Patent Publication Number: US-6903289-B2

Title: Circuit breaker employing an illuminated operating handle

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is related to commonly assigned, concurrently filed U.S. patent application Ser. No. 10/650,343, filed Aug. 28, 2003, entitled “Circuit Breaker Employing Illuminating Indicators for Open and Closed Positions”. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates generally to circuit breakers and, more particularly, to circuit breakers including an operating mechanism and an operating handle. 
   2. Background Information 
   Circuit breakers are disclosed, for example, in U.S. Pat. Nos. 3,329,913; 3,955,162; 4,151,386; 4,267,539; 4,926,148; and 4,963,847. 
   Hydraulic and electromagnetic circuit breakers typically comprise a movable contact, which is mounted on a movable arm, and a fixed or stationary contact. An operating handle is coupled to the movable arm via a linkage mechanism, part of which comprises a collapsible toggle assembly. The movable and stationary contacts are operated between contacts “open” and contacts “closed” positions by pivoting the operating handle. The circuit breaker further comprises a hydraulic or electromagnetic device which, in response to one or more predetermined electrical conditions, collapses the toggle assembly to a broken state, in order to trip “open” the separable movable and stationary contacts. Typically, the operating handle assumes one of two or three positions (e.g., “on”, “off” and “zipped”) corresponding to the contacts “closed” position, contacts “open” position, and contacts tripped “open” position. 
   Users who apply circuit breakers in relatively dark enclosures or other relatively dark environments desire a relatively quicker and more efficient mechanism than, for example, employing fixed or portable enclosure lighting for identifying when a circuit breaker has been turned off or tripped Otherwise, there is a “guessing game” of whether a circuit breaker is in the “on” position versus the “off” or tripped “off” position(s). 
   Accordingly, there is room for improvement in circuit breakers. 
   SUMMARY OF THE INVENTION 
   These needs and others are met by the present invention, which provides two illuminable indicators to indicate: (1) the “on” position (contacts “closed”); and (2) the “off” or tripped “off” positions (contacts “open” or contacts tripped “open” positions). Those indicators, in turn, are employed to illuminate the circuit breaker operating handle. Accordingly, this gives users, such as maintenance personnel, an instant indication of the circuit breaker status without having to employ, for example, fixed or portable enclosure lighting. Therefore, this permits the user to immediately locate the interrupted or otherwise opened circuit, and to reset or close the appropriate circuit breaker. 
   In accordance with the invention, a circuit breaker comprises: a housing including an opening; separable contacts within the housing; an operating mechanism for opening and closing the separable contacts, the operating mechanism including an operating handle having a portion protruding through the opening of the housing; means for providing a first output when the separable contacts are open and a second output when the separable contacts are closed; a first indicator cooperating with the first output of the means for providing, the first indicator being proximate the operating handle and being illuminated when the separable contacts are open; and a second indicator cooperating with the second output of the means for providing, the second indicator being proximate the operating handle and being illuminated when the separable contacts are closed, wherein one of the first and second indicators illuminates the operating handle. 
   The means for providing may include an auxiliary switch cooperating with the operating mechanism, the auxiliary switch having the first output and the second output. 
   The first indicator may be a first LED, and the second indicator may be a second LED. 
   The opening of the housing may include a first end and a second end. The operating handle may include a first position and a second position. The portion of the operating handle may include a first side proximate the first end of the opening in the first position and a second side proximate the second end of the opening in the second position. The first indicator may be disposed proximate the first end of the opening and proximate the first side of the operating handle in the first position thereof. The second indicator may be disposed proximate the second end of the opening and proximate the second side of the operating handle in the second position thereof. 
   The means for providing may include an auxiliary switch having an operating member cooperating with the operating mechanism, a common terminal, a normally closed terminal providing the first output and a normally open terminal providing the second output. 
   The first indicator may be a first LED including a first cathode and a first anode, and the second indicator may be a second LED including a second cathode and a second anode, which is electrically connected to the first anode of the first LED. 
   The opening of the housing may be a first opening. The housing may be a case including a second opening and a third opening. The first indicator may be a first LED, which protrudes through the second opening of the case. The second indicator may be a second LED, which protrudes through the third opening of the case. The first opening of the housing may include a first end and a second end. The operating handle may include a first position and a second position The portion of the operating handle may include a first side proximate the first end of the first opening in the first position and a second side proximate the second end of the first opening in the second position. The first LED may be disposed proximate the first end of the first opening and proximate the fist side of the operating handle in the first position thereof. The second LED may be disposed proximate the second end of the first opening and proximate the second side of the operating handle in the second position thereof. 
