GB2175142A - Circuit breaker - Google Patents

Description

1 GB2175142A 1

SPECIFICATION

Circuit breaker BACKGROUND OF THE INVENTION Field, of the Invention The present invention concerns single-pole and multipole electrical circuit breakers in which maximum contact opening is achieved in a circuit breaker of minimum size.

Discussion of the Related Art Commonly assigned US Patent Nos 3,959,755 to Harper et al and 4,117,285 to Harper disclose representative conventional circuit breakers, comprising a stationary electrical contact, a movable electrical contact mounted on a movable contact arm, means for manually opening and closing the contacts, and means for automatically opening the contacts in response to an overcurrent through the breaker. The component parts of the breaker are enclosed in an insulat- 15 ing plastic housing.

Commercial circuit breaker manufacturers generally manufacture a complete product line com posed of a number of breaker sizes, each one covering a different (although sometimes overlap ping) operating current range. To date each breaker size has required its own component and case sizes. In general, each component and case size combination is useful in circuits having 20 only a single current rating range. The need to have a different set of component and case sizes for each current rating has added to the overall cost of breakers of this general type. Heretofore, a variety of factors has dictated breaker sizes.

One such factor relates to the minimum gap requirement between contacts that must be met for a given current rating, when the breaker contacts are manually opened, as well as when they 25 -are tripped open automatically. (Many breakers separate their contacts a first distance when manually opened and a different distance when automatically tripped). It is necessary to make the breaker sufficiently large so that the minimum gap requirement is met in the manual and automatic modes, whichever results in a smaller gap. This requirement has an effect on the overall size of the breaker.

As the current carrying capacity (or rating) of the breaker increases, the gap between the electrical contacts of the breaker in the OFF (or open) position must increase proportionately.

Since known circuit breakers are generally capable of separating their electrical contacts only a relatively limited distance compared to the overall size of the breaker, it has been necessary to manufacture increasingly larger circuit breakers in order to obtain the greater spacing between 35 electrical contacts in the OFF position required for higher current ratings.

An object of the present invention is to permit a range of current ratings within a given overall size.

SUMMARY OF THE INVENTION

The invention provides a circuit breaker mechanism comprising: movable contact means mounted for Movement about a first pivot axis:

toggle means, including:

a first toggle link member coupled to said movable contact means for movement about a second pivot axis, said first and second pivot axes being spaced apart a distance D, and 45 a second toggle link member coupled to said first toggle link member for movement about a third pivot axis, said second and third pivot axes being spaced apart a distance D,; actuating means coupled to said second toggle link member for movement about a fourth pivot axis, said third and fourth pivot axes being spaced apart a distance D,; and means mounting said actuating means for movement about a fifth pivot axis, said fourth and fifth pivot 50 axes being spaced apart a distance D,, wherein D, D, D, and D, have the following relation ship:

D,: D, < D,: D, < D,: D, BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a side view of a circuit breaker in accordance with the present invention; Figure 2 is an end view of the circuit breaker of the present invention; Figure 3A is a side view of an operating handle for the circuit breaker in accordance with the invention; Figure 3B is a partial sectional view along line B-B of Fig. 3k Figure 4 is a side view of the toggle mechanism cam link of the invention; Figures 5A and 5B are end and side views, respectively, of the toggle mechanism housing link in accordance with the invention; Figures 6A-6C are side, top and end views, respectively, of a movable contact arm in 65 2 GB2175142A 2 accordance with the present invention; Figure 7A illustrates the switching means for a circuit breaker in accordance with the present invention in- a manually opened condition; Figure 78 illustrates the same switching means in a tripped open condition; Figure 7C illustrates the frame for a circuit breaker in accordance with the present invention; 5 Figure 8 is a part sectional view of the operating handle mounted in the breaker casing in accordance with the invention; Figure 9A is a partial sectional view of a portion of the breaker casing in accordance with a multipole embodiment of the invention, taken along line A-A in Fig. 9B.

Figure 9B is a partial side view of the multipole casing in accordance with the invention; Figure 10A is a sectional view of an alternate multipole casing of the invention, taken along line A-A of Fig. 110B; Figure 108 is a partial side view of the alternate multipole casing configuration of Fig. 10A; Figure 11A is a part sectional view of another casing configuration used in a multipole versions of the invention taken along the line A-A of Fig. 11 B; Figure 1 1B is a partial side view of the casing of Fig. 11 A; Figures 12A and 12B illustrate a shield employed in multipole circuit breakers of the present invention; Figure 13A and 138 show end and side views, respectively, of a trip lever in accordance with 2-0 the invention; Figure 14 is a side view of a circuit breaker of the present invention including the trip lever illustrated in Figs. 13A and 1313; Figure 15A and 15B are side and end views, respectively, of a handle link of the invention; Figure 16 illustrates selected elements of adjacent poles of a multipole circuit breaker in accordance with the invention, including adjacent casings, operating means, trip levers, and a shield between casings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to Figs 1-2, a preferred embodiment of a circuit breaker in accordance with the present invention is designated generally by reference numeral 10. The circuit breaker includes a 30 case 12 formed of electrically insulating material, such as plastic. Case 12 is formed from a pair of complementary casing halves 14 and 16, which are secured together by rivets or similar fasteners (not shown) through a plurality of upper and lower fastener holes 18 and 20.

