Patent Abstract:
The present invention relates generally to a lug landing accessory. More particularly, the invention encompasses a field installed lug landing accessory. The present invention is also directed to a novel lug landing kit that can be installed by an installer in the field. The invention further comprises a lug coupler comprising a set of bus bars, each of the set of the bus bars are secured to an electrically non-conductive housing of the lug coupler. The bus bar has at least one opening for the passage of at least one electrically conductive protrusion, and the bus bars are electrically connected to at least one corresponding breaker strap.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The instant patent application claims priority to and the benefit of pending U.S. Provisional Patent Application Ser. No. 61/142,693, filed on Jan. 6, 2009, titled “Field Installed Lug Landing Accessory,” the entire disclosure of which provisional application is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to a lug landing accessory. More particularly, the invention encompasses a field installed lug landing accessory. The present invention is also directed to a novel lug landing kit that can be installed by an installer in the field. The invention further comprises a lug coupler comprising a set of bus bars, each of the set of the bus bars are secured to an electrically non-conductive housing of the lug coupler. The bus bar has at least one opening for the passage of at least one electrically conductive protrusion, and the bus bars are electrically connected to at least one corresponding breaker strap. 
       BACKGROUND INFORMATION 
       [0003]    During the installation process of many modular panel boards, it becomes necessary for some applications to be electrically connected to the modular panel boards with specific connectors and/or lugs. In the case of existing units, a kit or means to easily or affordably provide such an electrical connection does not exist. For some applications the installers usually purchase a separate panel board accessory that mounts next to a standard unit so these specific connectors can be installed. This additional separate panel board unit or accessory takes up precious wall space. In some cases the installers prefer not to give up that extra wall space or in other situations there many not be extra wall space available in the vicinity of the modular panel board. Other manufacturers have their own solution to solve this problem. Some manufacturers have overcome the wall space issue, but they have put a burden on the supply chain in order to build these special units, while at the same time supporting a standard line of product. 
         [0004]    Therefore there is a need for improvement in a lug landing accessory and in particular a field installed lug landing accessory. 
         [0005]    U.S. Pat. No. 5,989,073 (Scott D. Kahoun), the entire disclosure of which is incorporated herein by reference, discloses a power block including an insulative block which is mounted to a panel and a plurality of connection mounts which are coupled to the insulative block. The insulative block includes a plurality of molded dividers and the connection mounts are located therebetween. Each connection mount includes at least one stud extending upward from the block and a conductor having first and second portions. The first portion of each conductor is conductively coupled to the one or more studs and the second portion extends through the block in a direction opposite the one or more studs. The second portion includes a free end provided with a connector directly couplable to a destination point. A preferred aspect of the invention is that the conductor is a copper braid partially covered in a tin plated copper sleeve. According to a first embodiment, the connector at the free end of the conductor is a sleeve extending over the free end and having a hole for directly receiving a lead from a power filter. According to a second embodiment, the second portion of the conductor is formed of solid copper and the connector is a tapered free end of the second portion of the conductor which is “pluggable” into resilient clips. According to a third embodiment, the second portion of the conductors are substantially elongate and flexible, and the connector at the free end is a sleeve having a coupling slot or hole. 
         [0006]    U.S. Pat. No. 6,379,196 (Randy Greenberg, et al.), the entire disclosure of which is incorporated herein by reference, discloses a termination connector for a circuit breaker. The termination connector preferably includes a plurality of single pole screw receiving members integrally attached by a molded housing for unitary attachment to a line or load end of a circuit breaker to assist in holding a nut or nut plate adjacent each screw hole in the circuit breaker&#39;s terminal straps. The molded housing preferably includes a line of perforations between each single pole screw receiving member so that the correct number of single pole screw receiving members can be retained and the others can be knocked off along the line of perforations. Provisions are disclosed for adaptation of the connector to metric or English standard nut hardware. In addition, the termination connector and circuit breaker are provided with mating attachment devices for providing a simple yet secure connection. 
         [0007]    U.S. Pat. No. 7,578,711 (Kristopher Scott Robinson), the entire disclosure of which is incorporated herein by reference, discloses certain exemplary embodiments that can provide a system, which can comprise a lug coupler that comprises a set of bus bars. Each of the set of bus bars can be adapted to be releasably attached to a corresponding terminal of a set of terminals of a circuit breaker. The system can comprise a set of studs adapted to engage a corresponding set of apertures defined by an end connector of one of a set of electrical leads adapted to be electrically coupled to the lug coupler. 
