MOLDED CASE CIRCUIT BREAKER BASE AND MID-COVER ASSEMBLY

BACKGROUND OF THE INVENTION

[0001] The present invention relates to molded case circuit breaker enclosures. More particularly the present invention relates to a base and mid-cover configuration for circuit breaker enclosures.

[0002] Circuit breaker enclosures are typically manufactured having a deep base for enclosing the components of a circuit breaker (i.e., a circuit breaker cassettes) and a cover having an opening for an operating handle (a bifurcated case). In existing circuit breaker enclosures, the base is constructed with sidewalls that extend to a height approaching or exceeding the height of the circuit breaker cassettes when upon the floor of the base. Other designs employ a divided cover, where in a mid-cover connects to the base and the top cover connects to the mid-cover and has an opening for the operating handle (a trifurcated case). The mid-cover may also comprise accessory recesses and/or trip actuator recesses positioned in mechanical cooperation with the operating handle of the circuit breaker. As with a bifurcated case, typical sidewalls of trifurcated case bases approach or exceed the height of the circuit breaker cassettes.

[0003] Typically, in trifurcated circuit breaker enclosures the height of the mid-cover wall is small in relation to the height of the base sidewalls. This is likely due to the limited purpose of existing mid-covers, i.e., to house accessories and trip actuators, which generally have a small height in comparison to the circuit breaker cassettes. The ratio of the mid-cover height Hmc to the base height Hb (Hmc/Hb) in prior circuit breakers molded case is less than about 0.45.

[0004] However, with relatively small Hmc/Hb ratios, manufacturing is difficult as the base must be relatively high for a very thin structure. This creates problems in the molding of the thermoplastic materials and increases the effort required to provide a finished product having thermoplastic resin and filler evenly distributed.

[0005] Further, a structural problem arises due to the high, thin sidewalls of the base. As gases are exerted when the circuit breaker cassettes trip, the stresses created cause the circuit breaker enclosure to deform and possibly crack at the base sidewalls.

[0006] Therefore, a need exist for a molded circuit breaker case that is easier to mold and that provides suitable structural integrity.

BRIEF SUMMARY OF THE INVENTION

[0007] A molded circuit breaker enclosure is provided having a base, a mid-cover, and a top-cover. The base includes generally parallel sidewalls, a bottom wall, a lined end dividing portion. The mid-cover comprises generally parallel sidewalls, and a load end dividing structure. Circuit breaker components, such as one or more circuit breaker cassettes, are positioned within the base of the circuit breaker. A mid-cover is removably affixed on top of the base sidewalls, and are secured there to, for example, on a pressed fit frictional engagement, interference engagement, fastener adhesive or any combination thereof. The top-cover has a slot to allow a handle to extend therethrough.

[0008] The circuit breaker enclosures must withstand mechanical stresses caused by the high gas pressure generated when a short circuit occurs. Accordingly, it is beneficial to transfer the stresses from the sidewalls of the base to the cover or the combined mid-cover and top-cover assembly. This may be accomplished by providing a step on the upper edge of the sidewalls of the base and a corresponding step on the bottom edge of the mid-cover sidewalls in a trifurcated case or cover sidewalls in a bifurcated case.

[0009] In an exemplary embodiment of the present invention, the ratio of the mid-cover sidewall height to the base sidewall height is at least 0.45. In a most preferred embodiment, the ratio is between 0.61 and 1.63.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]
FIG. 1 is a top perspective view of an assembled molded case circuit breaker;

[0011]
FIG. 2 is an exploded side perspective view of a molded case circuit breaker showing the enclosure structure and general internal components;

[0012]
FIG. 3 is a top perspective view of a molded case circuit breaker with mid-cover and base heights indicated;

[0013]
FIGS. 4 and 5 are cross-sectional views of a prior art circuit breaker case and a case of the present invention; respectively;

[0014]
FIGS. 6 and 7 are cross-sectional views of a prior art circuit breaker enclosure base mold and a base mold of the present invention, respectively;

[0015]
FIG. 8 is a cross-sectional view of a molded circuit breaker enclosure depicting internal forces imported upon the enclosure; and

