Panelboard having a parallel feeder bars distribution

A load center includes a pair of generally parallel busbars for distributing a single phase of electricity to circuit breakers through a multitude of stabs that form respective bridges between the pair of busbars to provide respective bidirectional paths for dissipating heat from each of the stabs to both of the busbars and to provide a connection point for a pair of circuit breakers installed into the load center.

FIELD OF THE INVENTION

The present invention relates generally to electrical equipment and, more particularly, to electrical enclosures having a parallel feeder bars distribution.

BACKGROUND OF THE INVENTION

Electrical enclosures, such as, for example, load centers, typically house multiple circuit breakers and/or related electrical accessories. Load centers typically include one main feeder bar or busbar per phase of electricity. To accommodate single and/or multi-phase circuit breakers, most load centers include multiple stabs, where each stab is configured to connect two branch circuit breakers with one of the busbars. This connection inherently creates a thermal limitation because the heat contributed by the two circuit breakers for each stab has to be dissipated through a single dissipation path, from the stab itself to the main feeder busbar, which creates a localized temperature rise. To combat these temperature rises, busbars have been oversized to allow temperature rises to remain lower than maximum allowed levels per safety regulations. However, busbars are typically made of copper, which is an expensive metal, so increasing the size of the busbars increases the costs of manufacturing the load center.

Thus, a need exists for an improved apparatus. The present invention is directed to satisfying one or more of these needs and solving other problems.

SUMMARY OF THE INVENTION

The present disclosure is directed to providing a load center, which can also be known as a panelboard. The load center can be configured to accept different makes, models, sizes, and types of circuit breakers and related electrical accessories. The load center includes an outer housing for mounting the load center into a building, such as a residential house. The housing has various inputs/outputs to receive electrical wires. For a load center in a typical single family home, the housing is mounted between two studs in a wall. The housing receives one or more live electrical lines from an electrical utility company. Each live electrical line electrically couples with a respective pair of generally parallel busbars. The pairs of generally parallel busbars are insulated from the housing and are rigidly positioned within the housing. Each of the pairs of generally parallel busbars supplies one phase of electricity to circuit breakers and/or related electrical accessories that are plugged into the load center.

The present disclosure includes a first set or plurality of stabs that is connected between a first pair of generally parallel busbars such that each one of the first set of stabs forms a bridge between a first one of the first pair of generally parallel busbars and a second one of the first pair of generally parallel busbars. For a load center configured to distribute two or more phases of electricity, the present disclosure further provides a second pair of generally parallel busbars and a second set of stabs that is connected between the second pair of generally parallel busbars such that each one of the second set of stabs forms a bridge between a first one of the second pair of generally parallel busbars and a second one of the second pair of generally parallel busbars. For a load center configured to distribute three phases of electricity, the present disclosure further provides a third pair of generally parallel busbars and a third set of stabs that is connected between the third pair of generally parallel busbars such that each one of the third set of stabs forms a bridge between a first one of the third pair of generally parallel busbars and a second one of the third pair of generally parallel busbars. The first, the second, and the third pairs of generally parallel busbars are arranged within the housing such that the first, the second, and the third set of stabs are staggered along a central axis of the load center. Additionally, each of the first, the second, and the third set of stabs includes a circuit breaker connecting surface. The circuit breaker connecting surfaces of each of the first, the second, and the third set of stabs can be coplanar. Each of the stabs of the present disclosure provide a respective bidirectional path for dissipating heat to the two generally parallel busbars connected thereto. Such bidirectional heat dissipation allows for a reduction in the size of busbars, which can result in material cost savings.

According to some embodiments a load center includes a housing, a first busbar, a second busbar, and a set of stabs. The first busbar is positioned within the housing for distributing a first phase of electricity entering the load center. The second busbar is positioned within the housing for distributing the first phase of electricity. The second busbar is generally parallel to the first busbar and electrically connected thereto. Each of the set of stabs is electrically connected to the first busbar and the second busbar.

According to some embodiments, a load center includes a housing, a first pair of generally parallel busbars, a first set of stabs, a second pair of generally parallel busbars, a second set of stabs, and a first insulating layer. The first pair of generally parallel busbars is positioned within the housing for distributing a first phase of electricity. The first set of stabs is physically and electrically connected between the first pair of generally parallel busbars. The second pair of generally parallel busbars is positioned within the housing for distributing a second phase of electricity. The second set of stabs is physically and electrically connected between the second pair of generally parallel busbars. The first insulating layer is positioned between the first pair of busbars and the second pair of busbars to electrically insulate the first phase of electricity from the second phase of electricity. The first and the second pairs of busbars are arranged within the housing such that the first set of stabs and the second set of stabs are staggered.