A boss 22 extends from the upper portion of case 12 and includes an opening 24 for a toggle handle 26. Handle 26 is also formed from a non-conductive material, typically molded 35 plastic A pair of surfaces 28 and 30 define opposite ends of opening 24 through which handle 26 passes.

The trip mechanism is designated generally by reference numeral 32. It includes a one-piece frame 34 which is fixedly mounted within case 12. Frame 34, described in more detail below with reference to Fig 7C, supports an overcurrent trip coil 36, which is connected through an 40 electrical lead 38 to a terminal 40.

Coil 36 surrounds a magnetic core 42. Preferably, although it does not form an essential part of the present invention, core 42 includes a delay tube. By way of example only, the coil and delay tube assembly may be of the type shown and described in commonly assigned U.S.

Patent No. 4,062,052 to Harper et al., the disclosure of which is incorporated herein in its 45 entirety by reference.

Magnetic core 42 terminates in a pole piece 44. Adjacent pole piece 44 is an armature 46 pivotally mounted on a pin 48 secured to frame 34. Armature 46 is rotatably biased in a clockwise direction (relative to Fig. 1) by a spring (not shown), and comprises a leg 50 and a counterweight 52. Counterweight 52 comprises an enlarged extension of armature 46, and may 50 include a slot 54 for receiving a pin 56 of an inertia wheel 58 rotatably mounted on frame 34.

The function of the inertia wheel is set forth in detail in commonly assigned U.S. Patent No.

3,497,838 to Merriken et al., the disclosure of which is incorporated herein in its entirety by reference.

Handle 26 is pivotally mounted- on a pin 60 secured in frame 34. Handle 26 includes a pair of 55 ears 62 and 64 with apertures for receiving a rivet or pin 66 which connects handle 26 to a cam link 68. Cam link 68 is pivotally connected by a rivet or pin 70 to a housing link 72. A sear pin 74, as is well known in the art, is rotatably mounted in housing link 72 and is biased in a clockwise direction by spring means (not shown). A sear striker bar 76 is secured to sear pin 74.

A rivet or pin 78 pivotally attaches housing link 72 to a movable contact arm 80. Arm 80 is pivotally mounted on a pin 83 secured to frame 34 and is biased in a counterclockwise direction by a spring 81. In the embodiment shown, arm 80 is also slidably mounted on pivot pin 83.

Contact arm 80 carries on the end thereof a movable contact 82 which is held, when the breaker is in the closed, or ON, position, against a stationary contact 84 mounted on terminal 65 3 GB2175142A 3 86. The circuit breaker is connected by terminals 40 and 86 into an electrical circuit, as is well known.

Coil 36 is electrically connected to contact arm 80 by a conductive braid 88. When the breaker is closed, a continuous electrical path is created through terminal 40, lead 38, coil 36, braid 88, contact arm 80, contacts 82 and 84, and terminal 86.

With reference to Figs. 3A and 313, handle 26 has a central opening 90 in a hub 91 for pivotally mounting handle 26 on pin 60. A pair of apertures 92 and 94 in ears 62 and 64 receive rivet 66, as described above.

Concentrically disposed with respect to opening 90 are a pair of arcuate ridges 96 and a pair of arcuate recesses 98. A pair of lateral protrusions 100 extends from opposite sides of handle 10 26, each protrusion having an aperture 102 therein. As seen in Fig. 3A, the center-to-center distance from the pivot axis of handle 26 to the center of apertures 92 and 94 where the handle is joined to cam link 68 is represented by a dimension D4' Referring to Fig. 4, cam link 68 includes an upper pivot opening 104 which receives rivet 66 connecting link 68 to handle 26. A lower pivot opening 106 receives rivet 70, connecting link 15 68 to housing link 72. A cam surface 108 includes a seat 110 against which sear pin 74 rests to lock links 68 and 72 of the toggle mechanism against relative movement. The distance between the centers of the upper and lower pivot openings 104 and 106 is represented by a dimension D, Referring to Figs. 5A and 513, housing link 72 includes a pair of spaced parallel plates 111 and 20 113 joined by a pair of upper and lower straps 115 and 117. Plates 111 and 113 each have an upper pivot opening 112a and 112b, respectively, to receive rivet 70, and pivotally connect link 72 to link 68. Plates 111 and 113 also have a lower pivot opening 1 14a and 1 14b, respec tively, for receiving rivet 78, to pivotally connect link 72 to contact arm 80. Sear pin 74 is rotatably mounted within a pair of openings 11 6a and 1 16b, respectively, in plates 111 and 25 113.

The rightmost plate 113, as seen in Fig. 5A, has an extension 118 which includes a tab 120 projecting laterally outward of housing link 72. Tab 120 acts as a stop for striker bar 76 of sear pin 74, as best seen in Fig. 1. The distance between the centers of the upper and lower pivot openings 112 and 114 is represented by dimension D2' As illustrated in Figs. 6A-6C, movable contact arm 80 includes a pair of sides 122 and 124, connected by a bottom plate 126. End plate 126 has an opening 130 therein for mounting movable contact 82 to arm 80. Sides 122 and 124 have openings 132a and 132b, respectively, for pivotally connecting arm 80 to housing link 72 by means of rivet 78.