[0016]
FIG. 9 is an enlarged view of a lap joint that may be employed within preferred embodiments of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0017] A molded circuit breaker case 10 is generally shown in FIG. 1. The molded circuit breaker case 10 generally includes an electronic trip unit (not shown) for overcurrent protection and also may include at least one auxiliary electrical accessory, such as auxiliary switches, shunt trip elements and under-voltage sensing units. Molded circuit breaker case 10 generally includes an insulated base 12, a mid-cover 14 and a top-cover 16. Disposed within the molded case are plurality of breaker cassettes 40, 50 and 60 (not shown) including line terminal straps 44, 54 and 64 and load terminal straps 46, 56 and 66 (shown in phantom view). Load terminal straps 46, 56 and 66 are physically and electrically separated from each other by base load terminal dividing walls 28 and two mid-cover line terminal dividing walls 30. When mid-cover 14 is attached to case 12, the downwardly extending mid-cover load terminal dividing walls 30 align with corresponding upstanding base line terminal dividing walls 28 integrally formed within the case to electrically isolate the bad connections within a multi-phase electrical circuit. Likewise, line terminal straps 44, 54 and 64 are physically and electrically separated from each other by two base load terminal divider walls (not shown) and two mid-cover line divider walls (not shown).

[0018] Mid-cover 14 is disposed generally between base 12 and top cover 16. Mid-cover 14 is secured to base 12 by a combination of fasteners and one or more frictional engagements such as a press fit engagement. Top-cover 16 is secured to mid-cover 14 by a plurality of fasteners. Further, circuit breaker case 10 may include load strap cover 18 and line strap cover 20 removably or permanently affixed to mid-cover 14 to prevent top access to the terminal straps 46, 56, 66 and 44, 54, 64 respectively. Load strap cover 18 and line strap cover 20 may be secured to mid-cover 14 in a press-fit manner. It is well known to one skilled in the art that alternative methods for securing the mid-cover to the base may be employed, for example, adhesives, interference engagements, fasteners, frictional engagements, or any combination thereof. It is also well know to one skilled in the art that top-cover 16, load strap cover 18 and line strap cover 20 may be secured to mid-cover 14 by a variety of methods, for example, adhesives, interference engagements, fasteners, frictional engagements, or any combination thereof.

[0019] Top-cover 16 includes an operating handle slot 82 (see FIG. 2) to allow circuit breaker operating handle 80 to pass therethrough. Operating handle 80 controls the circuit breaker cassettes via a connection with an internal mechanism (not shown).

[0020] Referring to FIG. 2, an exploded side perspective view of the circuit breaker molded case of the present invention is depicted. Base 12 comprises opposed upstanding sidewalls 32 and 34, base floor 36, upstanding baseline terminal divider walls 28, and upstanding load terminal divider walls 22. Sidewalls 32 and 34 comprise a top lipped edge, the outside of which received inside of the bottom edge of the mid-cover sidewalls in a pressed fit manner (described in further detail herein with reference to FIG. 9).

[0021] Circuit breaker cassettes 40, 50 and 60 are disposed in an upstanding fashion within base 12 upon base floor 36, such that cassette 40 is adjacent to sidewall 32, cassette 60 is adjacent to sidewall 34, and cassette 50 is disposed between cassette 40 and 60. The handle 80 is attached to an internal mechanism 70, which is coupled with the center cassette 50. Center cassette 50 is coupled with cassettes 40 and 60 by the drive pin 72. Cassettes 40, 50 and 60 engage and disengage simultaneously by drive pin 72. The height of the circuit breaker cassettes is greater than the height of the base sidewalls, as apparent by a view of an inserted cassette 40, shown in phantom at 40a.

[0022] Cassettes 40, 50 and 60 along with mechanism 70 are assembled into the base 12 and retain therein by mid-cover 14. Mid-cover 14 is connected to base 12 by any convenient means, such as screws 90, snap fit or adhesive bonding. Specifically, in the embodiment depicted in FIG. 2, mid-cover 14 is secured to base 12 generally by press fit engagements about the middle portion of opposing side-walls 92 and 94, and via fasteners or screws 90 through mid-cover line terminal divider walls 30 and mid-cover load end divider walls 24. Thus, side-walls 92 and 94 of mid-cover 14, in conjunction with sidewalls 32 and 34 of base 12, form protective walls for the outer side of circuit breaker cassettes 40 and 60. Further, base divider walls 18 and 22 and mid-cover divider walls 30 and 24 structurally depend from support portions extending generally from sidewall 32 and 34 of the base and sidewall 92 and 94 of the mid-cover, respectively, generally perpendicular to the divider walls and sidewalls.

