Integral module with lighted faceplate display

A faceplate assembly is provided. The faceplate assembly includes a faceplate having planar member with a first side and a second side, the planar member having a number of openings therethrough, the planar member first side having a number of opaque portions and a number of translucent portions, each planar member first side translucent portion disposed adjacent one planar member opening, a number of sources of localized illumination, each the source of localized illumination disposed adjacent the planar member second side and adjacent a planar member first side translucent portion, and wherein the source of localized illumination may be illuminated causing a selected planar member first side translucent portion to be illuminated.

BACKGROUND

Field

The disclosed concept pertains generally to a faceplate assembly and, more particularly, to a faceplate assembly, such as, for example, a lighted faceplate display wherein selected portions of the faceplate may be selectively illuminated. The disclosed concept further pertains to circuit breaker modules having such a lighted faceplate assembly.

Background Information

Circuit breakers are used, for example, in aircraft electrical systems where they not only provide over-current protection but also serve as switches for turning equipment on and off. Aircraft or subminiature circuit breakers, for instance, are typically relatively small to accommodate the relatively high-density layout of aircraft circuit breaker panels, which make circuit breakers for numerous circuits accessible to a user. Aircraft electrical systems can consist, for example, of hundreds of circuit breakers, each of which is used for a circuit protection function as well as a circuit disconnection function through a push-pull handle.

The circuit breaker push-pull handle is moved from in-to-out in order to open the corresponding load circuit. This action may be either manual or, else, automatic in the event of an overload or fault condition. If the push-pull handle is moved from out-to-in, then the load circuit is re-energized. If the load circuit had been automatically de-energized, then the out-to-in operation of the push-pull handle corresponds to a circuit breaker reset action.

It is known to mount a number of conventional aircraft or aerospace circuit breakers in a module. The module includes a frame assembly defining an enclosed space in which the circuit breakers are disposed. The module includes a faceplate having indicia (text, numbers, symbols, and lines grouping selected circuit breakers) thereon indicating the purpose or function of each circuit breaker. To ensure the indicia is visible, especially at night or other dark conditions, the module is typically backlit. That is, the faceplate is a translucent planar member having two coatings on one side. The first coating disposed on the planar member is a light color, typically white, and the second coating, which is disposed on the first coating, is a dark color, typically black or grey. The indicia are created by etching the indicia in the second coating. That is, a portion of the second coating is removed so that the first coating is visible. Further, a light is disposed in the module frame assembly enclosed space. The light illuminates the inner side of the planar member. Where the second coating is intact, the light does not pass through the planar member, the indicia however, is illuminated. Thus, there are dark portions of the faceplate, i.e. where the second coating is intact, and illuminated portions of the faceplate, i.e. the indicia. It is noted that the indicia are typically formed from thin lines and do not allow a substantial amount of light to pass therethrough. That is, the indicia are illuminated and easily visible, but the light is not sufficient to illuminate other portions of the outer face of the faceplate or adjacent objects. An incandescent light bulb in the module frame assembly enclosed space illuminates all indicia and, as such, cannot be used to illuminate a specific indicia, such as a warning indicia. This is a problem.

The planar member also includes a number of openings through which each circuit breaker push-pull handle passes so that handles are on the user side of the module. Thus, the push-pull handle may be the only visible portion of the aerospace circuit breakers during normal usage. Accordingly, the push-pull handle may also be used to indicate the status of the aerospace circuit breaker. For example, the push-pull handle may include a brightly colored, stem that is only visible when the push-pull handle is in the out position. Thus, if the push-pull handle is typically in the in position during use, a tripped circuit breaker in the out position would be noticeable as the brightly colored stem would be visible.

Typically, the indicia associated with each circuit breaker is spaced above or below, or otherwise adjacent to, each exposed handle. Thus, the planer member immediately adjacent the opening through which a handle passes is typically covered by the second coating. That is, the faceplate is mostly dark, other than the indicia.

There is room for improvement in such circuit breaker modules. For example, at night, or during other dark conditions, the push-pull handle brightly colored stem may not be visible as the module may be in the dark. Further, light from the indicia is insufficient to illuminate the push-pull handle. Thus, a circuit breaker may trip, causing the brightly colored portion of the stem to be exposed, but the pilot may not see the brightly colored portion of the stem due to poor lighting. Further, aircraft electronics may be able to determine other conditions associated with a circuit breaker other than a tripped status, i.e. a need for a test or diagnostic. The module described above does not provide a device for communicating such needs.

