CA1320744C - High-amp circuit breaker and a bistable element therefor - Google Patents

High-amp circuit breaker and a bistable element therefor

Info

Publication number
CA1320744C
CA1320744C CA000614640A CA614640A CA1320744C CA 1320744 C CA1320744 C CA 1320744C CA 000614640 A CA000614640 A CA 000614640A CA 614640 A CA614640 A CA 614640A CA 1320744 C CA1320744 C CA 1320744C
Authority
CA
Canada
Prior art keywords
contact
circuit breaker
bistable element
bar
housing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA000614640A
Other languages
French (fr)
Inventor
Thomas J. Stack
Jacek M. Korczynski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cooper Industries LLC
Original Assignee
Cooper Industries LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Cooper Industries LLC filed Critical Cooper Industries LLC
Application granted granted Critical
Publication of CA1320744C publication Critical patent/CA1320744C/en
Anticipated expiration legal-status Critical
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Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H73/00Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism
    • H01H73/22Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism having electrothermal release and no other automatic release
    • H01H73/24Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism having electrothermal release and no other automatic release reset by lever
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H73/00Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism
    • H01H73/22Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism having electrothermal release and no other automatic release
    • H01H73/30Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism having electrothermal release and no other automatic release reset by push-button, pull-knob or slide
    • H01H73/303Protective overload circuit-breaking switches in which excess current opens the contacts by automatic release of mechanical energy stored by previous operation of a hand reset mechanism having electrothermal release and no other automatic release reset by push-button, pull-knob or slide with an insulating body insertable between the contacts when released by a bimetal element

Abstract

ABSTRACT OF THE DISCLOSURE

A low voltage high-amp circuit breaker having a substantially rectangular bimetallic bistable element and a pair of terminals extending from the side thereof. The bistable element is attached to have one end move from a first normal electrically conductive position to a second non-electrically conductive position. The manual reset circuit breaker includes a manual reset lever and a non-conductive heat resistant extension blade connected to the reset lever via a rotatable shaft. The extension blade being positioned adjacent the moveable end of the bistable element and when the element is moved to its second position, the blade is moved to prevent the element from returning to its first conductive position until the circuit breaker is manually reset.

Description

1 32074~
~IIGN-A~P CIRCUIT ~E3REAKER AND ~ BI8TP-BLE 13LE:I~ENT T~IEREFOR

The present invention relates to a High-Amp Circuit breaker assembly and also to the bimetallic bistable element that is used in the assembly.

More particularly the assembly of the present invention has a manual reset or an auto reset mechanism which utilizes a substantially rectangular bimetallic bistable thermally active element to provide for over-load protection.

BACRGROUND
Circuit breakers which are panel mount or ~irewall mount usually have their terminals on different sides of the circuit breaker assembly. This makes it difficult to field wire the circuit breaker into the circuit to be protected.

Also the manual reset circuit breakers are generally c~nstructed so that it is not readily seen that the circuit breaker has opened to protect the circuit from an overload or a surge in current.

Both the manual and the auto reset high amp circuit breaker assemblies which are generally available are relatively difficult to manufacture. The bimetallic bistable elements used to open and close the breaker circuit usually require a relatively complex structure to operate with the quickness that is necessary to 1 3207~
protect a circuit from damage. The structure used is a cylindrical bimetallic disc that has a small clearance hole at the center. The dise is then stamped into a dome shaped element via a radial stamping die to a predetermined amount thus providing the necessary bistable condition. A finely threaded screw is placed through the center hole and engaged into a mating female thread within the units main housing. The screw is tightened to preload the central dome or hump. The disc has a pair of contacts on opposite sides of the diameter. In the assembly the disc eontaets have corresponding contacts attaehed to termination lugs. When the disc circuit breaker encounters an over-current, the disc goes from concave to convex to open the circuit and returns in the automatic reset style when the over-current is not present and a predetermined time has past to allow the element to sufficiently cool. The manual reset style operates similarly except that the bistable element is over-stressed so that when an over-current causes the convex condition, the element must be returned to the eoncave form by physical force via a push-button resetting mechanism.

