Patent Publication Number: US-8536475-B2

Title: Integrated en-style auxiliary barrier connector

Description:
BACKGROUND 
     The present disclosure relates to circuit breakers including circuit breakers approved for use in aircraft systems. 
     Circuit breakers are common in electrical applications. Circuit breakers include devices and systems that detect a fault condition in a given electrical circuit, and then open or “break” the circuit when the fault condition is detected. Opening the circuit is typically executed by separating electrical contacts to interrupt the circuit and/or a corresponding flow of electricity. Circuit breakers can be used with high voltage or low voltage electrical systems, and can use a variety of mechanisms for interrupting a circuit. For example, mechanisms can include mechanical, thermal, magnetic, and even manual techniques to open a circuit. 
     SUMMARY 
     Various standards, specifications, and regulations exist for particular types of circuit breakers, or for particular uses of circuit breakers. For example, the aircraft industry has many regulations governing aircraft components and systems, and it is common for certain components to be approved prior to general commercial or military use. Approval of aircraft components can take as long as several years to more than a decade. Thus, a new circuit breaker mechanism can take a relatively long time to receive regulatory approval. Because of long approval wait times, it is often preferable to continue using components and devices that have already been approved for use in aircraft. This makes it challenging, however, to use approved circuit breakers for new aircraft systems, such as aircraft systems that differ from conventional specifications, differ by manufacturer or differ by country of origin. 
     Certain aircraft circuit breakers include a switch mounted on the aircraft circuit breaker. This switch functions as an auxiliary contact signal for monitoring circuit breaker operation. This switch is distinct from a corresponding circuit breaker mechanism, and can be a micro switch or miniature switch. In such an aircraft circuit breaker, power is connected to the terminals. When the circuit breaker is tripped, a lever arm (or other mechanism) that opens the circuit also hits the electrical switch. Actuating the switch can cause a light in a cockpit to turn off (or on) to indicate that power is down for a corresponding circuit. 
     The U.S. aircraft circuit breaker market conventionally uses male connectors for such micro switches. That is, the micro switch provides male connectors to which a monitoring system can be connected. The European market, however, primarily uses female connectors for these auxiliary switches on aircraft circuit breakers. Such female connectors typically have a spring connector that can lock onto an inserted male connector to help prevent an attached wire from becoming detached. Redesigning aircraft circuit breakers (circuit breaker mechanisms) to accommodate a micro switch that uses female connectors is undesirable because such new circuit breaker designs would require governmental regulatory approval, and getting such approval can take well over a decade to acquire. 
     Techniques disclosed herein include a conversion technique that converts an aircraft circuit breaker having male auxiliary connectors (micro switch connectors) to an aircraft circuit breaker having female auxiliary connectors, such as those conventionally used on European-made aircraft. Techniques include adding a barrier to a conventional aircraft circuit breaker approved for U.S. markets. This barrier is located relatively close to an existing micro switch and circuit breaker terminals, and includes female auxiliary connectors integrated with the barrier, as well as a flexible circuit (that can include a diode or resistor for current flow) that connects the male connectors with the female connectors such that the female connectors can still receive separate male connectors in the female receptacles. Such a technique converts conventional aircraft circuit breakers into a European-style breaker without requiring a full European rebuild and re-qualification. Embodiments can include single and multiple phase versions, and configurations for use with high and low amperage. 
     Additionally, although each of the different features, techniques, configurations, etc., herein may be discussed in different places of this disclosure, it is intended that each of the concepts can be executed independently of each other or in combination with each other. Accordingly, the one or more present inventions, embodiments, etc., as described herein can be embodied and viewed in many different ways. 
     Also, note that this preliminary discussion of embodiments herein does not specify every embodiment and/or incrementally novel aspect of the present disclosure or claimed invention(s). Instead, this brief description only presents general embodiments and corresponding points of novelty over conventional techniques. For additional details and/or possible perspectives (permutations) of the invention(s), the reader is directed to the Detailed Description section and corresponding figures of the present disclosure as further discussed below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments herein, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, with emphasis instead being placed upon illustrating the embodiments, principles, concepts, etc. 
