Bus bar connector system

• US 4,468,547 A
• Filed: 01/27/1983
• Issued: 08/28/1984
• Est. Priority Date: 01/27/1983
• Status: Expired due to Fees

• Current Assignee: Challenger Caribbean Corporation, Commander Electrical Equipment, Inc.
• Original Assignee: Challenger Caribbean Corporation, Commander Electrical Equipment, Inc.
• Inventors: Belttary, Harold E.
• Primary Examiner(s): Shepperd, John W.
• Assistant Examiner(s): Kidorf, Renee S.
• Application Number:
  US06/461,410
• Time in Patent Office: 579 Days
• Field of Search: 200/294, 200/295, 339/262 F, 339/262 R, 361/353, 361/355
• US Class Current: 200/294
• CPC Class Codes: H01H 71/08 Terminals; Connections
• CPC Class Codes: H02B 1/056 Mounting on plugboards
• CPC Class Codes: Y10S 439/907 Contact having three contact surfaces, including diverse surface

Abstract

Each of a pair of low voltage, residential type circuit breaker housings includes a molded case, a mating cover, a spring clip, and a conductive contact member. The clip, generally U-shaped, has a stiff outer leg with smoothly formed edges, a base, and an inner leg forming two flat springs joined by a flat leg coupled to the base. The flat leg is case supported to stabilize the base and outer leg. The member has an outer conductive leg so formed that when the clip'"'"'s stiff outer leg'"'"'s inner surface opposes a connecting surface thereof, and spaced therefrom, a bus bar blade is receivable. The contact member includes a step having a riser in one direction joining at a roundly formed right angle with one end of its leg (the roundly formed angle and smoothly formed edges serving as lead-in contours for a bus bar blade) and a tread along a second orthogonally oriented direction, which tread rests on one of the flat springs. The contact member includes a formed configuration having one portion coupled to the leg'"'"'s other end and oriented parallel to the riser, a second portion coupled to the first portion extending in a third orthogonal direction but parallel to the riser, and a third portion coupled to and perpendicular to the second portion. The second portion has an aperture for receiving the other flat spring. A fixed contact can be housed on the second portion.

Claims

1. A bus bar connector system for a low voltage residential type circuit breaker comprising

(A) a molded, hollow, circuit breaker housing having a front, a back, one side, an opposite side, one end, and an opposite end, including

(1) a first opening in said front for an operating handle to pass therethrough,

(2) a support within said housing at said one end of said back of said housing at said one side thereof;

and

(3) a second opening at said one end of said back of said housing at said opposite side thereof, so that said support at said one side is oriented intermediate said second opening at said opposite side, said second opening extending along said one end of said opposite side from a position proximal to said back to a location between said front and said back of said opposite side,

(B) a spring clip of generally U-shape configuration having

(1) an outer leg, relatively stiff, with smoothly formed edges, said outer leg having an inner surface,

(2) a bight of said U-shaped spring clip, coupled to said outer leg, and

(3) an inner leg, having portions removed so as to produce two flat springs joined by a portion of a flat leg, said flat leg being coupled to said bight of said U-shaped spring clip, said flat leg being adapted to cooperate with said support so as to rigidly position said bight of said U-shaped spring clip and said outer leg relative to said circuit breaker housing; and

(C) a conductive contact member having

(1) an outer conductive leg, having a connecting surface, one end, and an opposite end, commensurate in length and width with said outer leg of said spring clip so that when said inner surface of said outer leg of said spring clip is positioned opposite to said connecting surface of said outer conductive leg of said member, and spaced therefrom, a bus bar blade can be received therebetween,

(2) a step having

(i) a riser along a first orthogonal direction that joins at a roundly formed right angle with said one end of said conductive leg, so that said roundly formed right angle and said smoothly formed edges serve as "lead-in" contours for said bus bar blade to be inserted therebetween, said

(ii) a tread along a second orthogonal direction adapted to rest upon one of said two flat springs, and

(3) a formed configuration having

(i) a first portion coupled to said other end of said conductive leg and oriented in a direction parallel to said riser,

(ii) a second portion coupled to said first portion, parallel to said riser, extending along a third orthogonal direction, and

(iii) a third portion, coupled to said second portion and perpendicular thereto, adapted to house a fixed contact,

said second portion having an aperture therewithin for receiving the other of said two flat springs.