These types of cireuit breakers for low voltage DC applications with high amperage ratings utilize generally large and broad forming radii that as a process exhibits high variability. This results in eireuit breakers whieh are relatively eostly to manufacture because the manufaeturing proeess is labor intensive.
Eaeh unit has to be individually calibrated at the faetory. The center adjusting screw for eaeh unit must be manually tightened to bring the contacts into a pre-load condition. Then each unit 1 3207~4 69~69-~9 must be tested to be sure it is properly calibrated to open and close as required to protect a circuit.

The present invention provides a high amperage circuit breaker comprising a pair of spaced terminals being placed in series with the circuit to be protected; a hea~ resistant electrical insulating plastic housing defining a body cavity, said body cavit~ having a base, a front wall, a rear wall and two side walls, a cover to close said housing; a rectangular thermally activated bistable mechanical element mounted in said cavity, at least one dimple formed on said bistable element; a first contaet being connected to one of said terminals, said first contact also connected to one end of said bistable element by means whereln the one end of said bistable element always remains stationary with respect to the first contact and in electrical contact with the first contact; a second electrical contact attached to the other end of said bistable element; said other end of said bistable element being free to move in a relatively vertical direction; a third contact electrically connected to said other terminal and being positioned relative to said second contact wherein said second and third contact are normally in electrical contact with each other when the bistable element is .tn a flrst position, and said first position being to close the circuit of the circuit breaker; said bistable element having a predetermlned current response to qui~kly deflect when there is a predetermined over current, said deflection causin~ said other end of said bistable element to move from said first position to a second position and to cause said second contact to separate from said third contact by a predetermined distance to open the circult of the circult breaker.

The bimetallic bistable thermally active element can be easily manufactured without the necessity of fine-tuning the calibration of each unit.

In one embodiment of the invention, the bistable thermally active element is rectangular with a width greater than 1/2 of its length. Through the snap action of each element inherent resis~ibility calibratlon for a partlcular over-load amperage is achieved. The element has at least one dimple formed thereon to provide the desired snap action.

In another embodiment of the lnvention there is a low voltage high-amp circuit breaker which is auto-setting and is either a firewall or panel mount. The circuit breaker has a generally central closed cavity with the rectangular bistable thermally responsive element, as described above mounted therein and connected to a pair of terminal means extendiny externally from the same side of the circuit breaker to allow for, easy electrical ~0 connectors to the circuit breaker.

1 3207l~4 In still another embodiment of t~le invention there is a manual-reset high-amp circuit breaker having a generally central closed cavity. The rectangular bistable thermally responsive element, as described above is mounted in said cavity. The one end of the bistable element is fixed to a contact for a first terminal and is generally not moveable. The other end of the bistable element has a secon~ contact thereon that is normally in electrical contact with a third contact that is for the second terminals.
A rotatable shaft is mounted in the cavity and extends outside of the housing. A manual reset lever is attached to the rotatable shaft and pivots when the shaft rotates. An extension blade is attached to the shaft and positioned adjacent the element contact. A spring means attached to said shaft. The extension blade and spring are positioned so as not to interfere with the normal on position of the circuit breaker-electrical contact between the second and third contacts when there is no overload. However, when there is an overload and the second contact snaps away from the third contact, and the spring turns the shaft to position the extension blade between the second and third contacts. The reset lever is rotated and visually shows that the circuit breaker is in its open condition. When the overload condition is terminated and a predetermined time has passed, the second contact is prevented from contacting the third contact by the extension blade. The circuit breaker remains open until it is manually reset. The circuit breaker remains tripped and nonconducting until it is manually reset. The reset lever is attached to the shaft so that when the reset lever is manually pivoted to its reset position, the extension blade is moved from 1 3~074~
between the second an~ third contacts to a ready non-insulatiny position. The second and third contacts are in their on or electrical contact position. The reset lever and both terminals are all on the same external side of the housing to provide for easy visual means to determine the condition of the circuit breaker and to provide an easy electrical access to the circuit breaker.

