Conductive bar, circuit breaker, distribution board, and method for manufacturing conductive bar

Abstract

The problem disclosed herein is to provide a conductive bar capable of facilitating construction. This conductive bar (1) is used in a circuit breaker (10) that cuts off a current. The conductive bar (1) comprises: a longitudinal conductor that is connected to an electric wire through which a current flows; and a sensor that is fixed to the conductor and performs detection relating to the current.

Description

Conductive bar, circuit breaker, distribution board, and method for manufacturing conductive bar

[0001] The present disclosure relates to a conductive bar, a circuit breaker, a distribution board, and a method for manufacturing a conductive bar, and more particularly to a conductive bar used in a circuit breaker that interrupts current, a circuit breaker including a conductive bar, a distribution board including a circuit breaker, and a method for manufacturing a conductive bar.

[0002] Patent Document 1 describes a mounting terminal block that is used in a circuit breaker and is capable of measuring a current flowing in an electric path (conductor).

[0003] Conventionally, bus bars have been provided for use in circuit breakers. In circuit breakers using bus bars, in order to accurately measure current, it is necessary to place a current sensor at a predetermined position relative to the conductor through which the current flows, which makes installation difficult.

[0004] Japanese Patent Application Laid-Open No. 2021-78290

[0005] An object of the present disclosure is to provide a conductive bar, a circuit breaker, a distribution board, and a method for manufacturing the conductive bar that can facilitate installation.

[0006] A conductive bar according to one aspect of the present disclosure is a conductive bar used in a circuit breaker that interrupts a current, and includes a longitudinal conductor connected to an electric wire through which the current flows, and a sensor fixed to the conductor for detecting the current.

[0007] A circuit breaker according to one aspect of the present disclosure includes the conductive bar and a circuit breaker body to which the conductive bar is attached.

[0008] A distribution board according to one aspect of the present disclosure includes the circuit breaker and a distribution board main body that houses the circuit breaker.

[0009] A manufacturing method of a conductive bar according to one aspect of the present disclosure is a manufacturing method by bending the conductive bar. The conductor has a longitudinal plate shape. The conductive bar further includes a plurality of protrusions formed on a main surface of the conductor along the longitudinal direction of the conductor. The sensor includes a substrate having a plurality of insertion holes into which the protrusions are respectively inserted, and a plurality of sensor elements each having a ring shape and mounted on the substrate so as to surround the insertion holes. The conductive bar further includes a fixing portion that fixes the substrate to the conductor when the protrusions are inserted into the insertion holes, respectively. The conductor is a first conductor connected to a first electric wire, and the conductive bar further includes a second conductor connected to a second electric wire. The plurality of protrusions are a plurality of first protrusions formed on a first main surface of the first conductor along the longitudinal direction of the first conductor. The conductive bar further includes a plurality of second protrusions formed on a second main surface of the second conductor along the longitudinal direction of the second conductor. The plurality of insertion holes are a plurality of first insertion holes into which the plurality of first protrusions are respectively inserted, and the substrate is further formed with a plurality of second insertion holes into which the plurality of second protrusions are respectively inserted. The plurality of sensor elements are a plurality of first sensor elements mounted on the substrate so as to surround the plurality of first insertion holes, respectively. The sensor further includes a plurality of second sensor elements, each having a ring shape, mounted on the substrate so as to surround the plurality of second insertion holes, respectively. The fixing portion fixes the substrate to the first conductor and the second conductor with the plurality of first protrusions and the plurality of second protrusions inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively. The plurality of first insertion holes and the plurality of second insertion holes are arranged in two rows along a first direction such that the first insertion holes and the second insertion holes alternate in a second direction intersecting the first direction. The fixing portion fixes the substrate to the first conductor and the second conductor in a state in which the plurality of first protrusions and the plurality of second protrusions are inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively, so that the first protrusions and the second protrusions are staggered in the second direction.The first conductor and the second conductor are arranged such that the longitudinal directions of the first conductor and the second conductor are aligned with the first direction, and the first main surface of the first conductor and the second main surface of the second conductor face a first orientation along the second direction. Each of the plurality of first protrusions has a first portion extending from the first main surface in the first direction along a third direction intersecting each of the first direction and the second direction, a second portion extending from a tip of the first portion in a direction from the first main surface toward the second main surface along the second direction, and a third portion extending from a tip of the second portion in the first direction along the third direction. Each of the second protrusions has a fourth portion extending from the second main surface in the first direction along the third direction, a fifth portion extending from a tip of the fourth portion in a direction from the second main surface toward the first main surface along the second direction, and a sixth portion extending from a tip of the fifth portion in the first direction along the third direction. Each of the first protrusions is integral with the first conductor and has a rectangular shape extending from the first main surface in the first direction along the third direction. Each of the second protrusions is integral with the second conductor and has a rectangular shape extending from the second main surface in the first direction along the third direction. The manufacturing method by bending the conductive bar includes a first insertion step, a second insertion step, a first bending step, and a second bending step. In the first insertion step, the first protrusions are inserted into the first insertion holes. In the second insertion step, the second protruding portions are inserted into the second insertion holes. In the first bending step, each of the first protruding portions inserted into the first insertion holes is bent into a shape consisting of the first portion, the second portion, and the third portion. In the second bending step, each of the second protruding portions inserted into the second insertion holes is bent into a shape consisting of the fourth portion, the fifth portion, and the sixth portion.

[0010] A manufacturing method of a conductive bar according to one aspect of the present disclosure is a manufacturing method of the conductive bar by welding the conductive bar. The conductor has a longitudinal plate shape. The conductive bar further includes a plurality of protrusions formed on a main surface of the conductor along the longitudinal direction of the conductor. The sensor includes a substrate having a plurality of insertion holes into which the plurality of protrusions are respectively inserted, and a plurality of sensor elements each having a ring shape and mounted on the substrate so as to surround the plurality of insertion holes. The conductive bar further includes a fixing portion that fixes the substrate to the conductor when the plurality of protrusions are inserted into the plurality of insertion holes, respectively. The conductor is a first conductor connected to a first electric wire, and the conductive bar further includes a second conductor connected to a second electric wire. The plurality of protrusions are a plurality of first protrusions formed on a first main surface of the first conductor along the longitudinal direction of the first conductor. The conductive bar further includes a plurality of second protrusions formed on a second main surface of the second conductor along the longitudinal direction of the second conductor. The plurality of insertion holes are a plurality of first insertion holes into which the plurality of first protrusions are respectively inserted, and the substrate is further formed with a plurality of second insertion holes into which the plurality of second protrusions are respectively inserted. The plurality of sensor elements are a plurality of first sensor elements mounted on the substrate so as to surround the plurality of first insertion holes, respectively. The sensor further includes a plurality of second sensor elements, each having a ring shape, mounted on the substrate so as to surround the plurality of second insertion holes, respectively. The fixing portion fixes the substrate to the first conductor and the second conductor with the plurality of first protrusions and the plurality of second protrusions inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively. The plurality of first insertion holes and the plurality of second insertion holes are arranged in two rows along a first direction such that the first insertion holes and the second insertion holes alternate in a second direction intersecting the first direction. The fixing portion fixes the substrate to the first conductor and the second conductor in a state in which the plurality of first protrusions and the plurality of second protrusions are inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively, so that the first protrusions and the second protrusions are staggered in the second direction.The first conductor and the second conductor are arranged such that the longitudinal directions of the first conductor and the second conductor are aligned with the first direction, and the first main surface of the first conductor and the second main surface of the second conductor face a first orientation along the second direction. Each of the plurality of first protrusions has a first portion extending from the first main surface in the first direction along a third direction intersecting each of the first direction and the second direction, a second portion extending from a tip of the first portion in a direction from the first main surface toward the second main surface along the second direction, and a third portion extending from a tip of the second portion in the first direction along the third direction. Each of the plurality of second protrusions has a fourth portion extending from the second main surface in the first direction along the third direction, a fifth portion extending from a tip of the fourth portion in a direction from the second main surface toward the first main surface along the second direction, and a sixth portion extending from the tip of the fifth portion in the first direction along the third direction. Each of the plurality of first protrusions is separate from the first conductor and has a rectangular shape extending from the first main surface in the first direction along the third direction. Each of the plurality of second protrusions is separate from the second conductor and has a rectangular shape extending from the second main surface in the first direction along the third direction. The manufacturing method of the conductive bar by bending includes a first bending step, a second bending step, a first insertion step, a second insertion step, a first welding step, and a second welding step. In the first bending step, each of the plurality of first protrusions is bent into a first shape consisting of the first portion, the second portion, and the third portion. In the second bending step, each of the plurality of second protrusions is bent into a second shape consisting of the fourth portion, the fifth portion, and the sixth portion. In the first inserting step, the plurality of first protrusions bent into the first shape are inserted into the plurality of first insertion holes. In the second inserting step, the plurality of second protrusions bent into the second shape are inserted into the plurality of second insertion holes. In the first welding step, each of the plurality of first protrusions inserted into the plurality of first insertion holes is integrated with the first conductor by welding.In the second welding step, each of the second protrusions inserted into the second insertion holes is integrated with the second conductor by welding.