Another pair of openings 134a and 134b (the latter not shown) in sides 122 and 124, 35 respectively, receives pin 83, for pivotally connecting arm 80 to frame 34. A pair of inwardly projecting stops 136a and 136b, respectively, act as a seat for one end of spring 81. The other end of spring 81 bears against frame 34 (Fig. 1), rotatably biasing arm 80 in a counter clockwise direction. A pair of surfaces 138a and 138b, respectively, is adapted to bear against frame 34 when the circuit breaker is opened, preventing further counterclockwise rotation of contact arm 80 about its pivot axis. The distance between the pivot axis of arm 80 and the axis of the pivotal connection between arm 80 and link 72 (Fig. 6A) is represented by dimension D, Fig. 7C shows a side view of the frame 34 separately. The frame includes a main body portion which includes an L-shaped back plate 340, on which coil 36 rests, and a pair of side members 341 (only one of which is shown in full in Fig. 7Q. Both side members have an upwardly extending arm 342 which terminates in a circular portion containing an opening 343 through which pivot pin 60 passes. Each side member 341 also a downwardly extending leg 344 which terminates in an end portion 345 having an opening 346 through which pivot pin 83 passes. Both side members 341 also contain openings 347 through which armature pivot pin 48 passes. In operation, when the breaker is opened, contact arm 80 pivots about pin 83 to the 50 point at which surfaces 138a and 138b strike the front face of L-shaped back plate 340.

A feature of this invention, which permits the same breaker mechanism to be used in breakers of different current ratings, is the dimensional relationship of the frame elements to each other.

The height or vertical distance between the centers of pivot pin openings 343 and 346 is represented by dimension D, The lateral distance between pin opening 343 and pivot pin opening 346 is represented by dimension D. Dimensions D, and D,, represent two legs of a right triangle, the hypoteneuse of which extends between and intersects the centers of pivot pin openings 343 and 346. The lateral distance between the pivot pin opening 346 and a plane containing the face of back plate 340 and extending parallel to the right triangle leg defined by dimension D, is represented by dimension D, Surfaces 138a and 138b of contact member 80 60 abut against the face of back plate 340 of frame 34 to terminate the counterclockwise rotation of contact arm 80, For purposes of the following discussion, the axis of pin 83, pivotally connecting contact arm to frame 34, will be designated the first pivot axis; the axis of rivet 78, pivotally connecting housing link 72 with contact arm 80, will be designated the second pivot axis; the axis of rivet 65 4 GB2175142A 4 70, pivotally connecting cam link 68 with housing link 72, will be designated the third pivot axis; the axis of rivet 66, pivotally linking handle 26 with cam link 68, will be designated the fourth pivot axis; and the pivot axis of handle 26 (through pin 60) will be designated the fifth pivot axis.

W - hen. the breaker 10 is in its closed, or ON position, the second, third and fifth pivot axes lie substantially along an imaginary straight line between the second axis at rivet 78 and the fifth axis at pin 60. The fourth pivot axis is slightly offset from that imaginary line (to the left as shown in Fig. 1). Spring 81 biases contact arm 80 in a counterclockwise direction. This in turn biases the toggle mechanism comprising links 68 and 72 toward a collapsed position. In the absence of a sear pin 74, this would cause contact arm 80 to rotate, thereby opening the breaker. In the ON, or closed position shown in Fig. 1, sear pin 74 bears against seat 110 of cam link 68, maintaining the toggle mechanism in its extended condition.

Sear pin 74 must be rotated in a counterclockwise direction, in a manner described in greater detail hereinafter, in order to trip open the circuit breaker. The arrangement of the present invention, in which the several pivot axes are aligned as indicated, minimizes the forces acting 15 between sear pin 74 and seat 110, thus maximizing sensitivity of the device. Otherwise, inordinately large forces would act between sear pin 74 and seat 110. A substantial force would be required to rotate the sear pin and trip the breaker, reducing its sensitivity.

While it has been indicated that the second, third and fifth pivot axes lie substantially along a straight line extending between the second and fifth axes, it is well known in the art that, if the 20 second ' third and fourth axes are in perfect alignment, the spring bias force acting on the toggle mechanism through contact arm 80 will not collapse the toggle when the circuit breaker is tripped. Therefore, the third pivot axis at rivet 70 must be offset slightly with respect to a line extending between the second axis at rivet 78 and the fourth axis at rivet 66. This offset is very slight, only to a degree sufficient to assure collapse of the toggle mechanism. Substantial 25 alignment of the second through fourth axes results in a reduction in the forces acting between sear pin 74 and seat 110 and increases the sensitivity of the breaker.

It is also necessary to displace the fourth axis at rivet 66 slightly with respect to a line between the second and fifth axes to assure that, under the influence of spring 81, handle 26, and thus the breaker mechanism in its entirety, will remain closed or ON once positioned as 30 shown in Fig. 1. Again, this offset is only to the minimum degree necessary to ass6re stability of the breaker in the ON position. Thus all of the second through fifth axes are considered to be substantially aligned.

In operation, when current through the circuit breaker exceeds a predetermined threshold, the strength of the magnetic field generated by coil 36 will be sufficient to attract armature 46 toward pole piece 44. As armature 46 pivots about pin 48, leg 50 contacts sear striker bar 76, rotating sear pin 74 in a counterclockwise direction. Rotation of sear pin 74 disengages the pin from seat 110 of cam link 68. In the absence of the restraint imposed by sear pin 74, the toggle mechanism comprising links 68 and 72 is free to collapse, allowing contact arm 80 to pivot in a counterclockwise direction under the influence of spring 81. Contacts 82 and 84 40 thereby separate, and the circuit through the breaker 10 is interrupted.

