Modular chassis housing

Abstract

Electrical power is often distributed initially via a busbar unit. A difficulty with one busbar unit is that small imperfections or breaks in an insulating skin of the busbar unit can breach the electrical insulation of the busbar member. It would be desirable to provide a housing that may be used instead of, or in addition to, an insulating skin. The invention is directed to a modular housing for a busbar unit having at least one busbar member and a plurality of tee-off terminals extending laterally of the busbar member, the housing including: (i) a lid having a top wall and at least two supporting walls extending from the top wall, the supporting walls having support formations that are configured to support the at least one busbar member at different points in a lengthwise direction, and the supporting walls being spaced to accommodate the plurality of tee-off terminals therebetween; (ii) a base that can be fitted to the lid, the base having a bottom wall that is oppositely disposed to the top wall of the lid when fitted together, the base having opposing side panels configured to define part of the tee-off openings such that the plurality of tee-off terminals can be retained in and can extend through the tee-off openings by fitting the lid to the base, wherein the housing has opposing end walls extending in a widthwise direction, formed at last in part by two of the supporting walls, the end walls of the housing being adapted to allow at least two housings to be connected end-to-end.

Description

MODULAR CHASSIS HOUSINGFIELD OF THE INVENTIONThe present invention relates to a modular housing for a busbar unit that is used to distributing electrical power. The housing is configured so that it can be connected to another housing to accommodate busbar units of various sizes.BACKGROUND OF THE INVENTIONElectrical power is a product of voltage and current and is often supplied at both high voltage and high current to maximise power transmission. The electrical power is often distributed initially via a busbar unit having at least one main busbar member and a plurality of tee-off terminals extending from the main busbar member. The tee-off terminals can be electrically connected to transformers, circuit breakers, switch boards and so forth.A busbar unit that is presently available comprises one or more main busbar members having a longitudinal axis, a set of tee-off terminals extending laterally from the main busbar member, and an insulating polymeric skin that is applied to the unit after assembly. A difficulty with the unit is that small imperfections or brakes in the insulating skin can breach the electrical insulation of the busbar member. These imperfections can be hard to see. For example, the insulating skin may have small breaches that may result from impacts with sharp objects such as an end of the screw driver piercing the skin. This can place maintenance workers, electricians and other users at risk of electrocution.It would therefore be desirable to provide a modular housing for a busbar unit that can be used instead of, or in addition to, the insulating skin described above.SUMMARY OF THE INVENTIONAn embodiment of the present invention relates to a modular housing for a busbar unit having at least one busbar member and a plurality of tee-off terminals extendinglaterally of the busbar member, the housing including: (i) a lid having a top wall and at least two supporting walls extending from the top wall, the supporting walls having support formations that are configured to support the at least one busbar member at different points in a lengthwise direction, and the supporting walls being spaced to accommodate the plurality of tee-off terminals therebetween; (ii) a base that can be fitted to the lid, the base having a bottom wall that is oppositely disposed to the top wall of the lid when fitted together, the base having opposing side panels configured to define part of the tee-off openings such that the plurality of tee-off terminals can be retained in and can extend through the tee-off openings by fitting the lid to the base, wherein the housing has opposing end walls extending in a widthwise direction, formed at last in part by two of the supporting walls, the end walls of the housing being adapted to allow at least two housings to be connected end-to-end.The term “lengthwise direction” or variations thereof, refers to the longitudinal direction of the main busbar members in the housing.The term “widthwise direction” or variations thereof, refers to a direction lateral to the lengthwise direction, and is denoted by the direction of the tee-off terminals.One of the advantages of the modular housing is that the busbar unit can be loaded into the base with the main busbar members supported by the support formations and with the tee-off terminals in position between the supporting walls, and the tee-off terminals can be held in an operative position in the tee-off openings by fitting the lid to the base.This may also in turn secure the busbar unit in an operative position in the modular housing.Another advantage is that two or more modular housings can be connected end-to-end to accommodate different lengths of the main busbar members. The length of the main busbar members may be described with reference to the number of lateral tee-off terminals.Number of busbars and tee-off terminalsThe housing may be configured to accommodate any number of the main busbar members, but ideally the housing may be configured to accommodate from 1 to 4 mainbusbar members. It will be recognised that each main busbar member may be supplied alternating electrical current of different phases.Ideally, the number of the supporting walls of the housing is at least one more than the number of the main busbar members that can be accommodated by the housing.The tee-off terminals can be located in channels that are formed between the support walls.The lid and base may be injection moulded from a polymer material. Each lid and cooperating base may be dimensioned to accommodate a busbar member of predetermined cross-sectional dimensions. Each lid and cooperating base may be dimensioned to accommodate a tee-off terminal of predetermined cross-sectional dimensions or pitch. Each base and lid for cooperatively mounting thereto may be colour coded for ease of selection.The supporting walls located at opposite ends may form at least one of the end walls of the housing. In other words, the supporting walls arranged first and last in the lengthwise direction form at least part of the ends walls of the housing.For example, the housing may accommodate one main busbar and at least two tee-off terminals, and the main busbar member will be supported on at least two of the supporting walls, and the housing will have at least two tee-off terminals that extend through the side wall. The tee-off terminals may extend through opposite side walls. In this example, the supporting walls will provide at least part of the two end walls, and one pair of the tee-off terminals is arranged therebetween.In another example, the housing may accommodate two main busbar members supported on the supporting walls and at least two pairs of the tee-off terminals, that is, a total of four tee-off terminals. In this example, the housing will have three of the supporting walls, in which two of the supporting walls will provide at least part of the end walls of the housing, and the third supporting wall is located intermediate thereof to form channels with the end walls.First and second formations - that orient the main busbars in an upright orientationThe support formations of the supporting walls may be a first recess in which the main busbars can be seated. Ideally, the recess is configured to support a web of the main busbars in an upward orientation.The first recess may be a saddle formation that receives the main busbars members.The lid of the housing may include divider walls extending from the top wall, the divider walls may be oriented in a widthwise direction and may include secondary recesses.Preferably, the supporting wall and the divider wall align when the lid and base are fitted together.Preferably, the first and secondary recesses align to form a slot in which a web of the main busbar members can be