The foregoing and additional aspects and embodiments of the present invention will be apparent to those of ordinary skill in the art in view of the detailed description of various embodiments and/or aspects, which is made with reference to the drawings, a brief description of which is provided next.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Although the invention will be described in connection with certain aspects and/or embodiments, it will be understood that the invention is not limited to those particular aspects and/or embodiments. On the contrary, the invention is intended to cover all alternatives, modifications, and equivalent arrangements as may be included within the spirit and scope of the invention as defined by the appended claims.

Referring toFIG. 1, an electrical enclosure or a load center100is shown according to the present disclosure. The load center100includes a housing110. The housing110can be made of a variety of materials including metal, plastic, fiberglass, and the like. The housing110can include a hinged door (not shown) or other means of sealing and/or covering the contents of the load center100. The housing110can also include an insulating base or pad111to cover all of or a portion of an interior surface of the housing110. The insulating base111is configured to electrically insulate the contents of the load center100from electrically conductive items outside the housing110(e.g., metal wall studs, screws, wires, etc.).

The load center100includes three pairs of generally parallel busbars120and three corresponding sets of stabs140(shown in more detail inFIG. 3A, discussed below), which are implemented to distribute three-phase power in the load center. That is, each pair of busbars and corresponding set of stabs are provided to supply a separate and distinct phase of electricity to one or more circuit breakers180coupled to the load center100. By generally parallel, it is meant that each pair of busbars120is designed and installed to be substantially parallel to one another, understanding that the practical limitations of mechanical and human imperfections can cause the busbars to be slightly skewed. As shown inFIG. 1, the circuit breakers180coupled with the load center100are three-phase circuit breakers; however, it is contemplated that the load center100can receive and supply power to single-phase circuit breakers, dual-phase circuit breakers, three-phase circuit breakers, or a combination thereof.

While specific numbers of pairs of busbars120and corresponding stabs140are described herein and shown in the Figures, it is contemplated that the load center100can include any number of pairs of busbars120and corresponding stabs140. For example, in some embodiments, the load center100is a single-phase load center that includes only one pair of busbars120and one corresponding set of stabs140. For another example, the load center100is a dual-phase load center that includes two pairs of busbars120and two corresponding sets of stabs140. For yet another example, the load center100is a three-phase load center that includes three pairs of busbars120and three corresponding sets of stabs140.

Referring toFIG. 2, a top view of the load center100is shown. As shown inFIG. 3A, the pairs of busbars120are formed from any electrically conducting material, as is known in the art, such as copper. The pairs of busbars120are positioned within the housing110such that each of the pairs of busbars120are electrically insulated from the housing100and from each other. The busbars120can be positioned between and held rigidly in place by a first block112and a second block114. The first and the second blocks112and114are attached or coupled to the housing110and/or the insulating base111such that the first and the second blocks112and114aid in electrically insulating the pairs of busbars120from the housing110. The first block112includes a first terminal112a, a second terminal112b, and a third terminal112c. Each of the first, the second, and the third terminals112a,b,cis configured to be electrically connected with a respective one of the pairs of busbars120.

Referring toFIGS. 2 and 3A, a first pair of generally parallel busbars120ais configured to be coupled with the first terminal112athrough a first attachment member121a. The first attachment member121acan be integral with, or attached to, one end of one or both of the first pair of generally parallel busbars120a. Similarly, a second pair of generally parallel busbars120bis configured to be coupled with the second terminal112bthrough a second attachment member121b. The second attachment member121bcan be integral with, or attached to, one end of one or both of the second pair of generally parallel busbars120b. Similarly, a third pair of generally parallel busbars120cis configured to be coupled with the third terminal112cthrough a third attachment member121c. The third attachment member121ccan be integral with, or attached to, one end of one or both of the third pair of generally parallel busbars120c.

Referring specifically toFIG. 2, the housing110includes one or more apertures positioned adjacent to the terminals112a,b,cand configured to receive electrical supply lines119a,b,c. The first, the second, and the third terminals112a,b,cinclude respective attachment means, such as, for example, a lug, screw, or bolt to aid in the electrical coupling and physical attachment of the electrical supply wires119a,b,c. The electrical supply wires119a,b,care electrically and physically coupled with the respective terminals112a,b,cvia the screws or the like to supply distinct and separate phases of electricity to the first pair of busbars120a, the second pair of busbars120b, and the third pair of busbars120c, respectively. For example, the first electrical supply wire119asupplies a first phase of electricity to the first pair of generally parallel busbars120avia the first terminal112a; the second electrical supply wire119bsupplies a second phase of electricity to the second pair of generally parallel busbars120bvia the second terminal112b; and the third electrical supply wire119csupplies a third phase of electricity to the third pair of generally parallel busbars120cvia the third terminal112c.

