Patent Publication Number: US-7898787-B2

Title: Power panel with angled connectors

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 61/104,165, filed Oct. 9, 2008, the disclosure of which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to power distribution systems. In particular, the present disclosure relates to a power panel with angled connectors. 
     BACKGROUND 
     Electrical circuit panels such as power distribution panels typically include a number of different circuit elements such as fuse holders and fuses, circuit breakers, input and output connectors and alarm signal LED&#39;s. For safety and other reasons, the electrical circuits of power distribution panels are enclosed within a housing structure. Therefore, the circuit elements listed above have typically been inserted into holes that have been formed in the housing structure, usually on a front or back panel of the housing structure. 
     Existing electrical circuit panels include connection blocks arranged on one side of the panel, with circuit protection elements arranged on an opposite side of the panel. In such arrangements, the connection blocks are connected to the circuit protection elements by wiring passing through the panel. The connection blocks are typically positioned flush with the front or back panel of the circuit panel, and receive connections of load or supply wires to be mounted to posts of input and output connections. Additional alarm circuitry or other circuit elements are included within the circuit panel, according to the specific operation of the panel. 
     This panel design has a variety of disadvantages. For example, when servicing the panel, it can be difficult to reach the circuitry among the intertwined cabling passing through the panel and connecting the connection blocks to the circuit protection elements. Additionally, when connecting a number of power supply cables or load cables to the connection blocks, it can be difficult to route the cables to the panel due to the linear arrangement and the required density of the connection blocks. 
     For these and other reasons, improvements to existing electrical circuit panels are desirable. 
     SUMMARY 
     In accordance with the following disclosure, the above and other problems are solved by the following: 
     In a first aspect, a power distribution panel is disclosed. The power distribution panel includes a panel enclosure having a front face, a rear face, and an interior. The panel also includes a first plurality of connection blocks, each of the first plurality of connection blocks located on the rear face of the panel enclosure and oriented at a first common angle relative to the rear face of the panel enclosure. The panel further includes a second plurality of connection blocks, each of the second plurality of connection blocks located on the rear face of the panel enclosure and oriented at a second common angle relative to the rear face of the panel enclosure. The panel includes a plurality of circuit protection modules located on the front face of the panel enclosure, and a plurality of conductive bars passing through the enclosure and connecting the input connection blocks to one of the plurality of circuit protection modules, each of the conductive bars including a generally straight portion passing from the front of the panel to the rear of the panel. 
     In a second aspect, a power distribution panel is disclosed. The power distribution panel includes a panel enclosure having a front face, a rear face, and an interior. The power distribution panel also includes a first plurality of connection blocks, each of the first plurality of connection blocks located on the rear face of the panel enclosure and having input and output connections oriented at a first common angle relative to the rear face of the panel enclosure, and a second plurality of connection blocks, each of the second plurality of connection blocks located on the rear face of the panel enclosure and having input and output connections oriented at a second common angle relative to the rear face of the panel enclosure. The power distribution panel further includes a plurality of circuit protection modules located on the front face of the panel enclosure, each of the circuit protection modules associated with one of the first or second plurality of connection blocks. The power distribution panel includes a plurality of conductive bars passing through the enclosure and connecting the input connection blocks to the associated one of the plurality of circuit protection modules, each of the conductive bars including a straight portion passing from the front of the panel to the rear of the panel and connecting between one of the plurality of circuit protection modules and one of the first and second pluralities of connection blocks. 
     In a third aspect, a method of assembling a power distribution panel is disclosed. The method includes attaching a first plurality of connection blocks to a rear face of a panel enclosure at a first plurality of angled mounting locations having a first common angle relative to the rear face of the panel enclosure, and attaching a second plurality of connection blocks to the rear face of the panel enclosure at a first plurality of angled mounting locations having a second common angle relative to the rear face of the panel enclosure. The method further includes locating a plurality of circuit protection modules at the front face of the panel enclosure, and connecting the first and second pluralities of connection blocks to the plurality of circuit protection modules with a plurality of conductive bars passing through the panel enclosure, each of the conductive bars including a generally straight portion passing from the rear of the panel to the front of the panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top rear perspective view of a power distribution panel, according to a possible embodiment of the present disclosure; 
         FIG. 2  is a top front perspective view of the power distribution panel of  FIG. 1 , 
         FIG. 3  is a top plan view of the power distribution panel of  FIG. 1 ; 
         FIG. 4  is a top rear perspective view of the power distribution panel of  FIG. 1 , with a top cover removed; 
         FIG. 5  is a top front perspective view of the power distribution panel of  FIG. 1 , with the top cover removed; 
         FIG. 6  is a top cross-sectional view of the power distribution panel of  FIG. 1 ; 
         FIG. 7  is an exploded perspective view of the power distribution panel of  FIG. 1 ; 
         FIG. 8  is a rear perspective view of the power distribution panel of  FIG. 1 , illustrating mounting of a connection block and power distribution bus; and 
         FIG. 9  is a close-up perspective view of a connection block mounting location on a rear of the power distribution panel of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     In general, a power distribution panel is disclosed. The power distribution panel, as explained in further detail below, includes angled connection blocks to allow convenient connection of power and load wiring to the power distribution panel. Further, the power distribution panel has an internal power bus arrangement allowing straight through connection of conductive bars, rather than tangled wiring passing through the panel, and around existing circuitry within the panel. 