         FIG. 1  is a perspective view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 2  is an exploded perspective view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 3A  is a top view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 3B  is a front view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 3C  is a side view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 4A  is a perspective view of an auxiliary barrier connector of an aircraft circuit breaker according to embodiments herein. 
         FIG. 4B  is a front view of an auxiliary barrier connector of an aircraft circuit breaker according to embodiments herein. 
         FIG. 4C  is a side view of an auxiliary barrier connector of an aircraft circuit breaker according to embodiments herein. 
         FIG. 4D  is a top view of an auxiliary barrier connector of an aircraft circuit breaker according to embodiments herein. 
         FIG. 5  is an exploded perspective view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 6A  is a front view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 6B  is a side view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 6C  is a top view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 6D  is a perspective view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 7  is an exploded perspective view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 8A  is a front view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 8B  is a side view of an aircraft circuit breaker according to embodiments herein. 
         FIG. 8C  is a top view of an aircraft circuit breaker according to embodiments herein. 
     
    
    
     DETAILED DESCRIPTION 
     Techniques disclosed herein include a conversion technique that converts an aircraft circuit breaker having male auxiliary connectors (micro switch connectors or leads) to an aircraft circuit breaker having female auxiliary connectors, such as those conventionally used on European-made aircraft. Techniques include adding a barrier to a conventional aircraft circuit breaker approved for U.S. markets. This barrier includes female auxiliary connectors integrated with the barrier, as well as a flexible circuit (that can include a diode or resistor for current flow) that connects the male connectors with the female connectors such that the female connectors can still receive separate male connectors in the female receptacles. Such a technique converts conventional aircraft circuit breakers into a European-style breaker without requiring a full European rebuild and re-qualification. Embodiments can include single and multiple phase versions, and configurations for use with high and low amperage. 
     In general, example embodiments can include a single-phase version, a three-phase version, and a version that handles up to 50 amps or more. The three-phase version can use the same internal mechanisms as the single-phase circuit breaker, but with three mechanisms ganged together. Another version locates a conversion barrier on the outside (instead of positioned between ganged circuit breakers) for applications of 50 amps and above to accommodate separate arc protection barriers that may be larger or designed for a larger wire size and current flow. Conversion techniques adapt certain aircraft circuit breakers without changing the configuration of terminals of the aircraft circuit breakers. Aircraft circuit breakers for up to 50 amps have two barriers with one barrier between each pair of terminals. Techniques can include embedding the female receptacles within one of these barriers. The auxiliary barrier can be molded to accommodate female spring connectors and provide/define the openings for female receptacles. 
     Now more specifically,  FIG. 1  is a perspective view that illustrates an example embodiment of an aircraft circuit breaker  100 . Aircraft circuit breaker  100  includes a housing that and has a front surface  102 , a rear surface  103 , a bottom surface  104 , a first side surface  106 , a second side surface  107 , and a top surface  108 , with each surface being generally rectangular. Accordingly, the aircraft circuit breaker  100  includes a housing that is generally rectangular or box-like is overall shape. Note that this rectangular shape is approximate and that embodiments can have rounded, beveled, or shaped joints. Also note that use of the terms top, bottom, rear, front, etc., is relative and not absolute in that such labels are used to distinguish surfaces relative to each other. For example, reset button  111  is positioned on the bottom surface  104 , but in actual installations, this surface may be oriented to appear as a side or top surface. 
     A first electrical terminal  114  and a second electrical terminal  115  protrude from the top surface  108 . These electrical terminals can use a screw connector, spring connector or any other connection mechanism to secure wires from a given circuit to be protected. The electrical terminals provide an electrical path into the aircraft circuit breaker housing. The aircraft circuit breaker  100  includes a circuit breaker mechanism enclosed within the housing. The circuit breaker mechanism electrically connects the first electrical terminal  114  to the second electrical terminal  115 , that is, the circuit breaker mechanism provides an electrical path between the electrical terminals. The circuit breaker mechanism is configured to interrupt electrical flow between the first electrical terminal and the second electrical terminal in response to detecting a fault condition. The circuit breaker mechanism can use any conventional interruption mechanism such as a mechanical or spring assembly. Certain embodiments include a circuit breaker mechanism approved by regulatory agencies, such as the Federal Aviation Administration (FAA), a United States government agency. 