Thus, there is a need for a circuit breaker module, and more specifically a faceplate assembly for a circuit breaker module, that provides a clearly visible indication of a circuit breaker's condition.

SUMMARY

These needs and others are met by embodiments of the disclosed concept which provides for a faceplate assembly and, more particularly, to a faceplate assembly, such as, for example, a lighted faceplate display wherein selected portions of the faceplate may be selectively illuminated. The disclosed concept further pertains to circuit breaker modules having such a lighted faceplate assembly.

In accordance with one aspect of the disclosed concept, a faceplate assembly includes a faceplate having planar member with a first side and a second side, the planar member having a number of openings therethrough, the planar member first side having a number of opaque portions and a number of translucent portions, each planar member first side translucent portion disposed adjacent one planar member opening, a number of sources of localized illumination, each the source of localized illumination disposed adjacent the planar member second side and adjacent a planar member first side translucent portion, and wherein the source of localized illumination may be illuminated causing a selected planar member first side translucent portion to be illuminated.

As another aspect of the disclosed concept, a circuit breaker panel electrical module includes a frame assembly, a number of circuit breakers, and a faceplate assembly, the frame assembly having a front member and a back member, the frame assembly front member and the frame assembly back member being spaced from each other and defining an enclosed space, each the circuit breaker having a body with an outwardly extending movable handle, the faceplate assembly including a faceplate and a number of sources for localized illumination, the faceplate including a planar member with a first side and a second side, the planar member having a number of openings therethrough, the planar member first side having a number of opaque portions and a number of translucent portions, each planar member first side translucent portion disposed adjacent a planar member opening, each the source of localized illumination disposed adjacent the planar member second side and adjacent a planar member first side translucent portion, the faceplate assembly coupled to the frame assembly front member, each the circuit breaker body disposed in the circuit breaker panel electrical module frame assembly enclosed space with each circuit breaker outwardly extending movable handle extending through a faceplate planar member opening, and wherein each the source of localized illumination may be illuminated causing one the planar member first side translucent portion to be illuminated.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As employed herein, the term “processor” shall mean a programmable analog and/or digital device that can store, retrieve, and process data; a computer; a workstation; a personal computer; a microprocessor; a microcontroller; a microcomputer; a central processing unit; a mainframe computer; a mini-computer; a server; a networked processor; or any suitable processing device or apparatus.

As employed herein, the statement that two or more parts are “connected” or “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts. Further, as employed herein, the statement that two or more parts are “attached” shall mean that the parts are joined together directly.

As used herein, and when used in reference to communicating data or a signal, “in electronic communication” include both hardline and wireless forms of communication.

As used herein, “correspond” indicates that two structural components are sized to engage each other with a minimum amount of friction. Thus, an opening which corresponds to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction. This definition is modified if the two components are said to fit “snugly” together. In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases. If the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening.

As used herein, a “coupling” or a “coupling component” is one element of a coupling assembly. That is, a coupling assembly includes at least two elements, or components, that are structured to be coupled together. It is understood that the elements of a coupling assembly correspond to each other or are otherwise structured to be joined together. For example, in a coupling assembly, if one coupling element is a bolt, the other coupling element is a nut. Further, it is understood that the two elements of a coupling assembly may not be described at the same time.

The disclosed concept is described in association with a circuit breaker panel for aircraft circuit breakers, although the disclosed concept is applicable to a wide range of circuit breaker panels.