[0023] Mid-cover 14 further includes a central support portion 96 formed between sidewalls 92 and 94 to cover the top surfaces of cassettes 40 and 60 and to provide structural integrity to the mid-cover. Central support portion 96 generally includes opposing upstanding walls 98 between which internal mechanism 70 is disposed and operating handle 80 passes through. Optional accessories may be disposed within mid-cover 14 between support portion walls 98 and either of mid-cover sidewalls 92 or 94.

[0024] The top portion end of circuit breaker cassettes 40, 50 and 60 are covered by mid-cover 14. The operating handle 80 is accessible via opening 82 upon top-cover 16. Top cover 16 is secured to mid-cover 14 by fasteners 92 which engage corresponding receptacles upon mid-cover 14. It is known that top-cover 16 may further include openings or viewing windows to access and/or see visual displays upon various accessories.

[0025] Referring to FIG. 3, an assembled molded case circuit breaker of the present invention is depicted, wherein the heights of the mid-cover sidewalls and base sidewall are indicated as Hb and Hmc. The height of base sidewalls 32 and 34, Hb, is depicted as 5.4 cm (2.125 inches). The height of the sidewalls 92 and 94 of mid-cover 14, Hmc, is depicted as 3.3 cm (1.3 inches). Thus, the ratio of the height of the mid-cover to the height of the base, Hmc/Hb, is 0.6117 in the depicted embodiment. Generally, prior art molded case circuit breaker the same overall size have a smaller ratio of the height of the mid-cover to the height of the base. That is, the height of the sidewall of mid-cover is typically 2.7 cm (1.063 inches) or less and the height of the base sidewall is typically 6 cm (2.362 inches) or more, providing a ratio of approximately 0.44-0.46 or less.

[0026] Referring now to FIG. 4 a cross-sectional view of a prior art circuit breaker case 10 is indicated. Upstanding circuit breaker cassettes 40, 50 and 60 are disposed within circuit breaker case 10. Internal mechanism 70 (shown in phantom) is pivotally attached to operating handle 80 and envelopes the sidewalls of center cassette 50 and common movement throughout cassettes 40, 50 and 60 is effectuated via drive pin 72 (shown in phantom). Also shown are heights Hb and Hmc. In prior art circuit breaker cases, upstanding cassettes 40, 50 and 60 extend to a height approaching Hb. Thus, the mid-cover sidewalls generally protect any accessories provided.

[0027] Referring now to FIG. 5 a cross-sectional view of a circuit breaker case 10 of the present invention is indicated. Upstanding circuit breaker cassettes 40, 50 and 60 are disposed within circuit breaker case 10 generally upon base floor 36, and internal mechanism 70 (depicted in phantom) is pivotally attached to operating handle 80 and envelopes the sidewalls of center cassette 50 whereby common movement throughout cassettes 40, 50 and 60 is effectuated via drive pin 72. The heights of base sidewalls 32 and 34 and mid-cover sidewalls 92 and 94, Hb and Hmc respectively, are indicated. In the configuration of the present invention, Hb is less than that of prior art circuit breakers and Hmc is greater than that of prior art circuit breakers. In the circuit breaker case of the present invention, upstanding cassettes 40, 50 and 60 extend to a height beyond Hb. Base sidewalls 32 and 34 enclose the lower portion of circuit breaker cassettes 40, 50 and 60. Mid-cover sidewalls 92 and 94 enclose the upper portion of circuit breaker cassettes 40, 50 and 60 via extended portions 93 and 95 having heights He. Additionally, mid-cover sidewalls 92 and 94 protect any accessories provided upon the mid-cover support portion 96.

[0028] A preferred embodiment of the circuit breaker case 10 of the present invention is fabricated by injection molding of a thermoplastic material. Thermoplastics include a polymeric resin and filler. For molded case circuit breakers, the preferred filler is glass particles, as they impart a high degree of hardness while maintaining the resiliency of the case, thereby minimizing breakage. However, for optimal injection molding manufacture, a consistent mixture of resin and filler is desired. The present invention facilitates such consistency by lessening the distance that the resin/filler distance must travel. Referring to FIG. 6 a cross-sectional view of a circuit breaker base mold of the prior art is indicated at 112. Thermoplastic resin/filler mixture is injected through mold apertures 118 in the direction indicated by arrows 120.

