Conductor assembly for power distribution systems

Abstract

The invention is entitled "Conductor assembly for power distribution system". The invention relates to an electrical conductor assembly for use in a power distribution assembly, the electrical conductor assembly comprising an electrical conductor and a housing covering at least a portion of the electrical conductor. A spring member is mounted to the housing and is configured to apply a compression force to the electrical conductor.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application Serial No. 62 / 927,040, filed October 28, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates generally to power distribution systems, and more specifically to flexible conductor base assemblies for power distribution systems. Background Technology

[0004] Electrical installations, such as electrical switching devices or electrical instruments used in power distribution systems, are typically mounted individually on or within electrical enclosures (e.g., but not limited to: panels; load centers; instrumentation circuit breaker panels), or in combination with other electrical instruments or switching devices (e.g., but not limited to circuit switching equipment and circuit breakers (such as circuit breakers), contactors, motor starters, motor controllers, and other load controllers) on or within electrical enclosures. Electrical enclosures are typically coupled to and supported by a structure such as, for example, the walls of a building, and include multiple electrical bus components.

[0005] In industrial applications, space is limited. Therefore, to maximize the space of the processing equipment and minimize the installation cost, it is beneficial to design the power distribution equipment, such as a power distribution panel, with the smallest footprint possible. In typical residential and commercial applications, circuit breakers have a consistent pole-to-pole spacing because the electro-mechanical equipment created for one pole is equally replicated for 2, 3, or more poles as needed. In hazardous locations, those same circuit breakers are enclosed or encapsulated to make them suitable for use in a flammable environment. In doing so, the encapsulation around each circuit breaker can be minimized in footprint to reduce the impact of an internal explosion. Therefore, the pole-to-pole spacing of circuit breakers in hazardous areas can not have a consistent pole-to-pole spacing increment as in regular breakers, thus the flexible bus has a significant advantage in manufacturing a circuit breaker panel system with any breaker, especially hazardous area rated breakers, or when using different manufacturers' designs in the same panel where the pole-to-pole spacing is not consistent. Additionally, power distribution panels typically include at least one rigid bus bar used as an electrical conductor for delivering electricity to the electrical switching devices. The rigid nature of the bus bar limits the positioning of the switching devices within the power distribution panel and the type of switching devices that can be used within the power distribution panel. Typical rigid bus bars include multiple connection points that are expensive to manufacture and increase assembly time. Further, the joints between two attached conductors can increase electrical resistance, creating hot spots in terms of heat within the encapsulation, which can lead to increased maintenance frequency and maintenance costs. For example, when a circuit breaker is bolted directly to the bus bar, there can be a relatively high electrical resistance between the joint connections. This is illustrated in Figure 1A where the conductor 1A includes an elongated rigid bus bar portion 3A having rigid branch conductors 5A attached to the bus bar portion by fasteners 7A, respectively. This system has increased electrical resistance, creating heat resistance, which leads to increased temperature or hot spots, further leading to increased maintenance frequency and maintenance costs. Additionally, the joints can loosen due to the temperature cycling increasing the resistance and the temperature rise at the connection points. Loosened connections can also lead to arcing, which can be an ignition source in a hazardous / flammable environment. Power distribution panels can also have exposed live conductors, which are a shock hazard to operators and maintenance personnel.

[0006] An example of another rigid conductor assembly of the prior art is illustrated in Figure 1B Each conductor 1B includes an elongated rigid center bus bar portion 3B and a plurality of rigid branch portions 5B extending laterally from the center bus bar portion. The branch portions 5B are bent to accommodate stacking of the plurality of conductor assemblies on top of each other to distribute electricity for a plurality of phases. However, this system is only configured to accommodate one switching device arrangement and limited switching device types. Additionally, Figure 1B the bus bars in are arranged for circuit breakers with a consistent pole-to-pole spacing. Figure 1Bbus designed for circuit breakers with inconsistent pole-to-pole spacing. However, as such and due to its inherent stiffness, if a circuit breaker needs to be replaced, the bus must be replaced. If circuit breakers of different pole counts are needed in the same system, multiple sections must also be spliced together. Thus, this bus arrangement requires a unique bus assembly for each circuit breaker system layout needed. Therefore, assuming an electrical system needs a new circuit breaker layout during the system's lifetime for any reason, due to the availability of parts, the bus assembly needs to be completely replaced, increasing costs and complicating the planning required for these maintenance events. Further, these logistical challenges impact production and inventory costs for products that have not yet been configured for a customer order. SUMMARY

[0007] In one aspect, an electrical conductor assembly for use in a power distribution assembly generally includes an electrical conductor and a housing covering at least a portion of the electrical conductor. A spring member is mounted to the housing and is configured to apply a compressive force to the electrical conductor.