[0011] Fig. 1 is a perspective view showing the appearance of a distribution board including a circuit breaker using a conductive bar according to an embodiment of the present disclosure. Fig. 2 is a perspective view showing the appearance of the conductive bar. Fig. 3A is a perspective view of a conductor included in the conductive bar, and Fig. 3B is a perspective view of a sensor fixed to the conductive bar. Fig. 4A is a top view of a first conductor and a second conductor included in a conductive bar according to a first modification, Fig. 4B is a perspective view of the first conductor and the second conductor, and Fig. 4C is a perspective view showing a state in which a plurality of first protrusions formed on the first conductor and a plurality of second protrusions formed on the second conductor are inserted into a plurality of insertion holes formed in a row in a substrate of a sensor included in the conductive bar. Fig. 5A is a perspective view of a first conductor and a second conductor included in a conductive bar according to a second modification, Fig. 5B is a perspective view showing a state in which a plurality of first protrusions formed on the first conductor and a plurality of second protrusions formed on the second conductor are inserted into a plurality of first insertion holes and a plurality of second insertion holes formed in two rows in a substrate of a sensor included in the conductive bar, Fig. 5C is a perspective view showing a state in which the plurality of first protrusions and the plurality of second protrusions inserted into the plurality of first insertion holes and the plurality of second insertion holes are bent, Fig. 6A is a perspective view showing the plurality of bent first protrusions and the plurality of bent second protrusions that are separate from the first conductor and the second conductor, Fig. 6B is a perspective view of the first conductor and the second conductor, and Fig. 6C is a perspective view of the first conductor and the second conductor integrated with the bent first protrusions and the bent second protrusions by welding.

[0012] (1) Overview First, an overview of the conductive bar 1 according to the embodiment of the present disclosure will be described with reference to FIGS. 1, 2, 3A, and 3B.

[0013] (1-1) Conductive Bar As shown in Fig. 1, the conductive bar 1 is a conductive bar 1 used in a circuit breaker 10 that interrupts current. The conductive bar 1 is attached to a circuit breaker body, which is the main body of the circuit breaker 10. The conductive bar 1 may also be called a "bus bar with a sensor."

[0014] (1-2) Circuit Breaker and Current As shown in Fig. 1, the circuit breaker 10 is one or more (for example, three) circuit breakers provided in the distribution board 100. The one or more circuit breakers 10 are housed in a distribution board main body, which is the main body of the distribution board 100. However, the circuit breaker 10 may be a circuit breaker used alone, and the type of the circuit breaker 10 does not matter.

[0015] The current is an AC current. In this embodiment, the AC current is a single-phase two-wire AC current.

[0016] (1-3) Distribution Board The distribution board 100 is, for example, a type that is attached to a DIN rail 200 attached to a wall surface, as shown in Fig. 1. However, the distribution board 100 may be a type that is attached directly to a wall surface, and the type of distribution board 100 is not important.

[0017] (1-4) Structure of the Conductive Bar As shown in FIG. 1, the conductive bar 1 includes a longitudinal conductor 11 and a sensor 12 fixed to the conductor 11 for detecting current.

[0018] (1-4-1) Conductor The conductor 11 is, for example, a bus bar (see FIG. 3A). The conductor 11 is connected to an electric wire through which a current flows. In this embodiment, the electric wire is an L-wire through which a single-phase two-wire AC current flows.

[0019] (1-4-2) Sensor In this embodiment, the sensor 12 includes a substrate 12S (see FIG. 3B) on which a Rogowski coil is mounted as the sensor element 12a. The substrate 12S is realized by a printed circuit board. Such a printed circuit board may be called an "RC (Rogowski Coil) sensor board."

[0020] (1-4-2a) Current-Related Detection In this embodiment, current-related detection includes measuring a current value and calculating a power value.

[0021] (1-4-2b) Printed Circuit Board The printed circuit board realizing the board 12S shown in FIG. 3B is also equipped with, in addition to the sensor element 12a that detects current, an ASIC (application specific integrated circuit) that measures the current value based on the detection result of the sensor element 12a, and an arithmetic circuit (microcomputer, etc.) that calculates the power value based on the measurement result of the ASIC.

[0022] By using a printed circuit board as the substrate 12S, it is possible to reduce the thickness of the conductive bar 1. Furthermore, by providing an ASIC and an arithmetic circuit on the printed circuit board, it is possible to make the conductive bar 1 multifunctional.

[0023] (1-4-3) Fixing of the Sensor to the Conductor Fixing the sensor 12 to the conductor 11 means, for example, that the conductor 11 shown in Fig. 3A and the sensor 12 shown in Fig. 3B are fixed by the fixing portion 13 shown in Fig. 2, thereby integrating the sensor 12 with the conductor 11. The fixing portion 13 is, for example, a resin housing, and fixing means, for example, housing the sensor 12 and the conductor 11 in the resin housing. Note that, for convenience, the fixing portion 13 is depicted in Fig. 2 as a resin housing made of transparent resin, but is generally made of opaque resin.

[0024] (1-5) Advantages In the conductive bar 1 configured as described above, the sensor 12 is fixed to the conductor 11 connected to the electric wire, so current detection can be performed accurately simply by attaching the conductive bar 1 to the circuit breaker 10. Therefore, the conductive bar 1 can facilitate installation.

[0025] Furthermore, the circuit breaker 10 including the conductive bar 1 and the distribution board 100 including the circuit breaker 10 can also facilitate installation.

[0026] (2) Details Next, the details of the conductive bar 1 will be described with reference to Figures 3A and 3B. Note that, in the following, descriptions of the previously mentioned items will be omitted or simplified.

[0027] (2-1) Details of the Conductor The conductor 11 has a longitudinal plate shape as shown in Fig. 3A. The conductive bar 1 further includes a plurality of protrusions 11a protruding from the main surface 11f of the conductor 11.

[0028] (2-1-1) Multiple Projections As shown in FIG. 3A, multiple projections 11a are formed on the main surface 11f of the conductor 11 along the longitudinal direction of the conductor 11.

[0029] (2-1-1a) Method for Forming Multiple Protrusions In this embodiment, the multiple protrusions 11a are formed on the main surface 11f of the conductor 11 by integral molding with the conductor 11. The integral molding of the multiple protrusions 11a and the conductor 11 means, for example, manufacturing an integrated product having a similar surface shape using a mold corresponding to the surface shape of the integrated product of the multiple protrusions 11a and the plate-shaped conductor 11, as shown in FIG. 3A . However, the multiple protrusions 11a may also be integrated with the conductor 11 by, for example, welding.

[0030] Specifically, the plurality of protrusions 11a are arranged at equal intervals in the longitudinal direction of the main surface 11f. The plurality of protrusions 11a protrude in a direction normal to the main surface 11f, away from the main surface.

[0031] In this embodiment, the plurality of protrusions 11 a protrude upward along the normal direction of the main surface 11 f (the up-down direction in FIG. 3A ). The orientation of the plurality of protrusions 11 a is upward when the main surface 11 f is the top surface (see FIG. 3A ), backward when the main surface 11 f is the rear surface, and forward when the main surface 11 f is the front surface.

[0032] (2-2) Details of the Sensor As shown in FIG. 3B, the sensor 12 has a substrate 12S and a plurality of sensor elements 12a.

[0033] (2-2-1) Substrate A plurality of insertion holes 12A are formed in the substrate 12S. A plurality of protrusions 11a are inserted into the plurality of insertion holes 12A, respectively.

