Abstract:
A modular power distribution system comprises a chassis and a backplane including a power input, and a plurality of module connection locations. A plurality of modules are mounted in the chassis, each module mounted to one of the module connection locations. Each module includes: (i) a circuit protection device; and (ii) a power output connection location. Bus bars connect front power inputs to the backplane.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of application Ser. No. 12/254,585, filed Oct. 20, 2008, which is a continuation of application Ser. No. 11/710,851, filed Feb. 26, 2007, now U.S. Pat. No. 7,440,262, which application claims the benefit of provisional application Ser. No. 60/873,620, filed Dec. 6, 2006, which applications are incorporated herein by reference in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a power distribution panel with circuit element modules. 
       BACKGROUND OF THE INVENTION 
       [0003]    Electrical circuit panels such as power distribution panels typically include a number of different circuit elements such as fuse holders and fuses, circuit breakers, input and output connectors and alarm signal LED&#39;s. For safety and other reasons, the electrical circuits of power distribution panels are enclosed within a housing structure. Therefore, the circuit elements listed above have typically been inserted into holes that have been pre-cut or pre-punched into the housing structure, usually on a front or back panel of the housing structure. 
         [0004]    These prior circuit panels are fixed and once the holes are formed in the housing, the type and arrangement of the components is limited. In order to manufacture different fixed circuit panels of the prior systems, a circuit panel manufacturer would punch out different patterns of holes in the front or back panels of the housing structure in order to accommodate different arrangements of circuit elements. Significant retooling time and costs are involved for offering different fixed panels. Assembly of the circuit elements is also difficult when the elements are inserted through holes. One solution is described and shown in U.S. Pat. No. 6,456,203. 
         [0005]    In addition, such panels are hardwired between the input and output connections, and the fuse and/or breaker locations. In some panels, redundant power connections are provided, controlled by an OR-ing diode including a heat sink. These features can take up significant space within the panel. There is a continued need for improved power distribution panels. 
       SUMMARY OF THE INVENTION 
       [0006]    A modular power distribution system comprises a chassis and a backplane including a power input, and a plurality of module connection locations. A plurality of modules are mounted in the chassis, each module mounted to one of the module connection locations. Each module includes: (i) a circuit protection device; and (ii) a power output connection location. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a front, top, and right side perspective view of one embodiment of a power distribution panel in accordance with the present invention. 
           [0008]      FIG. 2  is a rear, top, and left side perspective view of the power distribution panel of  FIG. 1 . 
           [0009]      FIG. 3  is a front view of the power distribution panel of  FIG. 1 . 
           [0010]      FIG. 4  is a right side view of the power distribution panel of  FIG. 1 . 
           [0011]      FIG. 5  is an exploded front, top, and right side perspective view of the power distribution panel of  FIG. 1 . 
           [0012]      FIG. 6  is an exploded front, top, and left side perspective view of the power distribution panel of  FIG. 1 . 
           [0013]      FIG. 7  is a top view of the power distribution panel of  FIG. 1 , shown with a top cover portion removed. 
           [0014]      FIG. 8  is a front view of the chassis of the power distribution panel of  FIG. 1 , shown without modules. 
           [0015]      FIG. 9  is perspective view of a first circuit module. 
           [0016]      FIG. 10  is a top view of the first circuit module. 
           [0017]      FIG. 11  is a bottom view of the first circuit module. 
           [0018]      FIG. 12  is a front view of the first circuit module. 
           [0019]      FIG. 13  is a right side view of the first circuit module. 
           [0020]      FIG. 14  is an exploded perspective view of the first circuit module. 
           [0021]      FIG. 15  is a perspective view of a second circuit module. 
           [0022]      FIG. 16  is a top view of the second circuit module. 
           [0023]      FIG. 17  is a bottom of the second circuit module. 
           [0024]      FIG. 18  is a front view of the second circuit module. 
           [0025]      FIG. 19  is a right side view of the second circuit module. 
           [0026]      FIG. 20  is an exploded perspective view of the second circuit module. 
           [0027]      FIG. 21  is a front, top, and right side perspective view of a second embodiment of a power distribution panel in accordance with the present invention. 
           [0028]      FIG. 22  is a rear, top, and left side perspective view of the power distribution panel of  FIG. 21 . 
           [0029]      FIG. 23  is a front view of the power distribution panel of  FIG. 21 . 
