Note: Descriptions are shown in the official language in which they were submitted.
BUS BAR INCLUDING A WIRING CONNECTOR ASSEMBLY
BACKGROUND OF THE INVENTION
TECHNICAL FIELD
This invention relates generally to electrical devices. More particularly, the
invention is directed to electrical distribution boxes and to the components
used
therein. Specifically, the invention is a bus bar for use in an electrical
distribution
box that includes a connector assembly which allows wires to be quickly and
easily engaged with the neutral bus bar without the use of screws and that
permits
insertion of a tool through a release port in a front face of the neutral bus
bar for
quick and easy disengagement of a previously secured wire.
BACKGROUND INFORMATION
Electrical distribution boxes are components that form part of an electrical
supply system for a building. The electrical distribution box divides an
incoming
power supply into subsidiary circuits. Each subsidiary circuit includes a
circuit
breaker or fuse that is located in the electrical distribution box. Hot and
neutral
wires from an external meter may connect to a main breaker on the electrical
distribution box. A plurality of circuit breakers is typically arranged in two
parallel
columns within the electrical distribution box. Wires (i.e., electrical
conductors)
must be secured to the circuit breakers, to a neutral bus and/or to a ground
bus.
Making electrical connections between the wiring and the proper terminals and
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buses inside of the electrical distribution box can be a time consuming an
labour-
intensive process.
Many types of electrical devices require an electrical connection to
electrical wiring that carries 110V, 22V and even up to 600V of AC. Electrical
devices such as wall outlets, light switches, circuit breakers neutral bus
bars and
ground buses may be provided with screw terminals to allow for attachment of
wires thereto. Screw terminals require that a screw be partially loosened, an
end
of a length of wire is stripped of insulation, the stripped length of wire is
wrapped
around the shaft of the screw, and then the screw is tightened to lock the
wire
and screw together. In other devices the screw terminals may be replaced with
a
quick connect system. In these instances, an end of a stripped piece of wire
is
inserted through an aperture in a spring-loaded connector. The connectors
typically have a spring-steel contact that is in close contact with an opposed
fixed
metal contact. The stripped end of the wire is inserted into the aperture that
is
defined between the two contacts. When inserted, the wire slightly bends the
spring metal contact and the wire is thus captured between the contacts. Since
both contacts are electrically conductive, the insertion of the wire closes
the
circuit and thereby allows current to flow through the circuit. In these types
of
connectors, the spring metal contact may be bent and shaped so that the angle
of the spring contact relative to the fixed contact is less than 90 degrees so
that
the inserted wire is able to push the spring contact back to allow space for
the
wire. Any force that attempts to withdraw the wire will cause the spring
contact to
tighten its grip on the wire and thus resist accidental removal of the wire.
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Typically, once the wire is inserted, the wire cannot be removed and must be
cut
if the switch or outlet is to be removed. Since it is essentially impossible
to remove
the wire once inserted in these connectors, it becomes necessary to cut the
wire
and throw away the entire switch, outlet, circuit breaker or bus. While this
is
acceptable for a relatively inexpensive wall outlet, the cost for discarding a
number of circuit breakers (at a cost of about $40-$50 per unit) or bus bars
quickly
adds up if an electrical distribution box is to be rewired.
SUMMARY
There is therefore a need in the art for electrical devices, such as neutral
bus bars or ground bus bars that may be quickly and easily connected to and
disconnected from an electrical distribution box without requiring cutting of
the
electrical wires engaged with the bus bar and then discarding the bus. The
neutral
bus bar disclosed herein solves some of the issues of the prior art and allows
for
quicker and easier connection and disconnection of the bus.
An electrical distribution box including a bus bar with a quick connect
assembly for engaging or disengaging wiring and a method of using the same is
disclosed herein. The bus bar housing defines an interior chamber and includes
a wall defining a plurality of holes and release ports therein A space bar
within
the chamber includes a plurality of spaced-apart fixed contacts and spring
contacts. Each spring contact includes an arm that moves towards or away from
the fixed contact and is partially aligned with one hole and one release port
in the
housing. The spring contact moves from an at rest position by inserting a wire
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through one of the holes. The spring contact locks the wire between itself and
the
fixed contact. The wire is release by inserting a tool through the release
port and
applying a linear force to the spring contact, thereby rotating the spring
contact
away from the fixed contact and releasing the wire.