Referring specifically toFIG. 3A, the three pairs of generally parallel busbars120a,b,cand corresponding set of stabs140a,b,care shown with the housing110removed and all insulating layers removed to illustrate a stacked and staggered configuration of the pairs of busbars120a,b,cand the corresponding set of stabs140a,b,c. That is, the first, the second, and the third pairs of generally parallel busbars120a,b,care stacked relative to each other such that at least a portion of each pair of busbars lies in a different vertical plane. Additionally, the first, the second, and the third pairs of generally parallel busbars120a,b,care staggered such that the first, the second, and the third pluralities of stabs140a,b,c, respectively, alternate along a coinciding central axis as described below.

The first pair of generally parallel busbars120ais shown on the top of the stack. The first pair of busbars120aincludes a first busbar120a1that is parallel with and coplanar with a second busbar120a2. The first busbar120a1and the second busbar120a2are shown as resembling flat sheets, although it is contemplated that, alternately, the first busbar120a1and/or the second busbar120a2can have an “L” configuration and/or a “C” configuration. The first busbar120a1and the second busbar120a2are physically and electrically connected by the first set of stabs140a1-7. WhileFIG. 3Aillustrates seven stabs140a, the first set of stabs140acan include any number of stabs, such as, for example, 1, 3, 5, 7, 10, 100, etc., to accommodate a variety of different numbers of circuit breakers within the load center100. While the first set of stabs140ais shown as having an open trapezoidal shape, it is contemplated that each one of the first set of stabs140acan have a “C” shape, a substantially flat sheet shape, or an “L” shape.

The second pair of generally parallel busbars120bis shown on the bottom of the stack. The second pair of busbars120bincludes a first busbar120b1that is parallel with and at least partially coplanar with a second busbar120b2. In other words, major corresponding surfaces122b1,122b2(shown inFIG. 3B) of each of the second pair of busbars120bshare a common plane. The first busbar120b1and the second busbar120b2are shown as having an “L” configuration, although it is contemplated that in some alternative embodiments the first busbar120b1and/or the second busbar120b2can have a flat sheet configuration like the first pair of busbars120aand/or a “C” configuration. The first busbar120b1and the second busbar120b2are physically and electrically connected by the second set of stabs140b1-7. WhileFIG. 3Aillustrates seven stabs in the second set of stabs140bfor connecting up to 14 circuit breakers, it is contemplated that the second set of stabs140bcan include any number of stabs that corresponds with the number of stabs in the first set of stabs140a, such as, for example, 1, 3, 5, 7, 10, 100, etc. While the second set of stabs140bis shown as having a “C” shape, it is contemplated that each one of the second set of stabs140bcan have a trapezoidal shape, a substantially flat sheet shape, or an “L” shape.

The third pair of generally parallel busbars120cis shown between the first and the second pairs of generally parallel busbars120a,bin the stack. The third pair of busbars120cincludes a first busbar120c1that is parallel with and at least partially coplanar with a second busbar120c2. In other words, major corresponding surfaces122c1,122c2(shown inFIG. 3B) of each of the third pair of busbars120cshare a common plane. The first busbar120c1and the second busbar120c2are shown as having an “L” configuration, although it is contemplated that the first busbar120c1and/or the second busbar120c2can alternately have a flat sheet configuration like the first pair of busbars120aand/or a “C” configuration. The first busbar120c1and the second busbar120c2are physically and electrically connected by the third set of stabs140c1-7. WhileFIG. 3Aillustrates seven stabs in the third set of stabs140c, it is contemplated that the third set of stabs140ccan include any number of stabs that corresponds with the number of stabs in the first set of stabs140a, such as, for example, 1, 3, 5, 7, 10, 100, etc. While the third set of stabs140cis shown as having a “C” shape, it is contemplated that each one of the third set of stabs140ccan have a trapezoidal shape, a substantially flat sheet shape, or an “L” shape.