Fig. 1 is a top front right per~spective view of a fire wall circuit breaker of the present invention haviny a manual reset;
Fig. 2 is a top plan view of F:ig. 1;
Fig. 3 is a top front right perspective view of an auto-reset panel mount circuit breaker of the present invention;
Fig. 4 is a bottom plan view of the circuit breaker of Fig.
3;
Fig. 5 is a partial section view taken along lines 5-5 of Fig. 2;
Fig. 6 is a partial top sectional view taken along lines 6-6 of Fig. 5;
Fig. 7 is a partial sectional view taken along lines 7-7 of Fig. 5;
Fig. 8 is a partial sectional view taken along lines 8-8 of Fig. 3;
Fig. 9 is a top view of the bimetalllc bistable element of the present invention;
Fig. 10 is a sectional view taken along lines 10-10 of Fig.
9;

1 3207~4 Fiy. 11 is a bottom plan view of Fig. ~.

The drawings show various views of the circuit breakers of the present invention.

Referring to ~ig. 1 and 2, we show a firewall mount high-amp manual reset circuit breaker 20. The circuit breaker has two external terminals 21, 22 extending from the same external side of the breaker. The terminals are preferably mounted on opposite sides of a central housing 23. Thus, the terminals may be reached easily from one side of the circuit breaker. On top of the central housing cover 23 is a blank preferably hollow raised housing 27 and a pivoting reset lever 2>3. The reset lever has a handle 29 which pivots about its end 31 as is described in more detail hereinafter. This blank housing 27 is utilized to give an aesthetic appearance to the circuit breaker and is shaped to complement the features of the reset lever. Also, the stationary portion 32 prevents the reset lever handle 2g from being accidentally turned in the direction of the stationary portion 32. If there was no stop means 32, the accidental turning of the reset handle 29 during shipping or use would most likely damage the circuit breaker and require replacement. The manual reset lever is in a side by side fit with the blank housing and is rotated or pivote~ in the direction Z shown when there is an overload current of a predetermined magnitude. When the reset lever is pivoted to its trip position (not shown), the circuit of the circuit breaker is opened to prevent electricity from 1 3207~
passing therethrough.

After the overload condition ceases and a predetermined time has passed the reset lever handle 29 can be returned manually to the position shown in Figs. 1 and 2 and return the circui~ breaker to its on or closed circuit position. A bimetallic bistable, thermally activated element 41 is mounted in the cavity 33. The bistable mechanical element is manufactured to have a predetermined overcurrent snap action. The bistable element 41 in a non-overload condition is in a first relatively horizontal position as shown in Fig. 5. When there is an overload, the bistable element heats up and deflects to snap into a second position ~not shown).

The bimetallic bistable element 41 is best shown in Figs. 9-11.
The bistable element is a known thermally reactive composite alloy. The bistable element has a top surface 42, bottom surface 43, a fixed end 44, a moveable end 46 and two sides 47, 48. A
weld disc 49 and a preferably silver contact 5l are welded to the moveable end 46 of the element. The weld disc is attached to the top surface 42 and the silver contact 51 to the bottom surface 43. Both the contact 51 and the weld disc 49 extend inwardly from the top edge of the end 46 and are preferably in the center of the end 46.

On the other end 44 there is an appropriate hole 52. Ad~acent each side 47 & 48 is a dimple 53. Each dimple has a diameter of 5/16 to 3/8 inches and a depth of 0.050 to 0.0~0 inches. The 1 32074~
dimples are concave on the top surface 42 convex on the bottom surface 43.
The length of the element is 1 5/16 to 1 1/2 inches and the width is 1 to 1 1/4 inches. Thus, the width is greater than 1/2 the length. The dimples along with the material used in the bistable element are predetermined such that the bistable element will provide an instantaneous snap action when it senses the predetermined overload.

