Plug-on neutral connector for use with a fault circuit interrupt circuit breaker

A plug-on neutral connector includes a neutral terminal plug arranged to be inserted into a neutral terminal of a circuit breaker, a conductive fastener, including a pass-through, electrically coupled to the neutral terminal plug and arranged to be fastened on a neutral bus bar of a load center, and a housing disposed over at least a portion of the conductive fastener.

BACKGROUND

The field of the disclosure relates generally to plug-on neutral connectors for use with a fault circuit interrupt circuit breaker, such as a ground fault circuit interrupt (GFCI) circuit breaker and/or an arc fault circuit interrupt (AFCI) circuit breaker, and more particularly to a plug-on neutral connector that includes a conductive fastener having a plurality of flexible conductive legs adapted to cooperatively engage a neutral bus bar of a load center.

AFCI and GFCI circuit breakers are well known and have recently made their way into more mainstream use (e.g., mainstream residential use). Traditionally, AFCI and GFCI circuit breakers have included a separate electrical connection (also referred to as a “pigtail” connection). Specifically, the pigtail connection may function to connect the AFCI or GFCI circuit breaker to a neutral bus bar of an electrical distribution center (or load center) that houses the AFCI or GFCI circuit breaker. Other known AFCI and/or GFCI circuit breakers have included various plug-on neutral connectors, which may be substituted for a pigtail connection and which may directly engage a neutral bus bar within a load center.

Drawbacks associated with common AFCI and/or GFCI circuit breakers may include cluttered load centers (e.g., in the case of circuit breakers utilizing pigtails), overlong or scrimped plug-on neutral connectors, frail plug-on neutral connectors susceptible to damage during circuit breaker installation and replacement, and/or plug-on neutral connectors not configured for interoperation with a variety of circuit breaker makes and models. Thus, a sturdy, adjustable length, plug-on neutral connector capable of robust interoperation with a variety of AFCI and/or GFCI circuit breakers is desirable.

BRIEF DESCRIPTION

In one aspect, a plug-on neutral connector is provided. The plug-on neutral connector includes a neutral terminal plug arranged to be inserted into a neutral terminal of a circuit breaker, a conductive fastener, including a pass-through, electrically coupled to the neutral terminal plug and arranged to be fastened on a neutral bus bar of a load center, and a housing disposed over at least a portion of the conductive fastener.

In another aspect, a circuit breaker is provided. The circuit breaker includes a neutral terminal, and a plug-on neutral connector. The plug-on neutral connector includes a neutral terminal plug arranged to be inserted into a neutral terminal of a circuit breaker, a conductive fastener, including a pass-through, electrically coupled to the neutral terminal plug and arranged to be fastened on a neutral bus bar of a load center, and a housing disposed over at least a portion of the conductive fastener.

In yet another aspect, a circuit breaker is provided. The circuit breaker includes a case, and a plug-on neutral connector. The plug-on neutral connector includes a first neutral terminal plug electrically coupled to a first neutral terminal of the circuit breaker, and a second neutral terminal plug electrically coupled to a second neutral terminal of the circuit breaker. The plug-on neutral connector also includes a conductive fastener, including a pass-through, electrically coupled to the first neutral terminal plug and arranged to be fastened on a neutral bus bar of a load center, and a housing disposed over at least a portion of the plug-on neutral connector and coupled to the case of the circuit breaker.

