Low-Profile Electronic Circuit Breaker Design for Dual-Circuit Protection
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Solution Overview
Problem
Conventional duplex electronic circuit breakers occupy two standard single-pole breaker locations due to their large profile, limiting the number of electrical circuits that can be protected in residential and commercial panelboards.
Innovation Solution
A low-profile electronic circuit breaker design with two branches that fit within a single standard single-pole circuit breaker mounting location, featuring a housing without load neutral terminals and an improved tripping mechanism that includes a moveable electrical contact and a tripping unit with a magnet, bimetal member, and armature, allowing for a narrower transverse width and increased circuit protection capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional duplex electronic circuit breaker is designed with two internal electrical branches to protect two circuits, then the circuit protection capacity is improved, but the transverse width of the housing increases to occupy two standard single-pole breaker locations
Solution Approach 1:
The patent merges two electrical branches into a single housing that occupies only one standard single-pole breaker location. The housing integrates two sets of electrical contacts, two trip mechanisms, and shared electronic components (processing circuit, sensors) to provide dual-circuit protection while reducing the transverse width to fit within a single 0.75-inch or 1-inch panelboard location, thereby doubling the circuit protection capacity per unit width.
2Adaptability or versatility
If a duplex electronic circuit breaker includes numerous electronic components (printed circuit boards, sensors, electromagnets) and mechanical components (contact arms, springs, armatures, magnets, bimetal elements), then the functional capability is improved, but the device complexity increases
Solution Approach 1:
The patent implements multi-functionality by designing a single electronic processing circuit that handles monitoring and tripping for both electrical branches, and a shared tripping mechanism that can interrupt both circuits. The housing contains universal components that serve dual purposes: two sets of electrical contacts for different circuits, shared sensors for detecting electrical conditions in both branches, and a common electronic processing circuit that responds to conditions in either branch, thereby reducing overall component count while maintaining comprehensive protection capabilities.
3Length of stationary object
If the housing is designed without load neutral terminals to reduce width, then the transverse width is reduced to fit in a single mounting location, but the electrical connection configuration becomes more constrained
Solution Approach 1:
The patent applies local quality by providing electrical terminals only where needed for the specific application. The housing includes load terminals for connecting electrical loads but deliberately omits load neutral terminals, creating a localized terminal configuration optimized for the intended use case. This selective terminal provision reduces the transverse width while maintaining adequate electrical connection capability for circuits that don't require separate neutral connections at the breaker, thereby achieving width reduction without completely sacrificing connection flexibility.
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 protection of up to twice as many electrical circuits within a fixed space, reducing the overall width of the circuit breaker to fit within a single standard mounting location while maintaining effective arc fault and ground fault detection and interruption capabilities.
Implementation Method 1
a tripping mechanism coupled to the moveable electrical contact and including a magnet, a bimetal member, and an armature
Implementation Method 2
a tripping mechanism coupled to the moveable electrical contact and including a magnet, a bimetal member, and an armature
Data Source
AI summary
A low-profile electronic circuit breaker includes first and second electrical branches coupled to respective first and second load terminals. The electronic circuit breaker also includes an electronic processing circuit configured to monitor an electrical condition in the first and second electrical branches. The electronic circuit breaker is packaged in a housing sized to occupy a standard single-pole breaker panelboard location. In some embodiments, the electronic circuit breaker has no load neutral terminals associated with the first and second load terminals. Methods of assembling an electronic circuit breaker are provided, as are other system and method aspects.