located, in an upright orientation.The supporting walls may have a plurality of U-shaped channels along a length of the lid to support the busbar member therealong. The base may also provide U-shaped channels along a length of the base to seat the busbar members therealong.Side walls oriented lengthwiseIdeally, the base has outer panels spaced along the bottom wall, wherein the side panels of the lid and the outer panels of the base are arranged to provide continuous side walls on opposite sides of the housing having the tee-off openings.The tee-off openings of the side wall align with the channels provided between the first supporting walls.The side walls extend from the top wall and bottom wall in the lengthwise direction.The tee-off openings may be provided at least in part by distal ends of the side panels of the lid being configured to receive the tee-off terminals.The distal ends of the side panels may include a first depression that at least in part receives the tee-off terminal. The first depression may at least in part define the tee-off opening of the side wall.A lip formation may also extend from the bottom wall, in which the lip has a second depression that at least in part receives the tee-off terminal. The second depression may at least in part define the tee-off opening of the side wall.The outer panels of the base and the side panels of the lid may be arranged alternatingly so that when fitted, the side panels are positioned adjacent to at least one of the outer side panels, and vice versa.The outer panels of the base may be separated by spacings and the side panels of the lid can be fitted into the spacings between the outer panels.The outer panels of the base may be connected to the supporting walls.Ideally, the outer panels define entrances to the channels formed between the supporting walls.The side panels of the lid may have a tongue formation.The side panels and the outer panels may have a tapered profile so that clearance between the tongue panels and the outer panels reduces as the lid is fitted on the base. Friction between the lid and the base therefore increases as the lid is fitted on to the base.Lid and base slide and clip togetherThe lid and base may have any suitable formation that facilitates the lid and base being fitted together.The lid may provide locating pins that extend inwardly from the top wall, the locating pins positioned to be received within recesses of the base to thereby align the lid to the base around the busbar unit. The locating pins of the lid and the recesses within the base may be hollow such that a fastener can be inserted from the top wall through the housing and into a platform to mount the housing to the platform.In one example, the lid and base are slidably engaged in which co-operating formations progressively interfit so that frictional engagement between the lid and base also increases.Ideally, the lid and base include co-operating sliding elements that slide relative to each other when the lid is moved from an initial aligned position to a final closed position.The co-operating sliding elements may include a projection extending from the lid, and an opening extending from the base that receives the projection and frictionallyengages to retains a head of the projection as the lid moves into the closed, fitted position.The co-operating sliding elements may include a clip having:i) a projection with an enlarged distal head and a narrower neck connecting the head to the lid; andii) a receiver formation having a pair of arms that define a constriction, the arms being connected to the base and resiliently movable away from each other, in which the head and the constriction of the arms are sized so that when the lid is moved toward the fitted position, the head engages the restriction, pushing the arms apart, allowing the lid to be pushed to fit the lid to the base, at which the head moves past the constriction and the arms recoil toward each other so that the head is secured inwardly of the constriction.Ideally, the top wall of the lid has access openings aligned with the head. A user can disengage the clip to remove the lid by inserting an objection, such as a screw driver, into the access opening to prize the arms apart and release the head from between the arms.The base and the lid may comprise at least one internal fastener for holding the lid and the base together. The internal fastener may comprise a pair of receiving arms and a protruding nose, respectively mounted to one of the lid and the base. The nose may extend from a pair of undercut shoulders, such that the pair of receiving arms snap fit around the nose, to hold the lid and base together.In some embodiments an access hole may be provided in at least one of the base and the lid in direct communication with at least one of the pair of receiving arms and the protruding nose, such that a tool can be inserted through the housing to release the lid from the base. The access hole may be provided to guide the tool between the receiving arms of the internal fastener to release the lid from the base.The internal fastener may be located between the plurality of U-shaped channels of the lid and the base. In some embodiments, the internal fastener may be located between a pair of supporting walls.The opposing side panels of the base may each be configured to form three fingers,extending from the bottom wall towards the top wall of the lid. Each finger may have a recessed distal end conforming to the shape of a tee-off terminal, such that when the lid is engaged with the base each tee-off terminal is encircled by the recessed distal and the lid. At least one of the supporting walls of the lid may form an outer panel, the outer panel configured to extend through a gap formed between two adjacent fingers of the base. The outer panel may be tapered to reduce in width as the outer panel extends away from the top wall of the lid.End-to-endThe end walls may be formed by two of the supporting walls extending from the lid and two of the divider walls extending from the base.The end walls may be adapted by having a stepped configuration having an inset section and a protruding section, whereby when two of the housings are placed end-to-end, the inset sections of the housings are overlapped by the protruding sections of an adjacent housing.One of the advantages of this feature is that the end-to-end connection of adjacent housings are not simply a matter of the lids of adjacent housings being interconnected, and the bases of the adjacent housing being interconnected. Rather, the lid of a first housing is connected to the base of an adjacent second housing, and the base of the first housing is connected to the lid of the adjacent second housing.The end walls may be adapted by having a stepped configuration in which, the supporting walls forming part of the end walls have a first lower inset section and a first lower protruding section, and the divider walls forming part of the end walls have a second upper inset section, and a second upper protruding section. The second upper protruding section overhangs the first lower inset section, and the first lower protruding section extends outwardly from the second upper inset section.A fastener can then be used to attach the lid to the base and vice versa.In another embodiment, the end walls made be adapted by having interfitting formations. Examples of the interfitting formations of the end walls may include any one or a combination of male and female formations such as a T-shaped rail that is received by a corresponding groove, or interfitting dove tail formations.End capsThe modular housing may include an end cap that can be fitted to the end wall at one end of the housing in which the main busbar member(s) terminate. The purpose of the end cap is to cover the support formations of the supporting wall forming part of the end wall. Thereby enclosing the ends of the busbar members within the housing.The end cap may connect to the interfitting formations of the end wall.The end cap may have an integrally formed body having protruding sections and inset sections that cooperate with the end walls of the housing.In one embodiment, the end cap may have an integrally formed body having two protrusion sections and two inset sections that co-operate with the end