           [0030]      FIG. 24  is a right side view of the power distribution panel of  FIG. 21 . 
           [0031]      FIG. 25  is an exploded front, top, and right side perspective view of the power distribution panel of  FIG. 21 . 
           [0032]      FIG. 26  is an exploded front, top, and left side perspective view of the power distribution panel of  FIG. 21 . 
           [0033]      FIG. 27  is a top view of the power distribution panel of  FIG. 21 , shown with a top cover portion removed. 
           [0034]      FIG. 28  is a front view of the chassis of the power distribution panel of  FIG. 21 , shown without modules. 
           [0035]      FIG. 29  is a front, top, and right side perspective view of a third embodiment of a power distribution panel in accordance with the present invention. 
           [0036]      FIG. 30  is a front, bottom, and right side perspective view of the power distribution panel of  FIG. 29 . 
           [0037]      FIG. 31  is a front perspective view of a first circuit module of the power distribution panel of  FIG. 21 . 
           [0038]      FIG. 32  is a rear perspective view of the first circuit module of  FIG. 31 . 
           [0039]      FIG. 33  is a front view of the first circuit module of  FIG. 31 . 
           [0040]      FIG. 34  is a side view of the first circuit module of  FIG. 31 . 
           [0041]      FIG. 35  is a top view of the first circuit module of  FIG. 31 . 
           [0042]      FIG. 36  is a bottom view of the first circuit module of  FIG. 31 . 
           [0043]      FIG. 37  is a cross-sectional view of the first circuit module of  FIG. 31 , taken along lines  37 - 37  of  FIG. 35 . 
           [0044]      FIG. 38  is an enlarged view of a portion of the first circuit module of  FIG. 37 , shown partially connected to a backplane connector. 
           [0045]      FIG. 39  is an exploded front perspective view of the first circuit module of  FIG. 31 . 
           [0046]      FIG. 40  is a front perspective view of a second circuit module of the power distribution panel of  FIG. 21 . 
           [0047]      FIG. 41  is a rear perspective view of the second circuit module of  FIG. 40 . 
           [0048]      FIG. 42  is a front view of the second circuit module of  FIG. 40 . 
           [0049]      FIG. 43  is a side view of the second circuit module of  FIG. 40 . 
           [0050]      FIG. 44  is a top view of the second circuit module of  FIG. 40 . 
           [0051]      FIG. 45  is a bottom view of the second circuit module of  FIG. 40 . 
           [0052]      FIG. 46  is a cross-sectional side view of the second circuit module of  FIG. 40 , taken along lines  46 - 46  of  FIG. 44 . 
           [0053]      FIG. 47  is an enlarged view of a portion of the second circuit module of  FIG. 46 , shown partially connected to a backplane connector. 
           [0054]      FIG. 48  is an exploded perspective view of the second circuit module of  FIG. 40 . 
           [0055]      FIG. 49  is a flow chart relating to the voltage disconnect monitor. 
           [0056]      FIG. 50  shows greater detail of a front of a power distribution panel including two of the first circuit modules of  FIG. 31 , including the label configurations. 
           [0057]      FIG. 51  shows greater detail of a front of the power distribution panel of  FIG. 21 , including the label configurations. 
           [0058]      FIG. 52  shows in greater detail a front of another power distribution panel including four of the second circuit modules of  FIG. 40 , including the labeling configurations. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0059]    Referring to  FIGS. 1-7 , a power distribution system or panel  10  is shown. Power distribution system  10  is a modular design including a panel construction having a chassis  12  and at least one removable circuit module  14 . In the illustrated embodiment, one first circuit module  16 , and two second circuit modules  18  are shown. First circuit module  16  is positioned in a left side of chassis  12  wherein the first circuit module  16  is of a first design. Two second circuit modules  18  are also shown positioned in a right side of chassis  12  wherein second circuit modules  18  are of a different design from first circuit module  16 . 
         [0060]    Each circuit module  14  includes circuit distribution components. In the preferred embodiment, the circuit distribution components include a circuit protection device, such as a fuse or a breaker, and a power output arrangement  60 . System  10  includes a power input arrangement  50  wherein the circuit protection devices within the modules  14  protect the circuit between the power input arrangement  50  and the power output arrangement  60 . 
