Circuit interrupting device with end-of life testing, reverse wiring and high voltage surge capability

• US 20090086389A1
• Filed: 07/14/2008
• Published: 04/02/2009
• Est. Priority Date: 09/30/2007
• Status: Active Grant

• Current Assignee: Huadao Huang
• Original Assignee: Huadao Huang
• Inventors: Lu, Huayang, Huang, Huadao
• Granted Patent: US 8,300,368 B2
• Time in Patent Office: Days
• US Class Current: 361/42
• CPC Class Codes: H01H 1/0015 Means for testing or for inspecting contacts, e.g. wear indicator measuring circuits G01R31/3274
• CPC Class Codes: H01H 83/04 with testing means for indicating the ability of the switch or relay to function properly

Abstract

The present invention provides a circuit interrupting device, preferably a ground fault circuit interrupter, which provides a quick and reliable connection/disconnection of electrical continuity through a combined use of a reset spring and a quick trip spring; an innovative circuit interrupting assembly containing a pair of input flexible metal pieces, a pair of user accessible load flexible metal pieces, and two pairs of fixed contacts on the load terminals; an automatic end-of-life testing mechanism by way of a simulated leakage current metal piece assembly; a reverse wiring protection by way of a reset start switch; an electrical surge protection through a power discharge mechanism; and a periodical end-of-life testing using a timer chip.

Claims

1. A circuit interrupting device having a pair of line terminals, a pair of load terminals, and a pair of user accessible load terminals, which are electrically separated from each other in a tripped state and electrically connected in a reset state;

wherein said circuit interrupting device comprises;

a reset directional lock coupled to a reset button;

wherein said reset directional lock comprises a reset spring and a quick trip spring, both sliding onto said reset directional lock;

wherein said reset spring is located at a top portion of said reset directional lock and said quick trip spring is located at the lower portion of said reset directional lock; and

a circuit interrupting assembly capable of establishing or disengaging electrical continuity within said circuit interrupting device;

wherein said reset spring and said quick trip spring urges said circuit interrupting assembly toward a circuit making and/or breaking position to establish and/or disengage electrical continuity.

2. The circuit interrupting device according to claim 1, wherein said reset spring and said quick trip spring are separated by an insulated middle support.

3. The circuit interrupting device according to claim 1, wherein said reset directional lock is larger in dimension in said upper portion than in said lower portion.

4. The circuit interrupting device according to claim 1, wherein a step is formed between said upper portion and said lower portion of said directional lock.

5. The circuit interrupting device according to claim 1, wherein said reset spring and said quick trip spring are coil springs.

6. The circuit interrupting device according to claim 1, wherein said reset directional lock has the same dimension in said upper portion and said lower portion.

7. The circuit interrupting device according to claim 1, wherein said quick trip spring is in a compressed condition when said circuit interrupting device is in said reset state, which causes said circuit interrupting assembly to quickly move toward said circuit breaking position when there is a fault.

8. The circuit interrupting device according to claim 1, wherein said circuit interrupting assembly comprises:

a pair of input flexible metal pieces, each having one end electrically connected to one of said pair of line terminals, the other end containing a movable contact;

a pair of user accessible load flexible metal pieces, each having one end electrically connected to one of said pair of user accessible load terminals, the other end containing a movable contact; and

a pair of fixed contacts on each of said pair of said load terminals;

wherein said movable contact on each of said pair of said input flexible metal pieces mates with one of said pair of said fixed contacts on each of said pair of said load terminals and said movable contact on each of said pair of said user accessible load flexible metal pieces mates with the other of said pair of said fixed contacts on each of said pair of said load terminals to establish said electrical continuity.

9. The circuit interrupting device according to claim 1, further comprising a reset support piece which is rested on top of a tripping mechanism;

wherein said reset support piece and said tripping mechanism each contains a through hole which is aligned with each other to allow said reset directional lock to pass through.

