Conductors for power distribution systems

Abstract

The present invention is entitled "Conductor for use in a power distribution system". An electrical conductor for use in a power distribution assembly includes a main conductor portion, which includes a conductive material. The main conductor portion extends along an axis. A plurality of flexible branch members include conductive material. The flexible branch members extend laterally from the main conductor portion. Each flexible branch member is selectively bendable and is configured for electrical connection to an electrical switching device.

Description

Technical Field

[0001] The present disclosure relates generally to power distribution systems, and more particularly to flexible conductor mounts for power distribution systems. Background Art

[0002] Electrical devices, such as electrical switchgear or meters used in power distribution systems, are typically mounted on or within electrical enclosures (e.g., not limited to distribution boards, load centers, instrument breaker panels), either alone or in combination with other meters or switchgear (e.g., not limited to circuit switching devices and circuit interrupters (such as circuit breakers), contactors, motor starters, motor controllers, and other load controllers). The electrical enclosure is typically coupled to and supported by a structure, such as, for example, a wall of a building, and includes a plurality of electrical bus members.

[0003] In industrial applications, available space is limited. Therefore, in order to maximize the space for processing equipment and minimize installation costs, it is beneficial to design distribution equipment (such as switchboards) with the smallest footprint possible. In addition, switchboards typically include at least one rigid busbar that serves as an electrical conductor for delivering electricity to electrical switching devices. The rigid nature of the busbar limits the positioning of switchgear within the switchboard and the types of switchgear that can be used within the switchboard. Typical rigid busbars include multiple connection points that are expensive to manufacture and increase assembly time. Further, the joint between two attached conductors may increase resistance, thereby creating hot spots in the sense of heat within the enclosure, which may lead to increased maintenance frequency and maintenance costs. For example, when a circuit breaker is bolted directly to a busbar, there may be a relatively high resistance between the joint connections. This is particularly true in industrial applications. Figure 1A , where conductor 1A comprises an elongated rigid busbar section 3A having rigid branch conductors 5A attached to the busbar sections respectively by fasteners 7A. The system has increased resistance, which creates heat resistance, which leads to increased temperature or hot spots, further resulting in increased maintenance frequency and maintenance costs. In addition, due to the increased resistance caused by temperature cycling and the temperature rise at the connection point, the joints may loosen. Loose connections may also cause arcing, which can be a source of ignition in hazardous / flammable environments. Switchboards may also have exposed live conductors, which are a shock hazard to operators and maintenance personnel.

[0004] Another example of a rigid conductor assembly in the prior art is Figure 1B. Each conductor 1B includes an elongated rigid center busbar portion 3B and a plurality of rigid branch portions 5B extending laterally from the center busbar portion. The branch portions 5B are bent to accommodate stacking multiple conductor assemblies on top of each other to distribute multiple phases of electricity. However, the system is only configured to accommodate one switchgear arrangement and a limited number of switchgear types. Therefore, the busbar arrangement requires a unique busbar assembly for each circuit breaker system layout required. Therefore, assuming that the electrical system requires a new circuit breaker layout for any reason during the life of the system, the busbar assembly needs to be completely replaced due to the availability of the components, thereby increasing costs and complicating the planning required for these maintenance events. Further, these logistics challenges affect the production and inventory costs of products that have not yet been configured for customer orders. Summary of the invention

[0005] In one aspect, an electrical conductor for use in an electrical distribution assembly generally includes a main conductor portion comprising a conductive material. The main conductor portion extends along an axis. A plurality of flexible branch members are comprised of the conductive material. The flexible branch members extend laterally from the main conductor portion. Each flexible branch member is selectively bendable and configured for electrical connection to an electrical switching device.

[0006] In another aspect, a power distribution assembly generally includes an enclosure and a flexible electrical conductor disposed in the enclosure. The flexible electrical conductor includes a main conductor portion composed of a conductive material. A plurality of branch members include conductive material extending laterally from the main conductor portion. Each branch member is selectively bendable and configured to be electrically connected to an electrical switching device.