walls of the housing. In other words, the ends cap be fitted to the end walls of either end of the housing.In some embodiments, the modular housing may comprise a plurality of cooperating lids and bases forming a plurality of modules mounted end-to-end around three busbar members, a first end of the housing sealed with an end cap and a second end of the housing comprising a junction compartment from which connection ends of each of the three busbar members extend. The modular housing may be mounted to a platform, the platform configured to support a plurality of circuit breakers mounted to the tee-off terminals of the three busbar members.Junction compartmentThe modular housing may include a junction compartment including a junction lid and a junction base. The main busbar members have a web element that is oriented in an upright manner in the housing. The web members twist through 90 degrees when exiting the housing to transition from an upright orientation to a flat, horizontal orientation as the connection ends of each busbar member protrudes from the junction compartment. These flat connection ends facilitate connection with power couplings.VentilationThe lid may include vents to allow air and / or heat to be vented from the housing. The vents may include slots in the top wall of the lid. Ideally, the vents include slots between the second support walls. The may be arranged lengthwise of the housing but are ideally arranged widthwise across the housing.The base may include vents to allow heat to be ventilated from the housing.At least one of the lid and the base may provide ventilation holes for the modular housing. The ventilation holes may be dimensioned to prevent tools or foreign objects from being inserted into the housing or brought into contact with the live busbar members.In a second aspect, the invention provides a modular housing for a busbar unit having at least one busbar member and a plurality of tee-off terminals that extend perpendicularly to the busbar member, the modular housing including at least one upper member and at least one lower member, the upper and lower members configured to provide a tailored enclosure for the busbar unit when interleaved together, such that terminal ends of the busbar member and associated tee off terminals protrude through the housing for access; the enclosure provides a top, a bottom, two end walls and two side walls, each of the end walls and side walls being partially formed from both the upper member and the lower member, to receive the busbar unit therebetween when the upper and lower members are brought together, wherein the two opposing side walls of the enclosure from which the tee-off terminals protrude are planar and the two opposing end walls of the enclosure from which the busbar member extends are staggered forming a first overhang formation and a second protruding formation at each of the opposing end walls for interlinking with at least one of a complementary modular housing and an end cap. In some embodiments the upper member may be a lid and the lower member may be a base of the housing.BRIEF DESCRIPTION OF THE DRAWINGSEmbodiments of the invention are illustrated by way of example, and not by way of limitation, with reference to the accompanying drawings, of which:Figure 1A is a perspective view of an uncoated busbar unit for use with a busbar housing of the present invention;Figure 1B is an exploded view of a modular busbar housing according to one embodiment of the invention to encapsulate the uncoated busbar of Figure 1B;Figure 1C is a cross-sectional end view of a busbar member, illustrating the transition of the section along the main body through 90 degrees.Figure 2 is a top perspective view of a lid and a base in accordance with an embodiment of the present invention, wherein the lid and base are in the process of being aligned and fitted together in the direction of the arrows, and a busbar unit shown in phantom-lines in which the lid will engage the tee-off terminals of the busbar, to secure the busbar in position within the housing;Figure 3 is a bottom perspective view of a lid of a modular housing for containing a busbar unit such as that shown in figure 2;Figure 4 is a top perspective view of the lid shown in figure 3;Figure 5 is a plan view of the lid shown in figure 2;Figure 6 is a top perspective view of a lid of the modular housing shown in figure 2;Figure 7 is a plan view of the base shown in figure 6;Figure 8A is a cross-sectional view of a clip in a release position, the clip comprising a head that extends from the underneath of the lid identified in circle A in Figure 3,Figure 8B is a cross-sectional view of a pair of arms that extends upwardly from the base identified in circle B in Figure 6;Figure 9 is an inner top perspective view of an end cap that can be fitted to one of the base and lid of figures 2 to 7 when assembled together to form a modular housing;Figure 10 is an outer top perspective view of the end cap shown in figure 9;Figure 11 is a top perspective view of a junction upper segment;Figure 12 is a top perspective view of a junction lower segment that fits with the junction upper segment shown in figure 11;Figure 13 is a top perspective view of a platform to which the modular housing can be mounted;Figure 14 is a plan view of an assembled modular housing according to one embodiment comprising the platform of figure 13, two pairs of the bases and lids illustrated in figures 2 to 7 connected end-to-end in a line, a pair of the junction upperand lower segments at a first end of the assembled modular housing, a busbar unit comprising three main busbar members extending lengthwise in which three connection terminals of the busbar members are exposed, an end cap at a second end of the assembled modular housing, and a total of twelve tee-off terminals extending widthwise;Figure 15 is a plan view of an assembled modular housing according to another embodiment comprising the platform of figure 13, six of the modular housings illustrated in figures 2 to 7 connected end-to-end in a line, a pair of junction upper and lower segments at opposing ends of the assembled modular housing , a busbar unit comprising three main busbar members extending lengthwise having three connection terminals at both ends, and a total of 28 tee-off terminals extending widthwise; andFigure 16 is a side view of the assembled modular housing in Figure 15, illustrating the full encasement of the main busbar members, only the three end connection terminals of each end being accessible.Embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments, although not the only possible embodiments, of the invention are shown.DETAILED DESCRIPTIONThe invention may be embodied in many different forms and should not be construed as being limited to the embodiments described below. The description includes reference numerals that identify the features described in the figures. However, to maintain clarity of the figures, all of the reference numerals have not been included in each figure.An embodiment of the invention will now be described in reference to Figures 1-16, which provides a modular housing (23) for a busbar unit (20) having at least one busbar member (21) and a plurality of tee-off terminals (22) extending laterally of the busbar member, the housing including: (i) a lid (25) having a top wall (32) and at least two supporting walls (33) extending from the top wall, the supporting walls having support formations (35) that are configured to support the at least one busbar member at different points in a lengthwise direction, and the supporting walls being spaced to accommodate the plurality of tee-off terminals (22) therebetween; (ii) a base (24) thatcan be fitted to the lid (25), the base having a bottom wall (46) that is oppositely disposed to the top wall (32) of the lid when fitted together, the base (24) having opposing side panels (28) configured to define part of the tee-off openings (15) such that the plurality of tee-off terminals (22) can be retained in and can extend through the tee-off openings (15) by fitting the lid to the base, wherein the housing (23) has opposing end walls (27) extending in a widthwise direction, formed at last in part by two of the supporting walls (33), the end walls (27) of the housing being adapted