ELECTRICAL LOAD CONTROL WITH FAULT PROTECTION

• US 20120257316A1
• Filed: 04/11/2011
• Published: 10/11/2012
• Est. Priority Date: 04/11/2011
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: KAMOR, Michael, KEVELOS, Adam
• Granted Patent: US 8,717,718 B2
• Time in Patent Office: Days
• US Class Current: 361/50
• CPC Class Codes: H01H 2071/042 with different indications for different conditions, e.g. contact position, overload, short circuit or earth leakage
• CPC Class Codes: H01H 2083/201 the other abnormal electrical condition being an arc fault
• CPC Class Codes: H01H 83/04 with testing means for indicating the ability of the switch or relay to function properly

Abstract

Electrical load controls are provided which include an electrical switch assembly and a fault protection device within a common housing. The switch assembly includes an actuator, and is responsive to actuation of the actuator to switch ON or OFF electricity to the load. The protection device automatically responds to a fault condition by overriding the switch assembly by automatically blocking electrical connection between phase input and output terminals and neutral input and output terminals of the load control. The actuator includes a single external interface element. In one embodiment, actuation of the actuator switches ON or OFF electricity via control of the fault protection device, and in another embodiment, movement of the interface away from the housing exposes within the housing an internal user interface for the fault protection device.

Claims

1. An electrical load control comprising:

a housing having an exposed surface, the exposed surface being sized and configured to fit within a device opening of a decorative wallplate, wherein the housing does not include a receptacle socket for receiving one or more blades of a plug;

a phase conductive path comprising a phase input terminal and a phase output terminal;

a neutral conductive path comprising a neutral input terminal and a neutral output terminal;

wherein each of the phase and neutral conductive paths is at least partially disposed within the housing, the phase and neutral conductive paths being arranged and configured to connect a source of electricity, connected to the phase and neutral input terminals, to a load connected to the phase and neutral output terminals;

a selectively operable electrical switch assembly disposed at least partially within the housing, the electrical switch assembly comprising a user-accessible actuator and being arranged and configured to selectively interrupt at least one of the phase or neutral conductive paths to control connection of the source of electricity to the load responsive to actuation of the user-accessible actuator;

a fault protection device disposed at least partially within the housing, the fault protection device being adapted and configured to control operation of the electrical switch assembly in response to a predetermined fault condition; and

wherein actuation of the user-accessible actuator operatively controls connection of the source of electricity to the load via the fault protection device by selectively inducing a simulated fault in the fault protection device, and wherein at least a portion of the user-accessible actuator extends beyond the housing and is sized and configured to occupy a substantial portion of the device opening of the decorative wallplate.

2. The electrical load control of claim 1, wherein the user-accessible actuator of the electrical switch assembly is operably coupled to a double-pole, single-throw (DPST) switch of the fault protection device.

3. The electrical load control of claim 2, wherein the DPST switch is electrically coupled between the input and output terminals of at least one of the phase or neutral conductive paths.

4. The electrical load control of claim 1, wherein the user-accessible actuator of the electrical switch assembly comprises a single external user interface element, the single external user interface element having an ON position and an OFF position, wherein actuation of the single external user interface element to the ON position initiates a RESET of the fault protection device, and actuation to the OFF position initiates a TEST of the fault protection device.

5. The electrical load control of claim 1, further comprising an indicator, the indicator being adapted and configured to indicate a state of at least one of the electrical switch assembly or the fault protection device.

6. The electrical load control of claim 1, wherein the fault protection device comprises at least one of a ground fault circuit interrupter (GFCI) or an arc fault circuit interrupter (AFCI).

7. The electrical load control of claim 1, wherein the electrical switch assembly comprises a support tray arranged and configured to accommodate the user-accessible actuator, and wherein the fault protection device further comprises a circuit board comprising a controllable electric contact, wherein the support tray comprises at least one actuating arm responsive to actuation of the user-accessible actuator, the at least one actuating arm closing or opening the at least one controllable electrical contact in response to actuation of the user-accessible actuator to selectively connect the source of electricity to the load.

8. The electrical load control of claim 1, wherein the user-accessible actuator of the electrical switching assembly is one of a rocker-type actuator, a toggle-type actuator, a slide-type actuator, a touch-type actuator, or a motion sensing-type actuator.

9. An electrical load control comprising:

a housing, wherein the housing does not include a receptacle socket for receiving one or more blades of a plug;

a phase conductive path having a phase input terminal and a phase output terminal;

a neutral conductive path having a neutral input terminal and a neutral output terminal;

wherein each of the phase and neutral conductive paths is at least partially disposed within the housing, the phase and neutral conductive paths being arranged and configured to connect a source of electricity, connected to the phase and neutral input terminals, to a load connected to the phase and neutral output terminals;

a selectively operable electrical switch assembly disposed at least partially within the housing, the electrical switch assembly comprising a user-accessible actuator and being arranged and configured to selectively interrupt at least one of the phase or neutral conductive paths to control connection of the source of electricity to the load responsive to actuation of the user-accessible actuator;

a fault protection device disposed at least partially within the housing, the fault protection device being adapted and configured to control operation of the electrical switch assembly in response to a predetermined fault condition; and

wherein the user-accessible actuator is coupled to the housing and configured for movement away from the housing to expose an internal user interface of the fault protection device, the internal user interface comprising a TEST button and a RESET button which facilitate user interaction with the fault protection device.

10. The electrical load control of claim 9, wherein the user-accessible actuator is movably or removably coupled to the housing.

11. The electrical load control of claim 9, wherein the fault protection device is electrically connected to the phase input terminal and the neutral input terminal, and the electrical switch assembly is electrically connected between the fault protection device and at least one of the phase output terminal or the neutral output terminal.

12. The electrical load control of claim 11, wherein the electrical switch assembly further comprises a relay and a relay controller, the relay controller being electrically coupled to the fault protection device, and wherein the relay is electrically connected between the fault protection device and at least one of the phase output terminal or the neutral output terminal.

13. The electrical load control of claim 9, further comprising an indicator, the indicator being adapted and configured to indicate a state of at least one of the electrical switch assembly or the fault protection device.

14. The electrical load control of claim 9, wherein the fault protection device comprises at least one of a ground fault circuit interrupter (GFCI) or an arc fault circuit interrupter (AFCI).

15. The electrical load control of claim 9, wherein the electrical switch assembly further comprises a support tray arranged and configured to accommodate the user-accessible actuator, and wherein the fault protection device further comprises a circuit board comprising a controllable electric contact, wherein the support tray comprises at least one actuating arm responsive to actuation of the user-accessible actuator, the at least one actuating arm closing or opening the at least one controllable electrical contact in response to actuation of the user-accessible actuator to selectively connect the source of electricity to the load.