[0008] In another aspect, a power distribution assembly includes an enclosure and a flexible electrical conductor disposed in the enclosure. The flexible electrical conductor includes a main conductor portion including an electrically conductive material and a plurality of branch members including an electrically conductive material, the plurality of branch members extending laterally from the main conductor portion. Each branch member is selectively bendable and configured for electrical connection with an electrical switching device. A plurality of housings cover portions of the flexible electrical conductor. Each housing includes a spring member mounted to the housing and configured to apply a compressive force to the flexible electrical conductor. BRIEF DESCRIPTION OF DRAWINGS

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

[0010] Figure 1B is a perspective view of another prior art conductor assembly;

[0011] Figure 2A is a perspective view of a power distribution assembly including an enclosure;

[0012] Figure 2B is Figure 2A is a front view of the power distribution assembly in

[0013] Figure 2C is Figure 2A is a front view of the power distribution assembly in

[0014] Figure 3is a perspective view of the conductor assembly showing the branch member of the conductor of the conductor assembly for attachment to a switchgear in a curved configuration;

[0015] Figure 4 is a front view of the segment portion of the conductor;

[0016] Figure 5 is a perspective view of the conductor in a curved configuration;

[0017] Figure 6 is Figure 3 is a perspective view of the conductor assembly in the folded configuration showing the branch member in a folded configuration;

[0018] Figure 7 is a perspective view of the conductor in a folded configuration;

[0019] Figure 8 is a perspective view of the housing of the conductor assembly;

[0020] Figure 9 is a front perspective view of the housing member of the housing;

[0021] Figure 10 is a rear perspective view of the housing member;

[0022] Figure 11 is a front view of the housing member;

[0023] Figure 12 is a rear view of the housing member;

[0024] Figure 13 is a fragment perspective view of the conductor assembly including a spring member;

[0025] Figure 14 is a schematic view of the conductor assembly including another embodiment of a spring member; and

[0026] Figure 15 is a schematic view of the conductor assembly including another embodiment of a spring member.

[0027] Throughout the drawings, corresponding reference numerals indicate corresponding parts. DETAILED DESCRIPTION

[0028] Referring to Figures 2A-3One 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 housing 24 can include a door or cover 25 or any other structure for providing access to the internal components of the enclosure 22. The housing 24 can also include an internal cover or "fixed panel" cover 27 of the interior of the housing. The "fixed panel" cover 27 has a cutout for receiving a switch device 32. An electrical conductor assembly 26 is housed within the enclosure 22 and includes a plurality of electrical conductors 30. The electrical conductors 30 are separated from one another by a shell 33 that mounts the conductors in the enclosure and at least partially covers the conductors to ensure that proper electrical spacing is maintained within the assembly 26. Thus, the shell 33 also insulates the conductors 30. In the illustrated embodiment, the plurality of conductors 30 and the plurality of shells 33 form the electrical conductor assembly 26. However, a single electrical conductor 30 and a single shell 33 can also be considered an electrical conductor assembly.

[0029] Each of the conductors 30 of the conductor assembly 26 is configured to be electrically connected to a plurality of electrical switch devices 32, such as, for example and without limitation, circuit breakers. In the illustrated embodiment, the plurality of conductors 30 facilitate the distribution of power for a plurality of phases. Although the switch devices 32 are described as circuit breakers, any known or suitable type and / or configuration of electrical switch device can be employed without departing from the scope of the present disclosure. To this end, the conductors 30 enable the combination of equipment from different circuit breaker manufacturers having different configurations within a single system. This combination of different circuit breakers is not possible in rigid busway systems. For this reason, it is standard for power distribution panel systems that incorporate rigid busways to designate a single suitable switch device manufacturer for use in the system. The conductor assembly 26 of the present disclosure alleviates the need for such a limitation. In one embodiment, the electrical conductors 30 are electrical buses that carry or transmit voltage, current, or power.

[0030] As used herein, the term "enclosure" refers to any suitable structure for housing electrical switch devices (e.g., without limitation, circuit switching devices and circuit interrupters such as circuit breakers, contactors, motor starters, motor controllers, and other load controllers), and expressly includes, without limitation, power distribution panels, load centers, and switch device boxes, as well as other structures or compartments covered with a panel, such as, for example and without limitation, in a wall of a building, on a workpiece of a machine, or on a vehicle.

[0031] As used herein, the statement that two or more parts are "attached" together shall mean that the parts are either directly joined together or joined together through one or more intermediate parts.