[0007] In yet another aspect, an electrical conductor assembly for use in a power distribution assembly generally includes an electrical conductor. A housing covers at least a portion of the electrical conductor. The housing insulates at least a portion of the electrical conductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1A is a perspective view of a prior art conductor assembly;

[0009] Figure 1B is a perspective view of another prior art conductor assembly;

[0010] Figure 2A is a perspective view of a power distribution assembly including an enclosure;

[0011] Figure 2B yes Figure 2A a perspective view of a power distribution assembly with an interior cover removed showing conductors within the enclosure and connected to a plurality of switchgear;

[0012] Figure 2C yes Figure 2B A front view of the power distribution assembly with a door of the enclosure removed;

[0013] Figure 3 is a perspective view of a conductor showing a conductor portion in a bent configuration and including a cap over the conductor portion;

[0014] Figure 4 for Figure 3 a front view of a conductor with all caps removed;

[0015] Figure 5 is a perspective view of another embodiment of a power distribution assembly including an enclosure and a conductor assembly within the enclosure and connected to a plurality of switch devices;

[0016] Figure 6 yes Figure 5 A perspective view of a conductor assembly in FIG.

[0017] Figure 7 yes Figure 6 An exploded view of the conductor assembly in FIG.

[0018] Figure 8 yes Figure 6 A perspective view of a conductor of a conductor assembly in FIG.

[0019] Fig. 9 yes Figure 8 Another perspective view of the conductor in;

[0020] Fig.10 yes Figure 8 A front view of the conductor in FIG.

[0021] Fig.11 is a perspective view of an insulating member of a conductor assembly; and

[0022] Fig.12 is another perspective view of an insulating member of a conductor assembly.

[0023] Corresponding reference numerals indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0024] Reference Figures 2A to 4, one embodiment of a power distribution assembly is generally shown at 20. The power distribution assembly 20 includes an electrical enclosure generally shown at 22. The enclosure 22 includes a housing 24, which can be made of any suitable material (such as stainless steel, plastic, etc.). The enclosure 24 may include a door or cover 25 or any other structure for providing access to the internal components of the enclosure 22. The enclosure 24 may also include an internal cover or a "fixed panel type" cover 27 inside the enclosure. The "fixed panel type" cover 27 has a cutout for receiving a switch device 32. Electrical conductors 30 are housed in the enclosure 22. The conductors 30 are configured to be electrically connected to a plurality of electrical switching devices 32, such as, for example and without limitation, circuit breakers. Although the switch devices 32 are described as circuit breakers, any known or suitable type and / or configuration of electrical switching devices may be used without departing from the scope of the present disclosure. To this end, the conductors 30 enable the combination of devices of different circuit breaker manufacturers having different structures within a single system. This combination of different circuit breakers is not possible in a rigid busbar system. For this reason, it is standard for switchboard systems containing rigid busbars to specify a single suitable switchgear manufacturer for use in the system. The conductor 30 alleviates the need for such a restriction. In one embodiment, the electrical conductor 30 is an electrical bus that carries or transmits voltage, current, or power.

[0025] As used herein, the term "enclosure" means any suitable structure for housing electrical switching devices (e.g., but not limited to circuit switching apparatus and circuit interrupters (such as circuit breakers), contactors, motor starters, motor controllers, and other load controllers), and expressly includes, but is not limited to, distribution panels, load centers, and switchgear boxes, as well as other structures or compartments covered with panels such as, for example and without limitation, in prepared openings in the walls of a building, on the workpiece of a machine, or on a vehicle.

[0026] As employed herein, the statement that two or more parts are "attached" together shall mean that the parts are joined together either directly or joined through one or more intermediate parts.

[0027] As used herein, the term "fastener" refers to any suitable connecting or tightening mechanism, including but not limited to rivets, screws, bolts, and combinations of bolts and nuts (such as, but not limited to locking nuts), and combinations of bolts, washers and nuts.