Referring toFIGS. 1 and 2, a circuit breaker panel2includes a number of circuit breaker modules4,5, and6(e.g., without limitation, two exemplary DC circuit breaker modules4and5and an exemplary AC circuit breaker module6, are shown) each having a connector7(FIG. 3), a monitoring module8having a connector9, and a frame10including a first connector12coupled to the frame10for the monitoring module8and structured to removably electrically and mechanically engage the monitoring module connector9. The circuit breaker panel2further includes a number of second connectors14coupled to the frame10for the number of circuit breaker modules4,5,6. Each of the number of second connectors14is structured to removably electrically and mechanically engage the connector7of a corresponding one of the number of circuit breaker modules4,5,6. A number of third connectors16,17,18are coupled to the frame10. As is known, the circuit breaker panel2also includes a plurality of conductors (not shown) which electrically connected the various connectors12,14. The conductors are further electrically connected between one of a number of third connectors16,17,18(e.g., for connection to an AC load or DC load). Additional details of the circuit breaker panel2are shown and described in U.S. patent application Ser. No. 13/086,442, filed on Apr. 14, 2011, which is assigned to Eaton Corporation and incorporated herein by reference.

Each of the number of circuit breaker modules4,5,6also includes a number of fasteners48(FIG. 6). The frame10also includes a number of apertures56(FIG. 1), each aperture56cooperating with one of the number of fasteners48of a corresponding one of the number of circuit breaker modules4,5,6to removably couple the corresponding one of the number of circuit breaker modules4,5,6to the frame10. Further, the circuit breaker modules4,5,6may include an electrical module70(shown schematically) configured to communicate with and control a faceplate110, described below. Such an electrical module70may be disposed on the circuit breaker modules4,5,6, or, electrical module70may be disposed at another location and be in electrical communication with a faceplate assembly100. Thus, the circuit breaker modules4,5,6include an electrical connector receptacle structured to be coupled to, and in electronic communication with both the electrical module70and a plug-in electrical connector154on the faceplate assembly100.

As shown inFIGS. 4 and 5, each of the number of circuit breaker modules4,5,6includes a number of connectors7or32, a plurality of circuit breakers34each including a body35with at least one line terminal36and at least one load terminal38, and a circuit structure supporting the circuit breakers34and electrically interconnecting the at least one line terminal36and the at least one load terminal38of each of the circuit breakers34with the number of connectors7or32. Each said circuit breaker34having a body35with an outwardly extending movable handle39. As is known, the handle39may be actuated, typically by an in/out motion, to open and close, or following a trip incident, reset the circuit breaker34.

As shown inFIG. 3, each circuit breaker module4,5,6also includes a frame assembly80, a number of circuit breakers34(as noted above), and a faceplate assembly100. The frame assembly80has a generally planar front member82and a generally planar back member84. The back member may be a circuit board having electrical conductors (not shown) with which the circuit breaker line and load terminals36,38are in electrical communication. The frame assembly front member82and the frame assembly back member84are spaced from each other and define an enclosed space86. That is, the frame assembly members82,84may include, for example, posts88extending from one of either the front member82or the back member84. The posts88may have a coupling89on their distal ends structured to be coupled to the other of either the front member82or the back member84. Further, the front member82includes an opening90sized to correspond to the faceplate110. The frame assembly80further includes face plate couplings92that are structured to be coupled to the faceplate fasteners160and to hold the faceplate110in compression. That is, as used herein, the faceplate110“in compression” means that the faceplate110is biased toward the enclosed space86and compresses objects having a greater height than the height between the faceplate110and the hack member84.

As shown inFIG. 6, the faceplate assembly100includes a faceplate110and a number of sources for localized illumination120. The faceplate110includes a planar member112with an outer, first side114and an inner, second side116. The planar member112has a number of openings118therethrough. The openings118are sized to correspond to the size of the circuit breaker handles39and to allow the circuit breaker handles39to pass through the planar member112. In an exemplary embodiment, the openings118are not snug, but do not allow light to pass therethrough. The planar member112is made from a clear or translucent material and is structured to allow light to pass therethrough. One side, or both sides, of the planar member112is coated with layers (not shown) of a light, opaque material, such as, but not limited to, a white material. A substantially dark and opaque material, such as, but not limited to, a black or grey material is then applied over top of the light opaque material. The outer layer of substantially dark and opaque material may be etched away so as to allow light to diffuse through the planar member112and the light, opaque material. The areas that are coated with the substantially dark and opaque material are, as used herein, “opaque portions”117(FIG. 1). The areas wherein the substantially dark and opaque material has been removed are, as used herein, “translucent portions”119(FIG. 1). It is understood that light cannot pass through the opaque portions117and can pass, or diffuse, through the translucent portions119. As discussed below, it is assumed that the coatings are disposed on the planar member outer, first side114, but it is understood that other configurations may be used.