[0034] (2-2-2) Multiple Sensor Elements The multiple sensor elements 12a each have a ring shape and are mounted on the substrate 12S so as to surround the multiple insertion holes 12A, respectively. Each of the multiple sensor elements 12a is a Rogowski coil, which detects the current flowing through the protrusion 11a inserted into the insertion hole 12A and outputs an electrical signal corresponding to the detected current.

[0035] (2-3) Fixing Section The conductive bar 1 further includes a fixing section 13 as shown in Fig. 2. As described above, the fixing section 13 is a resin housing that houses the conductor 11 and the sensor 12. More specifically, as shown in Fig. 3B, the fixing section 13 houses the conductor 11 and the sensor 12 in a state in which the multiple protrusions 11a of the conductor 11 are inserted into the multiple insertion holes 12A of the substrate 12S, thereby fixing the substrate 12S and therefore the sensor 12 to the conductor 11.

[0036] (2-4) Specific Examples of Sensors In this example, the substrate 12S is a printed circuit board, and the multiple insertion holes 12A are formed in the printed circuit board 12S. As shown in FIG. 3B , the multiple sensor elements 12a are mounted on the printed circuit board 12S so as to surround the multiple insertion holes 12A, respectively. Each of the multiple sensor elements 12a outputs an electrical signal corresponding to the current flowing through the protrusion 11a inserted into the insertion hole 12A.

[0037] According to this example, the sensor 12 can be made thinner, and the conductive bar 1 can also be made thinner.

[0038] As described above, the conductive bar 1 of this embodiment further includes a fixing portion 13, which fixes the substrate 12S to the conductor 11 with the multiple protrusions 11a of the conductor 11 respectively inserted into the multiple insertion holes 12A of the substrate 12S.

[0039] In such a conductive bar 1, the multiple protrusions 11a of the conductor 11 are inserted into the multiple insertion holes 12A of the substrate 12S and fixed in a predetermined position relative to the multiple sensor elements 12a, so that simply by attaching the conductive bar 1 to the circuit breaker 10, detection of multiple currents corresponding to the multiple protrusions 11a can be performed.

[0040] Therefore, for example, as shown in Figure 1, even if the distribution board 100 is equipped with multiple circuit breakers 10 and the conductor 11 of the conductive bar 1 is connected to multiple electric wires corresponding to the multiple circuit breakers 10, installation can be made easier.

[0041] (3) Modifications Next, various modifications of the conductive bar 1, including first to third modifications, will be described.

[0042] (3-1) Commonalities between the First to Third Modified Examples First, commonalities between the First to Third Modified Examples will be described with reference to Figures 4A to 6C. Figures 4A to 4C correspond to the first modified example, Figures 5A to 5C correspond to the second modified example, and Figures 6A to 6C correspond to the third modified example.

[0043] The current in the first to third modified examples is a single-phase three-wire AC current. The circuit breaker 10 is a circuit breaker 10 for a single-phase three-wire AC current, and is interposed between three electric wires, namely, the N wire, the L1 wire, and the L2 wire.

[0044] The detection of current in the first to third modified examples includes measurement of a current value on the L1 line, measurement of a current value on the L2 line, calculation of a power value, and detection of a ground fault.

[0045] The current value for the L1 line is measured by an ASIC based on an electrical signal from a first sensor element 12a (described later), and the current value for the L2 line is measured by an ASIC based on an electrical signal from a second sensor element 12b (described later).

[0046] The power value is calculated by a calculation circuit based on at least one of the measurement results of the current value for the L1 line and the measurement results of the current value for the L2 line, and the leakage current is detected by the calculation circuit based on both the measurement results of the current value for the L1 line and the measurement results of the current value for the L2 line.

[0047] (3-1-1) First Conductor In the first to third modified examples, the conductor 11 described above is the first conductor 11A as shown in FIGS. 4A and 4B, 5A, and 6B and 6C. The first conductor 11A is connected to the first electric wire. The first electric wire is one of the L1 wire and the L2 wire (for example, the L1 wire). In other words, the first conductor 11A in the first to third modified examples is a bus bar for the L1 wire.

[0048] (3-1-2) Second Conductor The conductive bar 1 in the first to third modified examples further includes a second conductor 11B as shown in FIGS. 4A and 4B, 5A, and 6B and 6C. The second conductor 11B is connected to a second electric wire. The second electric wire is the other of the L1 line and the L2 line (for example, the L2 line). In other words, the second conductor 11B in the first to third modified examples is a bus bar for the L2 line.

[0049] (3-1-3) Multiple First Protrusions In the first to third modified examples, the multiple protrusions 11a described above are multiple first protrusions 11a as shown in Figures 4A to 4C, 5A to 5C, and 6A and 6C. The multiple first protrusions 11a are formed on the first main surface 11Af of the first conductor 11A along the longitudinal direction of the first conductor 11A.

[0050] (3-1-4) Multiple Second Protrusions The conductive bar 1 in the first to third modifications further includes multiple second protrusions 11b as shown in Figures 4A to 4C, 5A to 5C, and 6A and 6C. The multiple second protrusions 11b are formed on the second main surface 11Bf of the second conductor 11B along the longitudinal direction of the second conductor 11B.

[0051] (3-1-5) Multiple First Insertion Holes In the first to third modified examples, the multiple insertion holes 12A described above are the multiple first insertion holes 12A as shown in Fig. 4C, 5B, and 5C. The multiple first protrusions 11a are inserted into the multiple first insertion holes 12A, respectively.

[0052] (3-1-6) Multiple Second Insertion Holes As shown in Fig. 4C and Fig. 5B and Fig. 5C, multiple second insertion holes 12B are further formed in the substrate 12S in the first to third modified examples. Multiple second protrusions 11b are inserted into the multiple second insertion holes 12B, respectively.

[0053] (3-1-7) Multiple First Sensor Elements In the first to third modified examples, the multiple sensor elements 12b described above are multiple first sensor elements 12a as shown in Fig. 4C, 5B, and 5C. The multiple first sensor elements 12a are mounted on the substrate 12S so as to surround the multiple first insertion holes 12A, respectively.

[0054] (3-1-8) Multiple Second Sensor Elements The sensor 12 in the first to third modified examples further includes multiple second sensor elements 12b as shown in Fig. 4C, 5B, and 5C. Each of the multiple second sensor elements 12b has a ring shape and is mounted on the substrate 12S so as to surround each of the multiple second insertion holes 12B.

[0055] (3-1-9) Fixing portion The fixing portion 13 in the first to third modified examples fixes the substrate 12S to the first conductor 11A and the second conductor 11B in a state where the multiple first protrusions 11a and the multiple second protrusions 11b are inserted into the multiple first insertion holes 12A and the multiple second insertion holes 12B, respectively.

[0056] (3-1-10) Advantages According to the first to third variants, a conductive bar 1 can be provided that can detect the current flowing through each of the first and second electric wires, and ultimately detect leakage current, simply by attaching it to the circuit breaker 10.

[0057] (3-2) Differences Among the First, Second, and Third Modified Examples As is clear from a comparison of Figures 4A to 4C with Figures 5A to 6C, there are differences between the first, second, and third modified examples, for example, with respect to the arrangement of the plurality of first insertion holes 12A and the plurality of second insertion holes 12B (described later). The differences in arrangement here refer to the fact that, in the first modified example, the arrangement of the plurality of first insertion holes 12A and the plurality of second insertion holes 12B is a single row arrangement as shown in Figure 4C (details will be described later), whereas in the second and third modified examples, the arrangement is a double row arrangement as shown in Figures 5B and 5C (details will be described later).

[0058] Furthermore, there are differences between the first modified example and the second and third modified examples in terms of the shapes of the first protruding portions 11 a and the second protruding portions 11 b, which are related to the differences in the arrangement of the first insertion holes 12 A and the second insertion holes 12 B. The difference in shape here refers to the fact that the first protruding portions 11 a and the second protruding portions 11 b in the first modified example have an L-shape and an inverted L-shape (details of which will be described later) as shown in FIG. 4B , whereas the second and third modified examples have an N-shape and an inverted N-shape (details of which will be described later) as shown in FIG. 5C .

[0059] On the other hand, there are no structural differences between the second and third modified examples, such as differences in arrangement and shape, but differences exist in the manufacturing methods. Therefore, when describing the structure of the second modified example, the drawings of the third modified example (FIGS. 6A to 6C) may be used. Also, when describing the structure of the third modified example, FIG. 5C of the second modified example may be used.