10. The circuit interrupting device according to claim 1, wherein said reset directional lock has a flat bottom surface.

11. The circuit interrupting device according to claim 9, further comprising a locking member extended into said tripping mechanism;

said locking member having a through hole which is partially aligned with said tripping mechanism in said tripped state, and aligned with said through hole in said tripping mechanism when said circuit interrupting device is resetting.

12. The circuit interrupting device according to claim 1, further comprising a simulated leakage current generating metal piece assembly comprising:

a simulated leakage current generating metal piece, a first metal switch piece, and a second metal switch piece;

wherein said simulated leakage current generating metal piece, said first metal switch piece, and said second metal switch piece are arranged in a triangular position with said first metal switch piece located at the bottom, said second metal switch piece located in the middle, and said simulated leakage current generating metal piece located at the top;

wherein said simulated leakage current generating metal piece assembly is electrically connected to one of said pair of line terminals; and

wherein said simulated leakage current generating metal piece assembly generates a simulated leakage current to automatically conduct an end-of-life test when the circuit interrupting device is properly wired to an AC power.

13. The circuit interrupting device according to claim 11, further comprising a reset start switch which is closed only upon a depression of said reset button;

wherein when said circuit interrupting device is properly wired and in said tripped state, and said circuit interrupting device has passed said end-of-life test, said closing of said reset start switch allows said circuit interrupting device to be reset.

14. The circuit interrupting device according to claim 1, further comprising a timer chip which periodically outputs a control signal to cause said circuit interrupting device to trip.

15. The circuit interrupting device according to claim 1, further comprising a power discharge mechanism;

wherein during a high voltage surge said power discharge mechanism protects said circuit interrupting device from being damaged due to said high voltage surge.

16. The circuit interrupting device according to claim 1, further comprising a test button, wherein a depression of said test button generates a simulated leakage current to conduct a manual end-of-life test of said circuit interrupting device.

17. The circuit interrupting device according to claim 1, wherein said circuit interrupting device is a ground fault circuit interrupter.

47. The circuit interrupting device according to claim 6, wherein said mating of said first metal switch piece with said second metal switch piece allows said SCR to be electrically connected to said solenoid coil.

18. A circuit interrupting device having a pair of line terminals, a pair of load terminals, and a pair of user accessible load terminals, which are electrically separated from each other in a tripped state and electrically connected in a reset state;

wherein said circuit interrupting device comprises a circuit interrupting assembly which comprises;

a pair of input flexible metal pieces, each having one end electrically connected to one of said pair of line terminals, the other end containing a movable contact;

a pair of user accessible load flexible metal pieces, each having one end electrically connected to one of said pair of user accessible load terminals, the other end containing a movable contact; and

a pair of fixed contacts on each of said pair of said load terminals;

wherein said movable contact on each of said pair of said input flexible metal pieces mates with one of said pair of said fixed contacts on each of said pair of said load terminals and said movable contact on each of said pair of said user accessible load flexible metal pieces mates with the other of said pair of said fixed contacts on each of said pair of said load terminals to establish said electrical continuity in said reset state; and

wherein said movable contact on each of said pair of said input flexible metal pieces disengages from one of said pair of said fixed contacts on each of said pair of said load terminals and said movable contact on each of said pair of said user accessible load flexible metal pieces disengages from the other of said pair of said fixed contacts on each of said pair of said load terminals to break said electrical continuity in said tripped state.

19. The circuit interrupting device according to claim 18, wherein each of said end of said pair of input flexible metal piece is adapted to pass through a differential transformer to be welded to a circuit board.

20. The circuit interrupting device according to claim 18, further comprising a tripping mechanism having a pair of lifting arms extended outward;

wherein said pair of input flexible metal pieces and said pair of user accessible load metal pieces of said circuit interrupting assembly are rest on said pair of lifting arms of said tripping mechanism;

whereby said tripping mechanism urges said pair of input flexible metal pieces and said pair of user accessible load metal pieces of said circuit interrupting assembly to move upward or downward to mate with or disengage from said pair of fixed contacts on each of said pair of said load terminals to establish or break electrical continuity in said circuit interrupting device.

