Abstract:
A circuit breaker includes a housing having a channel formed therein, the channel being defined by at least one side wall having a detent formed therein, a circuit breaker mechanism, a switch handle configured to toggle the circuit breaker, and an actuator module adapted to move the switch handle from the off position to the on position. The module includes a flexible portion having a protrusion formed thereon, the protrusion being sized, shaped and located to engage the detent when the module is mounted within the channel. The module also includes a locking clip moveable from an unlocked position, in which flexing of the at least one flexible portion is permitted, and a locked position, in which flexing of the at least one flexible portion is limited or prevented, such that when the module is mounted within the channel, removal of the module is inhibited.

Description:
FIELD OF THE INVENTION 
     The invention relates to remotely operated circuit breakers in general, and more particularly, to circuit breakers having a breaker handle that is remotely operated using a modular solenoid mechanism. 
     BACKGROUND OF THE INVENTION 
     A circuit breaker is a device that can be used to protect an electrical circuit from damage caused by an overload or a short circuit. If a power surge occurs in a circuit protected by the circuit breaker, for example, the breaker will trip. This will cause a breaker that was in the “on” position to flip to the “off” position, and will interrupt the electrical power leading from that breaker. By tripping in this way, a circuit breaker can prevent a fire from starting on an overloaded circuit, and can also prevent the destruction of the device that is drawing the electricity or other devices connected to the protected circuit. 
     A standard circuit breaker has a line and a load. Generally, the line receives incoming electricity, most often from a power company. This is sometimes referred to as the input into the circuit breaker. The load, sometimes referred to as the output, feeds out of the circuit breaker and connects to the electrical components being fed from the circuit breaker. A circuit breaker may protect an individual component connected directly to the circuit breaker, for example, an air conditioner, or a circuit breaker may protect multiple components, for example, household appliances connected to a power circuit which terminates at electrical outlets. 
     A circuit breaker can be used as an alternative to a fuse. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. When the power to a circuit shuts down, an operator can inspect the electrical panel to see which breaker has tripped to the “off” position. The breaker can then be flipped to the “on” position and power will resume. 
     In general, a circuit breaker has two contacts located inside of a housing. Typically, the first contact is stationary, and may be connected to either the line or the load. Typically, the second contact is movable with respect to the first contact, such that when the circuit breaker is in the “off,” or tripped position, a gap exists between the first and second contact, and the line is disconnected from the load. 
     In some applications, it is desirable to operate a circuit breaker remotely. For example, an operator may typically trip a circuit breaker manually to de-energize a protected circuit so that it can be inspected or serviced. However in some circuits, operating the breaker can produce a dangerous arc, creating a safety hazard for the operator. In still other circuits, the circuit breaker may be located in a confined or hazardous environment. In these situations, it is beneficial to operate the circuit breaker remotely. In other applications, such as in large office buildings, it may be desirable, for example, to automatically trip circuits powering large banks of overhead lights, such that entire floors or sections of floors can be automatically shut down in response to timed signals at night without requiring that each individual light switch have a timer. 
     Known approaches to remotely controlling circuit breakers include incorporating a mechanism into the circuit breaker which can intentionally trip the circuit breaker mechanism and/or reset it. Examples of such mechanisms are solenoids or motors used to activate the trip mechanism, and solenoids or motors which are used to reset the circuit breaker by rearming the trip mechanism, such as by physically moving the switch handle using a solenoid or other motor or mechanism that can be remotely operated. 
     However, the lifespan of a solenoid employed to reset a circuit breaker using the switching handle may be limited. In some cases, the rearming solenoid may wear out or otherwise fail far before the other components of the circuit breaker. This can require an unacceptably premature replacement of the entire circuit breaker as a unit, increasing costs. 
     In order to increase the number of cycles that such circuit breaker units can endure before failure, it would be conceivable to increase the robustness of the solenoid. However, this may increase the costs, power consumption, and/or size of the solenoid beyond acceptable limits. 
