Note: Descriptions are shown in the official language in which they were submitted.
ELECTRICAL SWITCHING APPARATUS AND CONDUCTOR ASSEMBLY THEREFOR
BACKGROUND
Field
The disclosed concept relates generally to electrical switching apparatus and,
more
particularly, to electrical switching apparatus, such as circuit breakers. The
disclosed concept also
relates to conductor assemblies for circuit breakers.
Background Information
Electrical switching apparatus, such as circuit breakers, provide protection
for
electrical systems from electrical fault conditions such as, for example,
current overloads, short
circuits, abnormal voltage and other fault conditions.
Typically, circuit breakers include an operating mechanism, which opens
electrical
contact assemblies to interrupt the flow of current through the conductors of
an electrical system in
response to such fault conditions. The electrical contact assemblies include
stationary electrical
contacts and corresponding movable electrical contacts that are typically
mounted on movable (e.g.,
pivotable) arms. The stationary and movable contacts are in physical and
electrical contact with one
another when it is desired that the circuit breaker provide electrical current
therethrough to a load.
When it is desired to interrupt the power circuit, the movable contact arm is
pivoted, thereby moving
the movable contact away from the stationary contact creating a space
therebetween.
The movable contact arms and other current carrying components, such as
conductor
assemblies are typically made from copper. Thus, as the cost of copper
increases, the cost of these
components increases.
There is, therefore, room for improvement in electrical switching apparatus,
such as
circuit breakers, and in conductor assemblies therefor.
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SUMMARY
These needs and others are met by embodiments of the disclosed
concept, which are directed to a conductor assembly, which among other
benefits,
reduces the amount of copper required.
As one aspect of the disclosed concept a conductor assembly is
provided for an electrical switching apparatus. The electrical switching
apparatus
includes a housing having an interior and an exterior. The conductor assembly
comprises: a first conductor member; a second conductor member; and a
plurality of
fasteners mechanically fastening and electrically connecting the first
conductor
member to the second conductor member. The first conductor member is made from
a first material and the second conductor member is made from a second
different
material.
The first conductor member and the second conductor member may
combine to form a bimetallic conductor assembly. The first material of the
first
conductor member may be copper, and the second material of the second
conductor
member may be aluminum.
The first conductor member may be structured to extend from the
exterior of the housing into the interior of the housing, and the fasteners
are structured
to fasten the second conductor member to the first conductor member within the
interior of the housing. The first conductor member may include a terminal
portion
and a mounting portion, and the second conductor member comprises a first end
and a
second end disposed opposite from the first end, wherein the fasteners fasten
the first
end of the second conductor member to the mounting portion of the first
conductor
member. The second conductor member may further comprise a bend between the
first end of the second conductor member and the second end of the second
conductor
member, in order that the second end is disposed at an angle with respect to
the first
end.
As another aspect of the disclosed concept, an electrical switching
apparatus employing the aforementioned conductor assembly, is disclosed.
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BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the disclosed concept can be gained from the
following description of the preferred embodiments when read in conjunction
with the
accompanying drawings in which:
Figure 1 is a side elevation view of a circuit breaker and conductor
assembly therefor, in accordance with an embodiment of the disclosed concept,
showing the circuit breaker in the ON position;
Figure 2 is an isometric view of the circuit breaker and conductor
assembly of Figure 1, showing the circuit breaker in the OFF position;
Figure 3 is a side elevation view of the circuit breaker and conductor
assembly of Figure 2, showing the circuit breaker in the TRIPPED position;
Figure 4A is an exploded isometric view of a movable contact arm
assembly, shown in Figure 3;
Figure 4B is an assembled side elevation view of the movable contact
arm assembly of Figure 4A;
Figure 5A is an exploded isometric view of the conductor assembly;
and
Figures 5B and 5C are assembled front and back isometric views of the
conductor assembly of Figure 5A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Directional phrases used herein, such as, for example, left, right, front,
back, top, bottom and derivatives thereof, relate to the orientation of the
elements
shown in the drawings and are not limiting upon the claims unless expressly
recited
therein.
As employed herein, the term "fastener" refers to any suitable
connecting or tightening mechanism expressly including, but not limited to
rivets,
screws, bolts and the combinations of bolts and nuts (e.g., without
limitation, lock
nuts) and bolts, washers and nuts.
As employed herein, the statement that two or more parts are
"coupled" together shall mean that the parts are joined together either
directly or
joined through one Or more intermediate parts.
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As employed herein, the statement that two or more parts are
"attached" shall mean that the parts are directly joined together, without any
intermediate parts.
As employed herein, the term "number" shall mean one or an integer
greater than one (i.e., a plurality).
Figure 1 shows a movable contact assembly 100 for an electrical
switching apparatus, such as for example and without limitation, a circuit
breaker 2, in
accordance with one non-limiting embodiment of the disclosed concept. The
circuit
breaker 2 includes a housing 4, separable contacts 6,8 enclosed by housing 4,
and an
operating mechanism, such as for example and without limitation an operating
handle
10, for opening and closing the separable contacts 6,8.
