Power distribution unit, circuit breaker mount and method for distributing power

Abstract

The invention relates to a power distribution unit, a circuit breaker mount and a method for distributing power. The power distribution unit includes an enclosure including a front panel, at least one side panel, and a rear panel. The power distribution unit also includes at least one power output socket mounted on the enclosure and at least one or more circuit breakers coupled to the circuit breaker mount. The circuit breaker may have a DIN rail mounting design and be connected in series with a corresponding power jack receptacle. The circuit breaker mount includes a base surface for attaching the circuit breaker mount to the power distribution unit, a mounting surface, and a top surface. The mounting surface of the circuit breaker mount includes a first mounting post and a second mounting post to allow the DIN rail mountable circuit breaker to be mounted in the power distribution unit.

Description

Technical Field

[0001] The present invention relates to rack mounted power distribution units and, more particularly, to panel mounts to allow additional types of circuit breakers to be implemented into a rack power distribution unit. Background Art

[0002] Computer servers are basic components of data centers, which provide computing power and storage required for various applications. In order to provide power to these computer servers, power distribution units (PDUs) are usually located near the servers. PDUs are devices designed to efficiently and safely distribute power from the main power supply to multiple electronic devices or equipment in data centers, industrial environments, office spaces, and various other applications. Traditional PDUs usually include a housing with multiple electrical sockets or receptacles that allow users to connect multiple devices. These PDUs are connected to the main power supply, such as a public power supply or an uninterruptible power supply (UPS). PDUs are used as intermediaries between power supplies and electronic devices, such as computer servers.

[0003] PDUs rely on circuit breakers as important safety components. Circuit breakers play a vital role in protecting electrical systems from potential risks such as overcurrent, short circuits, and other electrical faults. By quickly interrupting the flow of electricity when an abnormality occurs, circuit breakers prevent damage to equipment, reduce the risk of fire, and ensure the safety of those operating the equipment. Although conventional circuit breakers may be effective in PDUs, the continued innovation of PDUs and the increasing demand for more robust uninterrupted power require additional resources to incorporate various types of circuit breakers into PDUs.

[0004] Most modern circuit breakers are designed with DIN rail mounting packages. DIN rail mounts serve as a standardized mounting platform, facilitating the installation and organization of various electrical devices within control panels and distribution panels. The universal design of the DIN rail mount enables easy installation, replacement, and reconfiguration of circuit breakers, thereby enhancing overall flexibility and ease of maintenance. The combination of circuit breakers with DIN rail mounts streamlines electrical system installation, making it more efficient, cost-effective, and adaptable to a wide range of applications in modern electrical engineering. DIN rail mounted circuit breakers are not typically used in rack PDUs because access to the actuator of the circuit breaker needs to be provided from the front of the unit.

[0005] In view of the above, there is a need for a rack PDU that allows the use of DIN rail mounted circuit breakers in place of conventional PDU circuit breakers. The present invention provides a solution to this need by introducing a circuit breaker panel mount that can be secured within a standard rack PDU. This panel mount allows circuit breakers with DIN rail mounting tools to be installed and used in a rack PDU. The novel design of this panel mount allows a more diverse selection of circuit breakers to be used in a rack PDU, thereby reducing costs, increasing manufacturing capabilities, and additional electrical capabilities of the rack PDU. Summary of the invention

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] In an embodiment, the present disclosure relates to a power distribution unit (PDU). The PDU includes an enclosure including a front panel, at least one side panel, and a rear panel. The PDU also includes at least one power output socket mounted on the enclosure and at least one or more circuit breakers coupled to the circuit breaker mounting. The circuit breaker can have a DIN rail mounting design and be connected in series with a corresponding power outlet socket.