The first pair of generally parallel busbars120ahas a first central axis125athat is located equidistantly between the first busbar120a1and the second busbar120a2. Similarly, the second pair of generally parallel busbars120bhas a second central axis125bthat is located equidistantly between the first busbar120b1and the second busbar120b2and the third pair of generally parallel busbars120chas a third central axis125cthat is located equidistantly between the first busbar120c1and the second busbar120c2. According to some embodiments, the first central axis125a, the second central axis125b, and the third central axis125c, all coincide with each other or are one and the same. That is, the first central axis125acoincides with the second central axis125band the third central axis125c.

Referring toFIG. 3B, a cross-sectional front view of the stacked and staggered configuration of busbar pairs120a,b,cofFIG. 3Ais shown. As shown inFIG. 3B, the first pair of busbars120ais stacked above the third pair of busbars120c, both of which are stacked on top of the second pair of busbars120b. As described herein in reference toFIGS. 4A-G, each of the pairs of busbars120a,b,cis separated and electrically insulated using insulating layers (not shown inFIG. 3B) that are sandwiched between the pairs of busbars120a,b,c.

Referring generally toFIGS. 4A-4G, the pairs of busbars120and the sets of stabs140are described according to an implementation of the present disclosure. Referring specifically toFIG. 4A, a partial perspective view of the second pair of busbars120band the second set of stabs140bis shown. The first busbar120b1of the second pair of generally parallel busbars120bhas a substantially flat major surface122b1and opposing edge surfaces123b1,123b2. Similarly, the second busbar120b2of the second pair of generally parallel busbars120bhas a substantially flat major surface122b2and opposing edge surfaces124b1,124b2.

The second pair of generally parallel busbars120bis positioned within the housing110such that the substantially flat major surface122b1of the first busbar120b1is coplanar with the substantially flat major surface122b2of the second busbar120b2. As described above, the second pair of generally parallel busbars120bhas a second central axis125bthat is located equidistantly between the first busbar120b1and the second busbar120b2. Additionally, the opposing edge surfaces123b1and123b2of the first busbar120b1and the opposing edge surfaces124b1and124b2of the second busbar120b2are parallel with the second central axis125b.

The second set of stabs140bis positioned along the second central axis125bto physically and electrically connect the first busbar120b1with the second busbar120b2. That is, each one of the second set of stabs140bphysically and electrically couples the first busbar120b1with the second busbar120b2. As shown inFIG. 4A, each one of the second set of stabs140b, such as, for example, the second stab140b2, is coupled with the first busbar120b1via a first screw143band the second busbar120b2via a second screw143b. It is contemplated that each of the second set of stabs140bcan be coupled with the first and/or the second busbars120b1,120b2, via screw(s), nuts and bolts, welds, snap-fit connection, or a combination thereof.

Each of the second set of stabs140bhas a circuit breaker connecting surface145bthat is configured to be coupled with corresponding electrical connectors (not shown) of two separate and distinct circuit breakers. As shown, each of the second set of stabs140bincludes two apertures141b. Each of the apertures141bis configured to receive a screw, bolt, or the like to physically and/or electrically couple a circuit breaker, as shown in, for example,FIG. 4G, with the second pair of busbars120b. The circuit breaker connecting surfaces145bof each one of the second set of stabs140bare coplanar with one another. That is, for example, the circuit breaker connecting surface145bof the first stab140b1is coplanar with the circuit breaker connecting surface145bof the second stab140b2, the third stab140b3, the fourth stab140b4, the fifth stab140b5, etc. The coplanar circuit breaker connecting surfaces145bof the second set of stabs140bprovide a uniform platform for coupling circuit breakers. As will be explained below, the first and the third sets of stabs140a,calso include circuit breaker connecting surfaces145a,cthat are coplanar with the circuit breaker connecting surfaces145bof the second set of stabs140bsuch that multiphase circuit breakers, such as, for example, the circuit breakers180, shown inFIG. 1, can be physically and electrically connected with the first, the second, and the third phases of electricity entering the load center100.

As described above, each of the second set of stabs140bforms a bridge between the first busbar120b1and the second busbar120b2to (1) physically and electrically connect the first busbar120b1and the second busbar120b2and (2) provide a circuit breaker connecting surface145bthat is configured to be coupled with corresponding electrical connectors of two separate and distinct circuit breakers. In addition, each of the second set of stabs140bforms a bridge between the first busbar120b1and the second busbar120b2to (3) provide a bidirectional path for dissipating heat generated by electrical current conducted between the busbars and the attached circuit breakers from each one of the second set of stabs140bto the first busbar120b1and to the second busbar120b2.