   The operating handle may be generally transparent and may include a first recess receiving a portion of the first LED in the first position and may include a second recess receiving a portion of the second LED in the second position. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which: 
       FIG. 1  is a vertical elevation view of a circuit breaker incorporating the present invention, with one-half case being removed to show the general internal arrangement and to illustrate the separable contacts in the closed position. 
       FIG. 2  is a vertical elevation view, which is similar to  FIG. 1 , except with the separable contacts in the open position. 
       FIG. 3  is an isometric view of the operating handle of FIG.  1 . 
       FIG. 4  is a schematic diagram showing the auxiliary switch, the LEDs, the printed circuit board electrical connections and the resistor of FIG.  1 . 
       FIG. 5  is a plan view of the circuit side of the printed circuit board of FIG.  1 . 
       FIG. 6  is a plan view of the component side of the printed circuit board of FIG.  1 . 
       FIG. 7  is an isometric view showing the operating handle in the open position and one of the LEDs of FIG.  1 . 
       FIG. 8  is an isometric view showing the operating handle in the closed position and one of the LEDs of FIG.  1 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring to  FIGS. 1 and 2 , the invention will be described as applied to a circuit breaker  10  for use in direct current (DC) telecommunication systems (e.g., 60 VDC; 65 VDC; 80 VDC). It will become evident that the invention is applicable to other types of circuit breakers including those used in alternating current (AC) systems operating at various frequencies; to relatively smaller or larger circuit breakers, such as subminiature or miniature circuit breakers; and to a wide range of circuit breaker applications, such as, for example, residential, commercial, industrial, aerospace, and automotive. As further non-limiting examples, both AC (e.g., 110, 120, 220, 240, 480-600 VAC) operation at a wide range of frequencies (e.g., 50, 60, 120, 400 Hz) and DC operation (e.g., 42, 60 VDC) are possible. 
   The circuit breaker  10  is generally similar to ones disclosed in U.S. Pat. Nos. 3,955,162 and 4,926,148, for example, which are hereby incorporated by reference herein. The circuit breaker  10  includes an insulating housing  11  formed by abutting half-cases, such as  12  (the other half-case is not shown), an operating handle  22 , and terminals  34  and  36  for connecting the circuit breaker  10  to a load (not shown). The breaker operating mechanism, generally designated  14 , includes a frame  16  mounted on the housing  11  and various linkages rotatably supported thereon. An actuatable member  18  is moved by an internal actuator  20  attached to the operating handle  22 , wherein it is rotatably supported relative to the housing  11 . The operating handle  22  also has an external portion  19  protruding through an opening  23  of the housing  11 . At the other end of the housing  11  is a movable contact support  24  carrying a movable breaker contact  26  pivotally supported to rotate about a pin  28  on the frame  16 . The movable contact support  24  is joined to an actuator linkage mechanism  29  by a pin  30 , which allows the movable contact support  24  to be moved down (with respect to FIG.  2 ), in order that the movable breaker contact  26  closes against a fixed breaker contact  32  as shown in FIG.  1 . The fixed contact  32  is supported on the housing half-case  12  and is electrically connected to the external terminal  34 . As is discussed below, the movable contact  26  is electrically connected through a conductive circuit to the other external terminal  36 . These external terminals  34 , 36  are the mechanism by which the breaker  10  is electrically connected into a protected circuit (not shown). 
   The housing  11  supports a switch receptacle  38 . The half-case  12  is molded integrally with one half of the auxiliary receptacle  38  of the same resinous material. Similarly, the other half of the receptacle (not shown) is molded integrally with the other half-case (not shown). The half-cases mate to form the completed receptacle  38  when the breaker half-cases are assembled. The receptacle  38  is provided with recesses, such as  40 , preferably conforming to the shape and size of an auxiliary switch  42 . 
   The auxiliary switch  42  includes an operating member, such as a spring-loaded switch actuator, such as plunger  44 . A spring (not shown) urges the plunger  44  into an extended position as shown in  FIG. 2 , representing one condition of the auxiliary switch  42 , which corresponds to the open position of the separable contacts  26 , 32 . When depressed inwardly against the loading of its internal spring, the plunger  44  produces the other condition of the auxiliary switch  42 , which corresponds to the closed position of the separable contacts  26 , 32  of FIG.  1 . Between the plunger  44  and the movable contact support  24  of the operating mechanism  14 , and more specifically a surface  24   a  thereof, is a pivotally mounted auxiliary switch actuator member  46 . The auxiliary switch actuator member  46  is designed to be moved into the plunger  44 , in order to change the auxiliary switch condition. In this embodiment, the spring of the plunger  44  will return such plunger and the actuator member  46  to its rest position of  FIG. 2  when the movement of the operating mechanism  14  permits. 