[0028] Continue to refer to FIG. 2A to FIG. 2C and Figure 3, the electrical conductor 30 within the enclosure 22 comprises a flexible electrical conductor. The conductor 30 comprises an elongated flexible center conductor portion (broadly speaking, a main conductor portion) 34 and a plurality of elongated flexible branch members or conductors 36 extending laterally from the center conductor portion. Each branch member 36 is configured to be electrically connected to a switching device 32. Thus, the conductor 30 provides a flexible conductive base for making multiple electrical connections with different switching devices 32. The branch members 36 are selectively bendable so that the branch members can be bent in a first configuration to accommodate a first switching device arrangement, and then bent in a second configuration or more configurations different from the first configuration to accommodate a second or more switching device arrangements. Thus, the branch members 36 are elastically deformable. The center conductor portion 34 may also be elastically deformable. The conductor 30 (including the center conductor portion 34 and the branch members 36) may be bent or folded around a plurality of axes and / or twisted around an axis to configure the conductor into a desired configuration for a particular use. The bending, folding and / or twisting may be performed manually by an end user. Thus, the conductor 30 can be configured as needed to accommodate different sizes and shapes of switch devices 32. In addition, as will be explained in more detail below, the flexible nature of the conductor 30 allows the switch device 32 to be properly positioned when multiple conductors are stacked on top of each other within the enclosure 22 for distributing multiple phases of electricity.

[0029] Reference Figure 3 and Figure 4 , the flexible conductor portion 34 and each flexible branch member 36 each comprise a generally rectangular component. Other configurations of the conductor portion 34 and the branch members 36 are also contemplated without departing from the scope of the present disclosure. In one embodiment, the flexible branch members 36 are integrally formed with the flexible center conductor portion 34. However, the branch members 36 may be formed separately from the center conductor portion 34 and appropriately attached to the center conductor portion. Additionally, in a non-limiting example, eight (8) branch members 36 are shown for a total of sixteen (16) branch members, extending vertically outward from opposite sides of the center conductor portion 34 of the conductor 30. It should be understood that other numbers of branch members 36 are also contemplated. Further, the center conductor portion 34 may be shortened or lengthened to accommodate a desired number of branch members 36. As shown, the branch members 36 on one side of the center conductor portion 34 are aligned with the branch members on the opposite side of the center conductor portion along the longitudinal axis LA of the center conductor portion. Alternatively, one or more branch members 36 may be staggered or offset along the longitudinal axis LA of the center conductor portion 34 relative to branch members on opposite sides of the center conductor portion.

[0030] The center conductor portion 34 and the branch members 36 of the conductor 30 can each include a multilayer laminated conductive material, such as copper, aluminum, or any other suitable conductive material. The conductive material layer can also be plated with the same conductive material or another conductive material, such as tin, silver, aluminum, or any other suitable conductive coating. It should be understood that the center conductor portion 34 and the branch members 36 can have other configurations without departing from the scope of the present disclosure. An insulating cover or sleeve 40 surrounds at least a portion of the conductor 30 including the center conductor portion 34 and the branch members 36. In the illustrated embodiment, the cover 40 surrounds the center conductor portion 34 and the main portion of the branch members 36, but does not completely surround the entire conductor 30. As shown, the cover 40 substantially surrounds the entire center conductor portion 34 except for the free end portion 42 of the center conductor portion, and substantially surrounds the entirety of each branch member 36 except for the free end portion 44 of the branch member. The exposed free end portions 42, 44 are configured to be electrically connected to the switch device 32. For example, the main circuit breaker may be electrically connected to the free end portion 42 of the center conductor portion 34, and the branch circuit breaker may be electrically connected to the free end portion 44 of the branch member 36. Figure 2C As shown, the flexible connector 46 may connect the free end portion 42 of the center conductor portion 34 to the main circuit breaker 32 .

[0031] Reference Figure 3 , the cap 50 can cover the free end portions 44 of at least some of the branch members 36. For example, the cap 50 can be placed on the free end portions 44 of the branch members 36 that are not connected to the switch device 32. Additionally, the branch members 36 that are not connected to the switch device 32 can be bent or otherwise moved out of the area of ​​the other branch members to provide additional space within the enclosure for the switch device and to further insulate the exposed conductor ends from maintenance personnel. Figure 2B As shown, the bottom branch member 36 is rolled up, thereby shielding the ends of the branch members. Figure 3 , the cap 50 is formed of an insulating material such as the insulating cover 40 so that the conductive portion of the conductor 30 is not exposed. The cover 40 and the cap 50 can be formed as an overmolded part or formed by extrusion. In one embodiment, the portion of the cover 40 surrounding the center conductor portion 34 of the conductor 30 is overmolded on the conductor, and the portion of the cover surrounding the branch member 36 is extruded. However, without departing from the scope of the present disclosure, the entire cover 40 can be overmolded or extruded. Suitable materials for forming the cover 40 and the cap 50 include, but are not limited to, thermoplastics including polyvinyl chloride (PVC).