For example, as shown inFIG. 1, circuit breakers180can be connected with one or more of the second set of stabs140b. During operation of the load center100in, for example, a residential house, electrical current passes through the circuit breakers180, which creates heat in the circuit breakers180. Heat is dissipated from the circuit breakers180to the second pair of busbars120bin a bidirectional manner via the second set of stabs140b. That is, heat can travel from each one of the second set of stabs140bin one of two directions as each one of the second set of stabs140bis physically and electrically connected to the first busbar120b1and to the second busbar120b2. In other words, heat can travel from, for example, the second stab140b2in a first direction to the first busbar120b1or in a second direction to the second busbar120b2.

Now referring toFIG. 4B, the second pair of generally parallel busbars120band the second set of stabs140bofFIG. 4Aare shown having a second insulating layer150boverlaid thereon. Only a portion of the second insulating layer150bis shown to illustrate how the second pair of busbars120bextends beneath the second insulating layer150b. The second insulating layer150bcan be a single part or multiple parts. For example, the second insulating layer150bcan be broken into sections that electrically insulate respective portions of the second pair of busbars120b. It is contemplated that the second insulating layer150bis made of any electrically insulating material, such as, for example, plastic, rubber, etc.

The second insulating layer150bincludes an insulator base151b, phase barriers153b, and apertures155b. Each of the phase barriers153bextends perpendicularly from the insulator base151bto aid in electrically insulating the second phase of electricity entering the load center100through the second electrical supply line119bfrom the first phase of electricity entering the load center100through the first electrical supply line119aand from the third phase of electricity entering the load center100through the third electrical supply line119c. The phase barriers153bare configured to be received between circuit breakers and/or within respective slots in a multiphase circuit breaker, such as, for example, as shown inFIG. 1.

Each of the apertures155bis positioned to allow access to a respective underlying stab. For example, the first aperture155b1is positioned to provide access to the first stab140b1of the second set of stabs140b. Similarly, the second aperture155b2is positioned to provide access to the second stab140b2, and the third aperture155b3is positioned to provide access to the third stab140b3. That is, the apertures155bprovide a path for circuit breakers to physically and/or electrically couple with one of the underlying stabs, such as, for example, one of the second set of stabs140b.

The insulator base151bforms a substantially flat major surface152bthat at least partially rests on the substantially flat major surface122b1of the first busbar120b1of the second pair of busbars120band on the substantially flat major surface122b2of the second busbar120b2of the second pair of busbars120b, which provides a portion of the stacked and staggered configuration of busbars and stabs described herein.

Referring specifically toFIG. 4C, the second pair of generally parallel busbars120b, the second set of stabs140b, and the second insulating layer150bofFIG. 4Bare shown having the third pair of generally parallel busbars120cand the third set of stabs140coverlaid thereon. The first busbar120c1of the third pair of generally parallel busbars120chas a substantially flat major surface122c1and opposing edge surfaces123c1,123c2. Similarly, the second busbar120c2of the third pair of generally parallel busbars120chas a substantially flat major surface122c2and opposing edge surfaces124c1,124c2.

The third pair of generally parallel busbars120cis positioned within the housing110in the stacked and staggered configuration such that the substantially flat major surface152bof the insulator base151bis sandwiched between the substantially flat major surfaces122b1and122b2of the second pair of generally parallel busbars120band the substantially flat major surfaces122c1and122c2of the third pair of generally parallel busbars120c. Additionally, the third pair of generally parallel busbars120cis positioned within the housing110such that the substantially flat major surface122c1of the first busbar120c1is coplanar with the substantially flat major surface122c2of the second busbar120c2. As described above, the third pair of generally parallel busbars120chas a third central axis125cthat is located equidistantly between the first busbar120c1and the second busbar120c2. Additionally, according to some embodiments, the opposing edge surfaces123c1and123c2of the first busbar120c1and the opposing edge surfaces124c1and124c2of the second busbar120c2are parallel with the third central axis125c.

The third set of stabs140cis positioned along the third central axis125cto physically and electrically connect the first busbar120c1with the second busbar120c2. That is, each one of the third set of stabs140cphysically and electrically couples the first busbar120c1with the second busbar120c2. As shown inFIG. 4C, each one of the third set of stabs140c, such as, for example, the fifth stab140c5, is coupled with the first busbar120c1via a first screw143cand the second busbar120c2via a second screw143c. It is contemplated that each of the third set of stabs140ccan be coupled with the first and/or the second busbars120c1,120c2, via screw(s), nuts and bolts, welds, snap-fit connection, or a combination thereof.

