Universal PCB Layout for Multi-Configuration Plug-In Breakers

Solution Overview

Problem

Existing circuit breaker configurations require separate printed circuit boards (PCBs) for different configurations, leading to complex manufacturing, increased production costs, and cumbersome installation and maintenance processes.

Innovation Solution

A universal printed circuit board (PCB) with edge connectors and pin connectors, designed to interface with multiple configurations of plug-in circuit breakers, including 1-63A, 80-125A, and 200A types, without the need for separate PCBs for each configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate printed circuit boards are used for different circuit breaker configurations, then the PCB can be specifically optimized for each configuration, but the manufacturing complexity increases, production costs increase, and inventory management becomes cumbersome

Engineering Contradiction:

Improveconfiguration compatibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a universal printed circuit board design that can accommodate multiple circuit breaker configurations (1-63A, 80-125A, and 200A types) through a standardized connector interface. The PCB includes multiple edge connectors positioned to interface with different connector positions on various circuit breaker types, allowing a single PCB design to replace multiple configuration-specific PCBs, thereby reducing manufacturing complexity and inventory requirements while maintaining adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate printed circuit boards are used for different circuit breaker configurations, then each PCB can be optimized for its specific configuration, but production costs increase and installation/maintenance processes become more cumbersome

Engineering Contradiction:

Improveconfiguration compatibilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent implements a universal printed circuit board design that can accommodate multiple circuit breaker configurations (1-63A, 80-125A, and 200A types) through a standardized connector interface. The PCB includes multiple edge connectors positioned to interface with different connector positions on various circuit breaker types, allowing a single PCB design to replace multiple configuration-specific PCBs, thereby reducing manufacturing complexity and inventory requirements while maintaining adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple PCB configurations are maintained for different circuit breaker types, then each configuration can be precisely matched, but installation and maintenance become more complex and time-consuming

Engineering Contradiction:

Improveconfiguration matchingVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent implements a universal printed circuit board design that can accommodate multiple circuit breaker configurations (1-63A, 80-125A, and 200A types) through a standardized connector interface. The PCB includes multiple edge connectors positioned to interface with different connector positions on various circuit breaker types, allowing a single PCB design to replace multiple configuration-specific PCBs, thereby reducing manufacturing complexity and inventory requirements while maintaining adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent employs modular edge connectors that can be selectively activated or connected based on the specific circuit breaker configuration installed. This segmentation allows the universal PCB to adapt to different configurations by engaging only the relevant connectors, maintaining precise configuration matching while simplifying installation procedures

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250063663A1Printed circuit board for plug-in type breakers

Publication Date: 2025.02.20 VERTIV CORP

AI summary

A printed circuit board (PCB) is provided and includes a plurality of edge connectors, a pin connector, and a plurality of electrical lines each electrically connecting one of the plurality of edge connectors to the pin connector. The plurality of edge connectors are positioned on the PCB to enable the plurality of edge connectors to interface with respective connectors of a plurality of configurations of circuit breakers. The configurations may include a configuration including a first type of circuit breaker and a configuration including a second type of circuit breaker. The first and second types of circuit breakers may be 1-63 ampere (A) and 80-125A circuit breakers or 80-125A and 200A circuit breakers, or may be any of a variety of other types.