     Now referring to  FIGS. 1-9 , details regarding the structural features and assembly of a power panel  10  are discussed, in conjunction with a possible embodiment of the present disclosure. The panel  10  generally includes a panel enclosure  12  which has a front face  14 , a rear face  16 , and an interior area  18 . The panel enclosure  12  also includes a top side  20 , bottom side (not shown), and left and right sides  22 ,  24 , respectively. The panel enclosure  12  is preferably sized to fit into a telecommunications rack, and is generally made from metal and/or plastic components. The power panel  10 , in general, contains circuitry necessary for monitoring and regulating power distribution and circuit protection (not shown), which are typically mounted within the interior area  18  of the enclosure  12 . 
     Mounting brackets  13  connect to the left and right sides  22 ,  24  of the enclosure. The mounting brackets  13  are generally L-shaped and include a portion generally parallel with the front face  14  of the enclosure  12 . The mounting brackets  13  provide a structure for physical attachment of the panel  10  to a telecommunications rack (not shown). 
     Connection blocks  26  are located on the rear face  16  of the panel, and each includes input connection  28  and output connection  30 . Each of the connection blocks  26  are mounted at an angle with respect to the rear face  16  of the panel, and extend a common distance from the rear face of the panel. The angle of the connection blocks  26  is sufficient to allow access to a side of the connection block that is nearest one of the left and right sides, to allow connection of load or supply voltage cables to the connection blocks. In various embodiments the specific angle of the connection blocks will vary, depending upon the spacing and height of the connection blocks. 
     In the embodiment shown, a total of sixteen angled connection blocks are mounted to the rear face  16  of the panel  10 , with eight of the angled connection blocks located nearest to and angled toward the left side  22 , and eight of the angled connection blocks located nearest to and angled toward the right side  24 . By angled toward, it is intended that a side of the connection block is exposed toward that same side of the panel, to allow connection of a cable to the connection block, such that the cable extends toward and into the side of the connection block. 
     In the embodiment shown, the connection blocks  26  are generally rectangular, and form the angled arrangement by way of mounting to tabs  32  cut into the rear face  16  of the enclosure  12 . Each of the tabs  32 , best seen in  FIGS. 8-9 , is angled inwardly from the rear face  16 , to form a stepped connection location pattern. The tabs  32  include openings  34  allowing connection of the input and output connections to conductive bars  36  within the enclosure  12 . The tabs  32  also include screws  38  and screw receiving locations  40  that are used for mounting connection blocks  26 , which have complementary mounting features thereon (not shown). Other mounting arrangements for the connection blocks are possible as well. 
     In further embodiments, the connection blocks  26  themselves can include a formed, angled structure, and are mounted at mounting locations that are generally parallel to the overall linear rear face  16 . Other mounting arrangements for the connection blocks exist as well. 
     The input connections  28  and output connections  30  are preferably lug-type connections capable of receiving a screw-down connection of a cable. In the embodiment shown, the input connections  28  and output connections  30  are arranged on each connection block  26  such that the input connections reside above the output connections in a generally linear, symmetrical arrangement. In this embodiment, an equal number of input and output connections exist on each connection block. In further embodiments, the input and output connections can be arranged or numbered differently (e.g. by grouping the input connections on one connection block and output connections on a different connection block), while maintaining the angled arrangement of the connection blocks and resulting stepped cable connectivity. 
     Within the interior area  18  of the panel  10 , conductive bars  36  connect a portion of the input and output connections  28 ,  30  protruding through the rear of the connection blocks  26  to circuit protection modules  42  at an opposite side of the enclosure. The conductive bars  36  can be formed from bar stock or another conductive material, and include at least a portion that passes generally straight through the interior area  18  of the enclosure  12 . In the embodiment shown, a pair of conductive bars  36  connect between each conductive block  26  and circuit protection module  42 , with one conductive bar connecting from the input connections  28 , straight through the interior area  18  and to a first connection of the circuit protection module, and a second conductive bar connecting from a second connection of the same circuit protection module, straight through the interior area, and back to the output connections  30  of the same connection block. The conductive bars  36  can be bolted or otherwise fastened to the input and output connections  28 ,  30 , and allow removable insertion of a connector of the circuit protection modules  42 , as described further below. 
     Optionally each of the connection blocks  26  can be protected by a cover  44  (such as the example cover shown in  FIG. 1 ). The cover  44  protects users from contacting a circuit and inadvertently causing a short circuit. In the embodiment shown, the cover  44  blocks access to a front side of the connection block, while allowing wired connections to access the input connections  28  and output connections  30  of the connection blocks  26  from the side of the block. 