   Pivotally connected to the handle  22  is the linkage  29 . The movable contact support  24  is pivotally connected to the linkage  29 . The handle  22 , the linkage  29  and the movable contact support  24 , together with an electromagnetic tripping device or sensing element  87 , jointly comprise the operating mechanism  14  of the circuit breaker  10 . 
   The linkage  29 , which includes a first link  29   a  and a second link  29   b , is pivotally connected at its lower (with respect to  FIGS. 1 and 2 ) end to the movable contact support  24  and at its upper (with respect to  FIGS. 1 and 2 ) end to the handle  22 . 
   For locking the linkage  29  in the overcenter position during automatic resetting, the linkage  29  includes a latch mechanism comprising a spring biased latch  56  carried by the second link  29   b . The latch  56  is tripped by a pivotal armature  60  having three legs, namely, a first or unlatching leg  62 , a second or attractable leg  64  and a third or substantially balancing leg (not shown). The unlatching leg  62  engages (as shown in phantom line drawing in  FIG. 1 ) the latch  56  and turns it (counter-clockwise with respect to  FIGS. 1 and 2 ) to unlatch the linkage  29 , thereby allowing the linkage  29  to collapse under the bias of the opening spring  65  ( FIG. 2 ) when the attractable leg  64  is pivoted sufficiently toward the pole piece  70  of an electromagnet  72  (upon predetermined overload) to bring the unlatching leg  62  into engagement with the latch  56 . Further, the armature  60  pivots about a pin  61  carried by the frame  16 . 
   The electromagnet  72  comprises a solenoid coil  74  about a tube  76 , the latter projecting through a first leg  78  of the frame  16 . The second frame leg  79  extends longitudinally along the coil  74 , as shown. The tube  76  is of non-magnetic material and houses a movable core (not shown) of magnetizable material biased by a spring (not shown) disposed toward the lower (with respect to  FIGS. 1 and 2 ) end of the tube  76 . The moveable core is retarded in its upward (with respect to  FIGS. 1 and 2 ) movement by a liquid, preferably a silicone oil, within the tube  76  to provide a time delay below certain overload currents before tripping of the circuit breaker  10  takes place. The coil  74  has one end connected to the movable contact support  24  by a flexible conductor  84  and the other end connected by a conductor  86  to the terminal  36 . Thus, the electromagnetic tripping device or sensing element  87  is formed by the coil  74 , the tube  76 , the movable core within the tube  76 , and the armature  60  for tripping the circuit breaker  10  after a time delay period at certain overloads or substantially instantaneously at higher overloads. 
     FIGS. 1 and 2  show the closed and open positions, respectively, of the operating mechanism  14 , the operating handle  22  and the separable contacts  26 , 32 . In the present circuit breaker  10 , the tripped open position of the operating handle  22  is the same as the open position thereof. Alternatively, the invention is applicable to a circuit breaker (not shown) in which in a third, or tripped open position, the operating handle thereof is intermediate the on and off positions of  FIGS. 1 and 2 . Regardless, for the tripped open position, the linkage  29  is broken (not shown) by operation of the latch  56  and the electromagnetic tripping device or sensing element  87 . 
   In accordance with the present invention, as shown in  FIGS. 1 ,  2  and  4 , a circuit  100  ( FIG. 4 ) includes the auxiliary switch  42  and a printed circuit board (PCB)  102  (as best shown in  FIGS. 5 and 6 ) having a resistor  104 . The circuit  100  provides a first output  106  when the separable contacts  26 , 32  are open ( FIG. 2 ) (or tripped open) and a second output  108  when such separable contacts are closed (FIG.  1 ). A first indicator (e.g., an LED  110  having a first color, such as green) cooperates with the first output  106 , is proximate the operating handle  22  and is illuminated when the separable contacts  26 , 32  are open. A second indicator (e.g., an LED  112  having a second color, such as red) cooperates with the second output  108 , is proximate the operating handle  22  and is illuminated when the separable contacts  26 , 32  are closed. One of the first and second LEDs  110 , 112  illuminates the operating handle  22  (as best shown in FIG.  3 ). The printed circuit board  102  is suitably conformally coated with a suitable insulator, in order to electrically insulate the conductive traces thereon from internal conductive structures of the circuit breaker  10 . Also, a suitable insulator (e.g., RTV) is disposed on any other exposed conductive surfaces (e.g., solder connections; resistor leads). 
