Insulated Bus Bar Panelboard with Plug-In Connectors
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Solution Overview
Problem
Existing low voltage panelboards and power distribution systems pose safety risks due to exposed 'live' electrical connection points during installation and maintenance, lack insulation during manufacturing, and have limited compatibility with various electrical components, restricting their use with market-available products.
Innovation Solution
A panelboard and power distribution system with a central bus bar and insulating body, featuring isolated 'plug in' clamp connectors that secure with un-energized snap connections, providing insulation and universal compatibility through an open architecture design, reducing the need for additional insulation and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conducting parts are left non-insulated to facilitate assembly during manufacturing, then assembly ease is improved, but personnel safety deteriorates due to exposed live electrical parts
Solution Approach 1:
The bus bar is pre-insulated with insulating material before assembly, and the insulating cover is pre-assembled onto the bus bar. This preliminary insulation action eliminates the need for additional insulation steps during final assembly, while simultaneously protecting personnel from shock risk by enclosing live parts before they are connected to electrical components
2Manufacturing precision
If the panelboard is designed to accept only one type of electrical component, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The panelboard employs universal mounting structures and standardized connection interfaces that can accommodate multiple types of electrical components (circuit breakers, GFCIs, AFCIs, etc.). The insulating cover design with standardized wells and the open architecture allow different component types to be installed using the same mounting mechanism, achieving both manufacturing precision and broad adaptability
3Object-affected harmful factors
If additional insulating parts are added to protect personnel, then personnel safety is improved, but device complexity increases
Solution Approach 1:
The insulating cover is merged with the bus bar structure, forming an integrated insulated bus bar assembly. The insulating cover is not a separate additive component but is combined with the bus bar itself, reducing the number of discrete parts while maintaining personnel protection. The same insulating structure serves multiple functions: insulation, structural support, and component mounting housing
Data Source
AI summary
An electrical power distribution system or panelboard that includes a hollow central body with at least one insulated bus bar and a top non-energized metal mounting surface. A plurality of connection points are distributed along the bus bar for electrical device connections. The connection points are contained inside molded plastic holes or wells, and are electrically connected to the main bus bar. Electrical device connections are accomplished via connectors plugged into the holes or wells. The attachment of electrical devices of various sizes and configurations may be accommodated through the use of spacers.