[0032] 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 (e.g., but not limited to, lock nuts), and combinations of bolts, washers, and nuts.

[0033] Referring now to Figure 4 Each electrical conductor 30 includes a partially flexible electrical conductor. In the illustrated embodiment, each conductor 30 includes an elongated rigid central conductor portion 35, an elongated flexible central conductor portion 34 attached to the rigid conductor portion, and a plurality of elongated flexible branch members 36 attached to and extending laterally outwardly from the rigid central conductor portion 35. The branch members 36 can be attached to the rigid conductor portion 35 by any suitable means. For example, the branch members 36 can be attached to the rigid conductor portion 35 using threaded fasteners, rivets, welding, adhesives, clamps, or any other suitable attachment mechanism. In the illustrated embodiment, welds 37 attach the branch members 36 to the rigid central conductor portion 35. Thus, in one embodiment, the flexible branch members 36 are formed separately from the central conductor portion 35. Alternatively, a housing 33 can be used to attach the branch members 36 and the flexible central conductor portion 34 to the central conductor portion 35, as will be explained in greater detail below. Additionally, the branch members 36 can be integrally formed with the central conductor portion 35. Each branch member 36 is configured for electrical connection to a switch device 32. Thus, each conductor 30 provides a flexible electrically conductive base for multiple electrical connections to different switch devices 32. The elongated rigid central conductor portion 35 and the elongated flexible central conductor portion 34 can be broadly considered to be a main conductor portion. Alternatively, only the rigid central conductor portion 35 can be considered to be the main conductor portion. Additionally, the entire central conductor portion can be flexible.

[0034] The rigid conductor portion 35, the flexible conductor portion 34, and each flexible branch member 36 each include a generally rectangular component. Other configurations of the conductor portions 34, 35 and the branch members 36 are also contemplated without departing from the scope of the present disclosure. In the illustrated embodiment, the rigid conductor portion 35 and the flexible conductor portion 34 each include a generally rectangular cross-section. Other cross-sectional configurations of the conductor portions 34, 35 are also contemplated without departing from the scope of the present disclosure. Figure 4 In the illustrated embodiment, three (3) branch members 36 are shown extending perpendicularly outwardly from opposite sides of the rigid central conductor portion 35, and in Figure 5In the illustrated embodiment, eleven (11) branch members 36 are shown. It should be understood that other numbers of branch members 36 are also contemplated. Further, the center conductor portion 34 can be shortened or lengthened to accommodate the desired number of branch members 36. Additionally, while each branch member 36 is shown as extending laterally from both sides of the rigid conductor portion 35, one or more branch members can be split into two separate branch members and attached to opposite sides of the rigid conductor portion as appropriate. As shown, portions of the branch members 36 on one side of the center conductor portion 34 are aligned along the longitudinal axis of the center conductor portion with portions of the branch members on the opposite side of the center conductor portion. Alternatively, one or more branch members can be staggered or offset along the longitudinal axis of the rigid center conductor portion 35 relative to the branch members on the opposite side of the rigid center conductor portion.

[0035] The rigid center conductor portion 35 can comprise a standard copper bus member, and the flexible center conductor portion 34 and the branch members 36 can each comprise a plurality of layers of laminated conductive material, such as copper, aluminum, or any other suitable conductive material. The layers of conductive material 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 portions 34, 35 and the branch members 36 can have alternative configurations without departing from the scope of the present disclosure. An insulating covering or jacket 40 surrounds the flexible center conductor portion 34 and the flexible branch members 36 of the conductor 30. In the illustrated embodiment, the covering 40 surrounds a majority of the flexible center conductor portion 34 and the branch members 36, but not their entirety. As shown, the covering 40 substantially surrounds the entirety of the flexible center conductor portion 34, but does not cover the free end portion 42 of the flexible center conductor portion. Figure 5 Similarly, the covering 40 substantially surrounds the entirety of the branch members 36, but does not cover the free end portions 44 of the branch members. The exposed free end portions 42, 44 are configured for electrical connection with the switchgear 32. For example, the main circuit breakers can be electrically connected to the free end portion 42 of the flexible center conductor portion 34, and the branch circuit breakers can be electrically connected to the free end portions 44 of the branch members 36. See Figure 4The cap portion 50 can cover the free end portions 44 of at least some of the branch members 36. For example, the cap portion 50 can be placed over the free end portions 44 of the branch members 36 that are not connected to the switch devices 32. The cover 40 and the cap portion 50 can be formed by overmolding or by extrusion. In one embodiment, the cover 40 around the center conductor portion 34 of the conductor 30 is overmolded onto the conductor, and the cover around the branch members 36 is extrusion molded. However, all of the cover 40 can be overmolded or extrusion molded without departing from the scope of the disclosure. Suitable materials for forming the cover 40 include, but are not limited to, thermoplastics, including polyvinyl chloride (PVC) and Santoprene.