The bistable elements of the present invention can be accurately calibrated in mass. Bistable elements for a particular overload will generally all have the same size having the same number and size of dimples and made from the same material. Thus, only a representative sampling of the bistable elements and their respective high~amp circuit breakers are necessary. The advantages of mass producing the circuit breakers without the necessity of having individual calibration is one of the advantageous economical features of the present invention.
The high-amp low voltage circuit breakers which were generally used prior to our invention, use a disc construction which requires almost individual calibration.

~eferring to Fig. 5, the manual reset circuit breaker has an insulating plastic central housing 23 and an insulating plastic cover 24. The cover is sealed to the housing. Although rivets 26 are used to fix the cover to the housing, any appropriate fastening means can be used. Between the cover and the housing is an appropriate seal 54 which extends over the entire body 1 32074~
cavity.

Within the body cavity 33 and adjacent end wall 39, there is located a rotatable non-conductive insulating elastic shaft 56.
The shaft 56 has two ends 57, 58. The one end 5~ is inserted in a blind hole 59 formed in the base of the cavity and its other end 57 extending outside of the cavity and through the cover 23 for a predetermined distance. Another seal 61 aids in the sealing of the shaft 5~ from the exterior of the housiny cover.

The manual reset lever is pressure fitted onto the rod end 58 to provide the arrangement shown in Fig. 1. Therefore, when the circuit breaker is open, the reset lever is rotated or pivoted and in the direction Z for a predetermined distance. The rotated reset handle is a visual indication that the breaker must be reset. The resetting must be done manually.

The shaft or rod 56 has a first spring attaching bar 62 integrally extending therefrom. This bar 62 is used to connect one end of an extension spring 63. Spaced a predetermined distance below the first bar is a non-conductive heat resistan' second extension bar or extension blade 64. The second extension blade 64 extends a predetermined distance substantially radially from the shaft 56. The extension blade is spaced a predetermined distance above the base of the housing. Preferably, the extension blade has a rudder-like or similar form with a first straight edge, a predetermined width and a rounded portion. The 1 3207~
size and length of the second extension blade 6~ is de~ermined so that it can fit between the el ment contact 51 and a terminal contact 66 to maintain an electrical insulation therebetween and to keep the two contacts separated if desired. This will be described in greater detail hereinafter.

The bistable element 41 is mechanically staked at its one end 44 to the first terminal contact 67. The bistable element is sized and the rotatable shaft 56 is mounteclin the cavity such that the other end 46 is adjacent to the rotatable shaft. The mounting height of the bistable element in the cavity is such that the contact 51 is generally in the same plane as the second extension blade 64. The flat side surface of the second extension blade 64 rests against the end surface of the circular element contact 51 when the breaker circuit is in its closed position.

The second extension blade 64 is urged towards the contact 51 by the extension spring 63 which has its other end connected to the cover attachment and spring holder 68. This cover attachment and spring holder 68 is located on one side of the inside of the housing.

The second terminal has located within the housing the stationary contact 66 which is situated just below the element contact 51, adjacent to the rotatable shaft 56 and below the second extension blade 64. The extension blade is such that it extends at least to the center of the element contact 51 and the terminal contact 56 when the circuit breaker is in its open position.

1 32074~

In operation, the high-amp circuit breaker is in its normal closed position as shown in Fig. 5. The spring 63 is in its extended position urging the extension blade 64 towards and against the element contact 51. The terminal contact 66 and the element contact 51 are in electrical contact with each other.
When there is a predetermined overload in a circuit connected via terminals 21 and 22, the bistable element 41 snaps its end 46 to the second position wherein the element contact is raised a predetermined distance above the terminal contact and the blade 64 is then moved between the two cont;acts. The blade 64 in this position electrically insulates the two contacts from each other and prevents contact 51 from recontacting 66 until the breaker is reset. When referring to Fig. 1, when there is an overload, the reset lever is now moved in a direction such that the handle is moved away from the blank housing. In a preferred embodiment there will be a yellow or iridescent label that will indicate the circuit breaker needs resetting. However, even without the indication, it is readily observable that the breaker needs to be reset.