Each of the third set of stabs140chas a circuit breaker connecting surface145cthat is configured to be coupled with corresponding electrical connectors of two separate and distinct circuit breakers. As shown, each of the third set of stabs140cincludes two apertures141c. Each of the apertures141cis configured to receive a screw, bolt, or the like to physically and/or electrically couple a circuit breaker, as shown in, for example,FIG. 4G, with the third pair of busbars120c. The circuit breaker connecting surfaces145cof each one of the third set of stabs140care coplanar. That is, for example, the circuit breaker connecting surface145cof the first stab140c1is coplanar with the circuit breaker connecting surface145cof the second stab140c2, the third stab140c3, the fourth stab140c4, the fifth stab140c5, etc. The coplanar circuit breaker connecting surfaces145cof the third set of stabs140cprovide a uniform platform for coupling circuit breakers as described above in reference toFIG. 4A.

As described above, each of the third set of stabs140cforms a bridge between the first busbar120c1and the second busbar120c2to (1) physically and electrically connect the first busbar120c1and the second busbar120c2and (2) provide a circuit breaker connecting surface145cthat is configured to be coupled with corresponding electrical connectors of two separate and distinct circuit breakers. In addition, each of the third set of stabs140cforms a bridge between the first busbar120c1and the second busbar120c2to (3) provide a bidirectional path for dissipating heat from each one of the third set of stabs140cto the first busbar120c1and the second busbar120c2, in the same, or similar, manner as described above in reference to the second set of stabs andFIG. 4A.

As described above, the third set of stabs140cis positioned along the third central axis125c, which coincides with the second central axis, such that the third set of stabs140cis staggered with respect to the second set of stabs140b. That is, the second set of stabs140band the third set of stabs140care staggered such that respective portions of the second set of stabs140band respective portions of the third set of stabs140calternate along the second central axis and the third central axis. The respective portions are respective circuit breaker connection surfaces145b,cof the second and the third sets of stabs140b,c.

Now referring toFIG. 4D, the third pair of generally parallel busbars120c, the third set of stabs140c, the second insulating layer150b, the second pair of generally parallel busbars120b, and the second set of stabs140bofFIG. 4Care shown having a third insulating layer150coverlaid thereon. The third insulating layer150cis the same as, or similar to, the second insulating layer150bin that, the third insulating layer150ccan be a single part or multiple parts. It is contemplated that the third insulating layer150cis made of any electrically insulating material, such as, for example, plastic, rubber, etc.

The third insulating layer150cincludes an insulator base151c, phase barriers153c, and apertures155c. Each of the phase barriers153cextends perpendicularly from the insulator base151cto aid in electrically insulating the second phase of electricity entering the load center100through the second electrical supply line119bfrom the first phase of electricity entering the load center100through the first electrical supply line119aand from the third phase of electricity entering the load center100through the third electrical supply line119cin the same or similar manner as described above in reference to the phase barriers153bandFIG. 4B. Alternately, the third insulating layer150cdoes not include phase barriers, and the phase barriers153bof the second insulting layer150bprovide sufficient electrical insulation between phases.

Each of the apertures155cis positioned to allow access to a respective underlying stab. For example, the first aperture155c1is positioned to provide access to the first stab140b1of the second set of stabs140b. Similarly, the second aperture155c2is positioned to provide access to the first stab140c1of the third set of stabs140c. That is, the apertures155cprovide a path for circuit breakers to physically and/or electrically couple with one of the underlying stabs, such as, for example, one of the second and/or the third sets of stabs140b,c.

The insulator base151cforms a substantially flat major surface152cthat at least partially rests on the substantially flat major surface122c1of the first busbar120c1of the third pair of busbars120cand on the substantially flat major surface122c2of the second busbar120c2of the third pair of busbars120c, which provides a portion of the stacked and staggered configuration of busbars and stabs described herein.

Referring specifically toFIG. 4E, the third insulating layer150c, the third pair of generally parallel busbars120c, the third set of stabs140c, the second insulating layer150b, the second pair of generally parallel busbars120b, and the second set of stabs140bofFIG. 4Dare shown having the first pair of generally parallel busbars120aand the first set of stabs140aoverlaid thereon. The first busbar120a1of the first pair of generally parallel busbars120ahas a substantially flat major surface122a1and opposing edge surfaces123a1,123a2. Similarly, the second busbar120a2of the first pair of generally parallel busbars120ahas a substantially flat major surface122a2and opposing edge surfaces124a1,124a2.