[0032] Alternatively, while the insulating material of the cover 40 is shown as covering a portion, but not all, of the conductive material of the conductor 30, the insulating material of the cover 40 may extend over the entirety of the center conductor portion 34 and / or one or more branch members 36, thereby eliminating the need for a separate cap to cover the exposed free end portions 42, 44. In this case, a portion of the cover 40 may be removed from the center conductor portion 34 and / or one or more branch members 36 to expose the conductive material for connection to the switch device 32.

[0033] like Figure 2B and Figure 2C As shown, the flexible and insulating construction of the conductor 30 also facilitates stacking two or more conductors on top of each other to configure a distribution assembly for delivering multiple phases of electricity. In this arrangement, the first conductor 30 can be configured to distribute the electricity of the first phase to the first set of switch devices 32 in the enclosure 22, the second conductor 30 placed directly on the first conductor or at least generally placed on the first conductor can be configured to distribute the electricity of the second phase to the second set of switch devices 32 in the enclosure, the third conductor 30 placed directly on the second conductor or at least generally placed on the second conductor can be configured to distribute the electricity of the third phase to the third set of switch devices 32 in the enclosure, and so on. In the case where the conductors 30 are stacked on top of each other, the branch members 36 may not be fully aligned with the corresponding switch devices 32. This is particularly the case with multi-pole circuit breakers 32. Figure 2B and Figure 2C 2-pole circuit breaker 32 identified (2p) and 3-pole circuit breaker 32 (3p) The flexible configuration of the conductor 30 and in particular the branch member 36 allows for connection with the switchgear (including the multi-pole circuit breaker 32) by bending, twisting or otherwise manipulating the branch member to connect with the switchgear. (2p) , 32 (3p) An insulating cover 40 surrounding each of the conductors 30 insulates each conductor from any other conductor within the enclosure 22, thereby allowing the conductors 30 to be placed directly on top of each other without any interference between the phases.

[0034] Reference Figures 5 to 7, another embodiment of the power distribution assembly is generally shown at 120. The power distribution assembly 120 includes an electrical enclosure generally shown at 122. The enclosure 122 includes a housing 124 having a door or cover (not shown) or any other structure for providing access to the internal components of the enclosure 122. An electrical conductor assembly 126 is housed within the enclosure 122 and includes a plurality of electrical conductors 130. The electrical conductors 130 are separated from each other by insulating members 150 to ensure that appropriate electrical spacing is maintained within the assembly 126. The conductors 130 and the insulating members 150 are held together by a housing 160 forming the conductor assembly 126. Each conductor 130 of the conductor assembly 126 is configured to be electrically connected to a plurality of electrical switching devices 132, such as, for example and without limitation, circuit breakers. In the illustrated embodiment, the plurality of conductors 130 facilitates the distribution of multiple phases of electricity.

[0035] Reference Figures 8 to 10 , each electrical conductor 130 of the conductor assembly 126 comprises an electrical conductor that is at least partially flexible. Each conductor 130 comprises an elongated rigid center conductor portion 135, an elongated flexible center conductor portion 134 attached to the rigid center conductor portion, such that the conductor portions extend along a common longitudinal axis LA of the conductors, and a plurality of elongated flexible branch members 136 attached to the rigid center conductor portion 135 and extending laterally outward from the rigid center conductor portion. The branch members 136 may be attached to the rigid conductor portion 135 by any suitable means. For example, the branch members 136 may be attached to the rigid conductor portion 135 using threaded fasteners, rivets, welding, adhesives, clamps, or any other suitable attachment mechanism. Each branch member 136 is configured for electrical connection to the switch device 132. Thus, each conductor 130 provides a flexible conductive base for making multiple electrical connections with different switch devices 132. The elongated rigid center conductor portion 135 and the elongated flexible center conductor portion 134 may be broadly considered as the main conductor portion. Alternatively, only the rigid center conductor portion 135 may be considered as the main conductor portion.