In one aspect, the invention may provide a bus bar for an electrical
distribution box comprising a housing having a wall that bounds and defines an
interior chamber; said wall further defining a hole and a release port
therein,
where the hole and release port are in communication with the chamber; an
electrically conductive fixed contact located within the chamber; an
electrically
conductive spring contact located within the chamber; said spring contact
having
an arm that is selectively movable toward or away from the fixed contact;
wherein
the spring contact is partially aligned with the hole and is partially aligned
with the
release port; and wherein the spring contact is movable from a first position
to a
second position upon application of a force through the hole; and is moveable
from the second position to a third position upon application of a force
through
the release port.
In another aspect, the invention may provide a method using a neutral bus
bar of an electrical distribution box, said method comprising providing a
neutral
bus bar having a housing, a fixed contact and a spring contact located within
a
chamber defined by the housing; inserting a stripped end of the wire into a
hole
defined in the housing; deflecting the spring contact with the end of the
wire; and
capturing the end of the wire between the spring contact and the fixed
contact.
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The method may further include the step of deflecting the spring contact
includes applying a first linear force to the spring contact with the end of
the wire.
The method may further comprise inserting a tool through a release port
defined
in a wall of the housing; engaging the spring contact with the tool; applying
a force
to the spring contact using the tool; moving a portion of the spring contact
through
application of the linear force; opening a gap between the spring contact and
the
fixed contact; and withdrawing the end of the wire out of the hole in the
housing.
The step of applying a force to the spring contact using the tool comprises
applying a linear force to the spring contact and the step of moving the
portion of
the spring contact further comprises rotating the portion of the spring
contact in
response to the applying of the linear force.
In another aspect, the invention may provide an electrical distribution box
comprising a box housing defining an interior compartment; at least one bus
bar,
wherein each of the at least one bus bar comprises a bus bar housing having a
wall that bounds and defines an interior chamber; said wall further defining a
hole
and a release port therein, where the hole and release port are in
communication
with the chamber; an electrically conductive fixed contact located within the
chamber; an electrically conductive spring contact located within the chamber;
said spring contact having an arm that is selectively movable toward or away
from
the fixed contact; wherein the spring contact is partially aligned with the
hole
and is partially aligned with the release port; and wherein the spring contact
is
movable from a first position to a second position upon application of a force
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through the hole; and is moveable from the second position to a third position
upon application of a force through the release port.
In one aspect there is provided a bus bar for an electrical distribution box.
The bus bar comprises a housing having a wall which bounds and defines an
interior chamber. The wall further defines a hole and a release port therein,
where the hole and release port are in communication with the chamber.
Additionally, the hole and release port are oriented at an angle relative to
each
other. There is also provided an electrically conductive fixed contact located
within the chamber and an electrically conductive spring contact located
within
the chamber. The spring contact has an arm that is selectively movable toward
or away from the fixed contact and the spring contact is partially aligned
with the
hole and is also partially aligned with the release port. The spring contact
is
movable from a first position to a second position upon application of a force
through the hole and is moveable from the second position to a third position
upon application of a force through the release port.
In another aspect, there is provided a bus bar for an electrical distribution
box which comprises a housing having a wall which bounds and defines an
interior chamber. The wall further defines a hole and a release port therein,
where the hole and release port are in communication with the chamber. There
also provided an electrically conductive fixed contact located within the
chamber
and an electrically conductive spring contact located within the chamber. The
spring contact has an arm that is selectively movable toward or away from the
fixed contact. Furthermore, the spring contact is partially aligned with the
hole
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and is partially aligned with the release port. The spring contact is movable
from
a first position to a second position upon application of a force through the
hole
and is moveable from the second position to a third position upon application
of
a force through the release por. The which is received within the chamber of
the
housing. The spring bar is a generally C-shaped component having a top wall, a
middle wall, and a bottom wall and wherein one or more regions of the top wall
and middle wall are partially separated from a remaining portion of the spring
bar.
Each one of the one or more regions comprises one or more spring contacts
which are selectively movable relative to the remaining portion of the spring
bar.
In yet another aspect, there is provided a bus bar for an electrical
distribution box which comprises a housing having a wall that bounds and
defines
an interior chamber. The wall further defines a hole and a release port
therein,
where the hole and release port are in communication with the chamber. There
is provided an electrically conductive fixed contact located within the
chamber
and an electrically conductive spring contact located within the chamber. The
spring contact has an arm that is selectively movable toward or away from the
fixed contact wherein the spring contact is partially aligned with the hole
and is
partially aligned with the release port. The spring contact is movable from a
first
position to a second position upon application of a force through the hole and
is
moveable from the second position to a third position upon application of a
force
through the release port. The fixed contact and the spring contact are both
components of a spring bar which is received within the chamber of the
housing.