to allow at least two housings (23) to be connected end-to-end.Figure 1A is a perspective view of a chassis or busbar unit (20) according to one embodiment of the invention. The busbar unit (20) comprises three busbar members (21) extending longitudinally. Each busbar member (21) configured for connection to one of a three-phase power supply.Each busbar member (21) comprises a web (21a) of conductive material with connecting terminals (31) at one end, and a contorted section in which the web (21a) of the busbar members (21) is shaped from: i) a horizontal configuration in which the connecting terminals are laid out side-by-side in a horizontal plane as shown at the lefthand end of figure 1, to ii) an upright configuration in which the webs (21a) are oriented upright.The contorted section of each busbar member (21) has a 90° twist interconnecting a connecting terminal (31) with a main body (21b) of the busbar member which is oriented in an upright plane. The three busbar members (21) are located in a side-byside orientation across the busbar unit (20), each member including a similarly contorted section (21c) that provides a 90° twist (a dog leg) in the main body (21b) of the busbar member (21).Two lateral members (22a) (22b) are connected to each busbar member (21), providing pairs of tee-off terminals (22) from each of the three busbar members (21) Figure 1A showing a busbar unit (20) or chassis having 12 equidistantly spaced tee-off terminals, six per side. The lateral members (22a) (22b) are configured as L-shaped sections. A first leg of the L-shaped section disposed parallel and in touching contact with the main body (21b) of a busbar member (21). The second leg of the L-Shaped section disposed perpendicular to the main body (21b) of the busbar member (21) to extend across the busbar unit (20) for connection with a residual current circuit breaker(RCCB) or residua current breaker with over load protection (RCBO) often referred to as a “breaker”). The distal end of the second leg of the L-Shaped section having a two-pronged profile (22d) for engaging with an RCCB or mini-breaker 10 (see Figure 16).The tee-off terminals (22) shown in Figure 1B are 16mm in width with about 25mm of tee-off terminal protruding from the housing (23) for engagement with a cooperating circuit breaker. In some embodiments of the busbar unit (20) the tee-off terminals can be wider or narrower than 16mm in width, depending on the power requirements of the unit (20), for example 14mm width, 18mm width, 20mm width.The tee-off terminals (22) are spaced along the housing with a pitch of about 36mm (centre-to-centre). As with the width of the tee-off terminals (22) the pitch can also be varied to accommodate the power requirements of the busbar unit (20). The tee-off terminals (22) along a single busbar unit (20) can be of varying widths and pitches, depending on the power requirements therefrom.The busbar unit (20) as shown in Figure 1A does not have an insulating polymeric material coating. One of the advantages of the preferred embodiment is that the modular housing (23) encases the busbar unit (20), save for the terminal ends (31) of the main busbar members (21) and the tee-off terminals (22) so that a polymeric material is completely avoided. The modular housing (23) is constructed of any suitable insulating materials, including polymers, polycarbonate polymers, ABS and so forth.Figure 1B is an exploded view of the busbar unit (20) from Figure 1A, in position within a modular housing (23) according to one embodiment of the invention. The busbar unit (20) is seated on at least one lower portion (24) of the housing (23) which is mounted to a platform (42). The platform (42) having two side-platforms (42a, 42b) for supporting RCCB’s therealong for connecting with the tee-off terminals (22). Above the busbar unit (20) is a plurality of upper potions (25) of the housing (23). As the upper portions (25) ae positioned above the busbar members (21) the upper (25) and lower (24) portions interconnect about the busbar members (21) forming the protective housing (23) all around the busbar unit (20) such that only the tee-off terminals (22) and the connecting terminals (31) are exposed.Figure 1B also illustrates a junction compartment (30) formed from upper (57a) and lower (57b) segments that encapsulate the contorted section (21c) of the busbar members (21) and an end cap (29) to full seal the housing about the busbar unit (20).Figure 1C illustrates a cross-sectional view of a busbar member (21), looking end on at the member (21). The connecting terminal (31) is illustrated as having a width W. The width is about 40mm. A 10mm diameter hole (H) is centrally located in the connecting terminal (31) for connecting to power cables thereto. The busbar member (21) is illustrated to have a depth D. The depth D is constant along the length of the busbar member (21). The depth D of the busbar member (21) is 6.35 mm in a 630Amp busbar unit (20). Alternatively, the depth D of the busbar member (21) is 8.0mm in a 800Amp busbar unit (20).Figure 2 illustrates the components of the housing (23) in more detail. A first module (59) of the modular housing (23) for a busbar unit (20) includes a base (24) and a lid (25) that are aligned in anticipation of being fitted together. The busbar unit (20) is illustrated in phantom lines with the webs (21a) of the main busbar members (21) being illustrated in an upright orientation and extending lengthwise along the housing (23). For convenience, the terminals of the main busbar members (21) have not been illustrated and tee-off terminals (22) have been illustrated in position on a first side of the base (24) only. Tee-off terminals (22) would also be present on the opposing side of the base (24) but have been omitted from Figure 2 for clarity.The lid (25) and base (24) are configured to cooperatively interfit to form side walls (26) and end walls (27), in which the tee-off terminals (22) extend through tee-off openings in the side walls (26). The side panels (28) of the base (24) engage the tee-off terminals (22) to assist in securing the busbar unit (20) in position in the housing (23). Where the side panels (28) form continuous side walls (26), when connected with the lid (25).The lid (25) and base (24) of Figure 2 encapsulate the busbar unit (20) and prevent a user from inadvertently contacting the busbar members (21) within the housing (23). When two or more of the modules (59) illustrated in Figure 2 are assembled and connected end-to-end, to form modular housing (23) in a line (L) that can accommodate the busbar unit (20) illustrated in Figure 1. In addition, when additional modules (59) including an end cap (29) and a junction compartment (30) are added,the entire modular housing (23) encapsulates the busbar unit (20) and connecting terminals (31), the tee-off terminals (22) projecting from the housing (23), as shown in Figure 1B.The individual modules (59) forming the modular housing (23) will now be described.Figure 3 is a bottom perspective view of the lid (25). The lid (25) includes a top wall (32) and four supporting walls (33) extending from the top wall (32). The four supporting walls (33) extending continuously in the widthwise direction across the top wall (32) and have outer panels (34) that form part of the side wall (26) of the housing (23). The outer panels (34) have a tapered profile, increasing in dimension in the lengthwise direction when moving in a direction toward the top wall (32).The four supporting walls (33) each include recesses (35) in the form of U-shaped saddles that receive the web (21a) of the main busbar members (21) and support the main web (21a) in an upright orientation.Two of the four supporting walls (33) are outwardly facing and form part of the end walls (27) of the housing (23). The other two supporting walls (33) are inner supporting walls that are evenly spaced across the top wall (32) to define three channels (36) extending in a widthwise direction for accommodating the tee-off terminals (22).The channels (36) each have side entrances defined by the outer panels (34) at the ends of the supporting walls (33). The entrances also have a lip formation (37) having a depression (38) that at least partially receives the tee-off terminal (22).The inner supporting