[0060] (3-3) Details of the first modified example (3-3-1) Arrangement of multiple first insertion holes and multiple second insertion holes: Arrangement in a row In this modified example, the multiple first insertion holes 12A and multiple second insertion holes 12B are arranged in a row so that the first insertion holes 12A and the second insertion holes 12B are adjacent to each other, as shown in Figure 4C.

[0061] (3-3-2) Fixing the substrate to the first conductor and the second conductor The fixing portion 13 fixes the substrate 12S to the first conductor 11A and the second conductor 11B in a state in which the multiple first protrusions 11a and the multiple second protrusions 11b are inserted into the multiple first insertion holes 12A and the multiple second insertion holes 12B, respectively, so that the first protrusions 11a and the second protrusions 11b are adjacent to each other (see Figure 4C).

[0062] For example, when the substrate 12S and the first and second conductors 11A and 11B are in a positional relationship as shown in Figure 4C, the substrate 12S and the first and second conductors 11A and 11B are housed in a resin housing (see Figure 2), which is an example of the fixing portion 13, thereby fixing the substrate 12S to the first and second conductors 11A and 11B.

[0063] (3-3-3) Details of the first conductor and the second conductor More specifically, as shown in FIG. 4A, the first conductor 11A and the second conductor 11B are arranged so that the longitudinal directions of the first conductor 11A and the second conductor 11B are aligned along a first direction (left-right direction in FIG. 4A, etc.; the same applies below), and so that the first main surface 11Af of the first conductor 11A and the second main surface 11Bf of the second conductor 11B face each other in a second direction (front-back direction in FIG. 4A, etc.; the same applies below) that intersects with the first direction (left-right direction).

[0064] That is, the first conductor 11A and the second conductor 11B are arranged parallel to each other with the first main surface 11Af and the second main surface 11Bf facing each other.

[0065] (3-3-4) Details of the First Protrusion: L-Shape As shown in FIG. 4B , each of the multiple first protrusions 11a has an L-shape consisting of a first portion 111a and a second portion 112a. The L-shape here refers to the shape of the first protrusion 11a when viewed from one side of the first direction (left-right direction) (rightward in FIG. 4B and other figures; the same applies below). The first portion 111a extends along the second direction (front-to-back direction) from the first main surface 11Af toward the second main surface 11Bf (frontward in FIG. 4B and other figures; the same applies below). The second portion 112a extends from the tip of the first portion 111a in a first direction (upward in FIG. 4B and other figures; the same applies below) along a third direction (up-down direction in FIG. 4B and other figures; the same applies below) that intersects with both the first direction (left-right direction) and the second direction (front-to-back direction).

[0066] (3-3-5) Details of the Second Protrusion: Inverted L-Shape As shown in FIG. 4B , each of the multiple second protrusions 11b has an inverted L-shape consisting of a third portion 111b and a fourth portion 112b. The inverted L-shape here refers to the shape of the second protrusion 11b when viewed from one side (right) in the first direction (left-right direction). The inverted L-shape is symmetrical to the L-shape with respect to a line along the third direction (up-down direction). The third portion 111b extends along the second direction (front-back direction) from the second main surface 11Bf toward the first main surface 11Af (rearward in FIG. 4B and other figures; the same applies below). The fourth portion 112b extends in the first direction (upward) from the tip of the third portion 111b along the third direction (up-down direction).

[0067] (3-3-6) Advantages This modification provides a slim, longitudinal conductive bar 1 that can detect electrical leakage simply by attaching it to the circuit breaker 10. In addition, it is possible to simplify the structure of the first conductor 11A and the second conductor 11B that correspond to the substrate 12S on which the plurality of first insertion holes 12A and the plurality of second insertion holes 12B are arranged in a row.

[0068] In detail, in this modified example, the first conductor 11A and the second conductor 11B are arranged so that the longitudinal directions of the first conductor 11A and the second conductor 11B are aligned along a first direction (left-right direction) and so that they are closely opposed to each other in a second direction (front-back direction) that intersects with the first direction (left-right direction) (see Figure 4A).

[0069] Each of the first protrusions 11 a and the second protrusions 11 b has a portion extending in a first direction (upward) along a third direction (up-down direction) intersecting the first direction (left-right direction) and the second direction (front-rear direction), that is, a second portion 112 a and a fourth portion 112 b (see FIG. 4B ). This allows the first protrusions 11 a and the second protrusions 11 b to be inserted into a plurality of insertion openings on the distribution board 100 or the circuit breaker 10 side.

[0070] Each of the first protrusions 11a has a portion extending in a second direction (front) from the first conductor 11A toward the second conductor 11B along the second direction (front-rear direction), i.e., a first portion 111a, and each of the second protrusions 11b has a portion extending in a third direction (rear) from the second conductor 11B toward the first conductor 11A along the second direction (front-rear direction), i.e., a third portion 111b (see FIG. 4B ). This improves compatibility with the row arrangement of the first insertion holes 12A and the second insertion holes 12B (see FIG. 4C ), and ultimately with the row arrangement of the insertion openings on the distribution board 100 or the circuit breaker 10 side.

[0071] However, if at least one of the multiple first protrusions 11a and the multiple second protrusions 11b has a portion (first portion 111a and third portion 111b) extending in the second direction (front) or the third direction (rear) along the second direction (front-to-back direction), the effect of improving compatibility with the arrangement of multiple insertion ports on the distribution board 100 or circuit breaker 10 side (not limited to a single row arrangement) can be achieved.

[0072] (3-4) Details of the second modified example (3-4-1) Arrangement of multiple first insertion holes and multiple second insertion holes: arrangement in two rows In this modified example, the multiple first insertion holes 12A and multiple second insertion holes 12B are arranged in two rows along the first direction (left-right direction) so that the first insertion holes 12A and the second insertion holes 12B alternate in the second direction (front-back direction), as shown in Figures 5B and 5C.

[0073] (3-4-2) Fixing the substrate to the first conductor and the second conductor The fixing portion 13 fixes the substrate 12S to the first conductor 11A and the second conductor 11B in a state in which the multiple first protrusions 11a and the multiple second protrusions 11b are inserted into the multiple first insertion holes 12A and the multiple second insertion holes 12B, respectively, so that the first protrusions 11a and the second protrusions 11b are staggered in the second direction (see Figure 5B).

[0074] For example, when the substrate 12S and the first and second conductors 11A and 11B are in a positional relationship as shown in Figure 5B, the substrate 12S and the first and second conductors 11A and 11B are stored in a resin housing (see Figure 2), which is an example of the fixing portion 13, thereby fixing the substrate 12S to the first and second conductors 11A and 11B.

[0075] (3-4-3) Bending of the Multiple First Protrusions and the Multiple Second Protrusions After the substrate 12S is fixed to the first conductor 11A and the second conductor 11B, each of the multiple first protrusions 11a and the multiple second protrusions 11b is bent into a shape as shown in Figure 5C (N-shaped and inverted N-shaped: described below) so as to fit the arrangement of the insertion openings on the distribution board 100 side where the conductive bar 1 is attached.

[0076] (3-4-4) Details of the first conductor and the second conductor The first conductor 11A and the second conductor 11B are arranged so that the longitudinal directions of the first conductor 11A and the second conductor 11B are aligned along a first direction (left-right direction), and so that the first main surface 11Af of the first conductor 11A and the second main surface 11Bf of the second conductor 11B face in a first direction (upward) along a second direction (front-to-back direction).

[0077] That is, the first conductor 11A and the second conductor 11B are arranged parallel to each other with the first main surface 11Af and the second main surface 11Bf facing in the same direction (upward).

[0078] (3-4-5) Details of the First Protrusion: N-Shape As shown in FIG. 6A , each of the multiple first protrusions 11a has an N-shape consisting of a first portion 111a, a second portion 112a, and a third portion 113a. The N-shape here refers to the shape of the first protrusion 11a when viewed from one side (right) of the first direction (left-right direction). The first portion 111a extends in a first direction (upward) from the first main surface 11Af along a third direction (up-down direction). The third direction (up-down direction) intersects with both the first direction (left-right direction) and the second direction (front-rear direction). The second portion 112a extends in a second direction (front-rear direction) from the tip of the first portion 111a from the first main surface 11Af toward the second main surface 11Bf (front: second direction). The third portion 113a extends in the first direction (upward) from the tip of the second portion 112a along the third direction (up-down direction).