Additionally, the housing comprises a top housing and a bottom housing which
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are selectively engageable with each other wherein the top housing defines a
first
region of the chamber and the bottom housing defines a second region of the
chamber. The
spring bar is received partially within the first region of the
chamber and partially with in the second region of the chamber.
In still yet another aspect, there is provided a method for using a neutral
bus bar of an electrical distribution box. The method comprises:
providing a neutral bus bar having a housing that includes a wall that
bounds and defines an interior chamber; the wall further defining a hole and a
release port therein, where the hole and release port are in communication
with
the chamber; and wherein the hole and release port are oriented at an angle
relative to each other; an electrically conductive fixed contact located
within the
chamber; an electrically conductive spring contact located within the chamber;
the spring contact having an arm that is selectively movable toward or away
from
the fixed contact; wherein the spring contact is partially aligned with the
hole and
is partially aligned with the release port; and wherein the spring contact is
movable from a first position to a second position upon application of a force
through the hole; and is moveable from the second position to a third position
upon application of a force through the release port;
inserting a stripped end of a wire into the hole defined in the housing;
deflecting the spring contact with the end of the wire; and
capturing the end of the wire between the spring contact and the fixed
contact.
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In another aspect, there is provided an electrical distribution box. The
electrical distribution box comprises a box housing defining an interior
compartment and at least one bus bar, wherein each of the at least one bus bar
comprises a bus bar housing having a wall that bounds and defines an interior
chamber. The wall further defines a hole and a release port therein, where the
hole and release port are in communication with the chamber and are oriented
at
an angle relative to each other. An electrically conductive fixed contact
located
within the chamber is provided as well as an electrically conductive spring
contact
located within the chamber. The spring contact has an arm that is selectively
movable toward or away from the fixed contact wherein the spring contact is
partially aligned with the hole and is partially aligned with the release
port. The
spring contact is movable from a first position to a second position upon
application of a force through the hole and is moveable from the second
position
to a third position upon application of a force through the release port.
In yet another aspect, there is provided an electrical distribution box which
comprises a box housing defining an interior compartment, at least one bus
bar,
wherein each of the at least one bus bar comprises a bus bar housing having a
wall that bounds and defines an interior chamber. The wall further defines a
hole
and a release port therein where the hole and release port are in
communication
with the chamber. There is also provided an electrically conductive fixed
contact
located within the chamber and an electrically conductive spring contact
located
within the chamber. The spring contact has an arm that is selectively movable
toward or away from the fixed contact wherein the spring contact is partially
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aligned with the hole and is partially aligned with the release port. The
spring
contact is movable from a first position to a second position upon application
of a
force through the hole and is moveable from the second position to a third
position
upon application of a force through the release port. There is also provided
pair
of spaced-apart mounting brackets wherein each of the at least one bus bars
further comprise a first connector and a second connector and wherein each of
the mounting brackets engages one of the first connector or the second
connector and secures the at least one bus bar to the box housing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A sample embodiment of the invention is set forth in the following
description, is shown in the drawings and is particularly and distinctly
pointed out
and set forth in the appended claims.
Fig. 1 is a perspective view of an electrical distribution box with a front
cover removed and showing a neutral bus bar in accordance with an aspect of
the present invention;
Fig. 2 is an enlargement of the highlighted region of Fig. 1;
Fig. 3 is a perspective view of the neutral bus bar shown on its own;
Fig. 4 is a top view of the neutral bus bar;
Fig. 5 is a side view thereof;
Fig. 6 is a bottom view thereof;
Fig. 7 is an exploded view of the neutral bus bar;
Fig. 8 is a cross-sectional side view of the neutral bus bar;
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Fig. 9 is a cross-sectional view of the neutral bus bar taken along line 9-9
of Fig. 8;
Fig. 10 is a cross-sectional view of the neutral bus bar taken along line 10-
of Fig. 8;
5 Fig. 11 is an enlarged partial perspective view of the neutral bus bar
showing a portion of a wire about to be inserted into the neutral bus bar;
Fig. 11A is a cross-sectional view showing a portion of the neutral bus bar
and the wire that is positioned to be inserted into the same;
Fig. 12 is an enlarged partial perspective view of the neutral bus bar with
10 the portion of the wire inserted into the same;
Fig. 12A is a cross-sectional view showing the portion of the neutral bus
bar shown in Fig. 11A but with the wire inserted into the same;
Fig. 13 is an enlarged partial perspective view of the neutral bus bar
showing a wire engaged with the same and showing a tool positioned to
disengage the wire from the neutral bus bar;
Fig. 14 is an enlarged partial perspective view of the neutral bus bar with
the top housing removed and showing the tool engaged with the assembly and
the wire released therefrom;
Fig. 14A is a cross-section of a portion of the neutral bus bar with the tool
engaged with the assembly and the wire released therefrom; and
Fig. 14B is an enlargement of the highlighted region of Fig. 14.