walls (33) each comprise two lateral panels (33a, 33b), and a central panel (33c) between the widthwise panels that extend the entire width and project through the outer panels (34). The inner supporting walls (33) have pairs of cavities between the lateral and the central panels.As can best be seen in Figures 3 and 5, the supporting walls (33) that form part of the end wall (27) are truncated and have a cavity (60) that extends across approximately half the width of the end wall (27) which provides first inset sections (39) and first protruding sections (40). The first inset sections (39) and the first protruding sections (40) are offset relative to each other. Specifically, as can best be seen in the plan view of the lid (25) shown in Figure 5, the first protruding section (40) is located on the left side of the lid (25) at a first end and located at the right side at the opposite secondend. Similarly, the first inset section (39) is located on the left at the first end and is located on the right at the second end.The inner supporting walls (33) also provide cavities (61) that include two bore formations (41) for receiving sleeves and fasteners for securing the lid (25) either directly to the base (24) or to the platform (42), such as that shown in Figures 1B and 13.Two upper-lugs (43) extend downwardly from the cavities (60) of the outer supporting walls (33) at the ends of the lid (25). Each upper-lug (43) having an inner ring standing proud on an upper end of the lower-lugs (43). The upper-lugs (43) are configured to connect to lower-lugs (44) extending upwardly from a bottom wall (46) of the base (24), illustrated in Figure 6. The lower-lugs (44) have a central recess which receives the inner ring of the upper-lugs (43) to assist in aligning the lid (25) and base (24) when fitting the pair together.The two lateral panels (33a, 33b) of the inner supporting walls (33) each form a secondary cavity (61). Means for securing the base (24) to the lid (25) can be packaged within the cavities (61) to ensure that fixings and the like are kept away from the busbar members (21), minimising the possibility of electrical contact.In the embodiment shown in Figures 3-5, the housing (23) also has a two-part clip that can help secure the lid (25) in a fitted position on the base (24). The two-part clip includes a pair of resiliently deformable arms (45) located in the secondary cavity (61) of the internal support walls (33). The pair of arms (45) can be located in each of the cavities (61).A head formation (49) is formed protruding inwardly from the base (24), configured to be received and captured, by the resilient arms (45). Additional heads (49) are provided for corresponding pairs of arms (45). Illustrated in Figure 8, the leading ends of the arms (45) have inwardly tapered surfaces that define a constriction and, moving in a direction toward the top wall (32), an enlarged undercut is provided beneath the tapered surfaces. The base (24) includes the head (49) that is received by the arms (45).The base (24) illustrated in Figures 2, 6 and 7 comprises the bottom wall (46) including a series of ventilation slots (62) that are sized to prevent most inset sections and foreign objects from entering the housing via the slots (62). Dividing walls 47 areoriented in a widthwise direction extending from an underneath face of the bottom wall (46). The dividing walls (47) include lateral panels and a central panel to provide inner cavities, and the lateral panels and the central panel include inverted U-shaped formations (48) that straddle across the webs (21a) of the main busbar members (21) to assist in securing the busbar members (21) in an operative position.Illustrated in Figure 8, the head formations (49) have ramp surfaces (63) that extend outwardly in a direction toward the bottom wall (46), the head formations (49) include inwardly set shoulders below the ramp surfaces (63). Once the head formations (49) move past the constriction of the arms (45) and into the undercut, the lid (25) is fitted to the base (24).Figure 7 illustrates a plurality of square openings (50) provided in the bottom wall (46) of the base (24) which allows direct access to the shoulders of the head formations (49). In practice, this enables a screwdriver to be placed into the openings (50) to enable the resiliently deformable arms (45) to be prized apart to release the lid (25) from the base (24) as desired.As shown in Figure 6, the base (24) includes a first pair of legs (51) that align with the first and third channels (36) of the lid (25) and have a length that is selected to engage the tee-off terminals (22) located in the channels (36) and place downward pressure on the tee-off terminals (22).The base (24) also includes a second pair of legs which are in the form of hollow sleeves (52) that open at an upper face of the bottom wall (46). When the lid (25) and base (24) are fitted together the sleeves (52) are received by the bores (41) within the lid (25) which allow fasteners to pass from the top wall (32) through the sleeves (52) through the bores (41) and into the platform (42) for securing the base (24) and lid (25) in an assembled condition to the platform (42), illustrated in Figure 13.Returning to Figures 2 and 6, the base (24) has side panels (28) extending from the bottom wall (46) that are spaced by lower gaps. The distal end of the side panels (28) have an inwardly facing depression (28a) that engages the tee-off terminals (22) of the busbar unit (20) when the lid (25) is fitted to the base (24). The side panels (28) have tongues (28b) and side ridges (28c) that extend inwardly. The dimensions of the side panels (28) reduce movement between the lid (25) and base (24) in a direction toward the distal end of the side panels. Conversely, the size of the gaps between the sidepanels (28) reduces movement between the lid (25) and the base (24) in a direction toward the bottom wall (46).The outer panels (34) of the lid (25) also have a tapered profile in which the dimension of the outer panels (34) parallel to the side walls reduces in a direction moving away from the top wall (32). This tapering of the outer panels (34) provides a locating feature aligning the outer panels (34) with the gaps between the tongues (28b).In order to fit the lid (25) to the base (24), the side panels (28) of the base (24) are received in the upper gaps between the outer panels (34) of the lid (25) and similarly, the outer panels (34) of the lid (25) are received by the lower gaps between the side panels (28) of the base (24) in an interfitting manner. Once the side panels (28), outer panels (34) and the respective gaps have been aligned, the lid (25) can be moved toward the base (24) with the side panels (28) and the outer panels (34) sliding into the respective upper and lower gaps. Moreover, the tapered profiles of these components increase friction between the lid (25) and base (24) components as they are fitted together.One of the advantages of this embodiment is that the distal end (28a) of the side panels (28) engage the tee-off terminals (22) when the lid (25) and base (24) are fitted together and form an enclosure in which the busbar unit (20) is encapsulated. This minimises the risk of a person contacting the busbar unit (20) within the housing (23).The lid (25) and base (24) are configured in a number of ways that enable the lid (25) and base (24) to slidably fit together. Examples of the particular configurations of the lid (25) and base (24) that enable sliding engagement include the following:i) The tapered profiles of the outer panels (34), side panels (28) and the respective upper and lower gaps slidably interfit.ii) The side ridges (28c) of the side panels (28) engage the inner faces of the internal supporting walls (33), and the inwardly facing surfaces of the side ridges butt against and slide over end faces of the supporting side walls (33).iii) The head (49) of the clip slides through the pairs of resiliently deformable arms (45) of the clip.iv) The side panels (28) of the base (24) that align with the first inset sections of the end walls (27) of the lid (25) do not include a side ridge (28c). Rather, the side panel (28) sits flush with the outer face of the end wall (27) at the first inset section (54) (see Figure 