In Figure 1, the separable contacts 6,8 include a stationary contact 6
and a movable contact 8 (partially shown in hidden line drawing in Figure 1),
and are
shown in electrical contact with one another, corresponding to the circuit
breaker 2
being disposed in the ON position.
Figure 2 shows the operating handle 10, separable contacts 6,8, and
other circuit breaker components in their respective positions corresponding
to the
circuit breaker 2 being disposed in the OFF position, such that the movable
contact 8
(shown in hidden line drawing in Figure 2) is separated, and electrically
disconnected,
from the stationary contact 6, as shown. Figure 3 shows the circuit breaker 2
and
corresponding components (e.g., without limitation, separable contacts 6,8;
operating
mechanism 10; movable contact arm assembly 100) in their respective positions
corresponding to the circuit breaker 2 being disposed in the TRIPPED position.
It will be appreciated that while the example non-limiting embodiment
_____________________________________________________________ shown and
described herein includes a single movable contact ai in assembly 100 and
a single pair of separable contacts 6,8, any known or suitable alternative
number
and/or configuration of movable contact arms (e.g., 100) and corresponding
sets of
separable contacts (e.g., 6,8) could be employed, without departing from the
scope of
the disclosed concept.
Continuing to refer to Figures 1-3, and also to Figures 4A and 4B, the
example movable contact arm assembly 100 includes a first member 102 and a
separate second member 104, which is attached to the first member 102, as will
be
described in greater detail hereinbelow. Specifically, the first member 102 is
made
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from a first material and the second member 104 is made from a second,
different
material.
In one non-limiting embodiment, in accordance with the disclosed
concept, the first member 102 and the second member 104 combined to form a
bimetallic movable contact arm 100. The term "bimetallic" as used herein
refers to an
assembly of a plurality (e.g., at least two) of metal parts attached or
otherwise suitably
joined together (see, for example and without limitation, bimetallic movable
contact
arm 100, best shown in Figure 4B). For example and without limitation,
preferably
the first material of the first member 102 is steel, and the second material
of the
second member 104 is copper. In this manner, the amount of copper required for
the
movable contact arm assembly 100 is reduced. In other words, in accordance
with the
disclosed concept, rather than a single unitary piece of copper being used for
the
entire movable contact arm, in accordance with conventional designs, a
substantial
reduction in the amount of copper used is achieved by replacing copper with
steel or
another suitable material in the non-conducting portion of the movable contact
arm
assembly 100.
As shown in Figures 1-3, the aforementioned movable contact 8
(shown in hidden line drawing in Figures 2 and 3) is disposed on the second
member
104. Specifically, the first and second members 102,104 each include first
ends
106,110 and second ends 108,112, respectively. The first end 106 of first
member
102 cooperates with the operating mechanism 10 (e.g., without limitation,
opening
handle). The first end 110 of the second member 104 is attached to the second
end
108 of the first member 102. The movable contact 8 is disposed on the second
end
112 of the second member 104, as shown. It will be appreciated, however, that
the
movable contact 8 could alternatively comprise an integral portion or segment
of the
second member 104. In other words, it is not a requirement of the disclosed
concept
for the separable contact 8 to be a separate part that is attached to the
second member
104. It is anticipated that it could alternatively comprise an integral ponion
or
segment of the second member 104.
Referring again to Figures 4A and 4B, the second end 108 of the first
member 102 has a first shape, and the first end 110 of the second member 104
has a
second shape. The first shape of the first member 110 compliments the second
shape
of the second member 104, as shown. Specifically, as used herein, the term
"compliments" refers to two opposing shapes, surfaces or configurations of two
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separate parts that are structured to be attached together such that the
opposing
surfaces abut and correspond to one another so as to provide a precise
interface
between the two parts. This relationship will be appreciated, for example and
without
limitation, with reference to the non-limiting embodiment shown and described
with
respect to Figures 4A and 4B. In the example shown and described, the second
end
108 of the first member 102 includes a recess 114, and the first end 110 of
the second
member 104 includes a protrusion 116. As shown in Figure 4B the protrusion 116
is
disposed within the recess 114 to complete the movable contact arm assembly
100.
More specifically, the second end 108 of the example first member 102
preferably includes first and second opposing legs 118,120, wherein the recess
114 is
formed between such legs 118,120, as best shown in Figure 4A. Accordingly, the
protrusion 116 is disposed within the recess 114 between the first and second
legs
118,120 to complete the assembly 100, as shown in Figure 4B. Preferably, the
first
and second legs 118,120, which are made, for example and without limitation
from
steel, are compressed inwardly against the protrusion 116, which is made, for
example
and without limitation from copper, in order to further secure the copper
second
member 104 to the steel first member 102.