In yet another aspect, an electrical load center is provided. The electrical load center includes a neutral bus bar electrically connected to a power source, and including a neutral bus bar arranged to receive a neutral bus bar set screw. The electrical load center also includes a mounting rail disposed substantially in parallel with the neutral bus bar, a circuit breaker mounted on the mounting rail, and including a neutral terminal, and a plug-on neutral connector arranged to electrically connect the circuit breaker to the neutral bus bar. The plug-on neutral connector includes a neutral terminal plug arranged to be inserted into the neutral terminal of the circuit breaker, and a conductive fastener electrically coupled to the neutral terminal plug and arranged to be fastened on the neutral bus bar. The conductive fastener includes a first pass-through arranged to receive the neutral bus bar set screw. The plug-on neutral connector also includes a housing disposed over the conductive fastener. The housing includes a second pass-through disposed in alignment with the first pass-through and arranged to receive the neutral bus bar set screw.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate to a plug-on neutral connector arranged to be substituted within an electrical load center for a pigtail connection between an AFCI and/or GFCI circuit breaker and a neutral bus bar within the load center. The plug-on neutral connector includes a neutral terminal plug arranged for insertion into a neutral terminal of a circuit breaker and a conductive fastener extending from the neutral terminal plug and arranged to clip onto the neutral bus bar. In addition, in at least some embodiments, a length of the plug-on neutral connector is adjustable for use with a plurality of load center geometries.

FIG. 1is a front view of an exemplary electrical load center100. In the exemplary embodiment, load center100may include a first mounting rail104configured to receive a first plurality of circuit breakers, such as circuit breaker106, which may be organized along a first row108. Load center100may also include a second mounting rail110configured to receive a second plurality of circuit breakers, such as circuit breaker112, which may be organized along a second row114. To this end, first mounting rail104and second mounting rail110are elongated structural members and extend substantially parallel to a respective neutral bus bar (as described below). Accordingly, and as shown, circuit breaker106may be mounted on and supported by first mounting rail104, and circuit breaker112may be mounted on and supported by second mounting rail110. First mounting rail104and second mounting rail110may include any suitable electrically conductive material and may be configured to conduct electrical current.

Load center100may also include a first neutral bus bar116and a second neutral bus bar118. As used herein, first neutral bus bar116and second neutral bus bar118may include any suitable electrically conductive element, such as an elongated electrically conductive element. Moreover, in the exemplary embodiment, first neutral bus bar116and/or second neutral bus bar118may be electrically connected to a power source, such as a distribution transformer (not shown) configured to supply electrical power to load center100. Specifically, first neutral bus bar116and/or second neutral bus bar118may be electrically connected to a distribution transformer (such as through a neutral wire, as described below) to return electrical current flowing back to load center100from a load to the distribution transformer.

First neutral bus bar116may be spaced apart from first mounting rail104and disposed substantially parallel to first mounting rail104, and a first wiring gutter120may be defined between first neutral bus bar116and first mounting rail104. Likewise, second neutral bus bar118may be spaced apart from second mounting rail110and disposed substantially parallel to second mounting rail110, and a second wiring gutter122may be defined between second neutral bus bar118and second mounting rail110.

In the exemplary embodiment, first neutral bus bar116may be electrically coupled to a neutral wire124(e.g., to electrically couple first neutral bus bar116to a distribution transformer, as described above), and second neutral bus bar118may be electrically coupled to a ground wire126(which may extend, through a grounding element, to earth ground). However, in other embodiments, first neutral bus bar116may be electrically coupled to ground wire126, and second neutral bus bar118may be electrically coupled to neutral wire124. In other words, the orientation of first neutral bus bar116and second neutral bus bar118with respect to neutral wire124and ground wire126is not important, except, as described below, as it relates to the configuration of one or more circuit breakers106and/or112within load center100.

Circuit breaker106and circuit breaker112may include any suitable type of fault circuit interrupter circuit breaker. For example, circuit breaker106and circuit breaker112may include any combination of arc fault circuit interrupter (AFCI) circuit breakers and/or ground fault circuit interrupter (GFCI) circuit breakers. In addition, each of circuit breaker106and circuit breaker112may include a case, such as a molded plastic case. Further still, in some embodiments, one or more standard circuit breakers may be installed within load center100.

