Plug-on Neutral Connector for AFCI and GFCI Circuit Breakers

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Solution Overview

Problem

Existing AFCI and GFCI circuit breakers face issues with cluttered load centers due to pigtail connections, overlong or inadequate plug-on neutral connectors, fragile designs, and compatibility problems with various circuit breaker models, necessitating a sturdy, adjustable, and versatile plug-on neutral connector solution.

Innovation Solution

A plug-on neutral connector with a conductive fastener and adjustable length, featuring a neutral terminal plug for circuit breaker insertion and a housing for secure engagement with a neutral bus bar, allowing for robust interoperation with multiple AFCI and GFCI circuit breakers, and accommodating various load center geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pigtail connections are used to connect the circuit breaker to the neutral bus bar, then the circuit breaker can be connected to the neutral bus bar, but the load center becomes cluttered

Engineering Contradiction:

Improveconnection simplicityVSAvoidload center space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent combines the neutral terminal plug and the neutral bus bar connector into a single integrated plug-on neutral connector assembly. This merging eliminates the need for separate pigtail connections and multiple discrete components, thereby reducing clutter in the load center while maintaining electrical connectivity between the circuit breaker and neutral bus bar

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If traditional plug-on neutral connectors are used, then the neutral connection can be established, but the connectors are overlong or scrimped and not suitable for various load center geometries

Engineering Contradiction:

Improvecompatibility with circuit breakersVSAvoidconnector length

Core Design Contradiction:

Adaptability or versatilityVSLength of moving object

Solution Approach 1:

The patent incorporates a flexible conductive element within the plug-on neutral connector that can bend and adjust to different geometries. This dynamic flexibility allows the connector to adapt to various load center configurations and circuit breaker positions without being overly long or rigid, providing versatility across different installation scenarios

Inventive Principle:

Principle #15Dynamics

3Productivity

If simple plug-on neutral connectors are used, then installation is quick, but the connectors are frail and susceptible to damage during circuit breaker installation and replacement

Engineering Contradiction:

Improveinstallation speedVSAvoidconnector durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent designs the plug-on neutral connector with reinforced structural features and protective elements that preemptively compensate for the mechanical stresses and damages that occur during installation and replacement operations. This prior cushioning approach ensures the connector maintains its integrity and reliability throughout the installation process without requiring slower, more careful installation procedures

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10770254B2Plug-on neutral connector for use with a fault circuit interrupt circuit breaker

Publication Date: 2020.09.08 ABB (SCHWEIZ) AG

AI summary

A plug-on neutral connector includes a neutral terminal plug arranged to be inserted into a neutral terminal of a circuit breaker, a conductive fastener, including a pass-through, electrically coupled to the neutral terminal plug and arranged to be fastened on a neutral bus bar of a load center, and a housing disposed over at least a portion of the conductive fastener.