Similar numbers refer to similar parts throughout the drawings.
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DETAILED DESCRIPTION
Figs. 1 and 2 show an electrical distribution box 10 with a breaker bar 12
and a neutral bus bar 14 in accordance with an aspect of the present
invention.
It will be understood that only certain components that may be provided within
box 10 are illustrated in this figure for context. It should also be
understood that
while the description that follows relates to a neutral bus bar 14, the
principles
incorporated in bar 14 may be utilized in other components such as in a ground
bus.
Box 10 may comprise a housing fabricated from metal and including a rear
wall 10a, first and second side walls 10b (only one of which is shown in Fig.
1), a
top wall 10c and a bottom wall 10d. A cover (not shown) will typically be
engaged
with side wall 10b, top wall 10c or bottom wall 10d. The cover is selectively
between an open position and a closed position. When the cover is moved to a
closed position it blocks off access to an interior cavity 10e of the housing.
Rear
wall 10a may be mountable to a vertical support surface, such as a wall of a
building, in any suitable way. For example, one or more fasteners may be
inserted
through holes 10f in rear wall 10a of housing 10 and into the support surface.
A
plurality of apertures lOg may be defined in any of the walls 10b-10d.
Electrical
cables that supply power from a remote meter to electrical distribution box 10
may enter cavity 10e through a selected one or more of apertures 10g and be
connected to various components within box 10 by electrical conductors or
wires.
For example, the cables may be connected by suitable wiring to a main breaker,
to a plurality of circuit breakers, to neutral bus bar 14 or ground bus bars
etc.
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Figs. 3-7 show neutral bus bar 14 in accordance with an aspect of the
present invention in greater detail. Bus bar 14 includes a top housing 16, a
bottom
housing 18 and a spring bar 20. Spring bar 20, in association with cooperative
components on housing 16, 18 comprises a quick connect assembly for
connecting electrical wiring to bus bar 14.
Top housing 16 and bottom housing 18 may be fabricated from a
electrically non-conductive material such as plastic. As a result, bus bar 14
may
be touched by a user without running the risk of being shocked. Spring bar 20,
on the other hand, may be fabricated from an electrically conductive material
such as brass or plated steel. Spring bar 20 is received within a cavity
defined
by top housing 16 and bottom housing 18 and therefore will not accidentally be
touched by a user.
Top housing 16 may be an elongate member that may be substantially
rectangular in shape when viewed from the top. Top housing 16 may include a
top wall 16a, a first side wall 16b, a second side wall 16c, a first end wall
16d,
and a second end wall 16d'. Top wall 16a defines a plurality of release ports
16e
therein that are spaced at regular intervals from each other. A beveled edge
16f
bounds an entrance to each release port 16e. The bevel angles downwardly
toward release port 16e. The beveled edge 16f is provided to direct a
disengagement tool (as will be describe later herein) into release port 16e.
As
illustrated, each release port 16e is generally rectangular in shape and the
beveled edge 16f is also rectangular when viewed from above. This can be seen
more clearly in Fig. 11. It will be understood, however, that any desired
shape
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release port may be provided on top housing 16 (or on lower housing 18; and on
any accessible wall of top housing 16 or bottom housing 18.) When top housing
16 is engaged with bottom housing 18, the top and bottom housings 16, 18 bound
and define an interior chamber 22. Each release port 16e is in communication
with chamber 22.
Top wall 16a of top housing 16 also defines a plurality of holes 16g therein.
As illustrated, top wall 16a defines three holes 16g therein that are in
communication with chamber 22. A first hole 16g may be separated by a space
from a second hole 16g and a third hole 16g. The second hole 16g and third
hold
16g may be spaced from each other but be adjacent each other. First hole 16g
may be separated from the adjacent second and third holes 16g by a section of
top wall 16a that may define one or more release ports 16e therein. It will be
understood that fewer or more holes 16g may be defined in top housing 16 and
the location and placement of the holes 16g may be other than what is
illustrated
in the attached figures.
Second side wall 16c may define a plurality of semi-circular recesses 16h
on a lower edge thereof. Each recess 16h originates in a bottom surface 16j
(Fig.
7) of top housing 16 and extends for a distance upwardly towards top wall 16a.
