Schneider Electric Usa, Inc.

Jason D Potratz

Dennis William Fleege

Randall James Gass

David R Pearson

Chad Raymond Mittelstadt

William J Broghammer

Douglas P Vanwaart

Kim D Wheeler

Brett E Larson

Paul Andrew Reid

Jeffrey Owen Sharp

Chad Mittelstadt, I

The line power and neutral conductors for a circuit interrupter such as a miniature circuit breaker, using ground fault sensing via a current transformer, are arranged as a rigid conductor formed from a flat plate and surrounding and holding an insulated flexible conductor when passing through the Ground Fault Interrupter current transformer. The rigid conductor can provide a shaped current path to maximize the effectiveness of the current transformer.

Differential current sensing bussing method

The line power and neutral conductors for an arc fault sensing circuit interrupter such as in a miniature circuit breaker are arranged as a rigid conductor surrounding and holding an insulated flexible conductor when passing through the Ground Fault Interrupter current transformer. Voltage metering takes place across the rigid conductor to enable arc fault detection and ground fault detection in the miniature circuit breaker within the space of a single current transformer.

Integrated arc fault and ground fault current sensing package

Systems and methods for auto-monitoring a trip solenoid and a switching semiconductor in a circuit breaker comprises determining whether the trip solenoid or the switching semiconductor is open-circuited or otherwise non-operational. The trip solenoid has multiple windings therein and the switching semiconductor has multiple semiconductor switches therein. The circuit breaker automatically performs a designated action if one of the multiple windings or one of the semiconductor switches is determined to be open-circuited or otherwise non-operational. In some embodiments, the circuit breaker is a miniature circuit breaker.

Auto-monitoring redundancy for enhanced miniature circuit breaker reliability

A plug-on neutral circuit breaker includes a housing, a neutral terminal, and a biasing member. The neutral terminal is pivotally coupled to the housing and includes a body portion, a first leg, and a second leg. The first leg extends from the body portion in a first direction and the second leg extends from the body portion in a second direction. The biasing member is positioned within the housing and is configured to engage the second leg of the neutral terminal, thereby biasing the neutral terminal in a first rotational direction. The biasing of the neutral terminal in the first rotational direction causes a portion of the first leg of the neutral terminal to be urged into contact with a neutral bar of an electrical distribution apparatus in response to the plug-on neutral circuit breaker being installed in the electrical distribution apparatus.

Plug-on neutral connection

A method of assembling a load center featuring a dielectric barrier that securely retains a plug-on neutral rail without requiring any fasteners. The dielectric barrier and the rail are installed in the same Z-axis direction, which is orthogonal to a rear wall of an enclosure into which the load center is installed. Retention features in the dielectric barrier can create a snap-fit connection between the rail and the barrier, or the barrier can feature a support feature onto which the rail snaps as the rail is installed relative to the dielectric barrier in the Z-axis direction. The snap fit connections eliminate the need for any fasteners, and together with the Z-axis assembly, the assembly process is simplified and accelerated and the possibility of assembly error is reduced or eliminated.

Methods of assembling a neutral rail to a plug-on neutral load center

A circuit breaker is disclosed that has a neutral lock-out mechanism that prevents electrical connection between a power source and a load when a neutral rail is disconnected from the circuit breaker. The circuit breaker has a line connector, a load connector and a plug-on neutral line connector. A trip mechanism has an on position allowing electrical connection between the line connector and the load connector. The trip mechanism has a tripped position interrupting electrical connection between the line connector and the load connector in response to detection of a fault condition such as a short circuit. The trip mechanism also has an off position which is required before resetting the trip mechanism to the on position. A trip link is coupled to the trip mechanism. The trip link has a first position that prevents the trip mechanism from being reset to the on position. The trip link has a second position allowing the trip mechanism to be reset to the on position. A neutral lock mechanism is coupled to the plug-on neutral line connector. The neutral lock mechanism has a tension spring that retains the trip link in the first position when the neutral rail is disconnected from the neutral line connector. When the neutral rail is inserted into the neutral line connector, the tension spring is compressed and the trip link may move to the second position allowing the circuit breaker to be reset.

Circuit breaker with plug on neutral connection lock-out mechanism

A load center featuring a two-piece dielectric barrier that securely retains a plug-on neutral rail and methods of assembling the same. The barrier includes a shield and a base having a protrusion that cooperates with fingers of the shield to securely retain the conductor in the load center. The shield is installed over the base and rests on hooks protruding from the base. This creates a distance between the protrusion and the fingers to allow the conductor to be inserted through a gap between the fingers along the conductor's skinny edge. The conductor rotates 90 degrees until it rests on the protrusion. The base and shield are snapped together, causing the hooks of the base to attach to the shield. At the same time, the fingers of the base move downward to rest against the conductor so that it is sandwiched securely between the protrusion and the fingers.

Plug-on neutral load center having a rotating neutral rail retained by a two-piece dielectric barrier

A plug-on load center featuring snap-in or snap-on neutral rails that are retained securely in the load center on or between a dielectric barrier without requiring any fasteners and assembled by installing the dielectric components and neutral rail along the same direction orthogonal to a rear wall of an enclosure that houses the load center. The snap-in configurations feature dielectric barriers with fingers that create a snap-fit connection between the neutral rail and a shield member. The neutral rail is forced between the fingers, which separate and then snap back to their original position once the neutral rail is fully seated in the dielectric barrier. The snap-on configurations feature a neutral rail that is snapped onto the dielectric barrier and retained in the load without any fasteners. The barrier can include retention members that snap-fit into corresponding features of the neutral rail when it is installed onto the barrier.

Snap-in and snap-on neutral rail assemblies in a plug-on neutral load center

A debris collection slot or groove formed near the exit of a vent channel in a circuit breaker. Debris is produced during a circuit interruption, causing the debris to travel into the vent channel toward an opening where it exits the circuit breaker. Too much accumulated debris can lead to a ground strike or a cross-phase condition. The debris collection groove, formed near the exit opening of the vent channel, has no significant effect on the internal pressure generated during the circuit interruption. Multiple grooves can be formed near the exit opening for trapping more debris. When the vent channel is bent, the grooves are positioned on the outer curve of the last bend of the vent channel to trap the higher-density debris traveling around the curve.

Growing community of inventors

Raleigh, NC, United States of America

Jason D Potratz