Compact GFCI Module With Nested Toroidal Transformers
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Solution Overview
Problem
Existing ground fault circuit interrupters (GFCIs) are difficult to incorporate into various configurations due to their size and complexity, making it challenging to create compact modules for angled plugs, in-line plugs, and panel mounts.
Innovation Solution
A compact GFCI module is designed with a pair of toroidal transformers and a double pole single throw (DPST) relay, mounted in a housing, which can be connected to a printed circuit board (PCB) to detect unbalanced currents and low impedance conditions, allowing for self-contained assembly in different configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional GFCI components (transformers, relay, circuitry) are used, then ground fault detection function is achieved, but device size and complexity increase making it difficult to incorporate into various configurations
Solution Approach 1:
The patent combines multiple GFCI components (transformers, relay, circuitry) into a single integrated module housing. The module integrates a differential transformer, neutral transformer, DPST relay, and circuit board into one compact assembly that functions as a complete GFCI unit, reducing the number of separate components and simplifying installation.
Solution Approach 2:
The module is designed with universal mounting capabilities that allow it to be installed in various configurations including angled plugs, in-line plugs, and panel mounts. The standardized housing and mounting brackets enable the same module to serve multiple application types without requiring configuration changes.
2Adaptability or versatility
If GFCI circuitry is integrated into compact configurations (angled plugs, in-line plugs), then adaptability is improved, but space constraints make component integration difficult
Solution Approach 1:
The module employs a nested arrangement where the differential transformer and neutral transformer are positioned adjacent to each other with their cores oriented perpendicular to each other. The relay is mounted on the circuit board within the same housing space, creating a compact nested configuration that maximizes component density while maintaining electrical isolation.
Solution Approach 2:
The transformers are arranged with their cores oriented in perpendicular dimensions rather than linearly, utilizing three-dimensional space efficiently. The differential transformer core extends in one direction while the neutral transformer core extends perpendicular to it, allowing both components to fit within the compact module volume.
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 compact module enables the integration of GFCI circuitry into various configurations such as angled plugs, in-line plugs, and panel mounts, providing effective ground fault protection while maintaining a compact size comparable to commercial relays.
Implementation Method 1
The first transformer can be positioned over the second transformer forming a stacked arrangement. One of the transformers can be a differential transformer for detecting an unbalanced current flowing through a line side phase and neutral conductor
Implementation Method 2
The second transformer having a toroidal core is located adjacent to and magnetically coupled to the core of the first transformer
Implementation Method 3
The relay can include a relay frame that supports a bobbin wound with a coil of wire and a rod shaped metal core that passes through the center of the bobbin to secure it to the frame
Data Source
AI summary
A compact module with a pair of transformers and a double pole single throw relay (DPST) mounted onto a housing to create a self contained assembly for installation in a ground fault circuit interrupter (GFCI) as a unit. The first transformer has a core and is electrically coupled to a first set of terminals for connection to a printed circuit board (PCB). The second transformer is located adjacent to and magnetically coupled to the core of the first transformer and is electrically coupled to a second set of terminals for connection to the PCB. The DPST relay has a pair of stationary contacts and a pair of movable contacts for selectively connecting line phase and neutral conductive paths to a load.