[0036] 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 can extend over the entirety of the center conductor portion 34 and / or one or more of the branch members 36. In such a case, a portion of the cover 40 can be removed from the center conductor portion 34 and / or one or more of the branch members 36 to expose the conductive material for connection to the switch devices 32.

[0037] The branch members 36 can be selectively bent such that the branch members are capable of being bent in a first configuration to accommodate a first switch device arrangement, and subsequently bent in a second configuration or more configurations different from the first configuration to accommodate a second or more switch device arrangements. Thus, the branch members 36 are elastically deformable. The center conductor portion 34 can also be elastically deformable. The conductor 30, including the center conductor portion 34 and the branch members 36, can be bent or folded about multiple axes and / or twisted about an axis to configure the conductor into a desired configuration for a particular use. The bending, folding, and / or twisting can be accomplished manually by an end user. Thus, the conductor 30 can be configured as needed to accommodate different sizes and shapes of switch devices 32. Furthermore, as will be explained in greater detail below, the flexible nature of the conductor 30 allows the switch devices 32 to be properly positioned when multiple conductors are stacked on top of one another within an enclosure 22 for distributing multiple phases of electricity.

[0038] Referring to Figure 6 and Figure 7 The branch members 36 that are not connected to the switch devices 32 can be bent or otherwise moved out of the way of the other branch members to provide additional space within the enclosure for the switch devices and to further insulate the exposed conductor ends from service personnel. As shown in the illustrated embodiment, the unused branch members 36 can be bent back toward the housing 33, and the free end portions 44 can be inserted into the housing to shield the free ends of the branch members, as will be explained in greater detail below.

[0039] AsFigure 2B , Figure 3 and Figure 6 As shown, the flexible and insulated configuration of conductor assembly 26 also facilitates stacking two or more conductors on top of each other to configure the distribution assembly for delivering power to multiple phases. In this arrangement, a first conductor 30 mounted within a first housing 33 can be configured to distribute power of the first phase to a first set of switching devices 32 in the package 22; a second conductor 30 mounted within a second housing 33 and generally positioned above the first conductor can be configured to distribute power of the second phase to a second set of switching devices 32 in the package; a third conductor 30 mounted within a third housing 33 and generally positioned above the second conductor can be configured to distribute power of the third phase to a third set of switching devices 32 in the package, and so on. With conductors 30 stacked on top of each other, branch members 36 may not be perfectly aligned with the corresponding switching devices 32. This is particularly true for multi-pole circuit breakers 32. Figure 2B 32 two-pole circuit breakers were identified. (2p) and 3-pole circuit breaker 32 (3p) The flexible configuration of conductor 30 and, in particular, branch member 36, allows for connection to the switching device (including multi-pole circuit breaker 32) by bending, twisting, or otherwise manipulating the branch member to connect with the switching device. (2p) 32 (3p) They are electrically connected together. The housing 33 surrounding each conductor in the conductor 30 insulates each conductor from any other conductor within the package 22, thereby allowing the conductors 30 to be placed on top of each other without any interference between them.

[0040] See Figure 3 and Figures 8-12 Each housing 33 covers a portion of one conductor in the conductor 30 to cover the exposed conductor portion (i.e., the portion not covered by the cover 40), thereby forming a touch safety barrier on the conductor, allowing maintenance personnel to safely access the package 22. The housing 33 also spaces the conductor 30 from the other conductors in the package 22, preventing electrical interference between the conductors in the conductor assembly 26. Each housing 33 includes a first housing member 41 and a second housing member 41 attachable to the first housing member. The housing members 41 are configured such that a portion of the conductor 30 can be disposed between the housing members, and the housing members can be attached to each other to cover that portion of the conductor. Additionally, fasteners (not shown) may extend through the housing 33 and engage the rear surface of the package 22 to mount the housing 33 and the conductor 30 within the package. In one embodiment, the housing member 41 is typically a rigid structure.