Referring again to Figures 1-3, the example circuit breaker 2 further
includes a bimetal structure 12 and a flexible shunt 14. The flexible shunt 14
preferably extends between and electrically connects the second member 104 of
the
movable contact arm assembly 100 to the bimetal structure 12, as shown. It
will,
however, be appreciated that any known or suitable alternative type and/or
configuration of electrical connection (not shown) could be employed, without
departing from the scope of the disclosed concept.
In addition to the aforementioned movable contact arm assembly 100,
the example circuit breaker 2 includes a conductor assembly 200 (Figures 1-3,
5A, 5B
and 5C), which also functions to advantageously further reduce the amount of
copper
required to be used in the circuit breaker 2.
As best shown in Figures 5A-5C, the disclosed conductor assembly
200 includes a first conductor member 202, a second conductor member 204, and
a
plurality of fasteners 206,208 for mechanically fastening and electrically
connecting
the first conductor member 202 to the second conductor 204. The first
conductor
member 202 is made from a first material, such as for example and without
limitation,
copper, and the second conductor member 204 is made from a second, different
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material, such as for example and without limitation, aluminum. Accordingly,
the
first and second conductor members 202,204 combine to form a bimetallic
conductor
assembly 200, which substantially reduces the amount of copper required.
As shown in Figures 1-3, the first conductor member 202 is structured
to extend from the exterior 22 of the circuit breaker housing 4 into the
interior 20.
The fasteners, which in the example shown and described herein are rivets 206,
fasten
(e.g., rivet) the second conductor member 204 to the first conductor member
202
within the interior 20 of the housing 4. More specifically, the first
conductor member
202 includes a terminal portion 210, which is accessible from the exterior 22
of the
circuit breaker housing 4, and a mounting portion 212. The example mounting
portion 212 is an upturned flange (best shown in Figures 5A and 5C), wherein
the
second conductor member 204 includes opposing first and second ends 214,216,
and a
first pair 206 of the aforementioned rivets 206,208 fastens the first end 214
of the
second conductor member 204 to the upturned flange 212 of the first conductor
member 202, within the interior 20 of the circuit breaker housing 4, as shown.
In the
example shown and described herein, the second conductor member 204 further
includes first and second opposing sides 222,224, wherein the second side 224
of the
first end 214 of the second conductor member 204 is riveted to the upturned
flange
212 using the first pair of rivets 206, as best shown in Figures 5A-5C. It
will,
however, be appreciated that any known or suitable alternative number, type
and/or
configuration of fastener could be employed, without departing from the scope
of the
disclosed concept.
Referring to Figures 5A-5C, the second conductor member 204
preferably further includes a bend 218 disposed between the first and second
ends
214,216. Accordingly, as shown in Figure 5B, the second end 216 of the second
member 204 is disposed at an angle 220 with respect to the first end 214 of
the second
conductor member 204. As shown in Figures 1-3, this configuration of the
second
end 216 being disposed at an angle 220 (Figure 5B) with respect to the first
end 214,
functions to position the second end 216 of the second conductor member 204 of
the
conductor assembly 200 in the desired orientation with respect to other
internal
electrically conductive components, such as for example and without
limitation, the
bimetallic structure 12.
In the example of Figures 1-3, the second end 216 of the second
conductor member 204 is electrically connected to the bimetal structure 12 by
a
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flexible shunt 16, as shown. The example second conductor member 204 includes
a
second pair of rivets 208 disposed at or about the second end 216 of the
second
conductor member 204. In one non-limiting embodiment, the flexible shunt 16 is
mechanically fastened and electrically connected to the second end 216 of the
second
conductor member 204 by a corresponding one of the rivets 208. It will,
however, be
appreciated that any known or suitable alternative configuration and/or
mechanism for
electrically connecting the conductor assembly 200 to other circuit breaker
components (e.g., without limitation, bimetal structure 12) could be employed,
without departing from the scope of the disclosed concept.
It will further be appreciated that the aforementioned conductor
assembly 200 could be employed independently within any known or suitable
electrical switching apparatus (e.g., without limitation, circuit breaker 2 of
Figures 1-
3) with, or without, the aforementioned movable contact arm assembly 100
(Figures
1-4C).
Accordingly, the disclosed concept provides a number of assemblies
(e.g., without limitation, movable contact arm assembly 100; conductor
assembly
200) that utilize a unique bimetal structure that, among other benefits,
serves to
reduce the amount of copper required to be used within the circuit breaker 2
(Figures
-",3).
While specific embodiments of the disclosed concept have been
described in detail, it will be appreciated by those skilled in the art that
various
modifications and alternatives to those details could be developed in light of
the
overall teachings of the disclosure. Accordingly, the particular arrangements
disclosed are meant to be illustrative only and not limiting as to the scope
of the
disclosed concept which is to be given the full breadth of the claims appended
and
any and all equivalents thereof
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