Recesses 16h may be spaced at regular intervals from each other along second
side wall 16c. Regions of second side wall 16c, such as the regions that are
laterally aligned with holes 16g in top wall 16a, may be free of any recesses
16h.
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Fig. 7 also shows that one or more pegs 16k extend downwardly from
bottom surface 16j of top housing 16. Pegs 16k are provided to engage top
housing 16 with bottom housing 18, as will be later described herein.
Bottom housing 18 includes a bottom wall 18a, a first side wall 18b, a
second side wall 18c, a first end 18d, a second end 18e, a first connector
18f, a
second connector 18g and a flange 18h. Flange 18 may be positioned along a
longitudinal centerline of bottom housing 18 and extend outwardly from an
exterior of bottom wall 18a, being oriented generally at right angles to
bottom wall
18a. Flange 18 terminates at a lower edge 18h' located a distance vertically
remote from bottom wall 18a.
A lip 18j extends laterally outwardly from a region of second side wall 18c.
Lip 18j may run from proximate first end 18d to proximate second end 18e of
bottom housing 18. Bottom wall 18a, first and second side walls 18b, 18c and
first and second ends 18d, 18e, bound and define an interior compartment 18k
that forms part of the chamber 22 of neutral bus bar 14 when top housing 16
and
bottom housing 18 are engaged with each other.
Second side wall 18c may define a plurality of semi-circular recesses 18m
on an upper edge thereof. Each recess 18m originates in a top surface of
bottom
housing 18 and extends for a distance downwardly towards bottom wall 18a
thereof. Recesses 18m may additionally be defined in lip 18j. The recesses 18m
defined in lip 18j provide an additional surface for supporting a portion of a
wire
thereon as will be later described herein. Recesses 18m may be spaced at
regular intervals from each other along second side wall 18c and lip 18j.
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sections of bottom housing 18 may be free of recesses 18m. For instance, the
section of bottom housing 18 that is laterally aligned with first hole 16g and
second and third holes 16g, may be free of recesses 18m.
Each recess 18m is positioned to align with one of the recesses 16h on
top housing 18. When top housing 16 and bottom housing 18 are selectively
engaged together, recesses 16h and 18m together form holes 24 (Figs. 3 and 5)
that are in communication with chamber 22. It will be understood that other
differently shaped recesses 16h, 18m may be provided on top housing 16 and
bottom housing 18 and the resulting hole 24 may thereby be other than what is
illustrated in the attached figures; i.e., other than circular in shape.
Second side wall 18c may also define a plurality of U-shaped recesses
18n (Fig. 7) that may originate in an upper edge of bottom housing 18 and
extend
for a distance downwardly towards bottom wall 18a. Fig. 7 shows that three U-
shaped recesses 18n may be defined on bottom housing 18. A first one of the
recesses 18n may be positioned to laterally align with one of the holes 16g in
top
housing 16; and the second and third recesses 18n may each be laterally
aligned,
respectively, with one of the second and third holes 16g in top housing 16.
This
can be seen in Fig. 3. The first recess 18n is spaced a distance away from the
second and third recesses 18n. The second and third recesses 18n are spaced-
apart but located adjacent each other. A fourth recess 18p may be defined in
first
side wall 18b. Fourth recess 18p may be laterally aligned with the first
recess 18n
in second side wall 18c as can be seen from Fig. 7. It will further be
understood
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that fewer or more recesses 18n, 18p than what is illustrated in the attached
figures, may be provided on bottom housing 18.
Bottom housing 18 may also define two detents 18q (Fig. 7) that extend
upwardly from an interior surface of bottom wall 18a. Each detent 18q is
located
adjacent an interior surface of one of first end 18d and second end 18e.
Detents
18q are positioned to align with pegs 16k that extend downwardly from top
housing 16. Each detent 18q defines a bore (unnumbered) that is complementary
to one of the pegs 16k. Pegs 16k are received in the bores of detents 18q when
top housing 16 is engaged with bottom housing 18. It will be understood that
the
number of detents 18q provided on bottom housing 18 is complementary to the
number of pegs 16k provided on top housing 18. It will further be understood
that
fewer or more pegs 16k and detents 18q than what is shown in the attached
figures may be provided on bus bar 14. Additionally, the positions of the pegs
16k and detents 18q may be different than what is illustrated in the attached
figures.
Connectors 18f, 18g may extend outwardly from first end 18d and second
end 18e of bottom housing 18, respectively. Connectors 18f, 18g may be of any
suitable configuration for securing bus bar 14 to electrical distribution box
10 and
the configuration of connectors 18f, 18g shown herein are by way of example.