The resetting is a quick and easy operation. The lever is merely turned towards the blank housing and the shaft is rotated such that the extension blade 64 is moved from between the element contact 51 and the second terminal contact 66. The spring 63 is extended. As soon as the extension blade 64 is removed from between the two contacts 51 and 56, the element contact 51 returns to the position shown in Fig. 5 and the extension blade 1 3207~4 64 contacts the side of the element contact 51 as shown.

When referring to Fig. 3/ 4, and 8, there is shown an auto reset panel mount clrcuit breaker 70. The auto-reset panel mount circuit breaker has generally the same internal construction as the manual-reset firewall mount circuit breaker ~0 described above. We have shown a panel mount circuit breaker to illustrate a variety of circuit breakers on which our invention can be utilized. In the panel mount circuit breaker, the terminals 71 and 72 extend from below the central housing and would be on the opposite side of a reset lever. This is about the only difference between a firewall and panel mount. The difference between an auto-reset and the manual-reset for either the firewall or panel mount circuit breaker is elimination from the auto reset circuit breaker of the reset lever, the reset lever shaft, and its accompanying mechanisms such as the paddle and spring. However, the central housing cavity of the auto reset circuit breaker is usually the same as used in the manual reset circuit breaker except for the cover which will be a totally flat surface. For the ease of explanation, and brevity, we have not included an auto reset perspective view for a firewall mounted circuit breaker in that the perspective view would be the same except for the flat cover. We are showing a panel mount circuit breaker for the auto reset.

The panel circuit breaker 70 also has the advantageous structure of having both terminals 71 and 72 extending from a single side of the circuit breaker. This allows the terminals to be easily 1 3207~4 utilized for electrical connections.

The interior of the central housing of the auto reset circuit breaker is identical to the manual-reset housing cavity in that it contains the blind hole 59 and the spring post 68. This is done so that the base of the circuit breakers can be interchangeable for manual and auto-resets.

The auto reset has the same bistable element 41 as was previously described with regard to Figs. 9-11. The one end 44 of the bistable element is Eixedly electrically connected to a first terminal contact 73 by a mechanical skake. The other has the movable contact 51 electrically contacting a second terminal contact 74. The element contact 51 is movable relative to the terminal contact 74. The terminal contact 74 is appropriately electrically connected to the second terminal 72.

When an overload current is encountered, the bistable element end 46 snaps upwardly to a second position so that the element contact 51 separates a predetermined distance from the second terminal contact 74. This condition is maintained until the bistable element has cooled a predetermined amount and the bistable element snaps back to the first position shown in ~ig.
8. The bistable element will continue to snap act between the first and second positions at regular intervals so long as the overload condition exists.

In the panel mount circuit breaker there is a top cover 76 having 1 3207~4 a rectangular central portion 77 and triangu:Lar end portions 78.
The terminals 71, 72 extend from the bottom of the housing and are separated by a reinforcing partition 79. The housing cover 76 is attached to the central housing by way of rivets 26 and appropriate sealants. Between the cover and the housing is an appropriate seal 77 extending across the entire housing cavity.
The first and second terminals 71, 72 extend from the base of the central housing. The breaker 70 has a central cavity with a bottom, end walls and side walls.

While particular embodiments of the present invention have been disclosed, it is understood that various different modification are possible and are contemplated within the true spirit and scope of the appended claims. There is no intention, therefore, of limitations to the exact abstract or disclosure herein presented.

