Modular Interlocking Phase Barrier for Circuit Breakers
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Solution Overview
Problem
Existing phase barriers for electrical switching apparatus, such as circuit breakers, require custom components for different numbers of poles and use a high number of fasteners, which is inefficient and costly.
Innovation Solution
A modular interlocking phase barrier apparatus comprising separate phase barrier members and interlocking components, where each member has symmetrical slots and pins for secure assembly, allowing a single mold to produce adaptable phase barriers for various pole configurations with reduced fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom one-piece phase barriers are made for different circuit breaker pole configurations, then electrical insulation between terminals is ensured, but manufacturing complexity and component variety increase
Solution Approach 1:
The phase barrier is divided into multiple separate members (first phase barrier member, second phase barrier member, etc.) that can be assembled together using interlocking components. This segmentation allows the same basic components to be used across different pole configurations, reducing the need for custom one-piece barriers for each configuration while maintaining electrical insulation effectiveness.
Solution Approach 2:
The separate phase barrier members and interlocking components are designed to be universal parts that can be used across multiple circuit breaker pole configurations. The same basic members can be arranged and interconnected to create phase barriers for 2-pole, 3-pole, 4-pole, or other configurations, eliminating the need for different custom components for each application.
2Reliability
If one-piece custom phase barriers are used for different pole configurations, then electrical insulation is provided, but the number of fasteners required increases
Solution Approach 1:
Multiple phase barrier members are merged together through interlocking components that combine several fastening functions into integrated connection points. The interlocking components engage with recesses and protrusions on the phase barrier members, creating secure connections without requiring numerous separate fasteners for each connection point.
Solution Approach 2:
The phase barrier members are pre-formed with integrated recesses and protrusions that enable interlocking connections. This preliminary preparation of connection features eliminates the need for additional fasteners during assembly, as the members are designed to connect directly to one another.
3Ease of manufacture
If separate phase barrier members with interlocking components are used, then manufacturing complexity is reduced and fastener usage decreases, but assembly complexity may increase
Solution Approach 1:
The interlocking components feature asymmetric recesses and protrusions that provide directional guidance during assembly. The asymmetric design ensures that members can only be assembled in the correct orientation, simplifying the assembly process by eliminating the need for complex alignment procedures while reducing assembly complexity through intuitive fit.
Data Source
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AI summary
A circuit breaker (2) includes an enclosure (46) with a first side and a second side opposite and distal from the first side. A number of separable contacts (52) are enclosed by the enclosure. An operating mechanism (54) is structured to open and close the separable contacts. A plurality of terminals (12,14) are electrically interconnected with the number of separable contacts. The terminals protrude through the second side of the enclosure. A number of phase barrier apparatus (8,10) is disposed on the second side of the enclosure. Each of the number of phase barrier apparatus includes a plurality of separate phase barrier members (4), each of which is disposed about a corresponding one of the terminals, and a number of interlocking members (6). Each of the number of interlocking members (6) interlocks with an adjacent pair of the separate phase barrier members (4).