Connector 18f, 18g may be substantially identical to each other but be
positioned
as mirror images of each other. As best seen in Fig. 5, each connector may
include a first leg 26a, a second leg 26b and a third leg 26c. First and third
legs
26a, 26c are substantially parallel to each other and second leg 26b is
oriented
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at right angles to first and second legs 26a, 26c. Connectors 18f, 18g are
therefore generally Z-shaped (and reverse Z-shaped) when viewed from the side.
Each first leg 26a may be engaged with the respective first end wall 18d or
second end wall 18e and be oriented at right angles thereto. Each second leg
26b may be oriented generally parallel to first and second ends 18d, 18e and
extend outwardly and downwardly from first legs 26a. Second legs 26b may
extend for a distance below bottom wall 18a. Second legs 26b may terminate a
distance inwardly from lower edge 18h' of flange 18h. Each third leg 26c may
extend outwardly from a lower end of the associate second leg 26b and extend
in a direction outwardly away from the associate first or second end 18c, 18d.
Third legs 26c (and first legs 26a) may be aligned along a longitudinal axis
of
bottom housing 18. Third legs 26o may be aligned with each other when bus bar
14 is viewed from the side (as in Fig. 5) and may be positioned a distance "D"
inwardly from lower edge 18h' of flange 18h. A hole 26d (Fig. 7) may be
defined
in each third leg 26c. Each hole 26d is a through hole that extends between an
upper and lower surface of the third leg 26d within which hole 26d is defined.
A
gap 18r may be defined between each an inner surface of second leg 26b and
an outer end of flange 18h.
Referring to Figs. 7-9, 14A and 14B, spring bar 20 is shown in greater
detail. Spring bar 20 may be a generally C-shaped component having a top wall
20a, a middle wall 20b and a bottom wall 20o. One or more regions of top wall
20a and middle wall 20b are partially stamped out, cut out or otherwise
partially
separated from a remaining portion of the spring bar 20 in such a way that a
lower
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region of the stamped out, cut out or separated portion remains engaged with
middle wall 20b and bottom wall 20c. The one or more regions form one or more
spring contacts (or spring arms 28) that are selectively movable relative to
the
remaining portion of spring bar 20, as will be later described herein. The
remaining portion of spring bar 20 is substantially stationary and does not
move.
The partial separation of these one or more regions creates openings 20d in
the
spring bar 20 and openings 20d are defined partially in top wall 20a and
partially
in middle wall 20b or wherever the stamped out, cut out or separated portion
was
previously located. The shape of the stamped out or cut out portions may
resemble a reversed lower case "h" when viewed from the side as in Fig. 7. A
first part of each opening 20d stamped or cut into top wall 20a may be a
narrow
elongate slot that is similarly shaped and sized to release ports 16e that are
defined in top housing 16. The part of each opening 20d in middle wall 20b may
be wider and partially aligns with one of the holes 24 defined by top housing
16
and bottom housing 18. As indicated above, the openings 20d may be formed by
die-cutting or stamping out some of the metal of top wall 20a and middle wall
20b.
The cut metal remains attached to bottom wall 20c and may be bent in such a
way that it forms a contact spring or spring arm 28.
Spring arm 28 has a top leg 28a and a middle leg 28b. The middle leg 28b
extends upwardly and outwardly from a region of middle wall 20b and/or bottom
wall 12c of spring bar 20. Fig. 9 shows spring arm 28 in an at rest state. It
can be
seen that a region of middle wall 20b of spring bar 20 is oriented generally
at right
angles to bottom wall 20c (being separated by a curved corner region). Middle
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leg 28b of spring arm 28 angles away from an interior surface of the
vertically
oriented middle wall 12b at an angle of from about 50 up to about 15 . Top leg
28a extends rearwardly away from an upper end of middle leg 28b. Top leg 28a
(when spring arm 28 is in the at rest position shown in Fig. 9) may be
oriented
generally parallel to bottom wall 20c of spring bar 20. Top leg 28a may be
seated
just above that portion of the opening 20d which is defined by top wall 20a of
spring bar 20. Middle leg 28b may be seated in that portion of opening 20d
that
is defined in middle wall 20b. When space bar 20 is engaged between top
housing 16 and bottom housing 18, top leg 28a of each spring arm 28 is located
beneath one of the release ports 16e defined in top housing 16. This can be
seen
in Figs. 9-11. At least part of middle leg 28b of each spring arm 28 may be
aligned
with one of the holes 24 formed by recesses 16h and 18m when top and bottom
housings 16, 18 are engaged together. Each release port 16e and each
associated hole 24 in bus bar 14 has a region of one of the plurality of
spring
contacts (i.e., spring arm 28) extending thereacross. In other words, part of
each
spring arm 28 at least partially extends across one release port 16e and hole
24
on bus bar 14.