2. A bus bar connector system for a low voltage, residential type circuit breaker comprising

(A) a molded, hollow, circuit breaker housing having a front, a back, one side, an opposite side, one end, and an opposite end, including

(1) an opening in said front for an operating handle to pass therethrough,

(2) a slot extending along but distal to said one end of said one side of said housing from a position proximal to said back to a location intermediate said back and said front, and

(3) a support within said housing distal from said one end of said back so that said support is oriented intermediate said slot;

(B) a spring clip of generally U-shape configuration having

(1) an outer leg, relatively stiff, with smoothly formed edges, said outer leg having an inner surface,

(2) a base of said U-shaped spring clip, coupled to said outer leg of said spring clip, and

(3) an inner leg, having portions removed so as to produce two flat springs joined by a portion of a flat leg which is coupled to said base of said U-shaped spring clip, said flat leg of said spring clip being adapted to cooperate with said support so as to rigidly position said base of said U-shaped spring clip and said outer leg thereof relative to said circuit breaker housing; and

(C) a conductive contact member having

(1) an outer conductive leg, having a connecting surface, one end, and an other end, commensurate in length and width with said outer leg of said spring clip so that when said inner surface of said outer leg of said spring clip is positioned opposite to said connecting surface of said outer conductive leg of said member, and spaced therefrom, a bus bar blade can be received therebetween;

(2) a step having

(i) a riser along a first orthogonal direction that joins at a roundly formed right angle with said one end of said outer conductive leg, so that said latter-mentioned roundly formed right angle and said smoothly formed edges of said outer leg serve as "lead-in" contours for said bus bar blade to be inserted therebetween, and

(ii) a tread along a second orthogonal direction adapted to rest upon one of said two flat springs of said spring clip, and

(3) a formed configuration having

(i) a first portion coupled to said other end of said conductive leg and oriented in a direction parallel to said riser,

(ii) a second portion coupled to said first portion, parallel to said riser, extending along a third orthogonal direction, and

(iii) a third portion, coupled to said second portion and perpendicular thereto, adapted to house a fixed contact,

said second portion having an aperture therewithin for receiving the other of said two flat springs.

3. A bus bar connector system for a low voltage, residential type circuit breaker comprising

(A) a molded, hollow, circuit breaker housing having a front, a back, one side, an opposite side, one end, and an opposite end, including

(1) an opening in said front for an operating handle to pass therethrough,

(2) a raised molded feature therewithin at said one end of said back of said housing at said one side thereof;

and

(3) a slot at said one end of said back at said opposite side thereof, so that said raised molded feature at said one side is oriented intermediate said slot at said opposite side, said slot extending along said one end of said opposite side from a position proximal to said back to a location between said front and said back of said opposite side,

(B) a spring clip of generally U-shape configuration having

(1) an outer leg, relatively stiff, with smoothly formed edges, said outer leg having an inner surface,

(2) a base of said U-shaped spring clip, coupled to said outer leg, and

(3 ) an inner leg, having portions removed so as to produce two flat springs joined by a portion of a flat leg, said flat leg being coupled to said base of said U-shaped spring clip, said flat leg being adapted to cooperate with said raised molded feature so as to rigidly position said base of said U-shaped spring clip and said outer leg relative to said circuit breaker housing; and

(C) a conductive contact member having

(1) an outer conductive leg, having a connecting surface, one end and an other end, commensurate in length and width with said outer leg of said spring clip so that when said inner surface of said outer leg of said spring clip is positioned opposite to said connecting surface of said outer conductive leg of said member, and spaced therefrom, a bus bar blade can be received therebetween,

(2) a step having

(i) a riser along a first orthogonal direction that joins at a roundly formed right angle with said one end of said conductive leg, so that said roundly formed right angle and said smoothly formed edges serve as "lead-in" contours for said bus bar blade to be inserted therebetween, and

(ii) a tread along a second orthogonal direction adapted to rest upon one of said two flat springs, and

(3) a formed configuration having

(i) a first portion coupled to said other end of said conductive leg and oriented in a direction parallel to said riser,

(ii) a second portion coupled to said first portion, parallel to said riser, extending along a third orthogonal direction, and

(iii) a third portion, coupled to said second portion and perpendicular thereto, adapted to house a fixed contact,

said second portion having an aperture therewithin for receiving the other of said two flat springs.

