electronic components 60 are located outside the molded housing 6 and more specifically positioned adjacent to the rear exterior surface 36 thereof, and therefore do not occupy any space within the interior area 40. However, the processing capabilities provided by the circuit components 56 are in electronic communication with the exemplary first and second accessories 50, 52, which are themselves electrically connected to other components of the electrical device 8 and are operable to perform operations in accordance with the specific functions of the first and second accessories 50, 52, such as tripping the circuit interrupter 4, activating an alarm, etc. By positioning the substrate 58, and therefore the plurality of electronic components 60, outside of the molded housing 6 (i.e., adjacent the rear exterior surface 36), the additional data processing capability provided by the circuit components 56 does not occupy any significant space within the interior region 40, but is still accessible to the first and second accessories 50, 52 that are located within the first and second accessory cavities 44, 46 and that may cooperate with other portions of the electrical device 8 of the circuit interrupter 4. It should be appreciated that other attachment methods may be employed to attach the circuit components 56 to the molded housing 6, such as, without limitation, the use of threaded fasteners, clamps, etc.

[0028] In the exemplary embodiment shown, the rear housing portion 16 has a receptacle 98 formed therein and adjacent the rear exterior surface 36, into which the main portion 72 is received when the circuit component 56 is mounted to the molded housing 6 using the amount of adhesive 96. It should be understood that mounting methods other than using the amount of adhesive 96 may be employed without departing from the spirit of the present disclosure.

[0029] The main portion 72 and the plurality of electronic components 60 received in the socket 98 will typically have an overall thickness of about 0.047 to 0.060 inches, i.e., as measured in the direction of the depth of the socket 98 into the rear exterior surface 36. Depending on the configuration of the rear housing portion 16, the various electronic components of the plurality of electronic components 60 may be positioned on the substrate 58 as desired and electrically connected to the plurality of electrical conductors 68 to impart a flush surface to the rear surface of the circuit interrupter 4 that may be received in an appropriate switch gear cabinet or other cabinet.

[0030] exist Figure 8 An improved circuit interrupter 104 according to a second embodiment of the concepts disclosed and claimed herein is generally described in . Circuit interrupter 104 is similar to circuit interrupter 4, except that circuit interrupter 104 additionally includes an insulator 198 positioned adjacent to the molded housing 106 of circuit interrupter 104. Specifically, a quantity of adhesive 196 attaches insulator 198 to the substrate of circuit component 152 and thus to molded housing 106, and insulator 198 insulates various electronic components located on circuit component 152 from posts, fasteners, and other conductive structures that may be located on the rear housing portion of molded housing 106. Circuit component 152 and insulator 198 and quantity of adhesive 196 will have a combined thickness of no greater than about 0.060 inches or other suitable thickness, and impart a sufficiently thin profile to circuit interrupter 104 in which circuit interrupter 104 is easily received in a switch gear cabinet or other cabinet. Furthermore, it should be appreciated that the insulator 198 may be directly attached to the rear housing portion of the molded housing 106, such as by receiving a quantity of adhesive 196 directly between the insulator 198 and the rear housing portion rather than receiving a quantity of adhesive 196 between the insulator 198 and the circuit component 192, as shown. Figure 8 Other attachment methods may be used to attach the circuit components 152 and the insulator 198 to the molded housing 106, such as, without limitation, threaded fasteners, clamps, etc.

[0031] The improved circuit interrupter 204 according to the third embodiment of the concept disclosed and claimed herein is Fig. 92 is depicted in a partially exploded state. Circuit interrupter 204 is similar to circuit interrupter 4, except that circuit interrupter 204 includes a circuit component 256 that is constructed differently from circuit component 56. As described elsewhere herein, circuit component 56 is an integrally formed unit in which band portion 76 and main portion 72 are formed together as a single-piece, unitary structure. In circuit component 256, substrate 258 is formed separately from a plurality of bands 280A 280B, 280C, and 280D, which may be collectively or individually referred to herein by the numeral 280. In the exemplary embodiment shown, bands 280 are connected to substrate 258 using a plurality of small connectors.

[0032] The circuit component 256 includes a plurality of electronic components 260 located on a support 264, wherein the support 264 additionally includes a plurality of electrical conductors 268 electrically connected to the plurality of electronic components 260. In the exemplary embodiment shown, the substrate 258 can be, for example, a printed circuit board on which the plurality of electronic components 260 are physically located and to which the plurality of electronic components 260 are electrically connected, or it can be another type of structure, such as a flexible structure. A ribbon 280 extends from the substrate 258 and is connected thereto by the aforementioned connector. The ribbon 280 includes a plurality of additional electrical conductors 282 electrically connected to the plurality of electrical conductors 268 and, therefore, to the plurality of electronic components 260, so as to communicate data operations performed on the substrate 258 with accessories such as Figure 3 The first accessory 50 and the second accessory 52 shown for use in conjunction with the circuit interrupter 4 are in electronic communication.