         [0061]    Referring also to  FIG. 8 , chassis  12  includes a top  30 , a spaced apart bottom  32  and opposite sides  34 ,  36 . Adjacent to sides  34 ,  36  are brackets  38  for mounting to a rack, cabinet, or other telecommunications equipment. Chassis  12  includes a rear  40 . Chassis  12  defines an interior  42  having an open front  44 . Chassis interior  42  in the illustrated embodiment includes a first module receiving area  46  on a left side of chassis  12 , and a second module receiving area  48  on a right side of chassis  12 . A central area  49  of chassis  12  is provided. In some embodiments, central area  49  can be used for alarming and/or system management components. 
         [0062]    Panel  10  includes power input connectors or terminals  50  connected to internal bus bars  52 . A backplane  54 , such as a printed circuit board, is positioned adjacent to rear  40  of chassis  12 . Bus bars  52  connect input connectors  50  to backplane  54 . Modules  16 ,  18  interconnect with backplane  54  to enable power distribution through modules  16 ,  18 . Each module  16 ,  18  includes at least one power output connector  60 , and a circuit protection device  62 , such as a fuse or a breaker. 
         [0063]    As shown in  FIG. 7 , bus bars  52  are generally Z-shaped metallic bars extending from first ends  68  to opposite ends  70 . Opposite ends  70  define dual contact points  72  which can be mounted with fasteners (not shown) to backplane  54  to electrically interconnect bus bars  52  and backplane  54 . Ends  68  of bus bars  52  are mounted to input terminals  50  at input terminal mounts  76  of chassis  12 . 
         [0064]    Interior  42  of chassis  12  includes side supports  80  and central support  82 . Side supports  80  and central support  82  include a plurality of module guides  84  which define longitudinal slots for receipt of longitudinal rails of each of modules  16 ,  18 . Central support  82  defines an interior for receiving an alarm card  92 . Alarm card  92  mounts to alarm card connector  93  on backplane  54 . Alarm card  92  is optional if such functionality is employed by panel  10 . 
         [0065]    Each module  16 ,  18  includes a rear module connector  96 . Backplane  54  includes a front face  100 , and opposite rear face  102 . Positioned on front face  100  are a plurality of mating connectors  104  for electrically connecting to the module connectors  96 . 
         [0066]    Referring now in greater detail to  FIGS. 9-14 , first circuit module  16  is shown. Module  16  includes a frame  200  including a base  202 , and a front tray  204  with a front lip  206 . A vertical support  208  extends up from base  202  and defines a plurality of openings  210 ,  212  for output terminal units  220 , and fuses  222 , respectively. Base  202  also includes sides  226  and longitudinal rails  228 . A printed circuit board  230  connects between module connector  96  and the circuit elements including output terminal units  220  and fuses  222 . Fuse holder or block  240  with fuses  222  is held in place by a support tray  241  and a strap  242 . 
         [0067]    Referring now to  FIGS. 15-20 , one of the second circuit modules  18  is shown. Second module  18  includes a frame  300  including a base  302 , a front tray  304 , and a front lip  306 . A vertical support  308  defines a plurality of openings  310 ,  312  for output terminal units  320  and fuses  322 , respectively. Frame  300  includes sides  326 , and longitudinal rails  328 . A printed circuit board  330  connects between module connector  96  and the circuit elements including output terminal units  320  and fuses  322 . 
         [0068]    Modules  16 ,  18  mount to chassis  12  with fasteners (not shown) through holes  238 ,  338  in each module, and holes  66  in supports  80  of chassis  12 . Front trays  204 ,  304  are provided for cable management of the power output cables. Front lips  206 ,  306  also provide a convenient gripping surface. 
         [0069]    Because of the modular design for chassis  12  and modules  16 ,  18 , repair or replacement of parts is facilitated. Should upgrades become desirable, new modules can be provided. The modules also allow for distributed control functions, such as in the case of redundant (dual feed) applications. The OR-ing diodes or other controllers can be locally placed on each module. 
         [0070]    Each module includes the desired circuit protection components. Module  16  in the illustrated embodiment is a TPA type fuse. Modules  18  are GMT type fuses. Other fuse types or breakers can be used. 
         [0071]    Referring now to  FIGS. 21-52 , further embodiments of power distribution systems or panels similar to panel  10  are shown. In  FIGS. 21-28 , a similar panel  410  is shown having a chassis  412 , a first circuit module  416 , and two second circuit modules  418 . Alternatively, panel  410  can hold two first circuit modules  416 , or four second circuit modules  418 . 