The circuit may also be interrupted manually. If handle 26 is pivoted in a counterclockwise direction about the pivot axis at pin 60, rivet 66 securing cam link 68 to h - andle 26 orbits or rotates about pin 60 in a counterclockwise direction. Sear pin 74 remains engaged with seat 110 and links 68 and 72 remain locked in place, as shown in Figs. 1 and 7A. As rivet 66 45 traverses an arc centered on the axis of pin 60, links 68 and 72 are raised and rotated, as illustrated in Fig. 7A. Rivet 78, joining housing link 72 and contact arm 80, moves upwardly and traverses an arc centered on the axis of pin 83. This results in movement of the contact arm 80, separating contacts 82 and 84, and interrupting the circuit through the breaker.

Unique results may be obtained from a circuit breaker when specific relationships are estab- 50 lished between the various elements of the breaker operatively arranged as described above. As discussed earlier, it is necessary to maintain a minimum gap clearance for a given amperage rating in a circuit breaker. The gap must be made larger as the amperage rating increases.

However, it is not necessary to increase overall size, as compared to known circuit breakers, in order to widen the air gap between the electrical contacts when the breaker is in the open condition. The particular relationships, referenced above and discussed below, will maximize the gap between the open breaker contacts within given dimensional restraints in both the manually opened and automatically tripped modes of operation. Therefore, circuit breakers of relatively small overall dimensions may be manufactured for use at relatively high amperages and over a broad range of amperage ratings. Furthermore, the preferred spatial relationships between the 60 components of the present invention afford the unique result that contact arms of various sizes and current ratings may be interchanged and still function properly with the same toggle mecha nism.

In accordance with the invention, the above-defined dimensions D,-D, are maintained in parti cular relationships to each other in order to achieve uniquely advantageous results. Handle 26, 65 GB2175142A 5 cam link 68, housing link 72 and contact arm 80 are formed in such manner as to establish the desired relationships.

Figs. 7A and 7B illustrate the switching means of the present invention in the manually or normally tripped opened and trip-free conditions, respectively. When the breaker is tripped normally or is opened manually, handle 26 is rotated in a counterclockwise direction about the 5 pivot axis at pin 60, as indicated in Fig. 7A. When handle 26 is in its counterclockwise position, a gap G, is established between contacts 82 and 84. Fig. 7B illustrates the circuit breaker of the invention in the trip free (i.e., handle forcibly held ON) condition. When the breaker is tripped, contacts 82 and 84 separate a distance defined by gap G2. Gaps G, and G2 are maximized in a circuit breaker of given dimensions when dimensions D1, D, D3, D, D, D,, and D7 have the following relationships:

D,:D,<D,:D,<D,:D,; D7:D,<D,:D,<D,:D,<D,:D,<D2:D,<D,:D,; and D7:D,<D,,:D, When the above-described relationship is maintained among distances D, D2, Q,, D4, D,, ID,3, and D7, gap size G, is maximized, not only with respect to the overall dimensions of the circuit 20 breaker, but also with respect to the degree of travel of handle 26. Compared to known circuit breakers of comparable overall dimensions, gap G, is substantially increased while the range of arcuate motion of handle 26 is reduced to approximately 31' -32; this is substantially less handle travel than is characteristic of known devices. The present device thus constitutes a very fast-acting manual breaker, achieving increased gap distance for smaller movement of the manual 25 control means. The device of the invention will be capable of accommodating an equally wide range of amperage rating in the manually opened and automatically tripped open modes of operation. Consequently, neither mode of operation limits the range of usefulness of the present invention.

As an example, a device in accordance with the present invention may include parts having 30 the following dimensions:. D, =0.30 inch; D,=0.430 inch; D,=0.330 inch; D4=0.340 inch; D,=1.093 inch; ID,=0.240 inch; and D-,=0.126 inch. In this example, D,:D, is substantially 1.411.00 D,:D, is substantially 1.10A.00 D,:D, is substantially 1.13A.00 D,:D, is substantially 3.64A.00 D6:1D, is substantially 0.80A.00 D,:D, is substantially 0.42A.00 D,:D, is substantially 0.22A.00 D,:D, is substantially 0.12A.00 Gaps G,and G, will therefore be maximized at substantially 0.53 inch (13. 48 mm). This is sufficient to satisfy industry safety standards, such as German VDE and proposed IEC safety standards, which require only a three millimeter gap between contacts in the OFF or open position. The present invention satisfies these standards in a breaker of minimum dimensions and facilitates use of smaller breakers to satisfy requirements for minimum gap clearances.

The aforesaid industry safety standards also require a separation of at least 8 mm (0.315 inch) between "live" (electrically conductive) parts and accessible portions of the circuit breaker.

Accessible portions are defined as those areas of the circuit breaker which may be reached from 50 the exterior of the casing using a 2X4 millimeter probe. The distance is measured as the shortest distance from the accessible portion through a space or across a surface or surfaces leading to live parts. It has generally been necessary to enlarge or extend portions of circuit breakers and/or their casings in ordrr to satisfy this standard. The present invention meets this requirement without enlarging the overall dimensions of the circuit breaker.