     Referring now to the exploded view shown in  FIG. 2 , the aircraft circuit breaker  100  includes an electrical switch  120  located at the top surface  108  of the housing. The electrical switch  120  can protrude from the top surface, be integrated with the top surface, or otherwise be located at the top surface. The electrical switch  120  has male connectors  121  protruding from the electrical switch  120 . The electrical switch  120  has a switch mechanism that affects an electrical connection between the male connectors, that is, between a first and second male connector. Affecting this electrical connection means that the switch can either connect or disconnect an electrical path between the two connectors (open or close an electrical path or circuit. The electrical switch  120  is configured such that the switch mechanism is actuated in response to the circuit breaker mechanism interrupting electrical flow between the first electrical terminal  114  and the second electrical terminal  115 . Thus, the electrical switch can have components connected to the circuit breaker mechanism within the housing, or have components positioned to be triggered by mechanical action of the circuit breaker mechanism. 
     The aircraft circuit breaker  100  includes a barrier structure  130  attached to the housing. The barrier structure  130  is generally rectangular and elongated in shape, and has a length approximately equal to a length of the top surface  108 . The barrier structure  130  extends from a rear edge of the top surface  108  of the housing and is aligned approximately parallel with the rear surface  103  and perpendicular to the top surface  108 . An example of such an orientation is shown in  FIGS. 1 and 3C . The barrier structure  130  defines two female electrical connector receptacles  132 . Each defined female electrical connector receptacle  132  has a longitudinal axis approximately parallel with the rear surface  103 . The defined female electrical connector receptacles  132  have electrical contacts  133  disposed within each defined receptacle. Electrical contacts  133  can be embodied as spring clips that have a tab that can be pressed in by a male mushroom-shaped connector such that after a lip of the male connector passes the spring connector, the spring connector can rebound to lock the male connector in place. The male connector can be subsequently removed with a removal tool. 
     An electrical switch adaptation mechanism connects the male connectors  121  of the electrical switch  120  with the electrical contacts  133  of the defined female electrical connector receptacles  132  without obstructing the defined female electrical connector receptacles. In other words, the electrical switch adaptation mechanism can electrically couple the male connectors  121  to a side or bottom portion of the electrical contacts  133  of the defined female electrical connector receptacles  132 . 
     In one embodiment, this electrical switch adaptation mechanism includes a flexible circuit  125  that electrically connects the male connectors  121  of the electrical switch  120  with the electrical contacts  133  of the defined female electrical connector receptacles  132 . For example, the electrical contacts of the defined female electrical connector receptacles can protrude from a side surface of the barrier structure  130  and connect to the flexible circuit  125 . In alternative embodiments, the flexible circuit  125  includes a diode or resistor  126 . The electrical switch adaptation mechanism can include a cover  140  that environmentally covers the electrical switch  120 , flexible circuit  125 , and a portion of the electrical contacts  133  of the defined female electrical connector receptacles  132 . The flexible circuit can be constructed as a flexible circuit board that is embedded in between two layers of tape. This flexible circuit board can include wire leads to connect the male connectors to the female connectors. With the flexible circuit  125  being flexible, it can be folded onto itself or otherwise manipulated to fit within the cover  140 . 
       FIGS. 3A ,  3 B, and  3 C show the aircraft circuit breaker  100  of  FIG. 1  in top, front and side views respectively. Note that the cover  140  is shown in these views as covering the electrical switch adaptation mechanism. 