         [0072]    Chassis  430  includes air flow openings  440  on a top  430 , and on a bottom  432 . Chassis  430  further includes a forward facing ground  442  on top  430 . 
         [0073]    As with panel  10 , first circuit module  416  and second circuit modules  418  are removable from chassis  430 . Module  416  in the illustrated embodiment is a TPA type fuse with four fuses instead of two as noted in panel  10 . Modules  318  are GMT type fuses, each including four fuses, instead of three as noted above for modules  18 . 
         [0074]    Referring now to  FIGS. 26-28 , a baffle plate  480  is shown mounted to a bottom  432  of chassis  430 . Baffle plate  480  is spaced from bottom  432  by spacers  481  so as to allow airflow communication with openings  440  in bottom  432 . Baffle plate  480  also functions as an airflow blocker to block warm air from below chassis  430  from entering into chassis  430 , such as from heat emitting equipment mounted below. 
         [0075]    Referring now to  FIGS. 29 and 30 , a further embodiment of a panel  510  is shown. Panel  510  includes the same chassis  430  as for panel  410 , and four second modules  418 , two on each side. Panel  510  also is shown including baffle plate  480 . Baffle plate  480  also includes a front lip  482  positioned in an upward direction relative to a remainder of baffle plate  480 . Front lip  482  and the rest of baffle plate  480  can also function as a cable tray for holding cables extending to and from panel  510 , or for cables extending between equipment on either side of panel  510 . 
         [0076]    Referring now to  FIGS. 31-39 , first module  416  is shown in greater detail. Module  416  includes a frame  600  including a base  602 , and a front tray  604  with front lips  606 . Front tray  604  includes perforations  607  for use with cable ties. A vertical support  608  extends up from base  602  and defines a plurality of openings  610 ,  612  for output terminal units  620 , and fuses  622 , respectively. Base  602  also includes sides  626  and longitudinal rails  628 . Two printed circuit boards  630 ,  631  connect between module connectors  696  and the circuit elements including output terminal units  620  and fuses  622 . Fuse holder or block  640  with fuses  622  is held in place by a support tray  641  and a strap  642 . Various openings  646  are provided in base  602  and tray  641  to assist with ventilation. 
         [0077]    Referring now to  FIGS. 40-48 , second module  418  includes a frame  700  including a base  702 , and a front tray  704  with front lips  706 . Similar perforations  707  are provided for use as cable ties in front tray  704 . A vertical support  708  defines a plurality of openings  710 ,  712  for output terminal units  720  and fuses  722  respectively. Frame  700  includes sides  726 , and longitudinal rails  728 . A printed circuit board  730  connects between module connector  696  and the circuit elements including output terminal units  720  and fuses  722 . Various openings  746  are provided in base  702  to assist with ventilation. 
         [0078]    Referring now to  FIGS. 38 ,  47 , and  49 , a voltage disconnect feature is illustrated. One issue that can arise with removing of a module during operation is that arcing may occur between the connectors  696  of the modules, and the connectors  104  of the backplane. A voltage disconnect system  800  is provided to turn off the power to the module prior to removal of the module in order to prevent arcing. A selected pin  808  among pins  806  of connector  696  is provided with a shortened length. The shortened pin  808  will disengage first before the power connections disengage. This will provide an interrupt signal that will be received by a device, such as a microcontroller or a similar device on the module, to activate a voltage disconnect mechanism which turns off the current to the load. This will prevent arcing on the connectors and prevent damage from occurring. Furthermore, if the module is not completely inserted, the short pin  808  will prevent the voltage disconnect mechanism from activating and keep the output current turned off until the module is fully inserted. A visual indication will be displayed if the module is not fully inserted.  FIG. 49  illustrates an example flow chart illustrating the voltage disconnect feature. 
         [0079]    Each module  416 ,  418  includes various visual indicators to indicate system conditions. For example, there are provided visual indications for power, low voltage, blown fuse, and excess temperature through visual indicators  900 . 
         [0080]    Power input covers  910 , and power output covers  920  can be provided if desired. 
         [0081]    As shown in  FIGS. 50-52 , various arrangements for panels  410 ,  510 ,  1010  are shown using the same chassis  430 . Labels  1200 ,  1210 ,  1220  can be used to label each module  416 ,  418  as needed for each arrangement. Labels  1200 ,  1210 ,  1220  can be adhesively attached to each module  416 ,  418  as needed.