Circuit breaker106and circuit breaker112may be electrically coupled to first neutral bus bar116or second neutral bus bar118, depending upon the placement of a particular circuit breaker106or112within load center100. Specifically, a first plug-on neutral connector128may be coupled between circuit breaker106and first neutral bus bar116, and a second plug-on neutral connector130may be coupled between circuit breaker112and second neutral bus bar118. Application of one or more plug-on neutral connectors, such as first plug-on neutral128and/or second plug-on neutral connector130, may obviate the use of one or more pigtail connections between circuit breaker106and/or circuit breaker112and a respective neutral bus bar116or118. As described in greater detail below, a “plug-on neutral” connector, such as first plug-on neutral connector128and/or second plug-on neutral connector130may be configured to “plug on,” or connect to, a neutral bus bar, such as first neutral bus bar116or second neutral bus bar118. Thus, the terminology “plug-on neutral connector” may be used to describe a connector that couples to or engages on a neutral bus bar.

Load center100may include one or more other structures, such as one or more current carrying (or “hot” wires), such as hot wires132and134, one or more circuit breaker mounting brackets, and the like. However, these structures are not central to an understanding of load center100and are not described in additional detail herein.

FIG. 2is a perspective view of an exemplary plug-on neutral connector, such as second plug-on neutral connector130(as shown atFIG. 1). As shown, second plug-on neutral connector130may be electrically and mechanically coupled between a circuit breaker112and second neutral bus bar118. It will be appreciated that, although second plug-on neutral connector130is described below, the following description is equally applicable to any other plug-on neutral connector, such as, for example, first plug-on neutral connector128.

FIG. 3is a cutaway view of a portion of circuit breaker112coupled to plug-on neutral connector130, andFIG. 4is an exploded view of plug-on neutral connector130(shown atFIG. 2). With combined reference toFIG. 3andFIG. 4, circuit breaker112may include a first neutral terminal300that is arranged to receive a neutral terminal plug302of plug-on neutral connector130. In the exemplary embodiment, first neutral terminal300may include an aperture or a hole that is configured to receive neutral terminal plug302. Accordingly, neutral terminal plug302may include an elongated electrically conductive element, such as a flexible or elastic elongated electrically conductive element configured to slidably couple within first neutral terminal300. In addition, neutral terminal plug302may be secured within first neutral terminal300by any suitable means, such as, in one example, by way of a friction fit between neutral terminal plug302and first neutral terminal300.

To this end, and with specific attention toFIG. 4, neutral terminal plug302may terminate in any suitable connector type, such as, for example any connector capable of being plugged into or inserted within first neutral terminal300(e.g., a “plug-in” connector, such as aa banana plug). However, in other embodiments, neutral terminal plug302may include a plurality of concentrically arranged flexible conductive leaves.

In addition to neutral terminal plug302, plug-on neutral connector130may include a conductive fastener402arranged to engage on a neutral bus bar within load center100, such as, for example, second neutral bus bar118, such that conductive fastener402may be electrically and mechanically coupled to second neutral bus bar118. In the exemplary embodiment, conductive fastener402is mechanically and electrically coupled to neutral terminal plug302, such as by a flexible conductive element404(e.g., a wire), which may be coupled between neutral terminal plug302and conductive fastener402.

To couple flexible conductive element404between neutral terminal plug302and conductive fastener402, flexible conductive element404may be mechanically and electrically coupled to (or inserted within) an end406of a conductive receiving port408of conductive fastener402. In various embodiments, conductive receiving port408is a flexible or malleable sheet of material and/or a flexible or malleable hollow cylindrical element and may be crimped onto flexible conductive element404to secure flexible conductive element404within receiving port408, such that a secure electrical connection is formed between neutral terminal plug302and conductive fastener402.

In addition, in some embodiments, a length of conductive fastener402may be adjusted (e.g., increased and/or decreased), such that conductive fastener402is capable of being used within load centers of varying dimensions. Specifically, flexible conductive element404may be inserted to a desired distance within conductive receiving port408, such that a total length of conductive fastener402is adjustable for use with different load center geometries.

Conductive fastener402may, in addition, include a pass-through410, such as an aperture or a hole. Pass-through410may be shaped (e.g., circularly shaped) to receive or accommodate the passage of a neutral bus bar set screw (such as a set screw140), such that conductive fastener402may slide or snap over neutral bus bar set screw140without interfering with, or becoming caught on, set screw140.