21. The circuit interrupting device according to claim 20, further comprising a reset support piece resting on top of said tripping mechanism;

wherein both said reset support piece and said tripping mechanism contain a hole aligned with each other to receive a reset directional lock which is coupled to a reset button.

22. The circuit interrupting device according to claim 21, wherein said reset directional lock contains a reset spring and a quick trip spring.

23. The circuit interrupting device according to claim 21, wherein said pair of said input flexible metal pieces is rested between said reset support piece and said tripping mechanism.

24. The circuit interrupting device according to claim 18, further comprising a simulated leakage current generating metal piece assembly comprising:

a simulated leakage current generating metal piece, a first metal switch piece, and a second metal switch piece;

wherein said simulated leakage current generating metal piece, said first metal switch piece, and said second metal switch piece are arranged in a triangular position with said first metal switch piece located at the bottom, said second metal switch piece located in the middle, and said simulated leakage current generating metal piece located at the top;

wherein said simulated leakage current generating metal piece comprises a contact which is in contact with one of said pair of said input flexible metal pieces when said circuit interrupting device is in said tripped state;

wherein when said circuit interrupting device is properly wired and in said tripped state, said simulated leakage current generating metal piece generates a simulated leakage current to automatically conduct an end-of-life test of said circuit interrupting device.

25. The circuit interrupting device according to claim 24, wherein after said circuit interrupting device is reset, said simulated leakage current generating metal piece is separated from said one of said pair of input flexible metal pieces and stops generating said simulated leakage current.

26. The circuit interrupting device according to claim 24, wherein said one of said pair of said input flexible metal pieces is a neutral input flexible metal piece.

27. The circuit interrupting device according to claim 24, further comprising a reset start switch which is closed only upon a depression of said reset button;

wherein when said circuit interrupting device is properly wired and in said tripped state, and said circuit interrupting device has passed said end-of-life test, said closing of said reset start switch allows said circuit interrupting device to be reset.

28. The circuit interrupting device according to claim 18, further comprising a timer chip which periodically outputs a control signal to cause said circuit interrupting assembly to trip.

29. The circuit interrupting device according to claim 18, further comprising a power discharge mechanism, wherein during a high voltage surge said power discharge mechanism causes a discharge of electricity to protect said circuit interrupting device from being damaged due to said high voltage surge.

30. The circuit interrupting device according to claim 18, further comprising a test button, wherein a depression of said test button generates a simulated leakage circuit to manually conduct an end-of-life test of components of said circuit interrupting device.

31. The circuit interrupting device according to claim 18, wherein said circuit interrupting device is a ground fault circuit interrupter.

32. A circuit interrupting device having a pair of line terminals, a pair of load terminals, and a pair of user accessible load terminals, which are electrically separated from each other in a tripped state and electrically connected in a reset state;

wherein said circuit interrupting device comprises;

a simulated leakage current generating metal piece which is electrically connected to one of said pair of line terminals when said circuit interrupting device is in said tripped state, and electrically separated from said line terminals when said circuit interrupting device is in said reset state;

wherein when said circuit interrupting device is properly wired and in said tripped state, said simulated leakage current generating metal piece generates a simulated leakage current to automatically conduct an end-of-life test of said circuit interrupting device.

33. The circuit interrupting device according to claim 32, wherein said simulated leakage current generating metal piece has a contact which is in contact with an input flexible metal piece that is electrically connected to said one of said pair of line terminals when said circuit interrupting device is in said tripped state.

34. The circuit interrupting device according to claim 33, wherein said contact of said simulated leakage current generating metal piece is separated from said input flexible metal piece when said circuit interrupting device is in said reset state.

35. The circuit interrupting device according to claim 33, wherein said input flexible metal piece is electrically connected to a neutral line terminal.

36. The circuit interrupting device according to claim 35, wherein one end of said simulated leakage current generating metal piece is electrically connected to said neutral line terminal, and the other end of said simulated leakage current generating metal piece is in series with a simulated leakage current generating resistor, and is electrically connected to a hot line terminal via a solenoid coil.