[0079] (3-4-6) Details of the Second Protrusion: Inverted-N Shape As shown in FIG. 6A , each of the multiple second protrusions 11b has an inverted-N shape consisting of a fourth portion 111b, a fifth portion 112b, and a sixth portion 113b. The inverted-N shape here refers to the shape of the second protrusion 11b when viewed from one side (right) in the first direction (left-right direction). The inverted-N shape is symmetrical to the N shape with respect to a line along the third direction (up-down direction). The fourth portion 111b extends in a first direction (upward) from the second main surface 11Bf along the third direction (up-down direction). The fifth portion 112b extends from the tip of the fourth portion 111b along the second direction (front-rear direction) from the second main surface 11Bf toward the first main surface 11Af (rearward: third direction). The sixth portion 113b extends in the first direction (upward) from the tip of the fifth portion 112b along the third direction (up-down direction).

[0080] (3-4-7) Manufacturing Method by Bending The manufacturing method of the conductive bar 1 in this modified example is a manufacturing method by bending. The manufacturing method by bending is a method of manufacturing the conductive bar 1 having a plurality of Z-shaped first protrusions 11a and a plurality of Z-shaped second protrusions 11b as shown in Fig. 5C by inserting and fixing a plurality of plate-shaped first protrusions 11a that have been previously integrated with the first conductors 11A (for example, integrally formed by casting) and a plurality of plate-shaped second protrusions 11b that have been previously integrated with the second conductors 11B (for example, integrally formed by casting) into a plurality of first insertion holes 12A and a plurality of second insertion holes 12B, respectively, and then bending the same.

[0081] 5A , each of the first protrusions 11a is integral with the first conductor 11A and has a rectangular shape extending in a first direction (upward) from the first main surface 11Af along the third direction (upward). Also, each of the second protrusions 11b is integral with the second conductor 11B and has a rectangular shape extending in a first direction (upward) from the second main surface 11Bf along the third direction (upward).

[0082] (3-4-8) Details of the Manufacturing Method by Bending The manufacturing method by bending the conductive bar 1 includes a first insertion step, a second insertion step, a first bending step, and a second bending step. In the first insertion step, as shown in FIG. 5B , the first protrusions 11a are inserted into the first insertion holes 12A. In the second insertion step, as shown in FIG. 5B , the second protrusions 11b are inserted into the second insertion holes 12B. In the first bending step, each of the first protrusions 11a inserted into the first insertion holes 12A is bent into a shape consisting of a first portion 111a, a second portion 112a, and a third portion 113a as shown in FIG. 5C . In the second bending step, each of the second protrusions 11b inserted into the second insertion holes 12B is bent into a shape consisting of a fourth portion 111b, a fifth portion 112b, and a sixth portion 113b as shown in FIG. 5C .

[0083] According to the manufacturing method using bending, the manufacturing of the conductive bar 1 can be facilitated.

[0084] (3-4-9) Advantages This modification provides a compact, longitudinal conductive bar 1 that can detect electrical leakage simply by attaching it to the circuit breaker 10. In addition, it is possible to simplify the structure of the first conductors 11A and second conductors 11B that correspond to the substrate 12S on which the plurality of first insertion holes 12A and the plurality of second insertion holes 12B are arranged in two rows.

[0085] In detail, in this modified example, the first conductor 11A and the second conductor 11B are arranged so that the longitudinal directions of the first conductor 11A and the second conductor 11B are aligned along a first direction (left-right direction) and so that they face each other at a predetermined distance in a second direction (front-back direction) that intersects with the first direction (left-right direction) (see Figure 5A).

[0086] Each of the second protrusions 11b has a portion extending in the first direction (upward) along a third direction (up-down direction) that intersects with each of the first direction (left-right direction) and the second direction (front-rear direction), i.e., a third portion 113a and a sixth portion 113b. This makes it possible to insert the multiple first protrusions 11a and the multiple second protrusions 11b into multiple insertion openings on the distribution board 100 or the circuit breaker 10 side.

[0087] Each of the plurality of first protrusions 11a has a portion extending in a second direction (forward) from the first conductor 11A toward the second conductor 11B along the second direction (front-rear direction), i.e., second portion 112a, and each of the plurality of second protrusions 11b has a portion extending in a third direction (rear) from the second conductor 11B toward the first conductor 11A along the second direction (front-rear direction), i.e., fifth portion 112b. This improves compatibility with the two-row arrangement of the plurality of insertion ports on the distribution board 100 or circuit breaker 10 side (see FIGS. 5B and 5C ).

[0088] However, if at least one of the multiple first protrusions 11a and the multiple second protrusions 11b has a portion (second portion 112a or fifth portion 112) extending in the second direction (front) or the third direction (rear) along the second direction (front-to-back direction), the effect of improving compatibility with the arrangement of multiple insertion ports on the distribution board 100 or circuit breaker 10 side (not limited to a two-row arrangement) can be achieved.

[0089] (3-5) Third Modification The conductive bar 1 in this modification has the same structure as the conductive bar 1 in the second modification (see FIG. 5C). The difference between the conductive bar 1 in this modification and the conductive bar 1 in the second modification lies in the manufacturing method.

[0090] The manufacturing method of the conductive bar 1 in this modified example is a manufacturing method using welding. The manufacturing method using welding is as follows. Specifically, the plurality of plate-shaped first protrusions 11a, which are separate from the first conductors 11A, and the plurality of plate-shaped second protrusions 11b, which are separate from the second conductors 11B, are each bent in advance into the shape shown in FIG. 6A . Meanwhile, the first conductors 11A and the second conductors 11B, as shown in FIG. 6B , are positioned below the substrate 12S in positions along the array of the plurality of first insertion holes 12A and the array of the plurality of second insertion holes 12B. The substrate 12S, the first conductors 11A, and the second conductors 11B are then housed and fixed in a resin housing, which is an example of a fixing portion 13. Then, the plurality of bent first protrusions 11a and the plurality of bent plate-shaped second protrusions 11b (see FIG. 6A ) are welded to the first conductors 11A and the second conductors 11B in the resin housing, respectively, to manufacture the conductive bar 1 shown in FIG. 5C .

[0091] Specifically, each of the first protrusions 11a is separate from the first conductor 11A and has a rectangular shape extending in the first direction (upward) from the first main surface 11Af along the third direction (upward). Each of the second protrusions 11b is separate from the second conductor 11B and has a rectangular shape extending in the first direction (upward) from the second main surface 11Bf along the third direction (upward).

[0092] (3-5-1) Details of the Manufacturing Method by Welding The manufacturing method by welding of the conductive bar 1 includes a first bending step, a second bending step, a first inserting step, a second inserting step, a first welding step, and a second welding step. In the first bending step, each of the multiple first protrusions 11a is bent into a first shape consisting of a first portion 111a, a second portion 112a, and a third portion 113a as shown in FIG. 6A . In the second bending step, each of the multiple second protrusions 11b is bent into a second shape consisting of a fourth portion 111b, a fifth portion 112b, and a sixth portion 113b as shown in FIG. 6A . In the first inserting step, the multiple first protrusions 11a bent into the first shape are inserted into the multiple first insertion holes 12A. In the second inserting step, the multiple second protrusions 11b bent into the second shape are inserted into the multiple second insertion holes 12B. In the first welding step, the first protrusions 11a inserted into the first insertion holes 12A are welded together with the first conductors 11A shown in Fig. 6B as shown in Fig. 6C. In the second welding step, the second protrusions 11b inserted into the second insertion holes 12B are welded together with the second conductors 11B shown in Fig. 6B as shown in Fig. 6C.

[0093] The manufacturing method using welding can facilitate the manufacturing of the conductive bar 1 .

[0094] (3-5-2) Advantages This modification provides the same advantages as the second modification.

[0095] (3-6) Other Modifications (3-6-1) Modifications of the Printed Circuit Board The printed circuit board (board 12S) that realizes the sensor 12 may be any of various sensor boards on which sensor elements other than the Rogowski coil are mounted. Examples of sensor elements other than the Rogowski coil include, but are not limited to, a current transformer (CT) and a shunt resistor.

[0096] The sensor element may be mounted on the printed circuit board, and the ASIC, arithmetic circuit, etc. may be mounted on a separate board.