   Continuing to refer to  FIG. 4 , the auxiliary switch  42  includes a common terminal  114 , a normally closed (NC) terminal  116  providing the first output  106  and a normally open (NO) terminal  118  providing the second output  108 . The common terminal  114  of the auxiliary switch  42  is adapted to receive a common  120  from a power source, such as a power supply  122  (shown in phantom line drawing), external to the circuit breaker  10  of  FIGS. 1 and 2 . In addition to the auxiliary switch common terminal  114 , the first and second LEDs  110 , 112  include respective terminals, such as anode leads  124 , 126 , which are adapted to be energized through the PCB  102  and the resistor  104  from the external power supply  122 . As was discussed above in connection with  FIGS. 1 and 2 , the actuator member  46  engages and actuates the auxiliary switch plunger  44  in the closed or “on” position of the separable contacts  26 , 32  and is typically disengaged from such plunger in the open or “off” or tripped “off” position of such separable contacts. 
   As shown in  FIGS. 1 ,  2  and  7 , proximate the ends  128 , 130  of the operating handle opening  23  of the housing  11  are openings  132 , 134  (e.g., 3 mm) for the respective LEDs  110 , 112 , which protrude through those respective openings. 
   As shown by  FIGS. 3 ,  7  and  8 , the operating handle  22 , which is preferably generally transparent, includes a first recess  136  receiving a portion of the first LED  110  in the open position of the operating handle  22  ( FIGS. 2 and 7 ) and includes a second recess  138  receiving a portion of the second LED  112  in the closed position of the operating handle  22  (FIGS.  1  and  8 ). 
   Alternatively, in the event that a circuit breaker (not shown) employs an operating handle with an intermediate tripped open position, in that position, the first LED  110  would be set apart from, but would still generally illuminate the first recess  136  of the operating handle  22 . 
     FIG. 4  shows the auxiliary switch  42 , the LEDs  110 , 112  and the PCB  102 , which electrically connects together the LED anode leads  124 , 126 . The leads  124 , 125  of the LED  110  and the leads  126 , 127  of the LED  112  are directly electrically connected (or indirectly electrically connected through suitable conductors (not shown)) to plated-through component openings  140 , 142  and  144 , 146 , respectively, of the PCB  102  (FIGS.  5  and  6 ). In turn, the PCB  102  electrically connects the component opening  142  and, thus, the cathode lead  125  of LED  110  to a plated-through component opening  148  by conductive trace  149 , and electrically connects the component opening  146  and, thus, the cathode lead  127  of LED  112  to a plated-through component opening  150  by conductive trace  151 . Also, two conductive traces  152 , 153  electrically connect the component openings  140 , 144  and, thus, the common LED anode leads  124 , 126  to a plated-through component opening  154  for the resistor  104 . Another component opening  156  for the resistor  104  is electrically connected by a conductive trace  157  to a plated-through component opening  158 . The component side ( FIG. 6 ) of the printed circuit board  102  and the traces thereon are a mirror image of the circuit side (FIG.  5 ), except that the resistor  104 , of course, is hidden from view in FIG.  5 . 
   A first conductor  160  from the component opening  148  is electrically connected to the switch NC terminal  116 . A second conductor  162  from the component opening  150  is electrically connected to the switch NO terminal  118 . The switch common terminal  114  is electrically interconnected by a third conductor  164  with the common  120  of the power source  122 . The component opening  158  is electrically interconnected by a fourth conductor  166  with a voltage  168  of the power source  122 . Preferably, the conductors  160 ,  162 ,  164 ,  166  are electrically insulated. Alternatively, the conductors  164 , 166  may include suitable terminations (not shown) for suitable electrical connection to the external power source  122 . 
   In this manner, the LED anode leads  124 , 126  are electrically connected by the printed circuit board traces  152 , 153  to the resistor  104 , which is electrically energized by the power supply voltage  168  through the conductive trace  157 , the component opening  158  and the conductor  166 . The cathode lead  125  of the first LED  110  is electrically connected through the PCB  102  by the trace  149 , the component opening  148  and the conductor  160  to the switch NC terminal  116 . The cathode lead  127  of the second LED  112  is electrically connected through the PCB  102  by the trace  151 , the component opening  150  and the conductor  162  to the switch NO terminal  118 . 