Fig. 7 also shows that top wall 20a of spring bar 20 may define a U-shaped
cut-out 20e and a notch 20f. Cut-out 20e may extend from a free edge of top
wall
20a and terminate a short distance downwardly from a top end of middle wall
20b. Notch 20f similarly may extend from a free edge of top wall 20a and
terminate a short distance downwardly from the top end of middle wall 20b.
Notch
20f may also extend to a side edge of middle wall 20a. Cut-out 20e may be
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located so as to be vertically alignable with the first hole 16g in top
housing 16
and laterally alignable with the first U-shaped recess 18n in bottom housing
18.
A first hole 20g may be defined in middle wall 20a in a position that aligns
laterally
with first U-shaped recess 18n in bottom housing 18. A second hole and a third
hole 20g may be defined in middle wall 20b. Second and third holes 20g may be
located in a position that will laterally align with second and third U-shaped
recesses 18n in bottom housing 18 when spring bar 20 and lower housing 18 are
engaged. Notch 20g may be positioned vertically beneath second and third holes
16g in top housing and may be laterally aligned with second and third holes
20g
and second and third U-shaped recesses 18n in bottom housing 18.
When neutral bus bar 14 is assembled, spring bar 20 may be seated in
compartment 18k of bottom housing 18 such that bottom wall 20c of spring bar
may be located between detents 18a. First hole 20g may be aligned with first
U-shaped recess 18n; second hole 20g may be aligned with second U-shaped
15 recess 18n; and third hole 20g may be aligned with third U-shaped recess
18n.
Top housing 16 may be placed over top wall 20a of spring bar 20 and pegs 16k
may be inserted into the bores of detents 18q of bottom housing 18. Pegs 16k
may be press-fit or otherwise secured into the bores of detents 18q. Spring
bar
20 may thus captured in the chamber 22 defined between top housing 16 and
20 bottom housing 18.
Referring to Figs. 1 and 2, when neutral bus bar 14 is engaged in electrical
distribution box 10, each connector 18f, 18g is adapted to secure bus bar 14
to a
surface of electrical distribution box 10. A pair of mounting brackets 30 are
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provided to engage connectors 18f, 18g. Each connector 18f, 18g may be
engaged with a mounting bracket 30 provided on a plate 32 of box 10. A portion
30a of each mounting bracket 30 may be captured in gap 18r of the associated
connector 18f, 18g. Connectors 18f, 18g may be received through a slot (not
shown) of mounting bracket 30 and third legs 26c may rest on an upper surface
of plate 32. Fasteners (not shown) may be inserted through apertures 26d
defined in third legs 26c of connectors 18f, 18g, through aligned holes in
plate
32. If plate 32 is not welded or otherwise secured to rear wall 10a, the
fasteners
may further extend through apertures in rear wall 10a of box 10. Once neutral
bus bar 14 is engaged in box 10, electrical wiring may be connected thereto as
follows.
Referring to Figs. 11 and 11A, a wire 40 is shown in a position ready to be
engaged with neutral bus bar 14. (It will be understood that only an outermost
end of wire 40 is shown in Figs. 11 through 14B.) Wire 40 includes an end 40a
that has been stripped of insulation 40b. End 40a is moved in the direction of
arrow "A" (Fig. 11A) towards neutral bus bar 14. End 40a of wire 40 may be
inserted through a selected one of the plurality of holes 24 defined in bus
bar 14.
Fig. 12A shows that as end 40a of wire 40 enters hole 24, end 40a contacts a
region of middle leg 28b of spring arm 28 that is aligned with hole 24 and
applies
a force thereto, thus deflects spring arm 28 so that spring arm 28 moves from
a
first position (Fig. 11A) to a second position (Fig. 12A). In particular, end
40a of
wire move spring arm 28 inwardly towards first side walls 16b, 18b and
downwardly away from top wall 16a. Spring arm 28 is thus deflected from the at
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rest position shown in Fig. 11A to the position shown in Fig. 12A. End 40a of
wire
becomes trapped between the deflected region of middle leg 28b and a section
of top wall 20a of spring bar 20. This section is identified in Fig. 14 by the
reference character 20h. Top wall 20a, particularly section 20h, acts as a
fixed
contact for end 40a of wire 40 and spring arm 28 acts as a spring contact for
end
40a of wire 40. Since spring arm 28 is biased toward section 20h of top wall
20a,
end 40a of wire 40 is captured between the fixed contact 20h and spring
contact
of middle arm 28b of spring arm 28. Because both top wall 20a and middle arm
28b of spring arm 28 are fabricated from metal, these fixed and spring
contacts
are able to conduct electricity to and/or from wire 40. Because spring arm 28
is
biased towards top wall 20a, any attempt to pull wire 40 back out of hole 24
in
the opposite direction to arrow "A" simply increases the force with which wire
40
is retained between spring arm 28 and section 20h of top wall 20a. Wire 40
therefore will not become accidentally dislodged from neutral bus bar 14 and
will
remain electrically connected thereto.