     The barrier structure  130  can include a first member  135  that defines a first portion of the defined female electrical connector receptacles, and a second member  136  that defines a remaining portion of the defined female electrical connector receptacles. For example, the first member  135  defines two semi-cylindrical spaces, while the second member  136  defines corresponding semi-cylindrical spaces such that when the second member  136  is combined with the first member  135 , the combination defines two approximately cylindrical openings. In some embodiments, the first and second members  135  and  136  can be riveted together. Such connection can hold and position the electrical contacts  133  of the defined female electrical connector receptacles. These electrical contacts  133  can be embodied as contact springs positioned within the defined female electrical connector receptacles  132 . The contact springs  133  can have a portion protruding from the second member  136  of the barrier structure  130  and connected to the electrical switch adaptation mechanism. Such protrusion is shown in  FIGS. 4A ,  4 B, and  4 C. In other embodiments, the longitudinal axes of the defined female electrical connector receptacles are angled relative to each other resulting in non-parallel longitudinal axes, as shown in  FIGS. 4A ,  4 B, and  4 D. 
     Referring now to  FIGS. 5-6 , an alternative embodiment is shown illustrating aircraft circuit breaker  500 . In general, aircraft circuit breaker  500  can provide a three-phase version of aircraft circuit breaker  100 . Aircraft circuit breaker  500  includes a housing that has a front surface  502 , a rear surface  503 , a bottom surface  504 , a first side surface  506 , a second side surface  507 , and a top surface  508 , with each surface being generally rectangular. 
     The aircraft circuit breaker  500  includes three pairs of electrical terminals  514 ,  515 , and  516  protruding from the top surface  508 . The aircraft circuit breaker  500  includes three circuit breaker mechanisms enclosed within the housing. Each circuit breaker mechanism electrically connects one pair of electrical terminals to each other. That is, each circuit breaker mechanism within the housing electrically connects a first terminal of a given pair with a second terminal of that given pair. Each circuit breaker mechanism is configured to interrupt electrical flow between a respective pair of electrical terminals in response to detecting a fault condition. The fault condition can be detected by any of the circuit breaker mechanisms, such that tripping one circuit breaker mechanism causes each circuit to be interrupted. 
     An electrical switch  520  located at the top surface  508  of the housing is positioned between one pair of the three pairs of electrical terminals. The electrical switch  520  has male connectors  521  protruding from the electrical switch  520 . The electrical switch  520  has a switch mechanism that affects an electrical connection between the male connectors. This is a circuit connection distinct from a circuit that the aircraft circuit breaker  500  protects. The electrical switch  520  is configured such that the switch mechanism is actuated in response to one of the circuit breaker mechanisms interrupting electrical flow between a respective pair of electrical terminals. 
     The aircraft circuit breaker  500  includes a first barrier structure  550  attached to the housing, the first barrier structure  550  being generally rectangular and elongated and having a length approximately equal to a length of the top surface  508 . The first barrier structure  550  extends from the top surface of the housing such as to provide a first physical barrier between a first pair of the electrical terminals  514  and a second pair of the electrical terminals  515 . A second barrier structure  530  is attached to the housing. The second barrier structure  530  is generally rectangular and elongated and has a length approximately equal to a length of the top surface  508 . The second barrier structure  530  extends from (away from) the top surface  508  of the housing such as to provide a second physical barrier between the second pair of the electrical terminals  515  and a third pair of the electrical terminals  516 . The second barrier structure  530  defines two female electrical connector receptacles  532 . Each defined female electrical connector receptacle has a longitudinal axis approximately parallel with the rear surface  503 . The defined female electrical connector receptacles  532  have electrical contacts  533 . The aircraft circuit breaker  500  includes an electrical switch adaptation mechanism that connects the male connectors  521  of the electrical switch  520  with the electrical contacts  533  of the defined female electrical connector receptacles  532  without obstructing the defined female electrical connector receptacles. 
     The electrical switch adaptation mechanism can include a flexible circuit  525  that electrically connects the male connectors of the electrical switch with the electrical contacts of the defined female electrical connector receptacles. This flexible circuit can optionally include a diode or resistor  526 . The electrical switch adaptation mechanism can include cover  540  that environmentally covers the electrical switch  520 , flexible circuit  525 , and at least a portion of the electrical contacts  533  of the defined female electrical connector receptacles. The second barrier structure can include a first member  535  that defines a first portion of the defined female electrical connector receptacles, and a second member  536  that defines a remaining portion of the defined female electrical connector receptacles. The electrical contacts of the defined female electrical connector receptacles can be embodied as contact springs positioned within the defined female electrical connector receptacles. The contact springs can protruding from the second member  536  of the barrier structure and be connected to the electrical switch adaptation mechanism, such as by soldering to the flexible circuit  525 . In one embodiment, longitudinal axes of the defined female electrical connector receptacles are angled relative to each other resulting in non-parallel longitudinal axes. 