[0008] In an embodiment, the present disclosure relates to a circuit breaker mount for mounting a circuit breaker to a front panel of a power distribution unit. The circuit breaker mount includes a base, a mounting surface, and a top surface. The base includes left and right mounting tabs, left and right mounting holes, a base cavity that can cool the circuit breaker, and a base connector that connects the left and right mounting tabs. The mounting surface includes a first mounting post, a second mounting post, and a mounting cavity between the first and second mounting posts that allows the circuit breaker to be air cooled. The top surface includes a top mounting tab and a top mounting hole for mounting the circuit breaker mount to a PDU. The top surface also includes a top cavity for enabling air cooling of the installed circuit breaker.

[0009]

[0011] These and other features and aspects may be better understood with reference to the following drawings, description and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Detailed description is given with reference to the accompanying drawings.

[0011] Figure 1 illustrates a front orthogonal view of a power distribution unit (PDU);

[0012] Figure 2 An orthogonal view of a DIN rail circuit breaker mount is illustrated;

[0013] Figure 3 Picture shows Figure 1PDUs and Figure 2 a rear orthogonal view of a DIN rail circuit breaker mount; and

[0014] Figure 4 Picture shows Figure 1 PDUs and Figure 2 Top view of a DIN rail circuit breaker mount. DETAILED DESCRIPTION

[0015] Various aspects of the present disclosure are described more fully below with reference to the accompanying drawings, which form a part of the present disclosure and which illustrate example features by way of illustration. However, these features may be implemented in many different forms and should not be construed as limited to the combinations set forth herein; rather, these combinations are provided so that the present disclosure will be exhaustive and complete and will fully convey the scope. Therefore, the following detailed description is not intended to be limiting.

[0016] As shown throughout the various figures, the present disclosure is directed to a rack mounted power distribution unit (PDU) having a circuit breaker panel mount that allows DIN rail mountable circuit breakers to be used in the PDU. Figure 1 , illustrates a PDU 100 according to an exemplary embodiment of the present disclosure.

[0017] Figure 1 1 is a front orthogonal view illustrating a PDU 100 in an open position according to one embodiment of the present invention. The PDU 100 includes a rear panel 102, a right side panel 104, a left side panel 106, and a front panel 108. The PDU 100 may also include at least one rack mounting tab 110. The rack mounting tab 110 is configured to engage with a rack. In an embodiment, the PDU 100 may be considered a rack PDU (rPDU), wherein the rack PDU is mounted in a conventional server rack using at least one mounting tab 100. The PDU 100 also includes a circuit breaker 114. The circuit breaker 114 may be of a DIN rail type. As depicted, the circuit breaker 114 includes a user-accessible actuator that is presented and extends from the front panel 108. The actuator may have a first position for closing a circuit, a second position indicating an overload and thus opening a circuit, and a third position indicating a reset position. The presence of an actuator allows a user to operate the individual circuit breakers 114 and is a desirable feature of the PDU 100. DIN rail type circuit breakers are generally found for higher amperage ratings, which are necessary to support higher power densities.

[0018] Figure 21 is an orthogonal view illustrating a DIN rail breaker mount 116 according to the present invention. The DIN rail breaker mount 116 can be made using a material that can be bent, molded, or machined. However, a typical material for a DIN rail breaker mount can be steel or aluminum. The DIN rail breaker mount 116 includes a top surface 118. The top surface 118 can have a height of approximately 61 mm and a width of approximately 60 mm (2.35 inches). The top surface 118 includes a top cavity 120. The top cavity 120 allows air to flow on both sides of the top surface 118. When the circuit breaker 114 is installed in the DIN rail breaker mount 116, the air flowing in and around the top cavity 120 can cool the circuit breaker 114. The top surface 118 also includes a top connector 122, a left mounting tab 124, and a right mounting tab 126. A left mounting tab 124 and a right mounting tab 126 extend outwardly from the DIN rail breaker mount 116 at opposite ends of the top connector 122. Each of the left mounting tab 124 and the right mounting tab 126 has a width of approximately 13 mm (0.50 inches). The right mounting tab 124 may include a right mounting hole 128. The left mounting tab 126 may include a left mounting hole 130. The right mounting hole 128 and the left mounting hole 130 may be used to align the DIN rail breaker mount 116 with the front panel 108 of the PDU 100. Screws may pass through the mounting holes 128, 130 and be inserted into the front panel 108 to secure the DIN rail breaker mount 116 to the PDU 100. The diameter of each of the mounting holes 128, 130 is approximately 2.8 mm (0.11 inches).