In the exemplary embodiment, conductive fastener402may also include a plurality of flexible conductive legs, such as a first flexible conductive leg412and a second flexible conductive leg414. First flexible conductive leg412and second flexible conductive leg414may be substantially L-shaped and may extend from a surface415of conductive fastener402such that a gap416is defined between first flexible conductive leg412and second flexible conductive leg414.

In some embodiments, second plug-on neutral connector130may also include a c-shaped clip418. C-shaped clip418may include any suitable elastic material (e.g., metal, plastic, etc.) and may be engaged over and/or mechanically coupled to at least a portion of conductive fastener402to apply a pressure on flexible conductive legs412and414, such that flexible conductive legs412and414are maintained in contact with second neutral bus bar118during operation.

C-shaped clip418may, in addition, include a pass-through422, such as an aperture or a hole. Pass-through422may be shaped (e.g., circularly shaped) to receive or accommodate the passage of a neutral bus bar set screw (such as set screw140), such that conductive fastener402may slide or snap over neutral bus bar set screw140without interfering with, or becoming caught on, set screw140. To this end, pass-through422of c-shaped clip418may align with pass-through410of conductive fastener402, such that neutral bus bar set screw140is able to be inserted through or received in pass-through410and pass-through422without interference between second plug-on neutral connector130and set screw140of second neutral bus bar118.

In the exemplary embodiment, second plug-on neutral connector130may also include a housing424. Housing424may include any suitable electrically insulating material (e.g., plastic) and may be configured to fit over or mechanically couple on conductive fastener402. Thus, housing424may be used during installation to handle and manipulate (e.g., by an installation technician) second plug-on neutral connector130. Housing424may, in addition, include a pass-through426, such as an aperture or a hole. Pass-through426may align with pass through422of c-shaped clip418and pass-through410of conductive fastener, such that neutral bus bar set screw140is able to be inserted through or receive in pass-through426without interference between housing424and set screw140of second neutral bus bar118.

In operation, second plug-on neutral connector130may be coupled between circuit breaker112and second neutral bus bar118to make an electrical connection between circuit breaker112and second neutral bus bar118. More particularly, conductive fastener402may, via first flexible conductive leg412and second flexible conductive leg414, be coupled to (or snapped on) second neutral bus bar118, such that second plug-on neutral connector130is mechanically and electrically coupled to second neutral bus bar118. Likewise, neutral terminal plug302may be engaged with or inserted within first neutral terminal300of circuit breaker112to form a mechanical and electrical connection between circuit breaker112and second neutral bus bar118. In addition, neutral terminal set screw140may be inserted through pass-through426of housing, pass-through422of c-shaped clip418, and pass through410of conductive fastener402, such that neutral terminal screw140can be coupled on or screwed into second neutral bus bar118without interference from second plug-on neutral connector130. Finally, as will be appreciated, a neutral wire (not shown) running from an electrical load powered by load center100may be coupled to a second neutral terminal (not shown) of circuit breaker112.

As described above, although the foregoing description is provided with reference to circuit breaker112and second plug-on neutral connector130, it will be appreciated that the same description may apply to any other AFCI and/or GFCI circuit breaker mounted within load center100(e.g., circuit breaker106) in conjunction with a respective plug-on neutral connector (e.g., first plug-on neutral connector128).

FIG. 5is a perspective view of another exemplary plug-on neutral connector500. Plug-on neutral connector500is substantially similar to plug-on neutral connectors128and130(described above), with several exceptions. Accordingly, and as shown, plug-on neutral connector500may, like plug-on neutral connectors128and130, be mounted within load center100between an AFCI and/or GFCI circuit breaker502and a neutral bus bar504. In addition, like plug-on neutral connectors128and130, plug-on neutral connector500may include a housing506. However, unlike plug-on neutral connectors128and130, housing506of plug-on neutral connector500may be coupled to a case508of circuit breaker502.