     U.S. Patent Application Publication No. 2015/0101914 set out an improvement to this approach by disclosing a remotely resettable circuit breaker which includes a modular, replaceable resetting mechanism including a solenoid. 
     The present invention, however, aims to even further improve upon the design disclosed in U.S. Patent Application Publication No. 2015/0101914 by providing an improved mechanism for facilitating the installation and removal of the modular, replaceable resetting mechanism with respect to the housing of the circuit breaker. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, a circuit breaker includes a housing having a channel formed therein, the channel being defined by at least one side wall having a detent formed therein, a circuit breaker mechanism having a tripped state and an untripped state, a switch handle having an off position and an on position and configured to toggle the circuit breaker between the tripped state and the untripped state, and an actuator module adapted to move the switch handle from the off position to the on position. The actuator module is a self-contained modular assembly adapted to be attached to and removed from the housing as a unit, the actuator module including at least one flexible portion having a protrusion formed thereon, the protrusion being sized, shaped and located to engage the detent formed in the channel of the housing when the actuator module is mounted within the channel. The actuator module also includes a locking clip moveable from an unlocked position, in which flexing of the at least one flexible portion is permitted, and a locked position, in which flexing of the at least one flexible portion is limited or prevented, such that when the actuator module is mounted within the channel so that the protrusion engages the detent and the locking clip is in the locked position, removal of the actuator module is inhibited. 
     In some embodiments, the channel in the housing is defined by a pair of side walls facing one another, each of the pair of side walls having a detent formed therein. In some embodiments, the at least one flexible portion of the actuator module comprises a pair of legs, each having an outwardly extending protrusion formed thereon. 
     In some embodiments, the protrusion has a rounded or tapered forward surface adapted to promote flexing of the at least one flexible portion as the actuator module is slid into the channel of the housing. In certain of these embodiments, the protrusion has a rounded or tapered rearward surface to promote flexing of the at least one flexible portion as the protrusion is disengaged from the detent while the actuator module is removed from the channel of the housing. 
     In some embodiments, the locking clip comprises a generally flat member generally defining a plane, and the locking clip is slideable within the plane from the unlocked position to the locked position. In some embodiments, the locking clip is further moveable from the locked position to the unlocked position so as to facilitate removal of the actuator module from the channel of the housing. In certain of these embodiments, in the unlocked position the locking clip is positioned such that the pair of legs are flexible toward one another, and in the locked position the locking clip is positioned between the legs such that flexing of the legs toward one another is limited or prevented. 
     In some embodiments, the circuit breaker further includes a first plug connection disposed on the actuator module which engages a second plug connection disposed in the channel of the housing as the actuator module is slid into the channel. In certain of these embodiments, the first plug connection comprises a male plug connection extending from the actuator module and the second plug connection comprises a female plug connection formed within the channel. 
     In some embodiments, the actuator module further includes a solenoid. In some embodiments, the circuit breaker further includes a wiring harness having a terminal in electrical communication with the actuator module. In certain of these embodiments, the actuator module is remotely operable in response to a signal received by the terminal. 
     In some embodiments, the circuit breaker further includes a voltage coil configured to selectively trip the circuit breaker mechanism. In certain of these embodiments, the voltage coil is configured to trip the circuit breaker mechanism in response to detection of at least one of a ground fault and an earth leakage. In certain embodiments, the voltage coil is configured to trip the circuit breaker mechanism in response to a signal. 
     In accordance with another aspect of the present invention, a circuit breaker includes a housing having a channel formed therein, the channel being defined by a pair of side walls facing one another, each of the pair of side walls having a detent formed therein, a switch handle having an off position and an on position, and an actuator module adapted to move the switch handle from the off position to the on position. The actuator module is a self-contained modular assembly adapted to be attached to and removed from the housing as a unit, the actuator module including a pair of legs, each having an outwardly extending protrusion formed thereon, the protrusion being sized, shaped and located to engage the detents formed in the channel of the housing when the actuator module is mounted within the channel. The actuator module also includes a locking clip comprising a generally flat member generally defining a plane, the locking clip being slideable within the plane from an unlocked position, in which the locking clip is positioned such that the pair of legs are flexible toward one another, to a locked position, in which the locking clip is positioned between the legs such that flexing of the legs toward one another is limited or prevented, such that when the actuator module is mounted within the channel so that the protrusions engage the detents and the locking clip is in the locked position, removal of the actuator module is inhibited. 
     Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partially cut away perspective view of a circuit breaker illustrating aspects of the invention. 
         FIG. 2  is a partially cut away perspective view of the modular actuator module portion of the circuit breaker shown in  FIG. 1  with the actuator module portion installed on the body of circuit breaker but shown in an unlocked state. 
         FIG. 3A  is a perspective view of the modular actuator module portion of the circuit breaker shown in  FIG. 1  shown in an unlocked position. 
         FIG. 3B  is a perspective view of the modular actuator module portion of the circuit breaker shown in  FIG. 1  shown in a locked position. 
         FIG. 4  is a partial perspective view of the actuator module receiving portion of the body of the circuit breaker shown in  FIG. 1 . 
         FIG. 5A  is a partial cross-sectional view of the circuit breaker, taken along line  5 - 5  of  FIG. 2 , showing the modular actuator module portion installed on the body of the circuit breaker but shown in an unlocked state. 
         FIG. 5B  is a partial cross-sectional view of the circuit breaker, taken along line  5 - 5  of  FIG. 2 , showing the modular actuator module portion installed on the body of the circuit breaker and shown in an unlocked position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring first to  FIGS. 1, 3A, 3B and 4  illustrated is a circuit breaker  100  according to aspects of the invention. 
     Circuit breaker  100  includes a circuit breaker mechanism  105  which controls current flow between a line terminal  110  and a load terminal  115 . The line terminal  110  receives electricity from a power source such as a generator (not shown), which in some applications is supplied by a power company. Current may flow between line terminal  110  and load terminal  115  when mechanism  105  is in an untripped state. Current cannot flow between line terminal  110  and load terminal  115  when mechanism  105  is in a tripped state. 
     Mechanism  105  may be tripped by a tripping mechanism  120 . Tripping mechanism  120  may be activated by fault detector  125 . 
     Fault detector  125  is configured to activate the tripping mechanism  120  when a fault condition occurs, such as excess current. In some applications, fault detector  125  is a solenoid which is disposed in series with the line and load terminals. If the current through the solenoid exceeds a certain level, the solenoid generates an electromagnetic field sufficient to activate the tripping mechanism  120 . Optionally, such solenoid may also incorporate a plunger or other armature which activates the tripping mechanism when the current exceeds a certain level (not shown). 
     It is understood that other fault detection methods may also be employed to trip the tripping mechanism upon the occurrence of a specific condition. 
     Optionally, tripping mechanism  120  may be tripped by voltage coil  130 . Voltage coil  130  is configured to allow tripping mechanism  120  to be activated upon the occurrence of a specific condition or upon receiving a remote signal. Tripping mechanism  120  may also be tripped manually by moving switch handle  135  to an “off” position. 
     Tripping mechanism  120  may be reset (untripped) manually by moving switch handle  135  in the direction indicated by arrow  140 , to an “on” position (shown). Switch handle  135  may also be moved to the on position using remote resetting actuator module  145 . 
     Module  145  includes a piston  150  which is configured to extend in the direction of arrow  140  to move switch handle  135  into the on position when module  145  is activated. Those having skill in the art will understand that other types of actuators may be employed without departing from the invention. 
     Module  145  is removably attached to the housing  155  of breaker  100  by way of legs  300  with outwardly extending protrusions  305  that cooperate with detents  310  formed in a channel  315  within the housing  155  in which the module  145  is slideably received, as described in more detail below. 
