Nested Transformer Fault Circuit Interrupter for Wall Box Depth
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Solution Overview
Problem
Existing fault circuit interrupters have depth constraints due to stacked transformer designs, making it difficult to fit them within the limited space of electrical wall boxes while accommodating wiring and other components.
Innovation Solution
The design involves nesting transformers or sensors, where one transformer is positioned partially or entirely within another, allowing for a reduced depth configuration while maintaining space for wiring and other components within the wall box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transformers are stacked in a conventional configuration, then the fault circuit interrupter can provide complete fault detection functionality, but the device depth increases making it difficult to fit within wall box constraints
Solution Approach 1:
The patent applies nesting by placing one transformer partially or entirely within the hollow region of another transformer. This allows two transformers to occupy a reduced depth space while maintaining their individual functional capabilities for fault detection, thereby resolving the contradiction between complete functionality and compact depth.
Solution Approach 2:
The patent transitions from a conventional stacked arrangement (one dimension) to a nested configuration utilizing the hollow interior space of transformers (adding another spatial dimension). This dimensional change allows transformers to coexist in a smaller overall footprint, reducing device depth while preserving fault detection functionality.
2Length of moving object
If the device depth is reduced to fit wall box constraints, then installation space is improved, but the ability to accommodate wiring and connectors is compromised
Solution Approach 1:
By nesting one transformer within the hollow region of another, the patent reduces the overall device depth while the nested configuration itself creates available space within the transformer structures. This nested hollow space can accommodate wiring and connectors, thus resolving the contradiction between reduced depth and adequate wiring space.
3Ease of manufacture
If conventional transformer stacking is used, then manufacturing is straightforward, but the device complexity increases due to space constraints requiring additional components
Solution Approach 1:
The nesting configuration integrates two transformers into a single compact unit, reducing the need for additional external components and mounting structures that would be required in a stacked arrangement. This integration simplifies the overall device structure while maintaining manufacturing feasibility, resolving the contradiction between ease of manufacture and device complexity.
Data Source
AI summary
In one embodiment, there is a fault interrupter device comprising at least one sensor comprising at least one first transformer having at least one outer region forming an outer periphery and at least one inner hollow region. There is also at least one second transformer that is disposed in the inner hollow region of the at least one first transformer. The transformers can be substantially circular in configuration, and more particularly, ring shaped. In another embodiment there is a rotatable latch which is used to selectively connect and disconnect a set of separable contacts to selectively disconnect power from the line side to the load side. The rotatable latch is in one embodiment coupled to a reset button. In at least one embodiment there is a slider which is configured to selectively prevent the manual tripping of the device.