Specifically, the invention includes manual operating means and casing portions which coop erate to define tortuous paths and thereby provide maximum separation between accessible portions and live parts in a circuit breaker of minimum dimensions. Handle 26 includes arcuate ridges 96 and arcuate recesses 98, as previously described with reference to Figs. 3A and 3B.

Fig. 8 shows a portion of the handle and casing of the invention, illustrating the manner in 60 which they provide adequate separation between exterior portions of the circuit breaker and live conductive parts. Handle 26 includes a narrow portion 144 (see Fig. 8) which lies between inwardly extending portions 146 of boss 22 of casing 12. Narrowed portion 144 extends radially inwardly from an enlarged outer portion 27 toward the interior of casing 12 and terminates at ridges 96. Casing halves 14 and 16 in many respects are substantially mirror 6 GB2175142A 6 images ' of each other. Each casing contains an arcuate recess 140 and an arcuate ridge 142.

The arcs of recesses 140 and ridges 142 are centered on the axis of pin 60, pivotally mounting handle 26. Recess 140 and ridge 142 form a non-planar surface portion of each casing half 14 and 16 which is complementary to the non-planar surface portions of handle 26 formed by ridges 96 and recesses 98. The base 148 of narrowed handle portion 144 is at least potentially 5 accessible to the outside of the breaker. The shortest distance from base portion 148 to an electrically conductive, or---live-part within the casing will lie along a tortuous path or air gap which opens into the interior portion of the breaker at a point 152. The tortuous path through gap 150 is substantially longer than the straight line distance from point 148 to the interior of the casing. In a device constructed in the manner and proportions illustrated in Figs 10 3A, 313 and 8, the distance from point 148 through gap 150 to point 152 is about 0.33 inch (8.5 mm); whereas the vertical distance between points 148 and 152 is only about 0.14 inch (3.5 mm).

The arcuate form of ridges and recesses 96, 98, 140 and 142 permits normal pivotal movement of handle 26. The invention is not limited, however, to devices embodying pivotal manual operating means. A device embodying principles of the invention could take the form of, for example, operating means which moves linearly between the OFF and ON positions.

A circuit breaker in accordance with the present invention may also be used in multipole arrangements. As exemplified by the aforesaid U.S. Patent Nos. 3,444,488 and 3,786,380, multipole circuit breakers may comprise a plurality of single pole circuit breakers adjacent each 20 other and operatively connected. The circuit breaker of the present invention includes means adapting it for use in multipole arrangements, while overcoming the previously discussed drawbacks associated with know multipole circuit breakers, and while satisfying industry safety standards.

Figs. 9A and 913 illustrate the preferred embodiment of the casing in accordance with the 25 present invention, having particular utility in multipole configurations. The multipole arrangement requires that one or more connecting links pass through the adjacent casing walls of the several pole units. In order to satisfy industry safety standards, there must be minimum air gap of at least 8mm (0.315 inch) between the exterior of the case at the side opening and the closest conductive part inside the case. The embodiment shown in Figs. 9A and 913 incorporates a new 30 design which satisfies this requirement.

The drawing shows one case half; the other case half is substantially the same, except as noted below. Boss 22 extends upwardly from case 12. Wall portion 146 forms the inside wall of boss 22, and, together with the corresponding wall portion of the opposite case half, defines handle 26. Arcuate recess 140 and arcuate ridge 150 receive arcuate ridge 96 and arcuate recess 98, respectively, as described in detail above. A steppedarcuate recess 143 leads to a recess 188 surrounded by and extending inwardly from a raised surface portion 185 on the interior wall of casing 12 to receive an end of pivot pin 60. An arcuate opening 182 is located in the side wall of casing 12. A connecting member extends through adjacent openings 182 to connect the breaker mechanisms of adjacent pole units. The connecting member is described in 40 more detail below.

It is a feature of this invention that the interior casing wall portion in the region of opening 182 is built up relative to the remaining wall portion. In this way the most direct path between the exterior of the braker and the closest---live-part will equal or exceed the requisite 8mm minimum distance. In parfluclar, a wall segment 187 extends outwardly from the main interior 45 wail 189. The arc path created by this outwardly extending wall segment is substantially longer than the arc path that would be created absent such segment 187.

An alternate arrangement, which utilizes an externally mounted shield member rather than a built up interior wall segment, is shown in Figs. 10A-10B. Figs. lOA-10B illustrate a---right- casing half. A---left-casing half is substantially a mirror image of that shown. In this embodimerit, the casing includes a portion forming boss 22% an inner face portion 146% an arcuate recess 140' and an arcuate ridge 142% all corresponding to like numbered elements previously described with reference to Figs. SIA-913. In addition, an arcuate opening 182' is provided in the casing, permitting connecting member associated with the handle mechanism of one pole to extend through adjacent casing walls to an adjacent pole. The arcuate form of opening 182, is 55 designed to allow arcuate motion of the connecting member, as described below. A recess 188' on the interior wall of the casing receives an end of pivot pin 60, as seen in Fig. 2.

A recess 202 may be formed in the exterior wall of the casing surrounding opening 182' as an element of the alternate embodiment of the present invention that is discussed below. A pin 196 extends from the wall in the vicinity of opening 182'. It should be understood that, while 60 the opposite casing half (not shown) is substantially a mirror image of that illustrated in Figs.