4. A bus bar connector system for a low voltage, residential type circuit breaker comprising

(A) a molded, hollow, circuit breaker housing having a front, a back, one side, an opposite side, one end, and an opposite end, said opposite side having an external surface, including

(1) an opening in said front for an operating handle to pass therethrough;

(2) a raised molded feature therewithin at said opposite end of said back of said housing at one side thereof;

(3) a slot at said opposite end of said back at said opposite side thereof, so that said raised molded feature at said one side is oriented intermediate said slot, said slot extending along said opposite end of said opposite side from a position proximal to said back to a location between said front and said back of said opposite side, and

(4) a groove, oriented along said exterior surface of said opposite side, from a position proximal to said back to a position intermediate said location and said front of said opposite side, said groove having a width at least as wide as said slot and being located adjacent said slot distal from said opposite end;

(B) a spring clip of generally U-shape configuration having

(1) an outer leg, relatively stiff, with smoothly formed edges, said outer leg having an inner surface,

(2) a base of said U-shaped spring clip, coupled to said outer leg, and

(3) an inner leg, having portions removed so as to produce two flat springs joined by a portion of a flat leg, said flat leg being coupled to said base of said U-shaped spring clip, said flat leg being adapted to cooperate with said raised molded feature so as to rigidly position said base of said U-shaped spring clip and said outer leg relative to said circuit breaker housing; and

(C) a conductive contact member having

(1) an outer conductive leg, having a connecting surface, commensurate in length and width with said outer leg of said spring clip so that when said inner surface of said outer leg of said spring clip is positioned opposite to said connecting surface of said outer conductive leg of said member, and spaced therefrom, a bus bar blade can be received therebetween,

(2) a step having

(i) a riser along a first orthogonal direction that joins at a roundly formed right angle with said one end of said conductive leg, so that said roundly formed right angle and said smoothly formed edges serve as "lead-in" contours for said bus bar blade to be inserted therebetween, and

(ii) a tread along a second orthogonal direction adapted to rest upon one of said two flat springs, and

(3) a formed configuration having

(i) a first portion coupled to said other end of said conductive leg and oriented in a direction parallel to said riser,

(ii) a second portion coupled to said first portion, parallel to said riser, extending along a third orthogonal direction, and

(iii) a third portion, coupled to said second portion and perpendicular thereto, adapted to house a first fixed contact,

said second portion having an aperture therewithin for receiving the other of said two flat springs.

5. A bus bar connector system for a low voltage, residential type circuit breaker comprising

(A) a molded, hollow, circuit breaker housing having a front, a back, one side, an opposite side, one end, and an opposite end, said one side having an exterior surface, including

(1) an opening in said front for an operating handle to pass therethrough,

(2) a groove, oriented along said exterior surface at said one side thereof, from a position proximal to said back to a location intermediate said front and said back thereof, said groove being located along said opposite end of said one side thereof;

(3) a slot extending along but distal to said opposite end of said housing at said one side thereof from a position proximal to said back of said housing to a location intermediate said back and said location, said slot being located adjacent said groove distal from said opposite end, said groove having a width at least as wide as said slot; and

(4) a raised molded feature therewithin distal from said opposite end of said back of said opposite side thereof so that said raised molded feature of said housing is oriented intermediate said slot;

(B) a spring clip of generally U-shape configuration having

(1) an outer leg, relatively stiff, with smoothly formed edges, said outer leg having an inner surface,

(2) a base of said U-shaped spring clip, coupled to said outer leg of said spring clip, and

(3) an inner leg, having portions removed so as to produce two flat springs joined by a portion of a flat leg which is coupled to said base of said U-shaped spring clip, said flat leg of said spring clip being adapted to cooperate with said raised molded feature so as to rigidly position said base of said U-shaped spring clip and said outer leg thereof relative to said circuit breaker housing; and

(C) a conductive contact member having

(1) an outer conductive leg, having a connecting surface, one end, and an other end, commensurate in length and width with said outer leg of said spring clip so that when said inner surface of said outer leg of said spring clip is positioned opposite to said connecting surface of said outer conductive leg of said member, and spaced therefrom, a bus bar blade can be received therebetween;

(2) a step having

(i) a riser along a first orthogonal direction that joins at a roundly formed right angle with said one end of said conductive leg so that said roundly formed right angle and said smoothly formed edges serve as "lead-in" contours for a bus bar blade to be inserted therebetween, and

(ii) a tread along a second orthogonal direction adapted to rest upon one of said two flat springs, and

(3) a formed configuration having

(i) a first portion coupled to said other end of said conductive leg and oriented in a direction parallel to said riser,

(ii) a second portion coupled to said first portion, parallel to said riser, extending along a third orthogonal direction, and

(iii) a third portion, coupled to said second portion and perpendicular thereto, adapted to house a fixed contact,

said second portion having an aperture therewithin for receiving the other of said two flat springs.