PCB Coil Circuit Interrupter Layout for Receptacle Space Limits
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Solution Overview
Problem
Circuit interrupters such as GFCIs and AFCIs face space constraints when implemented in electrical receptacles, requiring innovative designs to accommodate their components effectively.
Innovation Solution
A circuit interrupter design incorporating a printed-circuit board with embedded coils and a test circuit, where the coils are used to sense current conditions, and a control system with a microcontroller to detect fault conditions, allowing for compact integration within the receptacle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coils are used in circuit interrupters, then fault detection capability is maintained, but device volume increases and space utilization deteriorates
Solution Approach 1:
The patent replaces traditional mechanical wire-wound coils with printed circuit board (PCB) coils. The PCB coils are formed by printing conductive traces on the board, eliminating the need for separate wire winding, mounting, and connection processes. This substitution significantly reduces the space required for coil components while maintaining the electromagnetic sensing capability necessary for fault detection in GFCI and AFCI devices.
Solution Approach 2:
The patent integrates the coil structure directly into the printed circuit board by forming conductive traces that serve dual purposes: as electrical connection pathways and as functional sensing coils. This merging of structural and functional elements eliminates the need for separate coil components, reducing overall device volume while preserving fault detection functionality.
2Adaptability or versatility
If more components are integrated into the receptacle, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The printed circuit board is designed to serve multiple functions simultaneously: it provides structural support, establishes electrical connections between components, and forms the functional coils for ground fault and arc fault detection. This multi-functionality reduces the number of separate components needed, simplifying the manufacturing process while enhancing device functionality.
Solution Approach 2:
By replacing traditional mechanical coil assembly processes with PCB trace printing, the patent simplifies manufacturing. The coils are created using standard PCB fabrication techniques (photoetching, plating) rather than requiring separate wire winding, mounting, and soldering operations, thereby reducing manufacturing complexity despite increased functional integration.
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
This design enhances the compactness of circuit interrupters within electrical receptacles while maintaining effective fault detection capabilities, thereby improving space utilization and safety features.
Implementation Method 1
The printed circuit board includes a slot through the printed-circuit board coil, wherein the line conductor is received by the printed-circuit board coil. The test circuit is electrically connected to the printed-circuit board coil and configured to determine a condition of the line conductor based on a signal of the printed-circuit board coil.
Data Source
AI summary
A circuit interrupter including a line conductor, a printed-circuit board, and a test circuit. The printed-circuit board coil is embedded on a printed circuit board. The printed circuit board includes a slot through the printed-circuit board coil, wherein the line conductor is received by the printed-circuit board coil. The test circuit is electrically connected to the printed-circuit board coil. The test circuit is configured to determine a condition of the line conductor based on a signal of the printed-circuit board coil.