10A-1013, and includes a recess 202 in the alternate embodiment, the other half need not include pin 196. The casing also includes an opening 174', to permit additional connecting members to pass between adjacent poles.

Figs. 11 A and 11 B illustrate a second form of casing in accordance with the alternate 7 GB2175142A 7 embodiment of the present invention. This embodiment is similar to that illustrated in Figs. 10A and 10B, except that it is adapted for use in breaker pole having a handle link (see Figs. 1 5A- 1 5B and related discussion below). Parts shown in Figs. 11 A and 11 B corresponding to those of Figs. 10A and 10B are similarly numbered. Boss 22', recess 140' and ridge 142' are unnecessary in this form of the casing, as there is no handle portion which extends from the casing nor is there any access to the interior of the housing in this region.

Figs. 12A and 12B illustrate a shield, or covering means 190, which may be interposed in the space defined by recesses 202 in adjacent pole casings in a multipole breaker in accordance with the alternate embodiment of the invention. Fig. 12A depicts the position of shield 190 and a connecting member 180 when the circuit breaker is in its closed or ON condition; Fig. 12B 10 shows the same elements when the breaker is opened. Phantom line 34 indicates the position of frame 34 within the casing.

Shield 190 also includes an arcuate slot 198, the center of radius of which substantially coincides with the center of opening 192. Arcuate slot 198 has a width sufficient to permit extension 180 to pass therethrough. Slot 198 in shield 190 and slot 182 in the casing cooperate to define a tortuous path. Together, they serve to maintain a sufficient effective distance between conductive parts of adjacent poles to meet industry safety standards.

Figs. 13A-13B illustrate an improved trip lever 154 of the present invention; Fig. 14 shows the trip lever mounted in a breaker. Lever 154 includes a first leg 156 and a second leg 158. A connecting member 160 joins legs 156 and 158 at one end of each leg. A flange 162 at the 20 other end of first leg 156 is adapted to be engaged by enlarged end 79 on rivet 78 (see Figs. 2 and 14) which connects housing link 72 to movable contact arm 80. A flange 164 on the other end of second leg 158 is adapted to strike sear striker bar 76. Connecting portion 160 includes a tapered. aperture 166 therein, shown partly in section in Fig. 13A. The internal diameter of aperture 166 decreases toward its innermost portion. A complementary tapered extension 168 25 extends from connecting portion 160. The diameter of extension 168 decreases toward its outer endmost portion. Aperture 166 and extension 168 have similar tapers, whereby an extension 168 of one trip [ever may be easily inserted yet snugly seated within an aperture 166 of a similar adjcent trip lever for frictional engagement with the adjacent trip lever. Legs 156 and 158 include a pair of aligned apertures 170 and 172, respectively, for pivotally mounting lever 154 30 on pin 48 in frame 34, as illustrated in Fig. 14. A pair of recesses 173 and 175 in leg 158 accommodates a spring (not shown) which biases lever 154 in a clockwise direction as viewed in Fig. 14. The circuit breaker casing includes openings 174 (see Figs. 913, 1 OB, 11 B) which permit an extension 168 of one breaker pole to project out from the pole casing and to extend into the housing of an adjacent breaker pole. Extension 168 of the last pole is simply cut off so 35 as not to protrude from the device.

When so arranged, trip levers 154 of adjacent poles mate with each other by means of extensions 168 and apertures 166. When properly joined together, the outer surface of one tapered extension 168 mates snugly and securely with the similarly tapered inner surface of an adjacent aperture 166. The closely fitting levers will therefore all pivot essentially simultaneously, 40 an improvement over known devices, in which manufacturing tolerances caused play in the mating mechanism. This resulted in compounded tripping delays from pole to pole.

If any pole of the multipole circuit breaker of the invention is tripped open by an overcurrent, upward motion of contact arm 80 will cause enlarged end 79 of rivet 78 (Fig. 14) to strike flange 162 of leg 156. This will cause the trip lever of the tripped pole to pivot about pin 48 in 45 a counterclockwise direction (as shown in Fig. 14). The several trip levers, joined by the improved mating means 166, 168 of the present invention, will rotate similarly and substantially simultaneously. Flange 164 of each trip lever will strike respective sear striker bars 76 of the other, still closed, breaker poles. This will trip open each pole of the multipole circuit breaker.

The trip lever of the invention is a substantial improvement over similar known devices. First, 50 as set forth above, tapered apertures 166 and tapered extensions 168 assure substantial alignment and simultaneous motion of all trip levers associated with all poles of the multipole circuit breaker. This results in essentially simultaneous tripping of all poles. Additionally, once rivet end 79 strikes flange 162 of a trip lever, the motion imparted to all trip levers is transferred directly to sear pin release means of each remaining pole. Thus, the complex and 55 lengthy sequence of mechanical movements associated with known devices is eliminated and the time delay between the initial tripping of one pole and tripping open of all other poles will be substantially reduced.

A multipole circuit breaker in accordance with the present invention also includes an improved manual switching arrangement which will be discussed with reference to Figs. 3A, 313, 15A and 60 15B.

Handle 26 (Figs. 3A, 313) includes a pair of oppositely extending lateral protrusions 100 having apertures 102 contained therein. These apertures, like apertures 166 of trip lever 154, are tapered, having an internal diameter which decreases toward the interior portion thereof.