As used herein, a “source of localized illumination”120is a light source that effectively illuminates a limited area and includes at least a light emitting diode (LED)122(FIG. 6) and an electroluminescent backlight124. A source of localized illumination120does not illuminate a general area and may be used to illuminate a warning indicia140, discussed below, thereby solving the problem associated with other lights such as an incandescent light bulb. An LED122produces a light that, essentially, is projected in a cone. That is, the light does not illuminate the general area in a manner similar to an incandescent bulb. Further, the LED122is typically small, having a size of about 2.0 mm×1.2 mm×75 mm. The LED122may be a single LED122capable of producing different colors. Further, LEDs122may be arranged on a strand126, i.e. a chain of LEDs122wherein selected LEDs122on the strand may be illuminated while others are not. Further, the LEDs122on the strand126may include LEDs122of different colors, or, clusters of LEDs122wherein different LEDs122in the cluster are different colors. As used herein, a “cluster” means LEDs in very close proximity such that all LEDs122in the cluster illuminate a single translucent portion119, as described below. A cluster of LEDs122acts as a single source of localized illumination120so that all LEDs122in the cluster illuminate a single “associated” planar member first side translucent portion119. Thus, a single first side translucent portion119, such as a first side translucent portion119shaped as an arrow, as described below, may be illuminated by a red LED122in the cluster or a green LED122in the cluster.

It is further noted that, for a large first side translucent portion119, such as, but not limited to a circular halo142(described below), a group of LEDs122may be structured to act as a single source of localized illumination120. In this configuration, the group of LEDs122is “associated” with the large first side translucent portion119. That is, the multiple LEDs122illuminate the large first side translucent portion119, but do not illuminate any other first side translucent portion119.

An electroluminescent backlight124(FIG. 3) is a thin planar member having an electroluminescent surface or body. The electroluminescent backlight124is applied, to the planar member112. The electroluminescent backlight124is capable of having selected portions illuminated. Thus, the portions of the electroluminescent backlight124are source of localized illumination120. These portions may be as small as about 0.010 in.×0.010 in. Further, the electroluminescent backlight124is capable of producing different color light. Thus, one portion of the electroluminescent backlight124may be illuminated in green, while another portion is illuminated in red, and other portions may be dark.

Further, a source of localized illumination120has changeable characteristics. These changeable characteristics are selected from the group including color (as noted above), strobe (flashing) or intensity. As used herein, “intensity” means the brightness of the source of localized illumination120. That is, the source of localized illumination120may be bright, dim, in between, or changing from one state to another, e.g. fading or brightening. The characteristics, including a combination of characteristics, may be selected for each source of localized illumination120. For example, and without limitation, one source of localized illumination120may be red and flashing, while another is green, bright and steady.

The planar member translucent portions119are disposed on the planar member first side114. Each planar member first side translucent portion119is disposed adjacent a planar member opening118. Each source of localized illumination120is disposed adjacent the planar member second side116. Further, each source of localized illumination120is disposed adjacent an associated planar member first side translucent portion119. As used herein, and when the coating creating the opaque and translucent portions117,119is on the outer, first side114, an “adjacent” source of localized illumination120is disposed on the opposite side of the planar member112from the planar member first side translucent portion119. It is understood that if the coatings are on the planar member inner, second side116, the “adjacent” source of localized illumination120is disposed immediately adjacent the translucent portion119. Further, each planar member first side translucent portion119has a single “associated” source of localized illumination120capable of illuminating only the “associated” planar member first side translucent portion119. That is, the light from an “associated” source of localized illumination120only causes the “associated” planar member first side translucent portion119to be illuminated and other planar member first side translucent portions119are not illuminated thereby. Thus, a single source of localized illumination120may be illuminated causing a selected planar member first side translucent portion119to be illuminated; i.e. the planar member first side translucent portion119“associated” with that single source of localized illumination120. It is understood that other sources of localized illumination120each have a different “associated” planar member first side translucent portion119.