In addition, housing506may include a first neutral terminal extension port510and a second neutral terminal extension port512. In the exemplary embodiment, first neutral terminal extension port510and second neutral terminal extension port512are holes or apertures formed in housing506. First neutral terminal extension port510may electrically couple to (and/or provide access to) a first neutral terminal (not shown) of circuit breaker502. Similarly, second neutral terminal extension port512may electrically couple to (and/or provide access to) a second neutral terminal (now shown) of circuit breaker502. Those of skill will appreciate that a first neutral terminal of circuit breaker502may be configured to couple circuit breaker502to neutral bus bar504, and a second neutral terminal may be configured to couple circuit breaker502to a neutral wire running from an electrical load into load center100. Thus, first neutral terminal extension port510and second neutral terminal extension port512may give access to a plurality of neutral terminals on circuit breaker502.

FIG. 6is a perspective view of an interior portion of plug-on neutral connector500(shown atFIG. 5). Like plug-on neutral connectors128and130, plug-on neutral connector500may include a first neutral terminal plug602(e.g., a conductive strip of metal) arranged to electrically and/or mechanically couple to a first neutral terminal of circuit breaker502(e.g., within first neutral terminal extension port510). However, plug-on neutral connector500may also include a second neutral terminal plug604(e.g., a conductive strip of metal) arranged to electrically and/or mechanically couple to a second neutral terminal of circuit breaker502(e.g., within second neutral terminal extension port512).

In the exemplary embodiment, first neutral terminal plug602may be coupled to a conductive fastener606, which may be substantially similar and/or identical to conductive fastener402. However, first neutral terminal plug602and second neutral terminal plug604may also include a first terminal block608and a second terminal block610, respectively. Both of first terminal block608and second terminal block may include an electrically conductive body of material tapped to receive a set screw. For example, first terminal block608may receive a first set screw612, and second terminal block610may receive a second set screw614. In addition, first terminal block608may be disposed within (and accessible from) first neutral terminal extension port510, and second terminal block610may be disposed within (and accessible from) second neutral terminal extension port512. In addition, and in the exemplary embodiment, housing506may include a first aperture514arranged to receive first set screw612and a second aperture516arranged to receive second set screw614. Thus, first aperture514and second aperture516may provide access, through housing506, to first set screw612and second set crew614, respectively.

In operation, plug-on neutral connector500may engage on neutral bus bar504substantially as described above with respect to second plug-on neutral connector130. Thus, a first neutral terminal of circuit breaker502may be electrically coupled to neutral through neutral bus bar504. Similarly, a neutral wire (not shown) running from an electrical load (not shown) powered by load center100may be tied to second terminal block610, such that the electrical load is coupled through second terminal block610to a second neutral terminal of circuit breaker502.

Embodiments of the plug-on neutral connector, as described above, thus facilitate substitution of a plug-on neutral connector for a pigtail connection between an AFCI and/or GFCI circuit breaker and a neutral bus bar within an electrical load center. The plug-on neutral connector includes a neutral terminal plug arranged for insertion into a neutral terminal of a circuit breaker and a conductive fastener extending from the neutral terminal plug and arranged to clip onto the neutral bus bar. In addition, in at least some embodiments, a length of the plug-on neutral connector is adjustable for use with a plurality of load center geometries.

Exemplary technical effects of the plug-on neutral connector described herein include, for example: (a) removal of a plurality of cumbersome pigtail connections from one or more wiring gutters of a load center; (b) implementation of one or more plug-on connectors in the load center, such that wiring clutter in the load center is reduced; (c) implementation of one or more plug-on connectors in the load center, such that the load center is maintained neatly and compactly; and (d) implementation of one or more sturdy, adjustable length, plug-on neutral connectors capable of robust interoperation with a variety of AFCI and/or GFCI circuit breakers.

Exemplary embodiments of a plug-on neutral connector and related components are described above in detail. The system is not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the configuration of components described herein may also be used in combination with other processes, and is not limited to practice with the systems and related methods as described herein. Rather, the exemplary embodiments can be implemented and utilized in connection with many applications where a plug-on neutral connector is desired.