The first pair of generally parallel busbars120ais positioned within the housing110in the stacked and staggered configuration such that the substantially flat major surface152cof the insulator base151cis sandwiched between the substantially flat major surfaces122c1and122c2of the third pair of generally parallel busbars120cand the substantially flat major surfaces122a1and122a2of the first pair of generally parallel busbars120a. Additionally, the first pair of generally parallel busbars120ais positioned within the housing110such that the substantially flat major surface122a1of the first busbar120a1is coplanar with the substantially flat major surface122a2of the second busbar120a2. As described above, the first pair of generally parallel busbars120ahas a first central axis125athat is located equidistantly between the first busbar120a1and the second busbar120a2. Additionally, the opposing edge surfaces123a1and123a2of the first busbar120a1and the opposing edge surfaces124a1and124a2of the second busbar120a2are parallel with the first central axis125a.

The first set of stabs140ais positioned along the first central axis125ato physically and electrically connect the first busbar120a1with the second busbar120a2. That is, each one of the first set of stabs140aphysically and electrically couples the first busbar120a1with the second busbar120a2. As shown inFIG. 4E, each one of the first set of stabs140a, such as, for example, the third stab140a3, is coupled with the first busbar120a1via a first screw143aand the second busbar120a2via a second screw143a. It is contemplated that each of the first set of stabs140acan be coupled with the first and/or the second busbars120a1,120a2, via screw(s), nuts and bolts, welds, snap-fit connection, or a combination thereof.

Each of the first set of stabs140ahas a circuit breaker connecting surface145athat is configured to be coupled with corresponding electrical connectors of two separate and distinct circuit breakers. As shown, each of the first set of stabs140aincludes two apertures141a. Each of the apertures141ais configured to receive a screw, bolt, or the like to physically and/or electrically couple a circuit breaker, as shown in, for example,FIG. 4G, with the first pair of busbars120a. The circuit breaker connecting surfaces145aof each one of the first set of stabs140aare coplanar. That is, for example, the circuit breaker connecting surface145aof the first stab140a1is coplanar with the circuit breaker connecting surface145aof the second stab140a2, the third stab140a3, the fourth stab140a4, the fifth stab140a5, etc. The coplanar circuit breaker connecting surfaces145aof the first set of stabs140aprovide a uniform platform for coupling circuit breakers as described above in reference toFIG. 4A.

As described above, each of the first set of stabs140aforms a bridge between the first busbar120a1and the second busbar120a2to (1) physically and electrically connect the first busbar120a1and the second busbar120a2and (2) provide a circuit breaker connecting surface145athat is configured to be coupled with corresponding electrical connectors of two separate and distinct circuit breakers. In addition, each of the first set of stabs140aforms a bridge between the first busbar120a1and the second busbar120a2to (3) provide a bidirectional path for dissipating heat from each one of the first set of stabs140ato the first busbar120a1and the second busbar120a2, in the same, or similar manner as described herein in reference to the second set of stabs andFIG. 4A.

As described above, the first set of stabs140ais positioned along the first central axis125a, which coincides with the second, and the third central axes, such that the first set of stabs140aare staggered with respect to the second set of stabs140band with respect to the third set of stabs140c. That is, the first set of stabs140a, the second set of stabs140b, and the third set of stabs140care staggered such that respective portions of the first set of stabs140a, respective portions of the second set of stabs140b, and respective portions of the third set of stabs140calternate along the first, the second, and the third central axes.

Now referring toFIG. 4F, a partial perspective view of the load center100is shown. The load center100is shown as having the first pair of generally parallel busbars120a, the first set of stabs140a, the third insulating layer150c, the third pair of generally parallel busbars120c, the third set of stabs140c, the second insulating layer150b, the second pair of generally parallel busbars120b, and the second set of stabs140bofFIG. 4Ewith a first insulating layer150aoverlaid thereon. The first insulating layer150ais similar to the second insulating layer150band the third insulating layer150cin that, the first insulating layer150acan be a single part or multiple parts. It is contemplated that the first insulating layer150ais made of any electrically insulating material, such as, for example, plastic, rubber, etc.

The first insulating layer150aincludes an insulator base151aand apertures155a. Each of the apertures155ais positioned to allow access to a respective underlying stab. For example, the first aperture155a1is positioned to provide access to the first stab140a1of the first set of stabs140a. Similarly, the second aperture155a2is positioned to provide access to the first stab140b1of the second set of stabs140band the third aperture155a3is positioned to provide access to the first stab140c1of the third set of stabs140c. That is, the apertures155aprovide a path for circuit breakers to physically and/or electrically couple with one of the underlying stabs, such as, for example, one of the first, the second, and/or the third sets of stabs140a,b,c. According to some alternative embodiments, the stabs protrude through the apertures155a.