Fig. 13 shows wire 40 captured in hole 24 of neutral bus bar 10. In order
to release wire 40 from its engagement with neutral bus bar 10, a portion of a
tool
42, such as an end 42a of a flat-head screwdriver, is inserted into the
release
port 16e associated with the particular hole 24 within which wire 40 is
engaged.
Tool 42 is moved downwardly in the direction of arrow "B" so that the end 42a
thereof enters release port 16e to contact spring contact, i.e., spring arm
28.
Beveled edge 16f that surrounds release port 16e aids in guiding end 42a of
tool
42 into release port 16e. As end 42a enters release port 16e, end 42a contacts
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first leg 28a of spring arm 28 seated below release port 16e and extending
upwardly through the opening 20d in top wall 20a of spring bar 20. Continued
linear movement of tool 42 in the direction of arrow "B" causes a linear force
to
be applied to spring arm 28 and moves the spring arm from the second position
(Fig. 12A) to a third position (Fig. 14A). In particular, application of the
linear force
to the spring contact, i.e., to spring arm 28, depresses first leg 28a and
second
leg 28b of spring arm 28 and causes them to be deflected inwardly and
rearwardly
in the direction of arrow "C" (Fig. 14A). Thus, the linear motion of tool 42
in the
direction of arrow "B" causes a rotary movement "C" of spring arm 28. The
spring
contact (i.e., spring arm 28) is thus moved away from the fixed contact (i.e.,
top
wall 20a) and a gap opens up between spring arm 28 and region 20h of top wall
20a of spring bar 20. This gap is sufficient to enable end 40a of wire 40 to
slide
out of hole 24 in the direction of arrow "D" (Fig. 14A) and therefore out of
its
engagement with neutral bus bar 10. When tool 42 is moved in the opposite
direction of arrow "B" the spring arm 28 moves under spring force back to its
at
rest position (Fig. 11A) and is therefore ready for insertion of another wire
into
neutral bus bar 14 through the same selected hole 24.
It will be seen that connecting a wire to the neutral bus bar 14 in
accordance with an aspect of the invention simply requires insertion of the
stripped end of the wire into a selected hole 24 in housing 16/18 and the
subsequent deflection of the spring arm as wire end 40a is inserted into hole
24.
Removal of wire 40 from neutral bus bar 14 simply requires insertion of a tool
into
a release port 16e associated with the selected hole 24, application of a
linear
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force in a downward direction through the release port 16e, deflecting spring
arm
away from an interior wall of the housing, creating a gap between the spring
arm
and the interior wall and withdrawing the wire 40 from hole 24.
It will be understood that instead of neutral bus bar 14 being comprised of
a top housing 16 and a bottom housing 18 that are selectively engaged, bus bar
may instead include a housing that is a substantially unitary component that
has
one side that is selectively removable to gain access into an interior chamber
and
into which spring bar 20 is inserted during fabrication. After insertion of
spring bar
20, the removable side may be removably secured or permanently secured to the
rest of housing, thereby sealing spring bar 20 within the chamber. In this
instance,
all of the various ports 16e, holes 16g, holes 24, recesses 18n, 18p will be
formed
in the exterior walls of the unitary housing.
It will be understood that a plastic coating may be applied around at least
top leg 28a of spring arm 28. The top leg 28a of each spring arm 28 with a
plastic
coating thereon may form a non-conductive release actuator that may be
contacted by a tool (such as tool 42 in Fig. 13) through release ports 16e and
be
less likely to potentially shock the user. The second leg 28b of spring arm 28
might not be coated with plastic and could therefore remain electrically
conductive.
In the foregoing description, certain terms have been used for brevity,
clearness, and understanding. No unnecessary limitations are to be implied
therefrom beyond the requirement of the prior art because such terms are used
for descriptive purposes and are intended to be broadly construed.
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Moreover, the description and illustration set out herein are an example
and the invention is not limited to the exact details shown or described.
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