[0097] (3-6-2) Modifications of the Multiple First Protrusions and the Multiple Second Protrusions Each of the multiple first protrusions 11a and the multiple second protrusions 11b (see FIG. 5C ) does not have to be bent depending on the arrangement of the insertion openings in the distribution board 100. In other words, when the arrangement of the insertion openings in the distribution board 100 corresponds to the multiple first protrusions 11a and the multiple second protrusions 11b before bending, for example, as shown in FIG. 5B , the first bending step and the second bending step in each of the manufacturing method by bending described above and the manufacturing method by welding described above are unnecessary.

[0098] The intervals between the multiple first protrusions 11a and the intervals between the multiple second protrusions 11b do not have to be equal.

[0099] In the two-row arrangement of the multiple first insertion holes 12A and the multiple second insertion holes 12B (see Figures 5B and 5C), the first insertion holes 12A and the second insertion holes 12B do not have to be arranged alternately, but may, for example, be arranged along the second direction (front-to-back direction).

[0100] (3-6-3) Modified Examples of the Fixing Section The fixing section 13 is not limited to a resin housing, and may be realized, for example, by a housing other than resin. A housing other than resin is, for example, a housing formed of an insulator other than resin. Examples of insulators other than resin include, but are not limited to, ceramic and glass. Alternatively, the fixing section 13 may be realized by a member other than a housing. Examples of members other than a housing include, but are not limited to, an insulating adhesive that bonds the conductor 11 and the sensor 12, and a holding member (for example, a clamp formed of an insulator) that holds the conductor 11 and the sensor 12 in place.

[0101] (3-6-4) Modifications of Current, Wires, etc. The current described in the overview and details may be a three-phase, three-wire AC current. In this case, the wire may be any of the L1 to L3 wires through which the AC current of the three-phase, three-wire system flows. The circuit breaker 10 is a circuit breaker 10 for AC current of a three-phase, three-wire system, and is interposed between the L1, L2, and L3 wires.

[0102] The conductive bar 1 may further include a third conductor connected to the L3 line in addition to the first conductor 11A connected to the L1 line and the second conductor 11B connected to the L2 line (see FIGS. 5B and 5C ). In this case, the conductive bar 1 further includes a plurality of third protrusions protruding from a third main surface of the third conductor. In addition to the plurality of first insertion holes 12A and the plurality of second insertion holes 12B (see FIGS. 5B and 5C ), the substrate 12S is further formed with a plurality of third insertion holes into which the plurality of third protrusions are inserted.

[0103] The first, second, and third insertion holes 12A, 12B, and 12C are arranged in three rows along the first direction (left-right direction) such that the first, second, and third insertion holes 12A, 12B, and 12C are aligned in the second direction (front-rear direction). However, in the three-row arrangement, the first, second, and third insertion holes 12A, 12B, and 12C do not have to be aligned in the second direction (front-rear direction) and may be aligned in a direction inclined with respect to the second direction (front-rear direction).

[0104] A plurality of third sensor elements are mounted on the substrate 12S, surrounding the plurality of third insertion holes. The ASIC measures the current values ​​corresponding to the L1 line, the L2 line, and the L3 line based on the electrical signals from the first sensor element 12a, the second sensor element 12b, and the third sensor element. The arithmetic circuit calculates a power value based on at least one of the three measured current values. The arithmetic circuit also detects the occurrence of a ground fault based on all three measured current values.

[0105] (4) Summary The conductive bar (1) according to the first aspect is a conductive bar (1) used in a circuit breaker (10) that interrupts current. The conductive bar (1) includes a longitudinal conductor (11) connected to an electric wire through which a current flows, and a sensor (12) fixed to the conductor (11) for detecting the current.

[0106] According to this aspect, in the conductive bar (1), the sensor (12) is fixed to the conductor (11) connected to the electric wire by the fixing portion (13), so that current detection can be performed accurately by simply attaching the conductive bar (1) to the circuit breaker (10). Therefore, installation can be simplified.

[0107] In the conductive bar (1) according to the second aspect, the conductor (11) of the first aspect has a longitudinal plate shape. The conductive bar (1) further includes a plurality of protrusions (11a). The plurality of protrusions (11a) are formed on a main surface (11f) of the conductor (11) along the longitudinal direction of the conductor (11). The sensor (12) includes a substrate (12S) and a plurality of sensor elements (12a). The substrate (12S) is formed with a plurality of insertion holes (12A) into which the plurality of protrusions (11a) are respectively inserted. The plurality of sensor elements (12a) each have a ring shape and are mounted on the substrate (12S) so as to surround the plurality of insertion holes (12A). The conductive bar (1) further includes a fixing portion (13). The fixing portion (13) fixes the substrate (12S) to the conductor (11) with the plurality of protrusions (11a) inserted into the plurality of insertion holes (12A), respectively.

[0108] According to this aspect, the conductive bar (1) has the plurality of protrusions (11 a) of the conductor (11) inserted into the plurality of insertion holes (12A) of the substrate (12S) and fixed at predetermined positions relative to the plurality of sensor elements (12 a), so that detection of the plurality of currents corresponding to the plurality of protrusions (11 a) can be performed simply by attaching the conductive bar (1) to the circuit breaker (10). Therefore, even when the conductor (11) is connected to a plurality of electric wires, installation can be simplified.

[0109] In the conductive bar (1) according to the third aspect, in the second aspect, the conductor (11) is a first conductor (11A) connected to a first electric wire. The conductive bar (1) further includes a second conductor (11B) connected to a second electric wire. The plurality of protrusions (11a) are a plurality of first protrusions (11a). The plurality of first protrusions (11a) are formed on a first main surface (11Af) of the first conductor (11A) along the longitudinal direction of the first conductor (11A). The conductive bar (1) further includes a plurality of second protrusions (11b). The plurality of second protrusions (11b) are formed on a second main surface (11Bf) of the second conductor (11B) along the longitudinal direction of the second conductor (11B). The plurality of insertion holes (12A) are a plurality of first insertion holes (12A). The plurality of first protrusions (11a) are inserted into the plurality of first insertion holes (12A), respectively. The substrate (12S) is further formed with a plurality of second insertion holes (12B). The plurality of second protrusions (11b) are inserted into the plurality of second insertion holes (12B), respectively. The plurality of sensor elements (12b) are the plurality of first sensor elements (12a). The plurality of first sensor elements (12a) are mounted on the substrate (12S) so as to surround the plurality of first insertion holes (12A), respectively. The sensor (12) further has a plurality of second sensor elements (12b). The plurality of second sensor elements (12b) each have a ring shape and are mounted on the substrate (12S) so as to surround the plurality of second insertion holes (12B), respectively. The fixing portion (13) fixes the substrate (12S) to the first conductor (11A) and the second conductor (11B) with the multiple first protrusions (11a) and the multiple second protrusions (11b) inserted into the multiple first insertion holes (12A) and the multiple second insertion holes (12B), respectively.

[0110] According to this aspect, a conductive bar (1) can be provided that can detect the current flowing through each of the first electric wire and the second electric wire, and can also detect leakage current, simply by attaching it to the circuit breaker (10).

[0111] In the conductive bar (1) according to the fourth aspect, in the third aspect, the plurality of first insertion holes (12A) and the plurality of second insertion holes (12B) are arranged in a row so that the first insertion holes (12A) and the second insertion holes (12B) are adjacent to each other. The fixing portion (13) fixes the substrate (12S) to the first conductors (11A) and the second conductors (11B) in a state in which the plurality of first protrusions (11a) and the plurality of second protrusions (11b) are inserted into the plurality of first insertion holes (12A) and the plurality of second insertion holes (12B), respectively, so that the first protrusions (11a) and the second protrusions (11b) are adjacent to each other.

[0112] According to this aspect, it is possible to provide a slim, longitudinal conductive bar (1) that can also detect electrical leakage simply by attaching it to a circuit breaker (10).

[0113] In the conductive bar (1) according to the fifth aspect, in the fourth aspect, the first conductor (11A) and the second conductor (11B) are arranged so that the longitudinal directions of the first conductor (11A) and the second conductor (11B) are aligned along a first direction, and so that the first main surface (11Af) of the first conductor (11A) and the second main surface (11Bf) of the second conductor (11B) face each other in a second direction intersecting the first direction. Each of the multiple first protrusions (11a) has a first portion (111a) and a second portion (112a). The first portion (111a) extends along the second direction from the first main surface (11Af) toward the second main surface (11Bf). The second portion (112a) extends in a first direction from the tip of the first portion (111a) along a third direction intersecting each of the first and second directions. Each of the multiple second protrusions (11b) has a third portion (111b) and a fourth portion (112b). The third portion (111b) extends in a direction (rearward) from the second main surface (11Bf) toward the first main surface (11Af) along the second direction. The fourth portion (112b) extends in the first direction from the tip of the third portion (111b) along the third direction.