Claims (14)

1. A high amperage circuit breaker comprising a pair of spaced terminals being placed in series with the circuit to be protected;
a heat resistant electrical insulating plastic housing defining a body cavity, said body cavity having a base, a front wall, a rear wall and two side walls, a cover to close said housing;
a rectangular thermally activated bistable mechanical element mounted in said cavity, at least one dimple formed on said bistable element;
a first contact being connected to one of said terminals, said first contact also connected to one end of said bistable element by means wherein the one end of said bistable element always remains stationary with respect to the first contact and in electrical contact with the first contact;
a second electrical contact attached to the other end of said bistable element;
said other end of said bistable element being free to move in a relatively vertical direction;
a third contact electrically connected to said other terminal and being positioned relative to said second contact wherein said second and third contact are normally in electrical contact with each other when the bistable element is in a first position, and said first position being to close the circuit of the circuit breaker;
said bistable element having a predetermined current response to quickly default when there is a predetermined over current, said deflection causing said other end of said bistable element to move from said first position to a second position and to cause said second contact to separate from said third contact by a predetermined distance to open the circuit of the circuit breaker.
2. The circuit breaker of claim 1 wherein the bistable element has at least two dimples formed on the upper face and adjacent opposite sides of said bistable element, and said bistable element having a length greater than a width with said width being greater than 1/2 the width.
3. The circuit breaker of claim 2 wherein, a vertical plane passing through a center of said first contact and a center of said second contact is perpendicular to a vertical plane passing through centers of said pair of dimples.
4. The circuit breaker of claim 3 wherein;
said dimples on said bistable element having a diameter of 5/16 to 3/8 inch and a central depth of 0.050 to 0.080 inches;
said first contact being connected to said one end of said bistable element by mechanical stake joint;
said second electrical contact attached to and extending from the underside of the other end of said bistable element; and said bistable element having a length and width that is at least 75% of the length and width of said cavity.
5. The circuit breaker of claim 2 wherein the circuit breaker is a manual-reset low voltage DC high-amp firewall mount circuit breaker wherein both terminals extend from a same side of the circuit breaker.
6. The circuit breaker of claim 4 wherein the circuit breaker is an auto-reset low voltage DC high-amp firewall mount circuit breaker wherein both terminals extend from a same side of the circuit breaker.
7. The circuit breaker of claim 2 wherein the circuit breaker is a manual-reset low voltage DC high-amp panel mount circuit breaker wherein both terminals extend from a same side of the circuit breaker.
8. The circuit breaker of claim 4 wherein the circuit breaker is an auto-reset low voltage DC high-amp firewall mount circuit breaker wherein both terminals extend from a same side of the circuit breaker.
9. The circuit breaker of claim 1 wherein said circuit breaker is a manual-reset comprising a plastic rotatable shaft having one end rotatably mounted in the said cavity base and the other end extending out of said housing for a predetermined distance, said shaft other end extending out of said cover for a predetermined distance;
a pair of longitudinally spaced first and second integral bars extending from said rotatable shaft, said second bar extending a predetermined distance from said first bar and being sized to provide predetermined electrical insulation, said second bar being in contact with the outer surface of said second contact when the electrical circuit is closed;
a spring attached to said first bar and said housing, said spring exerting a rotational force on said plastic shaft to urge the second bar in contact with and toward said second contact;
wherein when said second and third contacts are separated said spring rotates to position said second bar between said second and third contacts and electrically separates said second and third contacts from each other.
10. The circuit breaker of claim 2 wherein said circuit breaker is a manual-reset comprising a plastic rotatable shaft having one end rotatably mounted in the said cavity base and the other end extending out of said housing for a predetermined distance, said shaft other end extending out of said cover for a predetermined distance;
a pair of longitudinally spaced first and second integral bars extending from said rotatable shaft, said second bar extending a predetermined distance from said first bar and being sized to provide predetermined electrical insulation, said second bar being in contact with the outer surface of said second contact when the electrical circuit is closed;
a spring attached to said first bar and said housing, said spring exerting a rotational force on said plastic shaft to urge the second bar in contact with and toward said second contact;
wherein when said second and third contacts are separated said spring rotates to position said second bar between said second and third contacts and electrically separates said second and third contacts from each other.
11. The circuit breaker of claim 9 wherein, a blind hole is defined by said cavity base adjacent said rear wall, said rotatable shaft having said one end rotatably mounted in said blind hole said first bar being adjacent the top of said housing, said second bar being paddle shaped;
said dimples on said bistable element having a diameter of 5/16 to 3/8 inch and a central depth of 0.050 to 0.080 inches;
said first contact being connected to said one end of said bistable element by mechanical stake joint;
said second electrical contact attached to and extending from the underside of the other end of said bistable element; and said bistable element having a length and width that is at least 75% of the length and width of said cavity.
12. The circuit breaker of claim 10 wherein the circuit breaker is an auto-set low voltage DC high-amp panel mount circuit breaker wherein both terminals extend from a same side of the circuit breaker opposite said reset lever side.
13. The circuit breaker of claim 11 wherein the circuit breaker is an auto-set low voltage DC high-amp firewall mount circuit breaker wherein both terminals extend from a same side of the circuit breaker on the same side as said reset lever.
14. A high amperage manual reset D.C. circuit breaker comprising a heat resistant electrical insulating plastic housing defining a rectangular central body cavity, with a base , front wall,a rear wall and two side walls;
a blind hole defined by said cavity base adjacent said rear wall;
a pair of spaced terminal bolts extending through said base with a pair of contact nuts being external of said housing, said spaced terminals being placed in series with the circuit to be protected;
an insulating plastic rotatable shaft having one end rotatably mounted in said blind hole and the other end extending out of said housing for a predetermined distance;
a cover to close said housing;
a seal placed between said housing and said cover to seal said cover to said housing;
<34 means to permanently attach said cover to said housing;
said shaft other end extending out of said cover for a predetermined distance;
a seal ring attached to said cover and said shaft;
a pair of longitudinally spaced first and second integral bars extending from said rotatable shaft;
said first bar being adjacent the top of said housing;