[0033] In addition, the exemplary circuit component 256 includes a connector 278, which is located on the rear surface 262 of the support 264, that is, when the circuit component 256 is installed on the molded housing 206, the surface of the support 264 generally faces away from the molded housing 206 of the circuit interrupter 204. Therefore, the exemplary connector 278 also generally faces away from the molded housing 206. A plurality of electrical conductors 268 extend between the connector 278 and one or more strips 280, Fig. 9 In the exemplary embodiment shown, the strip includes strip 280D. However, it should be understood that the connector 278 may be located anywhere else on the circuit component 256 without departing from the spirit of the present disclosure, and this may include positioning the connector 278 on the front face of the support or on the edge of the support 264, even if this involves removing a portion of the molded housing 206 to create space for the connector 278.

[0034] The connector 278 may be advantageously connected to a mating connector 279 of a customer device 281 including one or more other components 283 that are in data communication with the circuit component 256. By way of example, the customer device 281 may be a switch gear cabinet having the circuit interrupter 204 mounted thereon, and the mating connector 279 may be located within a cavity of the switch gear cabinet. The other components 283 may be devices located within the exemplary switch gear cabinet or elsewhere, and may provide all or part of the functionality of known technologies (such as ZSI, ARMS, ModbusRTU, CAMs, etc.) and other technologies by way of example and not limitation. In addition, it should be understood that the connector 278 may also be provided on either or both of the circuit interrupters 4 and 104 for similar data connection with the other components 283 or alternative components that may be advantageously placed to be in data communication with the circuit interrupters 4, 104, and 204.

[0035] Thus, it can be seen that the improved circuit interrupters 4, 104 and 204 each include circuit components that provide data processing capabilities that are performed at a location external to the circuit interrupter and provided to accessories and other devices located within the circuit interrupter. This allows for enhanced data processing capabilities that can be used by the circuit interrupter, but without occupying the limited space available within the interior area of ​​such circuit interrupters. Other advantages will be apparent.

[0036] Although specific embodiments of the concepts disclosed in the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and substitutions of those details may be developed based on the overall teachings of the present disclosure. Therefore, the specific arrangements disclosed are merely illustrative and do not limit the scope of the concepts disclosed in the present invention, which is given by the full scope of the appended claims and any and all equivalents thereof.

Claims

1. A molded case circuit interrupter comprising: a molded housing including a first housing portion and a second housing portion, the molded housing having an interior region formed therein, the interior region being located between the first housing portion and the second housing portion; an electrical device located on the molded housing, the electrical device comprising a set of separable electrical contacts located within the interior region, a handle structured to at least initiate movement of the set of separable contacts between an open state and a closed state, and circuit components; an attachment positioned within the interior region and configured to perform an operation; the molded housing having an outer surface opposite the interior region, the outer surface including a front outer surface and a rear outer surface facing away from each other in opposite directions, the handle being positioned adjacent the front outer surface; The circuit assembly includes a substrate positioned adjacent the rear exterior surface and further includes a plurality of electronic components located on the substrate, the plurality of electronic components in electronic communication with the accessory configured to provide data processing capabilities; and The substrate includes a plurality of electrical conductors and a support member, the plurality of electrical conductors are located on the support member, the support member is formed of an electrically insulating material, and at least some of the plurality of electronic components are electrically connected to at least some of the plurality of electrical conductors.

2. The molded case circuit interrupter of claim 1 wherein said base plate is attached to said molded case.

3. The molded case circuit interrupter of claim 2, wherein the circuit component further comprises a quantity of adhesive, at least a portion of the quantity of adhesive being interposed between the substrate and the molded case and adhering the substrate to the molded case.

4. The molded case circuit interrupter of claim 1, wherein the molded case has a plurality of holes formed in at least one of the first case portion and the second case portion, and wherein at least a subset of the plurality of electrical conductors extends through at least some of the plurality of holes.

5. The molded case circuit interrupter of claim 4, wherein said circuit component further comprises a plurality of flexible strips extending from said base plate and comprising said at least one subset, each of said plurality of flexible strips having a length, a width, and a thickness, said length and said width being both substantially greater than said thickness, said length being substantially greater than said width.

6. The molded case circuit interrupter of claim 1 , wherein the molded case has a plurality of holes formed in at least one of the first case portion and the second case portion, and wherein the circuit component further comprises a plurality of additional electrical conductors electrically connected to one or more of the plurality of electrical conductors and extending through at least some of the plurality of holes.

7. The molded case circuit interrupter of claim 1 , wherein the circuit component further comprises a plurality of insulators formed at least in part of an electrically insulating material and located at least one of: on and adjacent to the circuit component, at least some of the insulators covering at least one of: electronic components of the plurality of electronic components and electrical conductors of the plurality of electrical conductors.

8. The molded case circuit interrupter of claim 7, wherein at least a subset of at least some of said insulators are each attached to at least one of at least one of said electronic component and said electrical conductor.

9. The molded case circuit interrupter of claim 8, wherein said at least a subset includes an insulator of said at least some of said insulators and an amount of adhesive attaching said insulator to said at least one of said electronic component and said electrical conductor.

10. The molded case circuit interrupter of claim 1 wherein the first housing portion is a front housing portion, the front exterior surface being located on the front housing portion, and wherein the second housing portion is a rear housing portion, the rear exterior surface being located on the rear housing portion.

11. The molded case circuit interrupter of claim 1 wherein said circuit component comprises a printed circuit board including said substrate and said plurality of electrical conductors.

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