Figs. 15A and 15B illustrate a handle link 176 in accordance with the present invention. 65 8 GB2175142A 8 Handle link 176 is operatively similar to handle 26, but does not include a portion, e.g., like handle portion 27, which extends outwardly of the casing to permit manual operation of the breaker pole with which handle link 176 is associated. Movement of handle link 176 results from movement of handle 26 of an associated pole to which it is joined.

Handle - link 176 is used in place of handle 26 in single handle multipole embodiments of the 5 invention. Handle link 176 includes an opening 90' in a hub 91' (corresponding to similarly numbered parts of handle 26) for pivotally mounting handle link 176 on pin 60 of its associated pole. Ears 62' and 64' contain apertures 92' and 94, respectively. Rivet 66 passes through aperture 92' and 94' to join handle link 176 to cam link 68.

A pair of lateral protrusions 178a, 178b extends from opposite sides of handle link 176.

Protrusions 178a, 178b are spaced from opening 90' a radial distance which corresponds to the radial distance between centers of aperture 102 and opening 90 of handle 26. A tapered extension portion 180 extends from one lateral protrusion 178a. The casing of the invention includes arcuate opening 182 which permit extensions 180 to extend into the casings of adjacent poles.

When the poles of the multipole circuit breaker are arranged adjacent each other, an extension of a breaker pole will seat snugly in a friction fit arrangement within aperture 102 of the pole containing handle 26. Thus, when handle 26 is pivoted about its axis, all handle links joined thereto will also pivot, whereby each pole will be substantially simultaneously opened or closed.

The precise fit of extensions 180 within apertures 102, in like manner as described above with 20 respect to apertures 166 and extensions 168, assures essentially simultaneous movement of all breakers and substantially reduces the time lag between opening or closing of respective breaker poles associated with known multipole circuit breakers.

In order to eliminate disadvantageous lag times in the manual activation of multipole breaker units, it may be necessary to limit the number of breaker poles that are joined in a multipole assembly. Although two breakers may be essentially simultaneously controlled by a single throw joining their respective handle mechanisms, even the use of handle link mechanisms of the present invention may not eliminate all delays in breaker activation when more than four-breaker multipole assemblies are used. Thus, for example, in a four-breaker multipole assembly of the present invention, the two central breaker poles are activated by externally connected toggle 30 handles 26 and the two outside breakers are joined to the inner breakers via handle links 176 described above and their respective tapered portions 180.

Fig. 16 illustrates adjacent poles of a multipole circuit breaker according to the invention and the manner in which the handle, handle link, and trip levers thereof are joined. Also illustrated in Fig. 16 is the manner in which shields 190 are utilized in the alternate embodiment. One pole 35 includes handle 26 pivotally mounted by hub 91. The tapered aperture 102 of lateral protrusion of handle 26 is received in tapered extension 180 of handle link 176. Handle link 176 is mounted for pivotal movement about hub 91'. The tapered extension 168 of connecting member of a first trip lever 154 is received in a tapered aperture 166' of another trip lever 154' associated with the other pole. Extensions 180 and 168 extend through openings 182 and 174, 40 respectively, of the adjoining walls of the poles. In the alternate embodiment, recesses 202 in adjoining walls together form a space 204 for receiving shield 190 therein.

When the circuit breaker is manually switched to the OFF or open position, extending 180 travels in a counterclockwise direction about the axis of its pivot mount 60, coincident with the axis of pin 196, into the position illustrated in Fig. 12A. Once extension 180 has traversed the 45 full length of arcuate slot 198, contact with the end portion 199 thereof rotates shield 190 in a counterclockwise direction, into the position illustrated in Fig. 12B.

Extensions 168 and 180, which mechanically link adjacent poles, are formed from non conductive material, to thereby electrically isolate adjacent poles from each other. Typically, handle link 176 and handle 26 are formed entirely of molded, non- conductive plastic. Likewise, 50 trip lever 154 is molded of non-conductive plastic material. In order to limit the overall dimen sions of individual poles, and thus the entire multipole circuit breaker, shield 190 is used in the alternate embodiment to maintain adequate separation between electrically conductive portions of adjacent poles, so that they may be brought into closer proximity to each other than would otherwise be possible.

Thus, frame 34 is the electrically conductive element of each pole which, in the region of opening 182, is closest to the wall of the pole. The distance between frame members of adjacent poles through openings 182 is the shortest distance between electrically conductive parts of adjacent poles. For safety purposes, it is necessary that this distance be sufficient to prevent arcing between adjacent poles. The aforementioned VIDE and IEC standards require at 60 least 0.315 inch (8 mm) between conductive portions of adjacent breaker poles. In the preferred embodiment of the invention, the tortuous path of the casing, and its thickness about opening 182 provide the requisite distance between conductive elements of adjacent poles. Shield 190 in the alternate embodiment maintains the required distance between adjoining breakers in circuit breakers of minimum overall dimensions.