[0114] According to this aspect, the structure of the first conductor (11A) and the second conductor (11B) corresponding to the substrate (12S) on which a plurality of first insertion holes (12A) and a plurality of second insertion holes (12B) are arranged in a row can be simplified.

[0115] In the conductive bar (1) according to the sixth aspect, in the third aspect, the plurality of first insertion holes (12A) and the plurality of second insertion holes (12B) are arranged in two rows along a first direction such that the first insertion holes (12A) and the second insertion holes (12B) alternate in a second direction. The second direction is a direction intersecting the first direction. The fixing portion (13) fixes the substrate (12S) to the first conductors (11A) and the second conductors (11B) in a state in which the plurality of first protrusions (11a) and the plurality of second protrusions (11b) are inserted into the plurality of first insertion holes (12A) and the plurality of second insertion holes (12B), respectively, such that the first protrusions (11a) and the second protrusions (11b) alternate in the second direction.

[0116] According to this aspect, it is possible to provide a compact longitudinal conductive bar (1) that can also detect electrical leakage simply by attaching it to a circuit breaker (10).

[0117] In the conductive bar (1) according to the seventh aspect, in the sixth aspect, the first conductor (11A) and the second conductor (11B) are arranged so that the longitudinal directions of the first conductor (11A) and the second conductor (11B) are aligned along a first direction, and the first main surface (11Af) of the first conductor (11A) and the second main surface (11Bf) of the second conductor (11B) face a first direction along the second direction. Each of the multiple first protrusions (11a) has a first portion (111a), a second portion (112a), and a third portion (113a). The first portion (111a) extends in a first direction from the first main surface (11Af) along the third direction. The third direction is a direction intersecting both the first direction and the second direction. The second portion (112a) extends from the tip of the first portion (111a) along the second direction, from the first main surface (11Af) toward the second main surface (11Bf). The third portion (113a) extends from the tip of the second portion (112a) in a first direction along the third direction. Each of the multiple second protrusions (11b) has a fourth portion (111b), a fifth portion (112b), and a sixth portion (113b). The fourth portion (111b) extends from the second main surface (11Bf) in the first direction along the third direction. The fifth portion (112b) extends from the tip of the fourth portion (111b) along the second direction, from the second main surface (11Bf) toward the first main surface (11Af). The sixth portion (113b) extends in the first direction from the tip of the fifth portion (112b) along the third direction.

[0118] According to this aspect, the structure of the first conductor (11A) and the second conductor (11B) corresponding to the substrate (12S) on which a plurality of first insertion holes (12A) and a plurality of second insertion holes (12B) are arranged in two rows can be simplified.

[0119] In the conductive bar (1) according to the eighth aspect, in the third aspect, the first conductor (11A) and the second conductor (11B) are arranged so that the longitudinal directions of the first conductor (11A) and the second conductor (11B) are aligned along a first direction and face each other in a second direction intersecting the first direction. Each of the first protrusions (11a) and the second protrusions (11b) has a portion (a second portion 112a and a fourth portion 112b in the first modification; a third portion 113a and a sixth portion 113b in the second and third modifications) extending in a first direction along a third direction intersecting the first and second directions. At least one of the plurality of first protrusions (11a) and the plurality of second protrusions (11b) has a portion extending in the second direction or the third direction along the second direction (in the first variant, the first portion 111a and the third portion 111b; in the second and third variants, the second portion 112a and the fifth portion 112b).

[0120] According to this aspect, each of the plurality of first protrusions (11a) and the plurality of second protrusions (11b) has a portion extending in a first direction along the third direction (the second portion 112a and the fourth portion 112b in the first modification; the third portion 113a and the sixth portion 113b in the second and third modifications), thereby enabling the plurality of first protrusions (11a) and the plurality of second protrusions (11b) to be inserted into a plurality of insertion ports on the circuit breaker (10). Furthermore, at least one of the plurality of first protrusions (11a) and the plurality of second protrusions (11b) has a portion extending in a second direction or a third direction along the second direction (the first portion 111a and the third portion 111b in the first modification; the second portion 112a and the fifth portion 112b in the second and third modifications), thereby improving compatibility with the arrangement of a plurality of insertion ports on the circuit breaker (10).

[0121] In the conductive bar (1) of the ninth aspect, in the eighth aspect, each of the multiple first protrusions (11a) has a portion extending in a second direction, which is a direction from the first conductor (11A) toward the second conductor (11B), along the second direction (first portion 111a in the first variant; second portion 112a in the second and third variants), and each of the multiple second protrusions (11b) has a portion extending in a third direction, which is a direction from the second conductor (11B) toward the first conductor (11A), along the second direction (third portion 111b in the first variant; fifth portion 112b in the second and third variants).

[0122] According to this aspect, each of the multiple first protrusions (11a) has a portion extending in a second direction along the second direction (first portion 111a in the first variant; second portion 112a in the second and third variants), and each of the multiple second protrusions (11b) has a portion extending in a third direction along the second direction (third portion 111b in the first variant; fifth portion 112b in the second and third variants), thereby improving compatibility with a single-row or double-row arrangement of multiple insertion ports on the circuit breaker (10) side.

[0123] In the conductive bar (1) according to a tenth aspect, in any one of the second to ninth aspects, the substrate (12S) is a printed circuit board, and the multiple insertion holes (12A) are formed in the printed circuit board (12S). The multiple sensor elements (12a) are mounted on the printed circuit board (12S) so as to surround the multiple insertion holes (12A), respectively.

[0124] According to this embodiment, the conductive bar (1) can be made thinner.

[0125] A circuit breaker (10) according to an eleventh aspect includes the conductive bar (1) according to any one of the first to tenth aspects and a circuit breaker body to which the conductive bar (1) is attached.

[0126] According to this aspect, the construction can be facilitated.

[0127] A distribution board (100) according to a twelfth aspect includes the circuit breaker (10) according to the eleventh aspect and a distribution board body that houses the circuit breaker (10).

[0128] According to this aspect, the construction can be facilitated.

[0129] A manufacturing method for a conductive bar (1) according to a thirteenth aspect is a manufacturing method by bending the conductive bar (1) of the seventh aspect. Each of the multiple first protrusions (11a) is integral with the first conductor (11A) and has a rectangular shape extending in a first direction from the first main surface (11Af) along the third direction. Each of the multiple second protrusions (11b) is integral with the second conductor (11B) and has a rectangular shape extending in the first direction from the second main surface (11Bf) along the third direction. The manufacturing method for a conductive bar (1) by bending includes a first insertion step, a second insertion step, a first bending step, and a second bending step. In the first insertion step, the multiple first protrusions (11a) are inserted into the multiple first insertion holes (12A). In the second insertion step, the multiple second protrusions (11b) are inserted into the multiple second insertion holes (12B). In the first bending step, each of the plurality of first protrusions (11a) inserted into the plurality of first insertion holes (12A) is bent into a shape consisting of a first portion (111a), a second portion (112a), and a third portion (113a). In the second bending step, each of the plurality of second protrusions (11b) inserted into the plurality of second insertion holes (12B) is bent into a shape consisting of a fourth portion (111b), a fifth portion (112b), and a sixth portion (113b).

[0130] According to this aspect, the manufacturing process can be simplified.

[0131] A manufacturing method for a conductive bar (1) according to a fourteenth aspect is a manufacturing method for the conductive bar (1) of the seventh aspect by welding. Each of the multiple first protrusions (11a) is separate from the first conductor (11A) and has a rectangular shape extending in a first direction from the first main surface (11Af) along the third direction. Each of the multiple second protrusions (11b) is separate from the second conductor (11B) and has a rectangular shape extending in the first direction from the second main surface (11Bf) along the third direction. The manufacturing method for the conductive bar (1) includes a first bending step, a second bending step, a first insertion step, a second insertion step, a first welding step, and a second welding step. In a first bending step, each of the multiple first protrusions (11a) is bent into a first shape consisting of a first portion (111a), a second portion (112a), and a third portion (113a). In a second bending step, each of the multiple second protrusions (11b) is bent into a second shape consisting of a fourth portion (111b), a fifth portion (112b), and a sixth portion (113b). In a first insertion step, the multiple first protrusions (11a) bent into the first shape are inserted into the multiple first insertion holes (12A). In a second insertion step, the multiple second protrusions (11b) bent into the second shape are inserted into the multiple second insertion holes (12B). In a first welding step, each of the multiple first protrusions (11a) inserted into the multiple first insertion holes (12A) is integrated with the first conductor (11A) by welding. In the second welding step, each of the second protrusions (11b) inserted into the second insertion holes (12B) is integrated with the second conductor (11B) by welding.