37. The circuit interrupting device according to claim 32, wherein said simulated leakage current generating metal piece is a part of a simulated leakage current generating metal piece assembly comprising, in addition to said simulated leakage current generating metal piece, a first metal switch piece and a second metal switch piece.

38. The circuit interrupting device according to claim 37, wherein said first metal switch piece has a contact which mates with a contact on said second metal switch piece when said circuit interrupting device is in said reset state and separated from each other when said circuit interrupting device is in said tripped state.

39. The circuit interrupting device according to claim 38, wherein said mating of said first metal switch piece and said second metal switch piece allows said circuit interrupting device to trip when a ground fault is detected.

40. The circuit interrupting device according to claim 32, wherein said simulated leakage current generating metal piece, said first metal switch piece, and said second piece are arranged in a triangular position with said first metal switch piece located at the bottom, said second metal switch piece located in the middle, and said simulated leakage current generating metal piece located at the top.

41. The circuit interrupting device according to claim 37, wherein when said circuit interrupting device is properly wired and in said tripped state, said first metal switch piece, said second metal switch piece, and said simulated leakage current generating metal piece are separated from each other.

42. The circuit interrupting device according to claim 38, wherein said simulated leakage current generating metal piece does not contact with said first metal switch piece and/or said second metal switch piece in either said tripped or said reset state.

43. The circuit interrupting device according to claim 37, wherein one end of said first metal switch piece is electrically connected to a line terminal via a solenoid coil, the other end is suspended below said second metal switch piece.

44. The circuit interrupting device according to claim 43, wherein said line terminal is a hot line terminal.

45. The circuit interrupting device according to claim 44, wherein one end of said second metal switch piece is electrically connected to a neutral line terminal, the other end of said second metal switch piece is suspended above said first metal switch piece.

46. The circuit interrupting device according to claim 45, wherein said second metal switch piece is electrically connected to a positive pole of a silicon controlled rectifier (SCR).

48. The circuit interrupting device according to claim 32, further comprising a reset start switch which is closed only when a reset button is depressed by a user, wherein when said circuit interrupting device is properly wired and in said tripped state, and said circuit interrupting device has passed said end-of-life detection, said closing of said reset start switch allows the circuit interrupting device to reset.

49. The circuit interrupting device according to claim 32, further comprising a timer chip which periodically outputs a control signal to cause said circuit interrupting device to trip.

50. The circuit interrupting device according to claim 49, wherein said timer chip allows said circuit interrupting device to periodically conduct said end-of-life test by tripping said circuit interrupting device which triggers an automatic generation of said simulated leakage current by said simulated leakage current switch.

51. The circuit interrupting device according to claim 32, further comprising a power discharge mechanism;

wherein during a high voltage surge said power discharge mechanism causes a discharge of electricity to protect said circuit interrupting device from being damaged due to said high voltage surge.

52. The circuit interrupting device according to claim 32, further comprising a test button, wherein a depression of said test button generates a simulated leakage current to conduct a manual end-of-life test of said circuit interrupting device.

53. The circuit interrupting device according to claim 32, wherein said circuit interrupting device is a ground fault circuit interrupter.

54. A circuit interrupting device having a pair of line terminals, a pair of load terminals, and a pair of user accessible load terminals, which are electrically separated from each other in a tripped state and electrically connected in a reset state;

wherein said circuit interrupting device comprises;

a reset start switch, which can be closed only for a duration of time when an user depresses a reset button and when said circuit interrupting device is in said tripped state;

wherein said closing of said reset start switch allows said circuit interrupting device to reset on the condition that prior to or at the time said reset start switch is closed, a simulated leakage current signal is sent to a gate of a silicon controlled rectifier (SCR).

55. The circuit interrupting device according to claim 54, wherein said reset start switch comprises a metal switch piece and an electric contact;

wherein one end of said metal switch piece is electrically connected to one of said pair of line terminals via a solenoid coil and the other end is suspended;

wherein said electric contact is electrically connected to a positive pole of a silicon controlled rectifier (SCR).