     FIG. 7  shows the illuminated operating handle  22  in the open position along with the second LED  112 , which is not illuminated. In this position, the first LED  110  ( FIG. 8 ) is illuminated and engages the first operating handle recess  136  (as best shown in FIG.  3 ). Conversely,  FIG. 8  shows the illuminated operating handle  22  in the closed position along with the first LED  110 , which is not illuminated. In this position, the second LED  112  ( FIG. 7 ) is illuminated and engages the second operating handle recess  138  (as best shown in FIG.  3 ). 
   The exterior portion  19  of the operating handle  22  of  FIG. 3  includes a first side  173  proximate the first end  128  of the housing opening  23  in the open position, and a second side  175  proximate the second end  130  of that opening in the closed position. The first LED  110  (as shown in  FIG. 8 ) is disposed proximate (in  FIG. 7 ) the first end  128  of the opening  23  and proximate the operating handle first side  173  in the open position. The second LED  112  (as shown in  FIG. 7 ) is disposed proximate (in  FIG. 8 ) the second end  130  of the opening  23  and proximate the operating handle second side  175  in the closed position. In this manner, in either of those positions, one of the LEDs  110 , 112  is illuminated and engages the corresponding one of the recesses  136 , 138 , respectively, and thus, illuminates the operating handle  22 . 
   The two individual LEDs  110 , 112  are located on opposite sides of the clear operating handle  22  (e.g., made of Lexan® polycarbonate). The auxiliary switch plunger  44  toggles the auxiliary switch  42 , which provides the two outputs  106 , 108  to the respective LEDs  110 , 112 . The first green LED  110  illuminates when the circuit breaker  10  is “tripped” or “off”, and the second red LED  112  illuminates when the circuit breaker  10  is “on”. As the circuit breaker  10  is toggled between “off” (or the tripped “off”) and the “on” positions, the LEDs  110 , 112  are toggled back and forth between the green light and the red light. 
   Alternatively, the operating handle  22  may be opaque (not shown) and two indicators (not shown) may be employed to illuminate corresponding exterior portions of such operating handle. 
   Although individual LED indicators  110 , 112  are disclosed, the invention is applicable to any suitable indicator(s), which may be suitably illuminated to show the open and closed positions of separable contacts, such as  26 , 32 , and, in turn, to illuminate a circuit breaker operating handle. For example, any suitable illuminable indicator(s) and combinations thereof may be employed (e.g., a dual indicator, two individual indicators; lamp(s), light(s); any suitable illuminating device(s)). 
   Alternatively, a different auxiliary switch (not shown) may be employed to output to the LED indicator  110  when the separable contacts  26 , 32  are tripped open, and to output to the LED indicator  112  when the separable contacts are not tripped open (e.g., open or closed) with the linkage  29  being unbroken. 
   In the exemplary embodiment, the first indicator  110  has a first color (e.g., green; any suitable color), and the second indicator  112  has a second different color (e.g., red; any suitable color). It will be appreciated that these colors may be swapped or that a wide range of suitable colors may be employed. Alternatively, one of the indicators  110 , 112  may employ a suitable color, and the other one of the indicators  110 , 112  may employ the same suitable color, which is illuminated with a suitable on/off modulation by a suitable circuit (not shown). Alternatively, a single indicator (not shown) may be employed which is illuminated in a suitable color for one of the “on” and “off” positions, and is illuminated in the same suitable color with a suitable on/off modulation by a suitable circuit (not shown) for the other one of the “on” and “off” positions. Alternatively, a third indicator may be employed for the tripped “off” position. 
   Although a circuit  100  including an auxiliary switch  42  providing the outputs  106 , 108  is disclosed, any suitable circuit and/or mechanism may be provided in order to provide outputs corresponding to the open and closed states of separable contacts. 
   Although an external power source  122  is shown, the invention is applicable to circuit breakers employing a suitable internal power source (not shown). 
   Although the resistor  104  is employed between the common LED anodes  124 , 126  and the power supply voltage  168 , the invention is applicable to circuits which employ a resistor between common LED cathodes and the power supply common  120 . 
   Although a single pole circuit breaker  10  is disclosed, the invention is applicable to circuit breakers and other electrical switching devices having any count of poles and with or without a suitable trip mechanism (e.g., hydraulic; electromagnetic; magnetic; thermal). 
   While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the fill breadth of the claims appended and any and all equivalents thereof.