Filler Plate Deformation Clamping for Loadcenter Deadfronts
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Solution Overview
Problem
Existing loadcenter and filler plate configurations require drilling or machining, which is inconvenient and potentially hazardous, especially when covering openings in deadfronts to protect live wires.
Innovation Solution
A filler plate design with a cover plate and attachment features, including legs and a fastener system, that securely covers openings in loadcenters without the need for drilling, using a deformation mechanism to clamp the deadfront in place and ensure electrical grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drilling or machining is used to attach the filler plate to the loadcenter, then the filler plate can be securely attached, but the process becomes inconvenient and potentially hazardous due to metal shavings and additional holes in the loadcenter
Solution Approach 1:
The patent replaces the traditional mechanical drilling and screw attachment system with a deformation-based clamping mechanism. The attachment feature deforms the filler plate to clamp onto the deadfront, eliminating the need for drilling holes or using screws that penetrate the loadcenter structure.
Solution Approach 2:
The attachment feature acts as an intermediary element between the filler plate and the deadfront. It provides a mechanical interface that clamps the filler plate to the deadfront surface without requiring penetration into the loadcenter, thus mediating the attachment function while avoiding the harmful effects of drilling.
2Device complexity
If a simple cover plate is used without attachment features, then the design is simple, but the filler plate cannot be securely attached to the loadcenter
Solution Approach 1:
The patent merges the attachment function with the filler plate structure by integrating the attachment feature directly onto the filler plate. This combination creates a unified component that both covers the opening and securely attaches to the deadfront, eliminating the need for separate attachment hardware.
Solution Approach 2:
The attachment feature is constructed from the filler plate material itself and performs the attachment function autonomously through deformation. The filler plate's own material is used to create the clamping mechanism, allowing the component to attach itself to the deadfront without requiring external fasteners or additional parts.
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 provides a safe and efficient method to cover openings in loadcenters, preventing accidental access to live components and eliminating the risk of metal shavings, while maintaining electrical integrity without additional holes in the loadcenter.
Implementation Method 1
the first leg is constructed to deform and reduce the first gap and clamp the first portion of the deadfront between the first leg and the cover plate
Implementation Method 2
the first leg is electrically coupled to the cover plate and constructed to ground the cover plate with the first portion of the deadfront
Data Source
AI summary
A filler plate for a loadcenter having an opening in a deadfront includes a cover plate constructed to cover the opening; a first leg coupled to and spaced apart from the cover plate to yield a first gap between the first leg and the cover plate, wherein the first gap is constructed to receive a first portion of the deadfront adjacent to the opening therein; and a second leg coupled to and spaced apart from the cover plate to yield a second gap between the second leg and the cover plate, wherein the second gap is constructed to receive a second portion of the deadfront adjacent to the opening therein.