7).The dividing walls (47) of the base (24) extend widthwise across the base (24). The first and last dividing walls also form part of the end walls (27) of the housing (23). As illustrated in Figures 6 and 7, the dividing walls (47) also provide second inset sections (54) and second protruding sections (55). The second inset sections (54) at a first end of the base (24) align with first protruding sections (40) at the second end of the lid (25) and vice versa.When the lid (25) and base (24) are fitted together, the end walls (27) of the housing (23) have a stepped formation and are formed by both supporting walls (33) and dividing walls (47) of the base (24) and lid (25) respectively. The stepped formation includes second protruding sections (55) that overhang the first inset sections (39) and the first protruding sections (40) extend outwardly of the second inset sections (54). The stepped formation allows the housing modules (59) to be placed end-to-end to form a bespoke housing (23) configured to house a busbar unit 20.Figures 9 and 10 illustrate an end cap (29) of the modular housing (23) that can be fitted to one end of the housing in which the main busbar unit (20) terminates. The end cap (29) is configured to provide a stepped profile to cooperate with the stepped ends of the housing modules (59), that is the inset profile (54) and protruding profile (55).The end cap (29) includes open bores (58) that align with corresponding lugs (43,44) in the end wall of the lid (25) and base (24) to allow a faster to pass through the first and second segments mounting the end cap (29) to the terminating end of the housing (23).The upper and lower lugs (56) may have openings that allow fasteners to be used to attach the end cap (29) to the end of the line, or alternatively to attach the end cap (29) and the end of the housing to the platform.The Figures 11 and 12 illustrate a junction compartment (30) of the modular housing (23). The junction compartment (30) comprises first (57a) and second segments (57b) that are fitted together to encapsulate the contortion sections (21c) of the main busbar members (21). When fitted together the junction compartment (30) has a narrow endwall (30a) that faces and interconnects to an end wall of the line (L) of the modular housing (23), and an opposite end wall (30b) from which the connecting terminals (31) of the busbar members 21 can protrude.The narrow end wall (30a) includes first and second sets of protruding sections (40,40a), and first and second sets of inset sections (39,54) that match with corresponding sections at the end wall of the line (L). An end lug (68) is provided in the protruding section of the narrow end wall (30a) that aligns with a corresponding lug (43,44) in the end wall of the line (L) to allow a fastener to pass through a lid (25) and a base (24) of a first module (59) of the line (L).The first (57a) and second (57b) segments are configured to ramp outwardly from the narrow end wall (30a) to the larger end wall (30b) and have ventilation openings in the first (upper) and second (lower) segments.The main busbar members (21) extend from the line (L) into upright openings in the narrow end-wall (30a) of the junction compartment (30) and connection terminals (31) of the main busbar members (21) extend through horizontal slots in the wide end-wall (30b).The first (57a) and second (57b) segments include internal supporting formations including U-shaped recesses (69) that each receive a portion of the main busbar members 21. Each of the first and second segments is provided with ventilation slots (62) to aid cooling of the busbar unit (20).Illustrated in in Figure 12, the first (57a) and second (57b) segments also include clips (63, 63a), for retaining the first and second segments (57a, 57b) together, similar to those described above and depicted in Figure 8. Similarly, access openings (64) are also provided in base walls of the first and second segments (57a, 57b) for allowing the clips (63, 63a) to be released.In addition to the clips (63, 63a), the first and second segments (57a, 57b) can be held together by:i) Fasteners received in internal lug formations of the first and second segments.ii) Fasteners can be received by the end lug formations for fastening the first and second protruding sections of the compartment to corresponding protruding sections of line.Figure 13 illustrates the platform (42) on which the housing (23) can be mounted. The platform (42) includes a sub-plate (65) and two superior plates (66) that flank either side of a central region (67) of the sub-plate (65). The modular housing (23) described herein can be mounted to the central region (67) of the sub-plate, as shown in Figures 14 and 15. Circuit breakers 10, and switches and other electrical hardware (not illustrated) can be mounted to the superior plates (66) and to the tee-off terminals (22).Figure 14 illustrates a modular housing (23) comprising two sets of the bases (24) and lids (25) of Figure 2 fitted end-to-end and mounted to the platform (42) in Figure 13. One of the end caps (29) is fitted to a terminating end of the housing (23) and a junction compartment (30) comprising upper and lower compartment segments (57a, 57b) that encapsulate the contorted sections (21c) of the main busbars member (21). The upper and lower compartment segments (57a, 57b) extend outwardly from the platform (42).Figure 15 illustrates a modular housing (23) comprising six sets of the bases (24) and lids (25) of figure 2 fitted end-to-end and mounted to the platform (42) of figure 13. As can be seen, the main busbar members (21) extend from opposite end of the housing (23) and junction compartments (30) are fitted to the contorted sections (21c) at either end of the main busbars (21). Tee-off terminals (22) extend laterally through tee-off openings through the side wall (26) of the housing.The housing (23) described herein offers extreme flexibility in its modular construction to safely enclose all manner of busbar units (20). The end cap (29) and junction compartments (30) can be reversed to accommodate a top feed or a bottom feed connection (ie. installed orientation depending on which end of the busbar unit (20) provides the connecting terminals (31)).Flush end plates (29) allows a pair of busbar units (20) to be mounted in coaxial alignment, with each of the end plates (29) face-to-face to create a double busbar unit (20) for mounting onto a standard pole board.Additional flexibility is provided in that different size and pitches of tee-off terminals can be accommodated in the busbar unit (20) and also by the modular housing (23).Shown in Figure 15 a plurality of housing modules (59) accommodate 6 tee-off terminals (2x3) and a plurality of housing modules (59’) accommodate 4 tee-off terminals (2x2).Various embodiments of the housing are contemplated to accommodate 630Amp and 800Amp variants of the busbar unit (20). Additionally, different pitches of tee-off terminals (22) can be catered for with embodiments of the base (24) and lid (25). The width of all housing components is common, as is the dimensions of the protruding section (40) and the inset section (39) to ensure cooperative mounting with common end caps (29) junction compartments (30) and adjacent modules (59).A bespoke busbar unit (20) can be installed in a building and a modular housing tailored to exactly fit the requirements of the unit (20), by selecting the necessary end caps, junctions, bases and lids to encase the busbar members (21). Each adjacent module (59, 59’) of the housing (23) is staggered by virtue of the recessed inset sections (39, 54) and the protruding sections (40, 55) to overlap with the adjacent module (59, 59’) providing a secure and robust housing (23) along the line (L) of the busbar unit (20).It will be appreciated by persons skilled in the art that numerous variations and modifications may be made to the above-described embodiments, without departing from the scope of the following claims. The present embodiments are, therefore, to be considered in all respects as illustrative of the scope of protection, and not restrictively.Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the example methods and materials are described herein.It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Claims