a paddle shaped bar extending a predetermined distance from said first bar, said second bar having a relatively straight side, said second bar being sized to provide predetermined electrical insulation;
a generally rectangular thermally activated bistable mechanical element, a pair of dimples formed on an upper surface of and adjacent opposite sides of said bistable element, said dimples having a diameter of approximately 5/16 to 3/8 inch and a central depth of approximately 0.050 to 0.080 inches;
a first contact being connected to one of said terminals, said first contact also connected to end of said bistable element by a washer and a mechanical stake joint wherein the one end of said bistable element always remains stationary with respect to the first contact and in electrical contact with the first contact;
a second electrical contact attached to and extending from the underside of the other end of said second electrical contact;
said other end of said bistable element being free to move in a relatively vertical direction;
a vertical plane passing through a center of said first contact and a center of said second contact being perpendicular to a vertical plane passing through centers of said pair of dimples;
a third contact electrically connected to said other terminal and being positioned below said second contact, said second and third contact normally being in electrical contact with each other to close the circuit of the circuit breaker;
said second bar having its side in contact with the outer surface of said second contact when the electrical circuit is closed;
a spring attached to said first bar and said housing, said spring exerting a rotational force on said plastic shaft to urge the second bar in contact with said second contact and toward said second contact;
said bistable element having a predetermined current response to quickly deform when there is a predetermined over current, said deformation causes said other end to vertically rise and to cause said second contact to separate from said third contact by a predetermined distance; and wherein said second and third contacts are separated said spring rotates to position said second bar between said second and third contacts and electrically separate said second and third contacts from each other.
CA000614640A 1989-09-28 1989-09-29 High-amp circuit breaker and a bistable element therefor Expired - Lifetime CA1320744C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/414,095 US5021761A (en) 1989-09-28 1989-09-28 High-amp circuit breaker and a bistable element therefor
US07/414,095 1989-09-28

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CA1320744C true CA1320744C (en) 1993-07-27

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