[0019] Figure 2Also illustrated is a DIN rail breaker mount 116 that may include a mounting surface 132. The mounting surface 132 includes a first mounting post 134, a second mounting post 136, and a mounting cavity 138. As illustrated in the exemplary embodiment, the mounting cavity 138 is the space between the first mounting post 134 and the second mounting post 136. When the circuit breaker is mounted in the DIN rail breaker mount 116, air flowing in and around the mounting cavity 138 can cool the mounted circuit breaker. It will be appreciated by those of ordinary skill in the art that the size and alignment of the first mounting post 134 and the second mounting post 136 are very similar to the size and alignment of a standard DIN rail mount. As depicted in the exemplary embodiment, the length of each of the first mounting post 134 and the second mounting post 136 is approximately 54 mm (2.10 inches), which is very similar to the length of a DIN rail. The distance between the first mounting post 134 and the second mounting post 136 is approximately 20 mm (0.78 inches). However, the size and alignment of the first and second mounting posts 134, 136 are not limited to the size and alignment of standard DIN rail mounts, and the mounting posts 134, 136 may be aligned to accommodate any type of circuit breaker mounting system.

[0020] Figure 2 It is also illustrated that the DIN rail breaker mount 116 may include a base surface 140. The base surface 140 includes a base cavity 142, a base mounting tab 144, and a base mounting hole 146. The length of the base surface 140 is approximately 62 mm (2.45 inches), and the width of the base surface 140 is approximately 35 mm (1.37 inches). The base cavity 142 is formed in the center of the base surface 140. When the circuit breaker is installed in the DIN rail breaker mount 116, air flowing in and around the base cavity 142 can cool the circuit breaker. As illustrated in the exemplary embodiment, the base mounting tab 144 extends outwardly from the base surface 140 at an approximately 90 degree angle by approximately 13 mm (0.5 inches). The base mounting tab 144 includes a base mounting hole 146. The base mounting holes 146 have a diameter of approximately 2.8 mm (0.11 inches) and can be used to align the DIN rail breaker mount 116 with the front panel 108 of the PDU 100. Screws can be inserted through the base mounting holes 146 and into the front panel 108 to secure the DIN rail breaker mount 116 to the PDU 100.

[0021] Figure 3A rear orthogonal view of a PDU 100 and a DIN rail breaker mount 116 according to an exemplary embodiment is illustrated. A circuit breaker 114 is shown mounted within the DIN rail breaker mount 116. In the exemplary embodiment, four circuit breakers are mounted within the DIN rail breaker mount 116. One of ordinary skill in the art will recognize that the illustrated circuit breaker 114 is considered a "single pole" circuit breaker. As depicted in the exemplary embodiment, a "single pole" circuit breaker has a width ranging from 12 mm to 13 mm (0.48 inches to 0.52 inches). Thus, four "single pole" circuit breakers having a combined width of 48 mm to 52 mm (1.8 inches to 2.1 inches) can be mounted within the DIN rail breaker mount 116. However, circuit breakers of other sizes may also be mounted within the DIN rail breaker mount 116. Two "two pole" circuit breakers will fit within the DIN rail breaker mount, and a single "four pole" circuit breaker will fit within the DIN rail breaker mount.A significant benefit of the present invention is that the DIN rail breaker mount 116 allows a variety of circuit breakers to be used with the rack PDU instead of traditional panel style breakers.