[0036] The rigid center conductor portion 135, the flexible center conductor portion 134, and each flexible branch member 136 each comprise a generally rectangular component. Other configurations of the conductor portions 134, 135 and the branch members 136 are also contemplated without departing from the scope of the present disclosure. In the illustrated embodiment, two (2) branch members 136 are shown extending vertically outward from opposite sides of the rigid center conductor portion 135. It should be understood that other numbers of branch members 136 are also contemplated. In addition, although each branch member 136 is shown as extending laterally from both sides of the rigid conductor portion 135, one or more branch members may be separated into two separate branch members and appropriately attached to opposite sides of the rigid conductor portion. In this embodiment, one or more branch members may be staggered or offset along the longitudinal axis of the rigid center conductor portion 135 relative to the branch members on the opposite sides of the rigid center conductor portion.

[0037] The rigid center conductor portion 135 may include a standard copper busbar member, and the flexible center conductor portion 134 and the branch member 136 may each include a multilayer laminated conductive material, such as copper, aluminum, or any other suitable conductive material. The conductive material layer may also be plated with the same conductive material or another conductive material, such as tin, silver, aluminum, or any other suitable conductive coating. It should be understood that the center conductor portions 134, 135 and the branch member 136 may have an excessive configuration without departing from the scope of the present disclosure. An insulating cover or sleeve 140 surrounds the flexible center conductor portion 134 and the flexible branch member 136 of the conductor 130. In the illustrated embodiment, the cover 140 surrounds the main portion of the flexible center conductor portion 134 and the branch member 136, but not their entirety. As shown, the cover 140 substantially surrounds the entirety of the flexible center conductor portion 134, but does not cover the free end portion 142 of the flexible center conductor portion. Similarly, the cover 140 substantially surrounds the entirety of the branch member 136, but does not cover the free end portion 144 of the branch member. The exposed free end portions 142, 144 are configured for electrical connection with the switchgear 132. For example, a main circuit breaker may be electrically connected to the free end portion 142 of the flexible center conductor portion 134, and a branch circuit breaker may be electrically connected to the free end portion 144 of the branch member 136.

[0038] Reference Figure 6 , Fig.11 and Fig.12As shown, each insulating member 150 receives one of the conductors 130 and isolates the conductor from the other conductors so that there is no electrical interference between the conductors in the conductor assembly 126. Each insulating member 150 includes a central passage 152 in a first side 153 of the block for receiving at least some of the center conductor portions 134, 135; and a cutout 154 in a side wall 156 of the central passage 152 for receiving a branch member 136 to at least partially position the conductor 130 in the insulating member. The protrusion 158 on the opposite second side 159 of the insulating member 150 is configured to be received in the cutout 154 in the adjacent insulating member 150 to help secure the conductor 130 received in the adjacent insulating member within the adjacent insulating member. Additionally, the second side 159 of the insulating member 150 has a generally mating configuration with the first side 153 of the insulating member so that the insulating members can be nested with each other to provide a compact arrangement for the conductor assembly 126. The longitudinal ends of the insulating member 150 include fastener holes 162 for connecting portions of the housing 160 to the insulating member to hold the insulating member and the conductor 130 together. The insulating member 150 can be fastened together in a variety of ways, including by snap fit. In one embodiment, the insulating member 150 is formed of molded plastic.

[0039] like Figure 6 and Figure 7 As shown, the housing 160 includes a front panel 164, a top panel 166, and a bottom panel 168. Fasteners (not shown) extend through fastener holes 170 in the top panel 166 and the bottom panel 168, and through the fastener holes 162 in the insulating member 150 to secure the top panel 166 and the bottom panel 168 to the insulating member 150, and place the top panel and the bottom panel in frictional engagement with the front panel 164 to hold the panels together around the insulating member. Other suitable configurations of the housing 160 and other means for coupling the conductor 130 and the insulating member 150 together may also be incorporated without departing from the scope of the present disclosure. For example, the housing 160 may include a plurality of snap-fit ​​components.

