L-Shaped Stab Base Pan Assembly for Electrical Enclosures
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Solution Overview
Problem
The existing base pan assemblies for connecting conductors to electrical devices like circuit breakers are complex and costly to manufacture and assemble due to the need for multiple components and intricate isolation of conductors and stabs.
Innovation Solution
A base pan assembly with a base pan element and stab element, featuring a lug with an opening for receiving the conductor, which includes a vertical stab portion and horizontal portion forming an L-shaped configuration, securely connecting to a circuit breaker while isolating conductors using electrically insulative materials and simplified manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components and intricate isolation structures are used to connect conductors to the base pan, then electrical isolation reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the base pan, isolation structures, and conductor connection elements into a single integrated base pan assembly. The insulative base pan itself serves as the isolation structure, eliminating the need for separate isolation components. This merging reduces device complexity while maintaining electrical isolation reliability through the inherent insulative properties and structural design of the integrated assembly.
2Reliability
If multiple separate assemblies and components are used to connect conductors and isolate them, then electrical isolation is achieved, but manufacturing cost increases
Solution Approach 1:
The patent integrates multiple functions (conductor support, electrical isolation, mechanical connection) into a single base pan assembly that can be manufactured as one piece or pre-assembled unit. This reduces the total component count and assembly steps, directly lowering manufacturing costs while maintaining reliable electrical isolation through the insulative material properties and structural configuration of the integrated design.
3Reliability
If intricate isolation structures and multiple components are used, then conductor isolation is improved, but assembly time and productivity decrease
Solution Approach 1:
The patent creates an integrated base pan assembly where isolation structures and conductor connection elements are combined into a single unit. This reduces the number of separate assembly operations needed, as the insulative base pan itself provides the isolation function rather than requiring separate isolation components to be installed. This significantly improves assembly efficiency while maintaining proper conductor isolation.
4Reliability
If multiple separate components are used for connecting conductors, then connection reliability is improved, but the number of parts and device complexity increase
Solution Approach 1:
The patent integrates the base pan, isolation structures, and conductor connection elements into a single assembled unit. The insulative base pan itself serves as both the support structure and isolation barrier, eliminating the need for separate isolation components. This merging reduces the total number of parts while maintaining connection reliability through the integrated design that ensures proper electrical separation and mechanical connection.
Data Source
AI summary
A base pan assembly for connecting to conductors and an electrical device. The base pan assembly includes a base pan element having walls for isolating each conductor. The base pan assembly also includes a stab element associated with each conductor wherein the stab element includes first and second portions formed in a substantially L shaped configuration. The first portion is adapted to be connected to the electrical device and the second portion is fastened to the base pan element. An end of the second portion is positioned between a pair of ribs. A fastening element is associated with each stab element, wherein the fastening element includes a post extending from the base pan element which is received by an aperture in the second portion. Further, the base pan assembly includes a lug associated with each conductor, wherein the lug receives the second portion and the associated conductor.