[0041] The first and second housing members 41 are identical in structure and each comprise a generally elongated, plate-like configuration. Each housing member 41 includes a main body 43 comprising a main body portion 45 and an extension portion 47 extending from a bottom end of the main body portion. The main body portion 45 has an elongated octagonal shape. However, other shapes and configurations are within the scope of the present disclosure. The extension portion 47 includes a first extension portion 49 and a second extension portion 51 extending from the first extension portion. The second extension portion 51 is stepped down from the first extension portion 49, thereby forming a shoulder 53 between these extension portions. The main body 43, including the main body portion 45 and the extension portion 47, has an inner surface 55 and an outer surface 57. A hole 59 extends through the main body 43 from the outer surface 57 to the inner surface 55. The hole 59 allows a fastener to extend through the housing 33 to attach the housing to the package 22. In the illustrated embodiment, there are four (4) holes 59. However, any number of holes can be present without departing from the scope of the present disclosure. Additionally, the holes can be omitted and the housing can be mounted to the package by other means.

[0042] The body 43 of each shell member 41 defines hole alignment structures disposed about each hole 59 at the inner surface 55 and the outer surface 57. A first hole alignment structure 61 is located on the outer surface 57 of the shell member 41 and is disposed about the top two holes 59. The first hole alignment structure 61 includes an annular protrusion 63 that extends outwardly from the outer surface 57 and configures the top two holes 59 as counterbores on the outer surface of the shell member 41. Thus, the first hole alignment structure 61 includes a flat bottomed hole portion 65 that enlarges another coaxial hole portion. A second hole alignment structure 67 is located on the outer surface 57 of the shell member 41 and is disposed about the bottom two holes 59. The second hole alignment structure 67 includes an annular protrusion 69 that extends outwardly from the outer surface 57 and an annular recess 71 disposed in the outer surface about the annular protrusion 69. The second hole alignment structure 67 (and specifically the annular protrusion 69) also configures the bottom two holes 59 as counterbores on the outer surface of the shell member 41. A third hole alignment structure 73 is located on the inner surface 55 of the shell member 41 and is disposed about the left two holes 59 (as viewed from the outer surface 57) in the shell member. The third hole alignment structure 73 includes an annular protrusion 75 that extends inwardly from the inner surface 55 and an annular recess 77 disposed in the inner surface and about the annular protrusion 75. The third hole alignment structure 73 (and specifically the annular protrusion 75) configures the left two holes 59 (as viewed from the outer surface 57) as counterbores on the inner surface of the shell member 41. A fourth hole alignment structure 79 is located on the inner surface 55 of the shell member 41 and is disposed about the right two holes 59 (as viewed from the outer surface 57) in the shell member 41. The fourth hole alignment structure 79 includes a first annular protrusion 81 that extends inwardly from the inner surface 55 and a second annular protrusion 83 that extends inwardly from the inner surface and is disposed about the first annular protrusion 81, forming an annular floor 85 therebetween. It should be appreciated that the hole alignment structures can have other configurations without departing from the scope of the present disclosure. Moreover, the hole alignment structures can be omitted.

[0043] Referring to Figure 10 and Figure 12A longitudinal channel 91 is formed in the inner surface 55 of the body 43 and extends longitudinally along the body between opposite ends of the body. The longitudinal channel 91 is sized and shaped to receive the central conductor portion 35 of the conductor 30. For example, the width of the longitudinal channel 91 can be slightly greater than the width of the central conductor portion 35 so that the central conductor portion is securely held within the channel. The longitudinal channel 91 has a first portion 93 extending from near the top end of the housing member 41 toward the bottom end of the housing member, a second portion 95 extending from the bottom end of the housing member toward the top end of the housing member, and a third portion 97 between the first and second portions. The first portion 93 is recessed below the second portion so that the portion of the longitudinal channel 91 at the first portion is deeper than the portion of the longitudinal channel at the second portion. As will be explained in greater detail below, the recessed first portion 93 provides clearance for the central conductor portion 35 and the extension portion 47 of the housing member 41 of another housing 33 when multiple housings are coupled together in a linear arrangement.

[0044] A transverse channel 99 is formed in the inner surface 55 of the body 43 and extends transversely through the body between opposite sides of the body. The transverse channel 99 is sized and shaped to receive the branch member 36 of the conductor 30. For example, the width of the transverse channel 99 can be slightly greater than the width of the branch member 36 so that the branch member is securely held within the channel. A clip 101 is provided in the transverse channel 99 on opposite sides of the longitudinal channel 91. The clip 101 is configured to engage the branch member 36, and in particular the cover 40 on the branch member, to prevent the cover from slipping off. In the illustrated embodiment, the clip 101 comprises a bar that extends the entire width of the transverse channel 99. However, the clip 101 can have other configurations without departing from the scope of the disclosure.