     In certain embodiments of the panel  10 , additional connection points can be included on the rear  16  of the enclosure  12  as well. For example, in the embodiment shown, a plurality of electrical pins  46  provide a communicative connection to circuitry within the panel to indicate alarm states of the panel (e.g. when a circuit breaker or fuse of one of the circuit protection modules  42  has been tripped, or if another electrical issue is detected within the panel. A plurality of grounding connections  48  can be located directly on the panel as well, and can provide connection point for a grounding connection  49  associated with the panel. 
     On the front face  14  of the panel  10 , a plurality of circuit protection modules  42  provide circuit protection (voltage and/or current regulation) for load devices connected to the panel at the connection blocks  26 . The circuit protection modules  42  are removably inserted into the enclosure  12 . In various embodiments, the circuit protection modules  42  can incorporate fuses or circuit breakers, as well as alarm circuitry used to notify a user or maintenance personnel of a tripped circuit event. The circuit protection modules  42  can be removably mounted within the enclosure  12 , including, for example, via a bullet-nosed connection  43  to a bus, such as can be formed by the conductive bars  36 . 
     Cover plates  50  can block the openings into which the circuit protection modules  42  are placed, in case no circuit protection module is in use for that circuit. The cover plates  50  can be punch-out type plates formed in the front side  14  of the enclosure  12 , or can be removable plates formed separately from the panel and attached thereto. 
     As seen most clearly in  FIGS. 7-8 , the circuit protection modules  42  are held within the interior area  18  of the enclosure  12  by a mounting frame  45 , and pass through a base plate  47  before connection to the conductive bars  36 . The mounting frame  45  guides insertion of the circuit protection modules  42  into the enclosure  12 , and support mounting of the base plate  47  within the enclosure as well. The base plate  47  is generally non-conductive, and includes openings for allowing connection of circuitry to auxiliary connections  41  on the circuit protection modules  42 , which can provide alarming and other features. The base plate  47  isolates the grounding connections  48  from the other components in the panel. 
     In the embodiment shown, the conductive bars  36  are affixed to the base plate  47 , and connect to the bullet-nosed connections  43  of the circuit protection modules  42  when such modules are inserted into the front face  14  of the panel. Other arrangements and connection types for the conductive bars can be possible as well, such that removable connection to the circuit protection modules is provided. 
     Also within the interior area  18 , a circuit panel  52  can be inserted from the front face  14  of the panel  10 , and can connect to a signal board  54 , upon which the signal pins  46  are mounted at the rear face  16  of the panel. In the embodiment shown, a card edge connector (not shown) on the circuit panel  52  connects to the signal board  54  for transmitting signals to and from the pins  46 . A circuit board  56  electrically connects to the auxiliary connections  41  of the circuit protection modules  42 . The circuit board  56  provides a route by which alarm states of each of the circuit protection modules  42  can be communicated within the rest of the panel  10  (and externally to the panel). In the embodiment shown, two such circuit boards are used, one for each of left and right sides of the panel and each connecting to four sets of auxiliary connections  41  on a corresponding sets of four circuit protection modules  42 . The circuit board  56  can then be arranged to connect to electrical pins, such as the pins  46 . Other circuitry arrangements are possible as well. 
     In an example of possible use of the panel  10 , service personnel can mount the panel to a telecommunications rack for use at a telecommunications distribution location. The service personnel route power source cables to the rear side of the panel  10 , from the left and right sides. The power source cables can be connected to each of the input connections  28  that are in an angled, stepped arrangement (due to the angled, stepped nature of the communication blocks  26 ) along the rear of the panel. Load cables can also be routed to the panel  10  from the left and right sides, respectively, and connected to each of the output connections  30  of the angled, stepped connection blocks  26 . The service personnel can then place a cover  44  over the connection block  26  to prevent accidental contact with one or both of the input and output connections  28 ,  30 . 
     As power is distributed to a load connected to the load cables, the circuit protection modules  42  or other circuitry within the panel  10  can detect a current or voltage that is above or below an expected value and take action accordingly. For example, an overcurrent event can blow a fuse or trip a circuit breaker that is included in a circuit protection module. The service personnel can replace the fuse or reset the circuit breaker, or can replace the entire circuit protection module, re-enabling power distribution via the connection block  26  and associated circuit protection module connected to that load. 
     In certain embodiments, the panel  10  is arranged to receive and distribute about 125 amps per circuit included in the panel. In further embodiments, additional or less current can be passed through the panel. In one example embodiment, 180 amps can be provided over all channels at 36 VDC and 135 amps can be provided over all channels at 48 VDC (to a total worst-case load current of 225 amps during surge events at 36 VDC). In these various embodiments, circuit breaker and/or fuse elements are selected to trigger a short circuit upon detection of an overcurrent event that is greater than a predetermined threshold. Other amperage and voltage ratings can be provided as well. 
     When the service personnel require access to the interior of the panel  10  (e.g. for access to the circuitry within the panel) a top cover can be removed from the panel, as shown in  FIGS. 4-6 . Due to the generally linear nature of the conductive bars  36 , the service personnel can easily access components within the panel, and can address circuit load and connectivity issues with respect to each module independently. Other advantages of the panel  10  exist as well, as previously described. 
     The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.