Circuit Breaker Mechanism Assembly Without Screws or Pins

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Solution Overview

Problem

Existing circuit breakers require complex and costly assembly processes that involve screws, pins, and other fixation elements, which can lead to material deformation and compromise the integrity of the molded base, and do not allow for pre-assembly testing.

Innovation Solution

A circuit breaker design that uses controlled deformation of tabs on the operating mechanism's legs to fix the mechanism to the molded base without screws or pins, allowing for pre-assembly testing and ensuring robustness and ease of replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If screws, pins, and other fixation elements are used to assemble the operating mechanism to the molded base, then the assembly is secure and stable, but the complexity of the assembly process increases and the molded base may be deformed

Engineering Contradiction:

Improveassembly stabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates screws, pins, and other traditional fixation elements from the assembly process. The operating mechanism is directly integrated with the molded base through injection molding, removing the need for separate fastening components and simplifying the assembly process while maintaining secure attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the operating mechanism and molded base into a single integrated component through injection molding. The operating mechanism is molded directly onto the base in one manufacturing step, combining what would traditionally be separate parts requiring multiple assembly steps with fasteners.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional assembly methods with screws and pins are used, then the operating mechanism can be securely fixed, but pre-assembly testing cannot be performed and replacement is difficult

Engineering Contradiction:

Improvefixation securityVSAvoidmechanism replaceability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The invention segments the circuit breaker into distinct modular components: the molded base, the operating mechanism, and the cover. While the base and mechanism are integrated through molding, the mechanism itself remains a separate replaceable unit that can be removed and replaced without affecting the base structure, facilitating easy maintenance and testing.

Inventive Principle:

Principle #1Segmentation

3Strength

If multiple fixation elements are used to secure the operating mechanism, then the connection is strong, but the material deformation and integrity of the molded base are compromised

Engineering Contradiction:

Improveconnection strengthVSAvoidmolded base deformation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention replaces the mechanical fastening system (screws, pins, and other fixation elements) with a chemical bonding system through injection molding. The material itself forms the connection between the operating mechanism and base, eliminating the need for separate mechanical fasteners and preventing deformation associated with drilling and fastener installation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables pre-assembly testing and maintenance without deforming the molded base, reducing costs and complexity while ensuring high-quality, reliable operation.

Implementation Method 1

at least one pair of tabs of a plurality of legs of said mechanism are deformed so as to conform to said molded base

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

The folded tabs are pressed against the molded base to create friction and mechanical interlocking

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP4576152A1Circuit breaker and method of assembling an operating mechanism on a circuit breaker molded base

Publication Date: 2025.06.25 WEG DRIVES & CONTROLS AUTOMAC O LTDA

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AI summary

The present invention relates to a circuit breaker (100) comprising a molded base (200), an operating mechanism (300) together with a separable pair of contacts (630, 631) and a molded cover (400), wherein: the molded base (200) comprises a plurality of grooves (220), a plurality of shoulders (222), a plurality of through openings (224); and said operating mechanism (300) comprises a plurality of side plates (310), at least one perpendicular protrusion (320), and a plurality of legs (330); wherein each leg (330) comprises a tab (364) comprising folding lines (375), and wherein said tab (364) can be inserted into said through openings (224) of at least one pair of grooves (220) of said molded base (200) and be folded so as to position at least one pair of grooves (370) over shoulders (222) of said molded base (200) of said circuit breaker (100); and the present invention also relates to a method of assembling said operating mechanism (300) on said molded base (200).