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not topreclude the presence or addition of further features in various embodiments of the invention.LEGENDRCCB / RCCO / Breaker 10 Lower Lugs 44 Tee-off opening 15 Arms 45 Busbar Unit 20 Bottom Wall 46 Main Busbar Member 21 Dividing Wall 47 Tee-Off Terminals 22 Inverted U-Shaped Formations 48 Modular Housing 23 Head Formations 49 Base 24 Square - 50 Lid 25 First Pair of Legs 51 Side Wall 26 Second Pair of Legs 52 End Wall 27 Downward Facing Depression 53 Side Panels 28 Second Inset Sections 54 End Cap 29 Second Protruding Sections 55 Junction Compartment 30 Upper and Lower Lugs 56 Terminals 31 First and Second Segment 57 Top Wall 32 End Lugs 58 Supporting Walls 33 Module 59 Outer Panels 34 Cavity 60 Recesses 35 Secondary Cavity 61 Channels 36 Ventilation Slots 62 Lip Formation 37 Ramp Surfaces 63 Depression 38 Access Openings 64 First Inset Sections 39 Sub-Plates 65 First Protruding Section 40 Superior Plates 66 Base Formations 41 Central Region 67 Platform 42 End Lugs 68 Upper Lugs 43 U-Shaped Formations in Junction 69 CLAIMS1. A modular housing for a busbar unit having at least one busbar member and a plurality of tee-off terminals extending laterally of the busbar member, the housing including:i) a lid having a top wall and at least two supporting walls extending from the top wall, the supporting walls having support formations that are configured to support the at least one busbar member at different points in a lengthwise direction, and the supporting walls being spaced to accommodate the plurality of tee-off terminals therebetween;ii) a base that can be fitted to the lid, the base having a bottom wall that is oppositely disposed to the top wall of the lid when fitted together, the base having opposing side panels configured to define part of the tee-off openings such that the plurality of tee-off terminals can be retained in and can extend through the tee-off openings by fitting the lid to the base,wherein the housing has opposing end walls extending in a widthwise direction, formed at last in part by two of the supporting walls, the end walls of the housing being adapted to allow at least two housings to be connected end-to-end.