[0132] According to this aspect, the manufacturing process can be simplified.

[0133] 100 Distribution board 10 Circuit breaker 1 Conductive bar 11 Conductor 11f Main surface 11A First conductor 11Af First main surface 11a First protrusion 111a First portion 112a Second portion 113a Third portion 11B Second conductor 11Bf Second main surface 11b Second protrusion 111b Fourth portion (Third portion) 112b Fifth portion (Fourth portion) 113b Sixth portion 12 Sensor 12S Substrate 12A First insertion hole (Insertion hole) 12B Second insertion hole 12a First sensor element (Sensor element) 12b Second sensor element

Claims

1. A conductive bar used in a circuit breaker that interrupts electric current, comprising: a longitudinal conductor connected to an electric wire through which the electric current flows; and a sensor fixed to the conductor for detecting the electric current.

2. The conductive bar according to claim 1, wherein the conductor has a longitudinal plate shape and further comprises a plurality of protrusions formed on a main surface of the conductor along the longitudinal direction of the conductor, and the sensor comprises: a substrate having a plurality of insertion holes into which the plurality of protrusions are respectively inserted; and a plurality of sensor elements each having a ring shape and mounted on the substrate so as to surround the plurality of insertion holes, and further comprises a fixing portion that fixes the substrate to the conductor with the plurality of protrusions inserted into the plurality of insertion holes, respectively.

3. The conductor is a first conductor connected to a first electric wire, and further comprises a second conductor connected to a second electric wire, the plurality of protrusions are a plurality of first protrusions formed on a first main surface of the first conductor along the longitudinal direction of the first conductor, and the second conductor is further comprised of a plurality of second protrusions formed on a second main surface of the second conductor along the longitudinal direction of the second conductor, the plurality of insertion holes are a plurality of first insertion holes into which the plurality of first protrusions are respectively inserted, the substrate is further formed with a plurality of second insertion holes into which the plurality of second protrusions are respectively inserted, the plurality of sensor elements are a plurality of first sensor elements mounted on the substrate so as to surround the plurality of first insertion holes, and the sensor further comprises a plurality of second sensor elements each having a ring shape and mounted on the substrate so as to surround the plurality of second insertion holes, The conductive bar according to claim 2 , wherein the fixing portion fixes the substrate to the first conductor and the second conductor with the plurality of first protrusions and the plurality of second protrusions inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively.

4. The conductive bar described in claim 3, wherein the plurality of first insertion holes and the plurality of second insertion holes are arranged in a row so that the first insertion holes and the second insertion holes are adjacent to each other, and the fixing portion fixes the substrate to the first conductor and the second conductor in a state where the plurality of first protrusions and the plurality of second protrusions are inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively, so that the first protrusions and the second protrusions are adjacent to each other.

5. The conductive bar according to claim 4, wherein the first conductor and the second conductor are arranged such that the longitudinal directions of the first conductor and the second conductor are aligned along a first direction, and the first main surface of the first conductor and the second main surface of the second conductor face each other in a second direction intersecting the first direction, and each of the plurality of first protrusions has: a first portion extending along the second direction from the first main surface toward the second main surface, and a second portion extending in a first direction from a tip of the first portion along a third direction intersecting both the first and second directions, and each of the plurality of second protrusions has: a third portion extending along the second direction from the second main surface toward the first main surface, and a fourth portion extending along the third direction from a tip of the third portion in the first direction.

6. The conductive bar according to claim 3, wherein the plurality of first insertion holes and the plurality of second insertion holes are arranged in two rows along a first direction such that the first insertion holes and the second insertion holes alternate in a second direction intersecting the first direction, and the fixing portion fixes the substrate to the first conductor and the second conductor in a state in which the plurality of first protrusions and the plurality of second protrusions are inserted into the plurality of first insertion holes and the plurality of second insertion holes, respectively, such that the first protrusions and the second protrusions alternate in the second direction.

7. The first conductor and the second conductor are arranged such that the longitudinal directions of the first conductor and the second conductor are aligned with the first direction, and such that the first main surface of the first conductor and the second main surface of the second conductor face a first orientation along the second direction, and each of the plurality of first protrusions has: a first portion extending from the first main surface in the first direction along a third direction intersecting each of the first and second directions; a second portion extending from a tip of the first portion in a direction from the first main surface toward the second main surface along the second direction; and a third portion extending from a tip of the second portion in the first direction along the third direction, and each of the plurality of second protrusions has: a fourth portion extending from the second main surface in the first direction along the third direction; and a fifth portion extending from the tip of the fourth portion in the second direction from the second main surface toward the first main surface along the second direction. The conductive bar according to claim 6 , further comprising: a sixth portion extending from a tip of the fifth portion in the first direction along the third direction.

8. The conductive bar according to claim 3, wherein the first conductor and the second conductor are arranged such that the longitudinal directions of the first conductor and the second conductor are aligned along a first direction and face each other in a second direction intersecting the first direction, and each of the plurality of first protrusions and the plurality of second protrusions has a portion extending in a first direction along a third direction intersecting each of the first direction and the second direction, and at least one of the plurality of first protrusions and the plurality of second protrusions has a portion extending in a second direction or a third direction along the second direction.

9. The conductive bar according to claim 8, wherein each of the plurality of first protrusions has a portion extending in the second direction, which is a direction from the first conductor toward the second conductor, along the second direction, and each of the plurality of second protrusions has a portion extending in the third direction, which is a direction from the second conductor toward the first conductor, along the second direction.

10. A conductive bar according to any one of claims 2 to 9, wherein the substrate is a printed circuit board, the plurality of insertion holes are formed in the printed circuit board, and the plurality of sensor elements are mounted on the printed circuit board so as to surround each of the plurality of insertion holes.

11. A circuit breaker comprising: a conductive bar according to any one of claims 1 to 10; and a circuit breaker body to which the conductive bar is attached.

12. A distribution board comprising: the circuit breaker according to claim 11; and a distribution board body accommodating the circuit breaker.

13. A method for manufacturing a conductive bar by bending as described in claim 7, wherein each of the plurality of first protrusions is integral with the first conductor and has a rectangular shape extending from the first main surface in the first direction along the third direction, and each of the plurality of second protrusions is integral with the second conductor and has a rectangular shape extending from the second main surface in the first direction along the third direction, the method comprising: a first insertion step of inserting the plurality of first protrusions into the plurality of first insertion holes; a second insertion step of inserting the plurality of second protrusions into the plurality of second insertion holes; a first bending step of bending each of the plurality of first protrusions inserted into the plurality of first insertion holes into a shape consisting of the first portion, the second portion, and the third portion; and a second bending step of bending each of the plurality of second protrusions inserted into the plurality of second insertion holes into a shape consisting of the fourth portion, the fifth portion, and the sixth portion.

14. A method for manufacturing a conductive bar by welding as set forth in claim 7, wherein each of the plurality of first protrusions is separate from the first conductor and has a rectangular shape extending from the first main surface in the first direction along the third direction, and each of the plurality of second protrusions is separate from the second conductor and has a rectangular shape extending from the second main surface in the first direction along the third direction, the method comprising: a first bending step of bending each of the plurality of first protrusions into a first shape consisting of the first portion, the second portion, and the third portion; a second bending step of bending each of the plurality of second protrusions into a second shape consisting of the fourth portion, the fifth portion, and the sixth portion; a first insertion step of inserting the plurality of first protrusions bent into the first shape into the plurality of first insertion holes; and a second insertion step of inserting the plurality of second protrusions bent into the second shape into the plurality of second insertion holes. A method for manufacturing a conductive bar, comprising: a first welding step of integrating each of the plurality of first protrusions inserted into the plurality of first insertion holes with the first conductor by welding; and a second welding step of integrating each of the plurality of second protrusions inserted into the plurality of second insertion holes with the second conductor by welding.

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