[0022] Figure 4 A top view of the PDU 100 and the DIN rail breaker mount 116 is illustrated according to an exemplary embodiment. The DIN rail breaker mount 116 may be mounted to the front panel 108 via screws passing through the left and right mounting holes 128, 130. Figure 4 It is also shown that the circuit breaker 114 can be aligned with each of the corresponding power outlet receptacles 112a, 112b, 112c, 112d, 112e, 112f of the circuit breaker 114.

[0023] Although the subject matter has been described in language specific to structural features and / or methodological acts, it will be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.

Claims

1. A power distribution unit, comprising: The enclosure comprises: Front panel; a first power outlet socket mounted on the enclosure; and A first circuit breaker mount is coupled to the front panel of the enclosure.

2. The power distribution unit according to claim 1, wherein: The first circuit breaker mount includes a mounting surface including a first mounting post and a second mounting post, wherein the first mounting post and the second mounting post are spaced apart.

3. The power distribution unit according to claim 1, wherein: The first mounting post and the second mounting post are spaced apart to receive a circuit breaker having a standard DIN rail mount.

4. The power distribution unit according to claim 1, wherein: The mounting surface also includes a mounting cavity formed by a space between the first mounting post and the second mounting post.

5. The power distribution unit of claim 1, further comprising a first circuit breaker electrically coupled to the first power outlet receptacle, the first circuit breaker physically coupled to the first circuit breaker mount.

6. The power distribution unit according to claim 1, wherein: The first circuit breaker includes a user accessible actuator.

7. The power distribution unit according to claim 6, wherein: The user-accessible actuator is configured to be in a first position to indicate a closed circuit.

8. The power distribution unit according to claim 7, wherein: The user-accessible actuator is configured to be in a second position to indicate an open circuit.

9. The power distribution unit according to claim 8, wherein: The user-accessible actuator is configured to be in a third position indicating a reset position.

10. The power distribution unit according to claim 1, wherein: The circuit breaker mounting member also includes a first mounting hole.

11. The power distribution unit according to claim 10, wherein: The circuit breaker mounting member also includes a second mounting hole.

12. The power distribution unit according to claim 11, wherein: The front panel of the enclosure includes a plurality of mounting locations.

13. The power distribution unit according to claim 12, wherein: The first mounting hole and the second mounting hole are configured to be mounted to the mounting location by a fastening device.

14. A circuit breaker mounting member, the circuit breaker mounting member being used to mount a circuit breaker to a front panel of a power distribution unit, the circuit breaker mounting member comprising: A base, the base comprising: Left mounting tab; Right mounting tab; Left mounting hole; Right mounting hole; a base connector connecting the left mounting tab and the right mounting tab; and a base cavity, wherein the base cavity is configured to allow cooling of the circuit breaker; A mounting surface, the mounting surface comprising: a first mounting post; and a second mounting post, wherein the first mounting post and the second mounting post are parallel to each other and are configured similar to a DIN rail mounting surface; and a mounting cavity, wherein the mounting cavity is configured to allow cooling of the circuit breaker; A top surface, the top surface comprising: a top cavity, wherein the top cavity is configured to allow cooling of the circuit breaker; and a top mounting tab, wherein the top mounting tab extends perpendicularly from the top surface; and Top mounting holes.

15. The circuit breaker mounting according to claim 14, wherein: The left mounting tab extends outwardly from the base connector.

16. The circuit breaker mounting according to claim 15, wherein: The right mounting tab extends outwardly from the base connector.

17. The circuit breaker according to claim 14, wherein: The circuit breaker is a single-pole circuit breaker.

18. The circuit breaker according to claim 14, wherein: The circuit breaker is a two-pole circuit breaker.

19. A method for distributing electric power, comprising: providing an enclosure having a front panel, at least one side panel, and a rear panel; mounting at least one power outlet socket on the enclosure; as well as At least one or more circuit breakers are coupled to a circuit breaker mount, wherein the circuit breaker mount is coupled to the front panel of the enclosure.

20. The method according to claim 19, wherein: The at least one or more circuit breakers are DIN rail mounted circuit breakers.

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