[0045] Referring to Figures 8-10The clip arms 103 extend from the right side of the main body 43 (as viewed from the front of the housing member 41) toward the inner surface 55 of the housing member 41. Each clip arm 103 includes an arm member 105 and a catch 107 extending transversely from the arm member 105. A slot 109 is formed on the left side of the main body 43 (as viewed from the front of the housing member 41) and is sized and shaped to receive the clip arm 103 of the other housing member 41 for attaching the housing members together to form the housing 33. Each catch 107 has an angled surface 111 that is configured to engage a ramped surface 113 in the slot 109 when the clip arm is inserted into the slot. Once fully inserted into the slot 109, the catch 107 will snap onto the surface of the main body 43 adjacent to the slot to secure the housing members 41 together. It should be appreciated that the clip arms 103 can have other configurations without departing from the scope of the present disclosure. Additionally, the housing members 41 can be attached to one another in other ways without departing from the scope of the present disclosure. Furthermore, other suitable configurations of the housing 33 and other means for mounting the conductor 30 in the package 22 can also be incorporated without departing from the scope of the present disclosure.

[0046] Referring to Figure 3, the conductor assembly 26 is formed by receiving the conductor 30 between the two housing members 41 and securing the housing members together around the conductor. The center conductor portion 35 of the conductor 30 is received in the longitudinal channels 91 of the housing members 41 and the branch members 36 of the conductor are received in the transverse channels 99. The longitudinal channels 91 can together form a longitudinal passageway for receiving the center conductor portion 35 and the transverse channels 99 can together form a transverse passageway for receiving the branch members 36. To align the housing members 41 relative to each other for attaching the housing members together, the hole alignment structures 73, 79 on the inner surfaces 55 of the housing members are aligned with each other and engage to guide the housing members for secure engagement. In one embodiment, the third hole alignment structure 73 around the left two holes 59 of the first housing member 41 mates with the fourth hole alignment structure 79 around the right two holes of the second housing member 41. Specifically, the annular protrusion 75 of the third hole alignment structure 73 is inserted between and rests on the floor 85 between the first and second annular protrusions 81, 83 of the fourth hole alignment structure 79. The first annular protrusion 81 of the fourth hole alignment structure 79 will simultaneously rest on the counterbore of the third hole alignment structure 73. Upon seating the annular protrusions 75, 81, 83, the clip arms 103 will be fully inserted into the slots 109, whereby the catch 107 will clip onto the surface of the main body 43 adjacent to the slots and secure the housing members together. Thus, the conductor 30 will be securely held within the housing 33 formed by the two housing members 41. For example, the surfaces of the longitudinal channels 91 will engage at least a portion of the center conductor portion 35 to hold the center conductor in place. The clips 101 in the transverse channels 99 will engage the branch members 36 to secure the branch members in place. More specifically, the clips 101 will engage the cover 40 of the branch members 36 to prevent the cover from sliding. In the event that the branch members 36 and / or the flexible center conductor portion 34 are not previously attached to the rigid center conductor portion 35, the attachment of the housing members 41 to each other can also attach the conductor portions together. The transverse channels 99 can also provide open space for the ends of the branch members 36 that are not attached to the switch device to be folded back and inserted into the housing so that the exposed ends 44 are shielded by the housing from contact with a user. In Figure 6 and Figure 7 this arrangement is shown. In one embodiment, the free ends of the branch members 36 are held in the transverse channels 99 by a press fit. Alternatively, the slots 112 in the mounting plate 114 of the enclosure 22 can receive the exposed ends 44 of the branch members 36 that are not connected to the circuit breaker 32 to insulate the ends of the branch members from a user Figure 2C .

[0047] See Figures 13-15, a spring member 121 can be disposed between the housing members 41 of the housing 33 to apply a compressive force to the conductor 30. Thus, the spring member 121 can provide additional structure for holding the components of the conductor 30 in place in the housing 33. Further, in embodiments in which the housing 33 is used to attach the branch member 36 to the center conductor portion 35, such as when soldering or other suitable attachment means is not used, the spring member 121 can be used to apply the force required by the attachment mechanism of the components serving as conductors. Thus, the spring member 121 is configured to provide a contact resistance sufficient for the components of the conductor 30 to form an electrical connection. In one embodiment, the spring member 121 is configured to provide at least about 50 lbs of force to the conductor 30 when the conductor is received in the housing 33.