         [0008]    However, this invention overcomes the problems and deficiencies of the known art and provides an inventive field installed lug landing accessory, which can be easily field installed on a standard line of panel board accessories. This invention also resolves any supply chain burden and provides the installer with a product that they can electrically connect to with their specific connector and/or lugs. This inventive accessory also complies with all agency requirements, i.e., UL, for use in the product in which this inventive accessory can be field installed. 
       PURPOSES AND SUMMARY OF THE INVENTION 
       [0009]    The invention is a novel field installed lug landing accessory. 
         [0010]    Therefore, one purpose of this invention is to provide a field installed lug landing accessory. 
         [0011]    Another purpose of this invention is to provide a reliable solution for field installing lugs. 
         [0012]    Yet another purpose of this invention is to provide a robust lug landing kit that can be field installed. 
         [0013]    Therefore, in one aspect this invention comprises a lug landing pad apparatus, comprising: 
         [0014]    a lug coupler comprising a set of bus bars, each of said set of bus bars secured to an electrically non-conductive housing of said lug coupler, said bus bar having at least one opening for the passage of at least one electrically conductive protrusion, said bus bar electrically connected to at least one corresponding breaker strap, and thereby forming said lug landing pad apparatus. 
         [0015]    In another aspect this invention comprises a lug landing pad apparatus, comprising: 
         [0016]    a lug coupler comprising a set of bus bars, each of said set of bus bars snapably connected, via an engagement of at least one bus bar snap, to an electrically non-conductive housing of said lug coupler, said bus bar having at least one opening for the passage of at least one electrically conductive protrusion, said bus bar electrically connected to at least one corresponding breaker strap, and thereby forming said lug landing pad apparatus. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    Although the scope of the present invention is much broader than any particular embodiment, a detailed description of the preferred embodiment follows together with drawings. These drawings are for illustration purposes only and are not drawn to scale. Like numbers represent like features and components in the drawings. The invention may best be understood by reference to the ensuing detailed description in conjunction with the drawings in which: 
           [0018]      FIG. 1  illustrates a front isometric view of the completed lug landing pad assembly of a first embodiment of this invention. 
           [0019]      FIG. 2  illustrates a side view of the completed lug landing pad assembly of the embodiment of this invention as illustrated in  FIG. 1 . 
           [0020]      FIG. 3  illustrates a rear isometric view of the completed lug landing pad assembly of the first embodiment of this invention as illustrated in  FIG. 1 . 
           [0021]      FIG. 4  is a detailed view showing the detail  4 , from  FIG. 3 , which is an enlarged view showing the bus bar snap of this invention engaged with an edge of the bus bar. 
           [0022]      FIG. 5  is a detailed view showing the detail  4 , from  FIG. 3 , which is an enlarged view showing the bus bar snap of this invention but without the bus bar. 
           [0023]      FIG. 6  illustrates a detailed cut-away view of a second embodiment of this invention illustrating in detail the profile of the A, B, and C phase cavities along with the corresponding bus bars and bus bar snaps. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    The inventive field installed lug landing pad accessory of this invention provides an alternative wiring option for contractors, electricians, or anyone who might install a circuit breaker in a standard panel board accessory. This inventive lug landing pad accessory can be field installed during the installation process, and it provides the convenience of installing compression or mechanical/pressure connectors and/or lugs on a standard line of panel board accessories. 
         [0025]    It should also be appreciated the way in which this lug landing pad accessory is assembled. The conservation of wall space, especially the width of the unit, during the installation process which is rather important in this industry is also achieved with this invention. This inventive lug landing pad accessory has been designed to minimize width, as required for multiple studs per phase arrangements. In addition to this, this inventive lug landing pad accessory design reduces the metal scrap associated with connecting multiple studs per phase arrangement bussing to a circuit breaker. This is achieved by forming the circuit breaker connecting bus in a z shape and having a second set of connector/lug connecting bus (out of the same material or a different material) also formed in a z shape attached to one another. Mechanically fastening these two z shaped bus bars of this invention allows the current path to change from a direction that is parallel to the bussing of the circuit breaker to a direction that is perpendicular to the circuit breaker. All of this is achieved using standard width bussing and without creating any scrap material. 
         [0026]    It should be understood that all of the phase bussing is coupled together by the use of a lug landing base or pad. This lug landing pad is made out of a non-electrically conductive material, such as, for example, plastic. The bus bars are fastened to the plastic base by the use of securing means, such as, snaps. Mechanical fasteners for attaching connectors and/or lugs to the bus are also retained by the lug landing base. This inventive assembly preferably travels as a kit and preferably contains no loose parts. This inventive kit makes it very easy to convert a standard circuit breaker unit to one that will accept the specific connectors and/or lugs as required by some of the customers or applications. 