The first insulating layer150adoes not include phase barriers. The phase barriers153b,153cof the second and the third insulating layers150b,cprotrude through the apertures155a. The first insulating layer150acan further include phase barriers the same as, or similar to, the phase barriers153b,153cdescribed above in reference toFIGS. 4B and 4D.

The insulator base151aforms a substantially flat major surface152athat at least partially rests on the substantially flat major surface122a1of the first busbar120a1of the first set of busbars120aand on the substantially flat major surface122a2of the second busbar120a2of the first set of busbars120a, which provides a portion of the stacked and staggered configuration of busbars and stabs described herein.

Now referring toFIG. 4G, the partial perspective view of the load center100ofFIG. 4Fis shown having two multi-phase circuit breakers180a,bcoupled thereto. Each of the circuit breakers180a,bincludes a first electrical connector182a, a second electrical connector182b, and a third electrical connector182c. The electrical connectors182a,b,cof each circuit breaker180a,bcorrespond with respective stabs for receiving respective phases of electricity. For example, the first electrical connector182aof the first circuit breakers180acorresponds with the second stab140a2of the first set of stabs140ato receive the first phase of electricity; the second electrical connector182bof the first circuit breakers180acorresponds with the second stab140b2of the second set of stabs140bto receive the second phase of electricity; and the third electrical connector182cof the first circuit breakers180acorresponds with the second stab140c2of the third set of stabs140cto receive the third phase of electricity. The first, the second, and the third electrical connectors182a,b,care positioned to be fixedly connected with the corresponding stabs via, for example, a screw.

The first, the second, and the third electrical connectors182a,b,ccan be configured to snap-on corresponding stabs such that each of the first, the second, and the third electrical connectors182a,b,cis physically and electrically connected to a respective stab.

It is contemplated that bidirectional heat dissipation, as described herein, allows for a reduction in a size or thickness of the pairs of busbars120as compared with prior art load centers that have stabs with unidirectional heat dissipation that are physically and/or electrically coupled with only one busbar for each phase of electricity being distributed in the load center. A reduction in a thickness of the busbars results in a reduction of copper needed to produce a load center, such as the load center100. It is contemplated that bidirectional heat dissipation, as described herein, also provides load centers that have an increased efficiency as compared with prior art load centers that have stabs with unidirectional heat dissipation that are physically and/or electrically coupled with only one busbar for each phase of electricity being distributed in the load center.

A load center having bidirectional heat dissipation, as described herein, can be made with 20 percent to 35 percent less copper compared to prior art load centers that have stabs with unidirectional heat dissipation that are physically and/or electrically coupled with only one busbar for each phase of electricity being distributed in a load center. A load center having bidirectional heat dissipation, as described herein, can be made with 25 percent to 30 percent less copper compared to prior art load centers that have stabs with unidirectional heat dissipation that are physically and/or electrically coupled with only one busbar for each phase of electricity being distributed in a load center.

For example, a three-phase, low-amperage (e.g., 250 Amps) prior art load center having three busbars that are each 0.187 inches thick by 1.5 inches wide and fifteen stabs that are 0.187 inches thick by 0.5 inches wide, requires a total of about 2.69 kilograms of copper to produce such a load center. However, a three-phase, low-amperage (e.g., 250 Amps) load center according to aspects of the present disclosure having three pairs of busbars, where each one of the busbars in each pair of busbars is 0.062 inches thick by 1.5 inches wide and fifteen stabs that are 0.125 inches thick by 0.5 inches wide, requires a total of about 1.97 kilograms of copper to produce such a load center. That is, a three-phase, low-amperage (e.g., 250 Amps) load center according to aspects of the present disclosure can be produced with about 0.72 kilograms (26.7%) less of copper than a comparable prior art load center have the same circuit breaker capacity.

A load center according to the aspects of the present disclosure having bidirectional heat dissipation, as described herein, can be made with less copper and be more efficient (e.g., lose less heat) compared to prior art load centers that have stabs with unidirectional heat dissipation that are physically and/or electrically coupled with only one busbar for each phase of electricity being distributed in a load center.

Instead of including the apertures141a,b,c, each one of the first, the second, and the third sets of stabs140a,b,ccan be configured to physically and electrically connect with one or more circuit breakers via a weld connection or a snap-fit connection. For a snap-fit connection, the circuit breakers include one or more jaw members configured to clamp or snap onto a portion of the circuit breaker connecting surface145a,b,c.