     Module  145 , and specifically the solenoid  200  thereof, is removably electrically connected to breaker  100  using a male plug connection  165  extending from the module  145  which engages a female plug connection  166  formed in the channel  315  within the housing  155  as the module  145  is slid into the channel  315  for mounting on the housing  155 . Thus, plug connection  165 ,  166  is preferably configured to electrically connect module  145  to breaker  100  as module  145  is installed. This can have advantages over more traditional configurations involving flying leads or the like of preventing stray wires, increasing the robustness of the connection, and/or improving ease of installation. Those having skill in the art will understand that various other configurations of plug connection  165 ,  166  are possible without departing from the invention, including other types of plugs. 
     Breaker  100  may optionally also include a neutral terminal  170  and a ground fault sensor  175 . Ground fault sensor may be configured to activate tripping mechanism  120  using voltage coil  130  when a fault condition is detected. 
     Breaker  100  may also includes a plug  180  which may be interfaced with a wiring harness (not shown) or another suitable external connection. Plug  180  is configured to communicate electrically with various components of breaker  100 , for example, to facilitate signaling to and from an external device or system, such as a power distribution system. Transmission of signals within breaker  100 , including from plug  180 , may be facilitated by a printed circuit board (“PCB”)  199 , or other suitable wiring or interconnections. 
     As shown, plug  180  includes remote resetting terminals  185 ,  190 , which may be used to transmit a reset signal to module  145  to activate piston  150  of solenoid  200 . Plug  180  also includes a voltage coil terminal  195 , which may be used to transmit an activation signal to voltage coil  130 . Here, voltage coil may be internally grounded, thus only one terminal is required. 
     Plug  180  may also include additional terminals  198  and  198 ′ which may be used to connect an auxiliary switch  197  to activate one or more of the components of breaker  100  as desired and/or to provide a signal indicative of circuit breaker status to an external device or system, such as a power distribution system. For example, this status signal may indicate that the breaker is untripped, that the breaker has been tripped due to overcurrent, that the breaker has been tripped due to a ground fault, etc. 
     Those having skill in the art will understand that other arrangements of signals may be supported by plug  180  without departing from the invention. 
       FIG. 2  is a cutaway view of remote resetting module  145 , illustrating aspects of the invention. 
     Module  145  includes a solenoid  200 . Solenoid  200  is configured to extend piston  150  in the direction indicated by arrow  210  when solenoid  200  is energized. Piston  150  is shown configured as an armature of solenoid  200 . However, those having skill in the art will understand that other types of electromechanical actuators may be used without departing from the invention. 
     Solenoid  200  may be activated using a remote signal, such as a signal supplied via PCB  199  from remote resetting terminals  185 ,  190 . 
     Solenoid  200  may be configured such that piston  150  is biased to a retracted position (shown). In this case, piston  150  will revert to the retracted position unless solenoid  200  is energized. This can have the advantage of preventing switch handle  135  ( FIG. 1 ) from being obstructed by piston  150  due to a power fault or other malfunction. 
     Referring now specifically to  FIGS. 5A and 5B , in combination with  FIGS. 3A, 3B and 4 , the module mounting aspect of the present invention is shown in greater detail. As mentioned above, the module  145  is removably attached to the housing  155  of breaker  100  by way of legs  300  with outwardly extending protrusions  305  that cooperate with detents  310  formed in a channel  315  within the housing  155  in which the module  145  is slideably received. 
       FIGS. 4, 5A and 5B  show the channel  315  formed within the housing  155  in more detail. Specifically, the channel  315  is defined by two generally parallel spaced apart walls  320 , which walls  320  are also generally parallel to the outer side walls of the housing  155 . Each of the walls  320  has a detent  310  formed, the purpose of which is described in more detail below. As discussed more fully above, a female plug connection  166  is provided at an end of the channel  315 , which female plug connection  166  electrically communicates with male plug connection  165  on module  145  so as to provide an electrical connection between module  145  and the body of circuit breaker  100 . 
     Referring more specifically now to  FIGS. 3A, 3B, 5A and 5B  the legs  300  of module  145  are shown in more detail. As can be seen, the legs  300  are defined by outwardly facing surfaces that are dimensioned to be in generally sliding engagement with the walls  320  of the channel  315  formed in the housing  155 . Each of the legs  300  includes an outwardly extending protrusion  305  that is sized, shaped and positioned so as to cooperate with a corresponding detent  310  formed in the walls  320  of the channel  315  when the module  145  is fully seated within the channel  315 . 