[0029] Referring to FIG. 7 a cross-sectional view of a circuit breaker base mold of the present invention is indicated at 113. Thermoplastic resin/filler mixture is injected generally by the same process as with the prior art mold 112, through mold apertures 118 in the direction indicated by arrows 120. However, Hb of the prior art base mold 112 is greater than Hb in base mold 113 of the present invention. Therefore, during the injection molding process, the molten thermoplastic resin/filler mixture that is injected is required to travel a lesser distance in base mold 113 as compared to base mold 112 of the prior art. The tendency of the thermoplastic mixture to separate is due to the lower viscosity of resin compared to the higher viscosity of resin/filler mixture. Consequently, by decreasing the height of the base sidewalls as provided in the present invention, a more consistent filler/resin mixture may be attained while using less injection force, thereby increasing manufacturing efficiency and improving filler mixture throughout the mold.

[0030] Referring now to FIG. 8, a circuit breaker case 10 of the present invention is shown in cross section without the components therein whereby a stress analysis is shown. Circuit breaker case 10 includes a base 12 having a floor 36 and opposing sidewalls 32 and 34 (whereby Hb indicates the height of base sidewalls 32 and 34), and a mid-cover 14 including a support 96 and opposing sidewalls 92 and 94. Sidewalls 92 and 94 further comprise opposing extended walls 93 and 95, respectively, that extend below mid-cover support structure 96. Base 12 including floor 36 and sidewalls 32 and 34, and mid-cover 14 including support 96 and sidewalls 92 and 94 are acted upon by mechanical forces indicated by arrows 232, 234, 236, 293, 295 and 296. The mechanical forces depicted are exerted by the discharge of gasses from the circuit breaker cassettes 40, 50 and 60 (not shown). The length of extended portions 93 and 95 is indicated by He. Forces 296 and 236, acting upon the mid-cover support structure 96 and the base floor 36 respectively, are generally constrained by screws 90 (see FIG. 2) disposed between mid-cover 14 and base 12. Forces 293 and 295 act upon the extended portions 93 and 95 respectively, and forces 232 and 234 act upon base sidewalls 32 and 34 respectively. Forces 232 and 234 urge base sidewalls 32 and 34 respectively outward, shown in phantom, to a distance Db. As the distance Do, increases, the tendency of base sidewalls 32 and 34 to crack or break generally about base sidewall-floor juncture points 33 and/or 35 increases. As Hb is decreased to a shorter height, as provided for in the present invention, the maximum Db also decreases thereby minimizing tendencies for the base sidewalls 32 and 34 to crack or break at points 33 and/or 35. Forces 293 and 295 urge extended portions 93 and 95 respectively outward, shown in phantom, to a distance Dmc. There is little tendency for Dmc to increase far enough as to crack or break extended portions 93 and 95, as He is relatively small compared to the restraint from support structure 96.

[0031] Additional support may be afforded at the junction of sidewalls 32 and 34 and extended portions 93 and 95, respectively, by the provision of a lap joint engagement. Such a configuration is depicted in FIG. 9, where a cross-sectional enlarged view of the juncture between a sidewall 32 of a base 12 and an extended portion 93 of a mid-cover 14 is provided. The lap joint is formed via a step portion 99 along the inside of extended wall 93 of mid-cover 14 at the lower end thereof and a corresponding and complementary step portion 31 along the outside of sidewall 32 of base 12 at the upper end thereof. The dimensions of the molded case and mid-cover allow for a secure press fit or a frictional engagement therebetween. In a preferred embodiment shown in FIG. 9, the heights x of step portions 33 and 99 are equivalent to the wall thickness x. In a most preferred embodiment, the widths of step portions 33 and 99 are approximately equivalent to half of the wall thickness x, or 0.5x.

[0032] Although the molded circuit breaker enclosure of the present invention is described herein with reference to a multi-pole circuit breaker, is understood by one skilled in the art that the enclosure design may be adapted for more or less cassettes as needed.

[0033] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

MOLDED CASE CIRCUIT BREAKER BASE AND MID-COVER ASSEMBLY

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