[0048] The spring member 121 can be configured in any suitable manner for providing the necessary compressive force to the conductor 30. For example, the spring member 121 can comprise a compression coil spring Figure 13 ). The coil spring 121 can be mounted to the interior surface 55 of one of the housing members 41 such that the coil spring is disposed between the housing member and the conductor 30. In one embodiment, the coil spring 121 is mounted at the juncture between the longitudinal slot 91 and the transverse slot 99. With the housing members 41 attached to one another, the coil spring 121 is biased against to provide a compressive force to the conductor 30 for holding the center conductor portion 35 and the branch member 36 together. The spring member 121 can also be a cantilever spring Figure 14 ). In this embodiment, one end of the cantilever spring 121 can be mounted to the interior surface 55 of one of the housing members 41, whereby at least a portion of the spring member is positioned to engage the conductor 30 when the housing members are attached to one another. This engagement will cause the cantilever spring 121 to flex from its natural position, thereby providing a compressive force to the conductor 30. The cantilever spring 121 can include a cam 123 configured to receive a tool (not shown) for relieving the pressure exerted by the spring on the conductor 30, such that the components of the conductor can be adjusted or removed as desired. The spring member 121 can also comprise a spring plate Figure 15 ). The spring plate 121 can be mounted to the interior surface 55 of one of the housing members 41 such that, when the housing members are attached to one another, the spring plate will be deformed by the conductor 30, thereby applying a compressive force to the conductor to hold the components of the conductor together. In one embodiment, the spring plate 121 is mounted at the juncture between the longitudinal slot 91 and the transverse slot 99. In one embodiment, the spring plate 121 is formed of spring steel. Other configurations of the spring member are also contemplated without departing from the scope of the disclosure.

[0049] Two or more housings 33 can also be connected to one another in a linear fashion, as Figure 3 and Figure 6As shown. For example, an extension 47 of the housing member 41 of the first housing 33 is received in the top of the second housing 33 between the two housing members forming the second housing, to connect the first housing to the top of the second housing. A shoulder 53 between the first extension 49 and the second extension 51 of the extension 47 of the first housing 33 abuts against a stop 115 placed on the inner surface 55 of the housing member 41 of the second housing 33 to properly position the first housing in the second housing. With the extension member 47 of the first housing 33 located between the housing members 41 of the second housing 33, when the housing members of the second housing are secured together, the first housing will be captured between the housing members of the second housing, thereby connecting the first housing and the second housing together. Overlapping the housings 33 in this way further ensures that leakage and clearance requirements are met by insulating the intersection between the housings. This process can be repeated to connect any desired number of housings 33 together. The housings 33 may also be connected to each other in other ways without departing from the scope of this disclosure.

[0050] Two or more shells 33 can also be stacked and connected to each other, such as Figure 3 and Figure 6 As shown. For example, the second hole alignment structure 67 of the bottom two holes 59 on the outer surface 57 of the bottom housing member 41 of the first housing 33 can mate with the corresponding first hole alignment structure 61 of the top two holes 59 on the outer surface 57 of the top housing member 41 of the second housing 33 to stack the first housing on top of the second housing. Specifically, the annular protrusion 69 of the second hole alignment structure 67 will be received in the countersunk hole 59 of the first hole alignment structure 61, such that the annular protrusion is positioned on the flat bottom hole portion -65, and the annular protrusion 63 of the first hole alignment structure is received in the annular recess 71 of the second hole alignment structure, thereby holding the housings 33 in place at least temporarily. Fasteners can then be inserted through at least one hole in the holes 59 to secure the housings 33 to the package 22, thereby securing the housings to each other. This will also cause the first housing and the second housing 33 to be slightly interleaved or offset, so that the second housing will extend below the first housing and the first housing will extend above the second housing. Therefore, the branch member 36 associated with the first housing 33 will be deviated from the branch member 36 associated with the second housing 33, which allows the use of multiple phases in the conductor assembly 26. This process can be repeated to stack any desired number of housings 33 on top of each other. Without departing from the scope of this disclosure, the housings 33 may also be stacked on top of each other in other ways.

[0051] The ability to connect multiple housings 33 together in a linear configuration and the ability to stack multiple housings on top of one another configures the power distribution assembly 20 for delivering multiple phases of electricity. Specifically, multiple conductors 30 can be installed in the package 22 and separated by insulating housings 33 for delivering multiple phases of electricity. Thus, a first conductor 30 can be configured to distribute a first phase of electricity to a first set of switch devices 32 in the package 22, a second conductor 30 can be configured to distribute a second phase of electricity to a second set of switch devices 32 in the package, and a third conductor 30 can be configured to distribute a third phase of electricity to a third set of switch devices 32 in the package. The housings 33 and insulating cover 40 insulate each conductor from the other conductors of the conductor assembly 26, allowing the conductors 30 to be stacked on top of one another without any interference between the phases. Thus, the housings 33 prevent short circuits between the phases when the conductors 30 are stacked on top of one another. It is contemplated that the conductor assembly 26 can have different numbers of conductors 30 for distributing different numbers of phases of electricity without departing from the scope of the present disclosure.