         [0027]      FIG. 1  illustrates a front isometric view of a completed lug landing pad assembly or kit or apparatus  23 , of a first embodiment of this invention. This completed lug landing pad assembly or kit or apparatus  23 , has a support base or an electrically non-conductive housing  20 , at least one electrically conductive protrusion  14 , such as, a stud  14 , and at least one bus bar  18 . To assemble a bus bar  18 , to the support base  20 , one could simply slide the bus bar  18 , in the appropriate support base phase cavity until at least one bus bar snap  28 , engages with at least one bus bar edge  19 , of the bus bar  18 , as more clearly illustrated with reference to  FIG. 4 . The electrically non-conductive housing  20 , has at least one mounting tab or feet  22 , which can be used to secure the lug landing apparatus  23 , to a modular panel board (not shown). It is preferred that the bus bar snap  28 , has an open area or bus bar snap cavity or opening  29 , so as to allow the bus bar snap  28 , to be able to move vertically when it either engages or disengages from the bus bar edge  19 . In order to further secure or strengthen the electrically non-conductive housing  20 , one could have at least one rib or strengthening feature  27 . For most applications it is preferred that the bus bar  18 , has at least one opening  13 , to allow for the passage of the stud  14 . It is preferred that the stud  14 , is a NEMA stud  14 . The electrically non-conductive housing  20 , is also preferably provided with at least one bus bar rail or track  24 ,  34 , which allow for the sliding motion of the bus bar  18 , into and out of the electrically non-conductive housing  20 . The bus bar rail or track  24 , tracks or holds one edge of the bus bar  18 , while the bus bar rail or track  34 , tracks or holds the opposite edge of the bus bar  18 . In order to control or stop the movement of the bus bar  18 , along the bus bar rail or track  24 ,  34 , the electrically non-conductive housing  20 , could also have at least one bus bar stop  26 . It is preferred that the bus bar stop  26 , works in conjunction with the bus bar snap  28 , this way when the bus bar  18 , is positioned into the electrically non-conductive housing  20 , the bus bar stop  26 , stops the movement of the bus bar  18 , at one end of the bus bar  18 , while the other end or the bus bar edge  19 , is engaged by the bus bar snap  28 . The electrically non-conductive housing  20 , can also have at least one insulation phase barrier or isolation tab  30 , to electrically insulate or isolate the various bus bar  18 , phases, such as, for example, A-Phase bus bar  11 , B-Phase bus bar  21 , C-Phase bus bar  31 . The lug landing apparatus  23 , is also provided with at least one breaker strap  10 . For some applications it is preferred that the breaker strap  10 , has at least one breaker strap laminate  15 . The breaker strap  10 , could also have at least one hole or opening  12 , for securing means (not shown), such as, a screw, a bolt, a rivet, to name a few. For some applications the breaker strap  10 , having the breaker strap laminate  15 , helps in heat sink purposes. For some applications the mounting feet or tab  22 , can also be used for fastening or securing the lug landing apparatus  23 , to at least one mounting bracket in the main breaker enclosure (not shown). 
         [0028]      FIG. 2  illustrates a side view of the completed lug landing pad assembly  23 , of the embodiment of this invention as illustrated in  FIG. 1 . As one can see that the bus bar  18 , is held in place at one end by the bus bar stop  26 , and by the bus bar snap  28 , at the opposite end. It is preferred that the stud  14 , has a head or a similar feature  16 , which is securely held inside the electrically non-conductive housing  20 . The stud  14 , could also be carriage bolt  14 , having a head  16 . The breaker strap  10 , along with the breaker strap laminate  15 , is electrically connected to the bus bar  18 , and is securely held inside the electrically non-conductive housing  20 , via at least one securing means  42 . The securing means  42 , could be a fastener, a hex bolt fastener, a rivet, a weld, to name a few. As illustrated in  FIG. 2 , the securing means  42 , passes through an opening or hole  43 , in the bus bar  18 , and the breaker strap  10 , and is secured to another fastening means  44 . The fastening means  44 , could be a nut, a hex nut, a rivet, a weld, to name a few. It is preferred that the electrically non-conductive housing  20 , has at least one cavity  49 , to accommodate the securing means  42 , the fastening means  44 , and the related components that are secured via the securing means  42 , and the fastening means  44 . 