     The protrusions  305  preferably have rounded (as shown in the FIGS.) or sloped forward edges to facilitate installation of the module  145  in the channel  315 . More specifically, as the module  145  is inserted into the channel  315 , the protrusions  305  on the legs  300  come into contact with the walls  320  of channel  315 . Further force applied on the module  145  causes the legs  300  to flex inwardly toward one another due to the cooperation between the protrusions  305  and the walls  320  of the channel  315 . This flexing is promoted by the rounded or sloped configuration of the protrusions  305 . 
     As the module is slid further into the channel  315 , the protrusions  305  eventually align with the detents  310  formed in the walls  320  of the channel  315 , such that the protrusions  305  engage the detents  310  and the legs  300  snap back outwardly toward their original positions. At the same time, the male plug connection  165  positioned on the module  145  engages the female plug connection  166  provided in the end of the channel  315  such that the module  145  now receives power from the body of the circuit breaker  100 . The module  145  is now mounted in place within the channel  315 . 
     However, since it is intended that the module  145  be readily replaceable, the protrusions  305  preferably have rounded (as shown in the FIGS.) or sloped rearward edges to facilitate removal of the module  145  from the channel  315 . Such can be accomplished by reversing the above-described insertion steps. 
     Specifically, the module  145  is grasped and a pulling force is applied. As the module  145  is removed from the channel  315 , the protrusions  305  on the legs  300  are pulled out of the detents  310  and again come into contact with the walls  320  of channel  315 . Further pulling force applied on the module  145  causes the legs  300  to flex inwardly toward one another due to the cooperation between the protrusions  305  and the walls  320  of the channel  315 . 
     As the module  145  is slid further out of the channel  315 , the protrusions  305  eventually clear the walls  320  of the channel  315 , such that the legs  300  snap back outwardly toward their original positions. At the same time, the male plug connection  165  positioned on the module  145  has been disengaged from the female plug connection  166  provided in the end of the channel  315  such that the module  145  now no longer receives power from the body of the circuit breaker  100 . 
     Of course, it will be recognized that during use, the unintentional unplugging of the module  145  from the body of the circuit breaker  100  is to be avoided. Toward this end, a locking clip  330  is provided, the purpose of which is to lock the module  145  in place in the channel  315  once it has been mounted and snapped into place. In the particular embodiment shown in the FIGS., the locking clip  330  takes the form of a guillotine-style member that is slideable up and down. However, those skilled in the art will recognize that other configurations for the locking clip  330  are certainly possible. 
     The locking clip  330  is moveable (indicated by arrow  335  in  FIG. 5A ) between an unlocked position (shown in  FIGS. 2, 3A and 5A ), in which position the mounting clip  330  does not interfere with inward flexing of the legs  300 , thereby allowing for the module  145  to be slid into and removed from the channel  315 , and a locked position (shown in  FIGS. 1, 3B and 5B ), in which position the mounting clip  330  limits or prevents inward flexing of the legs  300  (best seen in  FIG. 5B ), thereby preventing the protrusions  305  from disengaging the detents  310  once the module  145  has been mounted within the channel  315 . 
     As a consequence, once the module  145  has been mounted within the channel with the protrusions  305  snapped into the detents  310 , and the locking clip  330  has been moved to the locked position, it is very difficult, if not impossible without causing permanent damage, for the module  145  to be removed from the channel  315  without first moving the locking clip  330  back to the unlocked position. However, if it is desired to replace the module  145 , it is an easy matter for an operator to simply move the locking clip  330  to the unlocked position, and then unsnap the module  145  from its mounted position and slide it out of the channel  315 , as described above. 
     The present invention, therefore, provides an improved mechanism for facilitating the installation and removal of the modular, replaceable resetting mechanism with respect to the body of the circuit breaker. 
     Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many modifications and variations will be ascertainable to those of skill in the art.