[0040] A plurality of conductors 130 separated by insulating members 150 configure the power distribution assembly 120 for delivering multiple phases of electricity. Thus, the first conductor 130 can be configured to distribute the electricity of the first phase to the first group of switch devices 132 in the enclosure 122, the second conductor 130 can be configured to distribute the electricity of the second phase to the second group of switch devices 132 in the enclosure, the third conductor 130 can be configured to distribute the electricity of the third phase to the third group of switch devices 132 in the enclosure, and the fourth conductor 130 can be configured to distribute the electricity of the fourth phase to the fourth group of switch devices 132 in the enclosure. The insulating block 150 and the insulating cover 140 insulate each conductor from the other conductors of the conductor assembly 126, thereby allowing the conductors 130 to be stacked on top of each other without any interference between the phases. Therefore, when the conductors 130 are stacked on top of each other, the insulating member 150 prevents short circuits between the phases. It is conceivable that the conductor assembly 126 can have different numbers of conductors 130 for distributing electricity of different phases without departing from the scope of the present disclosure.

[0041] Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention as defined in the appended claims.

[0042] As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

1. An electrical conductor assembly for use in a power distribution assembly, comprising: An electrical conductor, the electrical conductor comprising: a main conductor portion, the main conductor portion comprising an electrically conductive material, the main conductor portion extending along an axis; and a plurality of flexible branch members comprising an electrically conductive material, the flexible branch members extending laterally from the main conductor portion, each flexible branch member being selectively bendable and configured for electrical connection to an electrical switching device; and A shell, the shell covering at least a portion of the electrical conductor, the shell insulating at least a portion of the electrical conductor, the shell including an insulating member, the insulating member including: a central channel for receiving at least some of the main conductor portion; and a cutout in a side wall of the central channel for receiving the flexible branch member to position the electrical conductor at least partially in the insulating member and allow the flexible branch member to extend from opposite sides of the shell.

2. The electrical conductor assembly according to claim 1, wherein The conductive material of the main conductor portion and the plurality of flexible branch members includes a multi-layer laminated conductive material.

3. The electrical conductor assembly according to claim 1, wherein: At least a portion of the main conductor portion is flexible.

4. The electrical conductor assembly according to claim 3, wherein: The main conductor portion is flexible in its entirety.

5. The electrical conductor assembly of claim 1, further comprising an insulator disposed around the main conductor portion and the plurality of flexible branch members.

6. The electrical conductor assembly according to claim 5, wherein: The insulating member is disposed around only a portion of at least one of the flexible branch members, such that a free end of the flexible branch member is exposed and free of the insulating member.

7. The electrical conductor assembly according to claim 5, wherein: The insulating member is disposed around the entirety of at least one of the flexible branch members.

8. The electrical conductor assembly according to claim 1, wherein: The main conductor portion is elongated and has a first side and a second side opposite the first side, a first flexible branch member extending laterally from the first side of the main conductor portion, and a second flexible branch member extending laterally from the second side of the main conductor portion.

9. The electrical conductor assembly according to claim 8, wherein: The first and second flexible branch members extend laterally from the main conductor portion at a common point along the axis of the main conductor portion.

10. The electrical conductor assembly according to claim 1, wherein: The main conductor portion and the plurality of flexible branch members are formed separately from each other, and the flexible branch members are attached to the main conductor portion.

11. The electrical conductor assembly according to claim 1, wherein: The housing includes a first passageway for receiving the main conductor portion and a second passageway for receiving the at least one branch member.

12. The electrical conductor assembly of claim 1, further comprising an insulator disposed around the at least one branch member.

13. The electrical conductor assembly according to claim 1, wherein: The housing includes a plurality of housing members attached to each other.

14. An electrical conductor assembly according to claim 13, wherein: The housing components have mating alignment features to properly position the housing components relative to each other for attaching the housing components to each other.

15. A power distribution assembly comprising: Packages; and An electrical conductor assembly as claimed in any preceding claim, arranged in the enclosure.

16. The power distribution assembly of claim 15, further comprising a plurality of electrical conductors disposed in the enclosure, the electrical conductors being insulated from one another.

17. The power distribution assembly according to claim 16, wherein: The power distribution assembly is configured to distribute multiple phases of electricity and to accommodate multiple electrical switching devices having different spacings between poles.

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