         [0029]      FIG. 3  illustrates a rear isometric view of the completed lug landing pad assembly  23 , of the first embodiment of this invention as illustrated in  FIG. 1 . As one can see that the bus bar  18 , is held on one side via the bus bar snap  28 , while the two adjacent sides of the bus bar  18 , are held within the bus bar rail or track  24 ,  34 , and the forth edge of the bus bar  18 , is held in place via the bus bar stop  26 . The enlarged view of the bus bar snap area or detail  4  is more clearly shown with reference to  FIG. 4 . The ribs  27 , can also be strengthening ribs  27 , which can be used to prevent the movement of the bus bar  18 , especially, during the application of tightening torque on the connector studs  14 . The electrically non-conductive housing  20 , can also be provided with at least one rib  37 , to further strengthen the electrically non-conductive housing  20 . 
         [0030]      FIG. 4  is a detailed view showing the detail  4 , from  FIG. 3 , which is an enlarged view showing the bus bar snap  28 , of this invention engaged with an edge  19 , of the bus bar  18 . As one can see that the electrically non-conductive housing  20 , has a bus bar snap cavity or opening  29 , to allow pivotal movement of the bus bar snap  28 , when it is used to either engage or disengage from the bus bar  18 . The ribs  37 , can also be strengthening ribs  37 , which can be used to prevent cracking of the base of the electrically non-conductive housing  20 , especially, during the application of tightening torque on the connector studs  14 . For some applications the rib  37 , can also be used as a spacer  37 . 
         [0031]      FIG. 5  is a detailed view showing the detail  4 , from  FIG. 3 , which is an enlarged view showing the bus bar snap  28 , of this invention but without the bus bar  18 . The bus bar snap  28 , preferably has a bus bar snap extension  39 , which is held in place via rib or bus bar snap rail  38 . The bus bar snap extension  39 , could also be secured or welded to the rib or bus bar snap rail  38 . The bus bar snap extension  39 , allows for the pivotal movement of the bus bar snap  28 . For some applications the rib or bus bar snap rail  38 , could also be used as a spacer  38 , or as a resting surface  38 , for resting or holding the surface of the bus bar  18 . For some applications the rib or bus bar snap rail  38 , could be strengthening ribs  38 , to further strengthen the electrically con-conductive housing  20 . The bus bar rail or track  24 ,  34 , can be a channel like feature  24 , or a flat step like surface  34 , or just a flat wall surface  24 ,  34 . 
         [0032]      FIG. 6  illustrates a detailed cut-away view of a second embodiment  33 , of this invention illustrating in detail the profile of the A, B, and C phase cavities along with the corresponding bus bars  18 , and bus bar snaps  28 . Also shown in  FIG. 6  is the phase stud arrangement and bus hardware used in this particular embodiment  33 . Bus hardware is optional and could be replaced with welds or other fastening methods. The construction of the embodiment  33 , shown in  FIG. 6  consists of at least two sets of studs  14 , per phase. The number of sets of studs  14 , is dependent on the amperage required for the end use. To clarify, there are preferably two studs  14 , per set, and a set includes at least one stud  14 , assembled towards the front of the lug landing pad assembly, and one towards the back of the lug landing pad assembly. It should be appreciated that A-phase bus bar  11 , is electrically connected to an A-phase breaker strap  10 , while a B-phase bus bar  21 , is electrically connected to a B-phase breaker strap  10 , and the C-phase bus bar  31 , is electrically connected to a C-phase breaker strap  10 . For some applications the electrically non-conductive housing  20 , could have at least one rib  47 . The rib  47 , can be used as a spacer  47 . The rib  47 , can also be used to strengthen the electrically non-conductive housing  20 . 
         [0033]    The electrically non-conductive housing  20 , is made from a material, such as, for example, nylon, polytetrafluoroethylene (PTFE), plastic, electrically non-conductive material, electrically non-conductive composite material, to name a few. 
         [0034]    The breaker strap  10 , the stud  14 , the bus bar  18 , are made from an electrically conductive material, such as, for example, copper, aluminum, silver, electrically conductive metallic material, electrically conductive composite material, to name a few. 
         [0035]    It should be appreciated that the embodiments are shown in a three-phase electrical configuration, however, a person skilled in the art can easily modify the lug landing apparatus  23 ,  33 , into a single-phase configuration, such as, by not installing center bus lugs. 
         [0036]    While the present invention has been particularly described in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.

Technology Classification (CPC): 7