56. The circuit interrupting device according to claim 54, wherein said simulated leakage current is generated by a simulated leakage current generating metal piece which is electrically connected to one of said pair of line terminals when said circuit interrupting device is properly wired and in said tripped state.

57. The circuit interrupting device according to claim 56, wherein said simulated leakage current signal sent when components of said circuit interrupting device are working properly.

58. The circuit interrupting device according to claim 54, wherein said simulated leakage current signal is sent via a leakage current detection IC chip to a gate of said SCR.

59. The circuit interrupting device according to claim 54, wherein said closing of said reset start switch in the presence of said simulated leakage current signal allows a solenoid coil to be energized to urge a circuit interrupting assembly moving toward a circuit closing position to establish an electrical continuity of said circuit interrupting device.

60. The circuit interrupting device according to claim 54, nothing happens when said reset start switch closes in the absence of said simulated leakage current control signal.

61. The circuit interrupting device according to claim 55, wherein said closing of said reset start switch in the presence of said simulated leakage current signal allows said electric contact to be electrically connected to the other of said pair of line terminals.

62. The circuit interrupting device according to claim 61, wherein said one of said pair of line terminal is a hot line terminal, and the other of said pair of line terminals is a neutral line terminal.

63. The circuit interrupting device according to claim 54, further comprising a power discharge mechanism to protect said circuit interrupting device from being damaged due to a high voltage surge.

64. The circuit interrupting device according to claim 54, further comprising a timer chip which periodically outputs a control signal to cause said circuit interrupting device to trip.

65. A circuit interrupting device having a pair of line terminals, a pair of load terminals, and a pair of user accessible load terminals, which are electrically separated from each other in a tripped state and electrically connected in a reset state;

wherein said circuit interrupting device comprises a power discharge mechanism comprising;

a pair of input power connecting pieces, each being electrically connected to a hot or a neutral wire of said input power source respectively;

wherein each of said input power connecting pieces has an end extended to a discharge metal piece having a tip; and

wherein said tip of said discharge metal piece of one input power connecting piece faces, but does not contact with, said tip of said discharge metal piece from the other input power connecting piece;

a timer chip that periodically outputs a control signal to cause said circuit interrupt device to trip;

wherein when said circuit interrupting device is tripped, a simulated leakage current generating metal piece generates a simulated leakage current to perform an automatic end-of-life test of said circuit interrupting device.

66. The circuit interrupting device according to claim 65, wherein during a high voltage surge said discharge metal pieces of said input power connecting pieces cause a discharge of electricity through said tips of said discharge metal pieces to protect said circuit interrupting device from being damaged due to said high voltage surge.

67. The circuit interrupting device according to claim 65, wherein said high voltage surge is a lightning.

68. The circuit interrupting device according to claim 65, wherein said hot line terminal is electrically connected to the neutral line terminal through a solenoid coil and a metal oxide varistor (MOV).

69. A circuit interrupting device having a pair of line terminals, a pair of load terminals, and a pair of user accessible load terminals, which are electrically separated from each other in a tripped state and electrically connected in a reset state;

wherein said circuit interrupting device comprises a power discharge mechanism comprising;

a timer chip which periodically sends out a signal to a gate of a silicon controlled rectifier (SCR) to cause said circuit interrupting device to trip when said circuit interrupting device is in said reset state;

wherein said timer chip allows said circuit interrupting device to periodically conduct an end-of-life test.

70. The circuit interrupting device according to claim 69, wherein said end-of-life test is performed by a simulated leakage current generating metal piece which automatically generates a simulated leakage current when said circuit interrupting device is properly wired and in said tripped state.

71. The circuit interrupting device according to claim 70, wherein said simulated leakage current signal is sent to said gate of said SCR.

72. The circuit interrupting device according to claim 71, wherein a depression of a reset button after said simulated leakage current signal is sent to said gate of said SCR allows said circuit interrupting device to be reset.