[0052] Having described the application in detail, it will be apparent that modifications and variations are possible without departing from the scope of the application defined in the appended claims.

[0053] As various changes could be made in the above constructions and methods without departing from the scope of the application, it is intended that all matter contained in the above description be interpreted as illustrative and not in a limiting sense.

Claims

1. An electrical conductor assembly for use in a power distribution assembly, comprising: a flexible electrical conductor; the flexible electrical conductor including a main conductor portion comprising an electrically conductive material, and at least one branch member comprising an electrically conductive material, the at least one branch member extending laterally from the main conductor portion; a housing covering at least a portion of the electrical conductor, the housing including first and second housing members attached to one another, a longitudinal channel formed in an inner surface of one of the housing members and extending longitudinally between opposite ends of the housing member, the longitudinal channel sized and shaped to receive the main conductor portion of the electrical conductor; and a transverse channel formed in an inner surface of the housing member and extending transversely through the housing member between opposite sides of the housing member, the transverse channel sized and shaped to receive the at least one branch member of the electrical conductor; and a spring member mounted to the housing and configured to apply a compressive force to the electrical conductor.

2. The electrical conductor assembly of claim 1, wherein the branch member is selectively bendable and configured for electrical connection to an electrical switching device.

3. The electrical conductor assembly of claim 2, wherein the electrically conductive material of the at least one branch member includes a plurality of laminated electrically conductive material layers.

4. The electrical conductor assembly of claim 2, wherein the spring member is configured to apply sufficient force to the flexible electrical conductor such that the main conductor portion and the at least one branch member are electrically connected.

5. The electrical conductor assembly of claim 4, wherein the spring member is configured to provide at least 50 lbs of force to the flexible electrical conductor.

6. The electrical conductor assembly of claim 2, wherein the housing and the spring member provide the only attachment mechanism for connecting the at least one branch member to the main conductor portion.

7. The electrical conductor assembly of claim 1, wherein the spring member includes one of a coil spring, a cantilever spring, and a spring plate.

8. The electrical conductor assembly of claim 7, wherein the spring member includes a cantilever spring and a cam configured to receive a tool to move the cantilever spring to relieve the compressive force on the electrical conductor to allow adjustment of the electrical conductor in the housing.

9. The electrical conductor assembly of claim 1, wherein the first and second housing members have mating alignment structures to properly position the housing members relative to one another for attachment of the housing members to one another.

10. The electrical conductor assembly of claim 1, wherein the housing insulates the at least a portion of the electrical conductor.

11. The electrical conductor assembly of claim 1, wherein the housing is rigid.

12. A power distribution assembly, comprising: an enclosure; a flexible electrical conductor disposed in the enclosure, the flexible electrical conductor comprising: a main conductor portion comprising an electrically conductive material; and a plurality of branch members comprising an electrically conductive material, the plurality of branch members extending laterally from the main conductor portion, each branch member being selectively bendable and configured for electrical connection to an electrical switching device; and a plurality of housings covering portions of the flexible electrical conductor, each housing comprising a spring member mounted to the housing and configured to apply a compression force to the flexible electrical conductor, each housing further comprising a first housing member and a second housing member attached to one another, a longitudinal channel formed in an inner surface of one of the housing members and extending longitudinally between opposite ends of the housing member, the longitudinal channel being sized and shaped to receive the main conductor portion of an electrical conductor, and a transverse channel formed in an inner surface of the housing member and extending transversely through the housing member between opposite sides of the housing member, the transverse channel being sized and shaped to receive one of the branch members of an electrical conductor.

13. The assembly of claim 12, wherein the spring member is mounted at a junction between the longitudinal channel and the transverse channel.

14. The assembly of claim 12, wherein each housing is rigid.

15. The assembly of claim 12, wherein the assembly is configured to distribute electricity for a plurality of phases.

16. The assembly of claim 12, wherein each spring member is configured to apply sufficient force to the flexible electrical conductor such that the main conductor portion and a corresponding branch member are electrically connected.

17. The assembly of claim 16, wherein each spring member is configured to provide at least 50 lbs of force to the flexible electrical conductor.

18. The assembly of claim 16, wherein the housing and the spring member provide the only attachment mechanism for connecting the branch members to the main conductor portion.

19. The assembly of claim 12, wherein the spring member comprises one of a coil spring, a cantilever spring, and a spring plate.

20. The assembly of claim 12, wherein the housing comprises a first housing member and a second housing member attached to one another.

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