Circuit Breaker Module With Dilatant Faceplate
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Solution Overview
Problem
Circuit breaker housing assemblies require improved assembly elements and faceplates need enhanced rigidity to prevent deformation, especially in high-density aircraft electrical systems where conventional solutions like metallic bushings increase costs and flexibility issues arise.
Innovation Solution
A miniature circuit breaker module design featuring a frame and faceplate with molded bodies and pins that align and couple without metallic bushings, providing a rigid structure through latching pins and alignment components, and a dilatant faceplate that becomes more rigid when compressed, reducing deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic bushings are used to couple housing assembly bodies, then assembly strength is improved, but material cost and manufacturing cost increase
Solution Approach 1:
The patent removes the metallic bushing component entirely from the housing assembly. Instead of using separate metallic bushings to couple the first and second bodies, the invention integrates the coupling function directly into the molded housing bodies themselves, eliminating the need for this intermediate component and reducing material costs.
Solution Approach 2:
The patent combines the coupling function with the housing bodies by integrating molded-in coupling features directly into the plastic housing components. This merging of functions eliminates the need for separate metallic coupling elements and simplifies the manufacturing process.
2Ease of manufacture
If a flexible faceplate material is used, then ease of assembly is improved, but structural rigidity deteriorates causing deformation
Solution Approach 1:
The patent changes the material parameter of the faceplate from flexible to rigid. By using a rigid material for the faceplate, the invention maintains structural integrity and prevents deformation while still allowing for practical assembly procedures.
Solution Approach 2:
The patent employs composite construction by integrating the faceplate as part of the molded housing assembly, creating a unified rigid structure that combines the faceplate with the housing bodies through molded-in features, thereby enhancing overall structural rigidity.
3Adaptability or versatility
If the faceplate area is increased, then functionality is improved, but rigidity deteriorates causing flexing and bowing
Solution Approach 1:
The patent uses composite construction by integrating the faceplate with the housing bodies through molded-in coupling features, creating a unified rigid structure that prevents flexing and bowing even when the faceplate area is increased for enhanced functionality.
Solution Approach 2:
The patent changes the material parameter from flexible to rigid, allowing the faceplate to maintain its shape and rigidity even when scaled to larger dimensions, thereby preventing deformation while preserving expanded functionality.
4Reliability
If conventional housing assembly methods are used, then assembly reliability is maintained, but assembly efficiency deteriorates
Solution Approach 1:
The patent merges multiple assembly steps into a single molded operation by integrating coupling features directly into the housing bodies during the molding process. This eliminates the need for separate assembly operations to install metallic bushings, thereby improving assembly efficiency while maintaining reliability.
Solution Approach 2:
The patent performs the coupling feature creation during the initial molding process rather than as a subsequent assembly step. By preliminarily forming the coupling features as part of the housing manufacturing, the invention eliminates later assembly operations and improves overall assembly efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the structural integrity and assembly efficiency of circuit breaker modules by eliminating metallic bushings and improving faceplate rigidity, reducing material costs and deformation, while maintaining operational functionality.
Implementation Method 1
a dilatant faceplate that becomes more rigid when compressed, reducing deflection
Data Source
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AI summary
A circuit breaker module (10) includes a faceplate (14) with a number of passages (16) and a number of circuit breakers (20), each circuit breaker (20) including an operating mechanism (22), conductor assembly (24), and a housing assembly (30). Each circuit breaker housing assembly (30) includes a first body (32), a second body (34), and a plurality of pins (36). The first body (32) defines a cavity (37). The second body (34) defines a cavity (38). The first body (32) and the second body (34) have complimentary shapes. At least one of the first body (32) or the second body (32) includes a plurality of pin cavities (37). The pins (36) and pin cavities (50) disposed in an alignment pattern. The first body (32) and the second body (34) are coupled to each other defining an enclosed space (18), the enclosed space (18) structured to accommodate an operating mechanism (22) and conductor assembly (24).