9 GB2175142A 9 In the alternate embodiment, in the absence of shield 190, with extension 180 in the position illustrated in Fig. 1213, the effective distance between frames 34 of adjacent poles would be the straight line distance between the frames plus twice the distance L, where -L- is the distance between the closest proximate edges of frame 34 and opening 182'. Shield 190 increases the total effective distance between adjacent frames by increasing the distance between the edge of 5 frame 34 and the casing opening. As shown in Fig. 1213, -L- represents the distance between the edge of casing opening 182' and shield opening 198 when the breaker is in the OFF position. With extension 180 and shield 190 in the positions shown in Fig. 1213, the effective distance between adjacent frames 34 is the straight line distance therebetween plus twice the distance (L+U), where (L+U) is the distance between the closest proximate edges of frame 34 10 and arcuate slot 198. Therefore, shield 190 increases the effective distance between frames 34 of adjacent poles by an amount equal to 2U. This increased distance facilitates maintenance of adequate separation between adjoining frames in circuit breakers of smaller dimensions than was heretofore possible.

While the reference has been made to frames 34 as the conductive elements which are 15 closest to each other, it should be understood that, if the particular arrangement of elements differs from that illustrated and other conductive elements are closer to an opening such as 182, the minimal distance between adjoining ones of such other conductive elements would be of primary concern.

While the invention, in its various aspects, has been described with reference to the accom- 20 panying figures, it should be understood that the invention is not limited to the details shown in the figures, the invention being limited only by the claims appended hereto.

Attention is drawn to our copending application no. 8325673 from which this application is divided, and which contains an identical disclosure but claims a different aspect of the disclosed apparatus.

Claims (1)

1. A circuit breaker mechanism, comprising: movable contact means mounted for movement about a first pivot axis:

toggle means, including:

a first toggle link member coupled to said movable contact means for movement about a second pivot.axis, said first and second pivot axes being spaced apart a distance ID, and a second toggle link member coupled to said first toggle link member for movement about a third pivot axis, said second and third pivot axes being spaced apart a distance D2; actuating means coupled to said second toggle link member for movement about a fourth 35 pivot axis, said third and fourth pivot axes being spaced apart a distance D,; and means mounting said actuating means for movement about a fifth pivot axis, said fourth and fifth pivot axes being spaced apart a distance D, wherein D, D2, ID, and D, have the following relation ship:

D,:D,<D4:D,<D2:D,.

2. A circuit breaker according to claim 3. A circuit breaker according to claim 4. A circuit breaker according to claim 5. A circuit breaker according to claim D,:D, is substantially 1.43A.00, ID,:1D, is substantially 1.10A.00, and D4:13, is substantially 1-13A.00.

6. A circuit breaker according to claim a frame having a main body portion; a first arm extending outwardly from said main body portion and having actuator mounting 50 means for mounting said actuating means for movement about said fifth pivot axis; and a second arm extending outwardly from said main body member and having contact mounting means for mounting said movable contact means about said first pivot axis; wherein said actuator mounting means and said contact mounting means have pivot centers which together define the end points of the hypotenuese of a right triangle, the sides of which have dimensions D, and D,; and wherein the pivot center of said contact mounting means is spaced from a plane parallel to the side of said right triangle of dimension D, and containing said main body portion of said frame; and wherein ID, D, and D, have the following relationship:

D,: D, < D,: D, 7. A circuit breaker according to claim 6, wherein D, D, D,, ID, D, D, and D7 have the following relationships:

D.,:D,<D,,:D,<D,:D,<D,:D,<D,:D,<D,:D,.

1, wherein D,:D, is substantially 1.43A.00. 1, wherein ID,:1D,is substantially 1.10A.00. 1, wherein D,:D, is substantially 1.13A.00. 1, wherein 1, further comprising:

8. A circuit breaker according to claim 7, wherein ID,:1D, is substantially 3.64A.00.

GB2175142A 10 9. A circuit breaker according to claim 7, wherein D,:D, is substantially 0.80A.00.

10. A circuit breaker according to claim 7, wherein D7D, is substantially 0.42A.00.

11. A circuit breaker according to claim 7, wherein ID,D5 is substantially 0.22A.00.

12. A circuit breaker according to claim 7, wherein D7:1D. is substantially 0.12A.00.

13. A circuit breaker according to claim 7, wherein ID,D1 is substantially 1.43A.00 D,:D, is substantially 1.10A.00 D,:D, is substantially 1.13A.00 D,D, is substantially 3.64A.00 DeD, is substantially 0.80A.00 D7D, is substantially 0.42: 1.00. 4. A circuit breaker frame, comprising:

a main body portion; a first. elongated member extending outwardly from said main body portion and having an end portion containing first means for pivotally mounting a first part of a breaker actuating mecha- 15 nism; and a second elongated member extending outwardly from said main body portion and having an end portion containing second part of said breaker actuating mechanism; wherein the centers of said first and second pivot mounting means define the end points of 20 the hypoteneuse of a right triangle, the sides of which have dimensions D, and D,; and wherein the center of said second pivot mounting means is spaced from a plane parallel to the side of said right triangle of dimension D, and containing said main body portion of a distance D,; and wherein D, D, andD, have the following relationship:

D,:D,<D,:.D,.

A circuit breaker according to claim 14, wherein DjD, is substantially 0.22A.00 D,:D, is substantially 0.12A.00 16. A circuit breaker according to claim 14, wherein DjD, is substantially 0.22A.00.

17. A circuit breaker according to claim 14, wherein DD, is substantially 0.12A.00.

18. A circuit breaker as claimed in claim 1 and as substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

Printed in the United Kingdom for Her Majesty's Stationery Office, Dd 8818935, 1986, 4235. Published at The Patent Office, 25 Southampton Buildings. London, WC2A 1 AY, from which copies may be obtained.