2. The modular housing of claim 1, wherein the supporting walls have a plurality of U-shaped channels along a length of the lid to support the busbar member therealong.

3. The modular housing of claim 1 or claim 2, wherein the base also provides U-shaped channels along a length of the base to seat the busbar members therealong.

4. The modular housing of any one of claims 1-3, wherein the lid provides locating pins that extend inwardly from the top wall, the locating pins positioned to be received within recesses of the base to thereby align the lid to the base around the busbar unit.

5. The modular housing of claim 4, wherein the locating pins of the lid and therecesses within the base are hollow such that a fastener can be inserted from the top wall through the housing and into a platform to mount the housing to the platform.

6. The modular housing of any one of claims 1-5, wherein the opposing side panels of the base are each configured to form three fingers, extending from the bottom wall towards the top wall of the lid.

7. The modular housing of claim 6, wherein each finger has a recessed distal end conforming to the shape of a tee-off terminal, such that when the lid is engaged with the base each tee-off terminal is encircled by the recessed distal end and the lid.

8. The modular housing of claim 7, wherein at least one of the supporting walls of the lid forms an outer panel, the outer panel configured to extend through a gap formed between two adjacent fingers of the base.

9. The modular housing of claim 8, wherein the outer panel is tapered to reduce in width as the outer panel extends away from the top wall of the lid.

10. The modular housing of any one of claims 1-9, wherein at least one of the lid and the base provides ventilation holes for the modular housing.

11. The modular housing of any one of claims 1-10, further comprising at least one internal fastener for holding the lid and the base together.

12. The modular housing of claim 11, wherein the internal fastener comprises a pair of receiving arms and a protruding nose, respectively mounted to the lid and the base.

13. The modular housing of claim 12, wherein the nose extends from a pair of undercut shoulders, such that the pair of receiving arms snap fit around the nose, to hold the lid and base together.

14. The modular housing of claim 12 or claim 13, wherein an access hole is provided in at least one of the base and the lid in direct communication with at least one of the pair of receiving arms and the protruding nose, such that a tool can be inserted through the housing to release the lid from the base.

15. The modular housing of claim 14, wherein the access hole is provided to guide thetool between the receiving arms of the internal fastener to release the lid from the base.

16. The modular housing of any one of claims 11-15, wherein the internal fastener is located between the plurality of U-shaped channels of the lid and the base.

17. The modular housing of any one of claims 11-15, wherein the internal fastener is located between a pair of supporting walls.

18. The modular housing of any one of claims 11-17, wherein the lid and base are injection moulded from a polymer material.

19. The modular housing of any one of claims 11-18, wherein each lid and cooperating base is dimensioned to accommodate a busbar member of predetermined cross-sectional dimensions.

20. The modular housing of any one of claims 11-18, wherein each lid and cooperating base is dimensioned to accommodate a tee-off terminal of predetermined cross-sectional dimensions or pitch.

21. The modular housing of claim 19 or claim 20, wherein each base and lid for cooperatively mounting thereto is colour coded for ease of selection.

22. The modular housing of any one of claims 1-21, wherein the housing comprises a plurality of cooperating lids and bases forming a plurality of modules mounted end-to-end around three busbar members, a first end of the housing sealed with an end cap and a second end of the housing terminating with a junction compartment from which connection ends of each of the three busbar members extend.

23. The modular housing of claim 22, wherein the modular housing is mounted to a platform, the platform configured to support a plurality of circuit breakers mounted to the tee-off terminals of the three busbar members.

24. A modular housing for a busbar unit having at least one busbar member and a plurality of tee-off terminals that extend perpendicularly to the busbar member, the modular housing including at least one upper member and at least one lower member, the upper and lower members configured to provide a tailored enclosure for the busbar unit when interleaved together, such that terminal ends of thebusbar member and associated tee off terminals protrude through the housing for access;the enclosure provides a top, a bottom, two end walls and two side walls, each of the end walls and side walls being partially formed from both the upper member and the lower member, to receive the busbar unit therebetween when the upper and lower members are brought together,wherein the two opposing side walls of the enclosure from which the tee-off terminals protrude are planar and the two opposing end walls of the enclosure from which the busbar member extends are staggered forming a first overhang formation and a second protruding formation at each of the opposing end walls for interlinking with at least one of a complementary modular housing and an end cap.57a                        * 20 H 42b ............. / 7 57b 21c 31           ?\ 21b \ \ 3 Figure 1B M "          29 24 \ \         42a 42 D J 1       Figure 1C - 2621a

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