Each first side translucent portion119is an indicia, and more preferably a warning indicia140. A warning indicia140is structured to clearly be associated with a single planar member opening118and thus be associated with a single circuit breaker34. For example, a warning indicia140may be a halo142(circle, double circle, broken circle, etc.) disposed about the planar member opening118through which a circuit breaker handle39extends. Thus, the halo142is disposed about the circuit breaker handle39. When the source of localized illumination120associated with that specific first side translucent portion119is illuminated, the halo142is illuminated. Thus, the specific circuit breaker34associated with the halo142can easily be identified. Another warning indicia140is a highlight144. A highlight144is a planar member first side translucent portion119having a specific shape, such as, but not limited to a circle, square, star, rectangle, arrow (shown), or triangle. The highlight144is disposed adjacent to a single planar member opening118. That is, the highlight144will always be closer to a single planar member opening118than any other. As used herein, a “warning indicia”140is an indicia structured to attract a user's attention; simple alphanumeric text is not a warning indicia140. More than one warning indicia140may be associated with a single circuit breaker34. For example, a single circuit breaker34may have an associated halo142and a highlight144. Thus, different information regarding the circuit breaker34may be conveyed at one time.

Further, the source of localized illumination120for each first side translucent portion119is structured to change characteristics in response to the condition of the associated circuit breaker34. For example, a circuit breaker34may trip due to an arc fault or a ground limit. In response to one condition, e.g. an arc fault, the source of localized illumination120may produce a solid red light in a halo142, whereas for a ground fault, the source of localized illumination120may flash a yellow light in a highlight144. Thus, the combination of a selected illumination characteristic and a selected first side translucent portions119provides a “fault identification.” As used herein, a “fault identification” is a combination of the characteristics of a source of localized illumination120, e.g. color, flashing etc., and the nature, e.g. shape, location, etc., of the warning indicia140. In this example, two different shaped translucent portions119were identified. It is understood that a single shaped translucent portion119may be used for different fault identifications. For example, if a circuit breaker34has a single associated first side translucent portion119, say a halo142, the halo142could flash yellow, i.e. the source of localized illumination120may flash a yellow light, when a ground fault is detected and be a steady red, i.e. the source of localized illumination120may provide a red light, when an arc fault is detected. As another example, a halo142may be a broken (dashed) circle having multiple arc segments. Each arc segment is an individual first side translucent portion119having an associated source of localized illumination120. The arc segments may be sequentially illuminated thereby creating the appearance of movement about the halo142. This may be one “fault identification” for the circuit breaker34associated with the halo142. Alternatively, the sources of localized illumination120for the segments may act in concert, e.g. all producing a constant light or a flashing light, thus illuminating the entire halo142. This may be a different “fault identification” for the circuit breaker34associated with the halo142.

The circuit breakers34may have at least the following conditions: arc fault, ground fault, degrading CVD thermal, ACFI, GF, and diagnostic. The circuit breakers34may have additional sensors, not shown, structured to rely relevant information such as, but not limited to, temperature. Preferably, each fault identification is associated with one circuit breaker condition. That is, in an exemplary embodiment, a steady red light always means an arc fault, regardless of the specific circuit breaker34. It is noted that the fault identification may be the only indication for the circuit breaker34. That is, the circuit breaker may not include a mechanical indicia, such as, but not limited to, a colored handle or stem.

It is further noted that each circuit breaker module4,5(FIG. 2),6includes an electrical module70(FIG. 3, as noted above) configured to communicate with the faceplate110and an electrical connector receptacle152that is in electrical communication with the electrical module70. The faceplate110includes a plug-in electrical connector154configured to correspond to the electrical connector receptacle152. That is, the plug-in electrical connector154is shaped to fit in the electrical connector receptacle152and includes conductors positioned to communicate with conductors in the electrical connector receptacle152.

The faceplate110is structured to be coupled to the frame assembly front member82by faceplate fasteners160. Further, the faceplate planar member112is structured to be a compressive member. As noted above, the frame assembly face plate couplings92are structured to be coupled to the faceplate fasteners160and to hold the faceplate110in compression. Thus, when the faceplate110is coupled to the frame assembly100, the circuit breakers34in the frame assembly enclosed space86will be compressed and the circuit breaker terminals36,38will be biased toward the frame assembly back member84.