     Referring now to  FIGS. 7 ,  8 A,  8 B, and  8 C, an alternative embodiment is shown illustrating aircraft circuit breaker  700 . In general, aircraft circuit breaker  700  can provide a three-phase version of aircraft circuit breaker  100  for higher amperage applications. 
     Aircraft circuit breaker  700  includes a housing that has a front surface  702 , a rear surface  703 , a bottom surface  704 , a first side surface  706 , a second side surface  707 , and a top surface  708 , with each surface being generally rectangular. Three pairs of electrical terminals ( 714 ,  715 ,  716 ) protruding from the top surface  708 . Three circuit breaker mechanisms enclosed within the housing. Each circuit breaker mechanism electrically connects one pair of electrical terminals to each other. Each circuit breaker mechanism is configured to interrupt electrical flow between a respective pair of electrical terminals in response to detecting a fault condition. 
     The aircraft circuit breaker  700  includes an electrical switch located at the top surface of the housing and positioned between one pair of the three pairs of electrical terminals. The electrical switch has male connectors protruding from the electrical switch. The electrical switch has a switch mechanism that affects an electrical connection between the male connectors. The electrical switch is configured such that the switch mechanism is actuated in response to one of the circuit breaker mechanisms interrupting electrical flow between a respective pair of electrical terminals. 
     A first barrier structure  750  is attached to the housing. The first barrier structure  750  is generally rectangular and elongated and has a length approximately equal to a length of the top surface. The first barrier structure  750  extends from the top surface of the housing such as to provide a first physical barrier between a first pair of the electrical terminals  714  and a second pair of the electrical terminals  715 . A second barrier structure  760  is attached to the housing. The second barrier structure  760  is generally rectangular and elongated and has a length approximately equal to a length of the top surface. The second barrier structure  760  extends from the top surface  708  of the housing such as to provide a second physical barrier between the second pair of the electrical terminals  715  and a third pair of the electrical terminals  716 . 
     The aircraft circuit breaker  700  includes a third barrier structure  730  attached to the housing. The third barrier structure  730  is generally rectangular and elongated and has a length approximately equal to a length of the top surface. The third barrier structure extends from a rear edge of the top surface of the housing and is aligned approximately parallel with the rear surface  703  and perpendicular to the top surface  708 . The third barrier structure defines two female electrical connector receptacles  732 . Each defined female electrical connector receptacle  732  has a longitudinal axis approximately parallel with the rear surface. The defined female electrical connector receptacles  732  have electrical contacts. The aircraft circuit breaker  700  includes an electrical switch adaptation mechanism that connects the male connectors of the electrical switch with the electrical contacts of the defined female electrical connector receptacles without obstructing the defined female electrical connector receptacles. The electrical switch adaptation mechanism can include a flexible circuit that electrically connects the male connectors of the electrical switch with the electrical contacts of the defined female electrical connector receptacles, and can optionally include a diode or resistor. The electrical switch adaptation mechanism can includes a cover  740  that environmentally covers the electrical switch, flexible circuit, and a portion of the electrical contacts of the defined female electrical connector receptacles. The third barrier structure can include a first member that defines a first portion of the defined female electrical connector receptacles, and a second member that defines a remaining portion of the defined female electrical connector receptacles. These portions can be riveted or otherwise connected. The electrical contacts of the defined female electrical connector receptacles can be contact springs positioned within the defined female electrical connector receptacles, with the contact springs protruding from the second member of the barrier structure and connected to the electrical switch adaptation mechanism. The aircraft circuit breaker  700  can include a fourth barrier structure  770  to fully protect electrical terminals from each other. 
     While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present application as defined by the appended claims. Such variations are intended to be covered by the scope of this present application. As such, the foregoing description of embodiments of the present application is not intended to be limiting. Rather, any limitations to the invention are presented in the following claims.