U.S. patent application number 16/167871 was filed with the patent office on 2019-02-21 for loadcenters with improved backpan to back wall assembly fasteners allowing one direction assembly and related enclosures and methods.
The applicant listed for this patent is Eaton Intelligent Power Limited. Invention is credited to Tony Ray Benson, Roger Wayne Lanter, JR..
Application Number | 20190058310 16/167871 |
Document ID | / |
Family ID | 63582954 |
Filed Date | 2019-02-21 |
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United States Patent
Application |
20190058310 |
Kind Code |
A1 |
Benson; Tony Ray ; et
al. |
February 21, 2019 |
LOADCENTERS WITH IMPROVED BACKPAN TO BACK WALL ASSEMBLY FASTENERS
ALLOWING ONE DIRECTION ASSEMBLY AND RELATED ENCLOSURES AND
METHODS
Abstract
Loadcenters with an enclosure having an interior compartment and
a back wall that includes at least one lance, typically a plurality
of longitudinally spaced apart lances that project inwardly toward
a front of the enclosure. Each lance comprises an aperture. The
loadcenters also include a back pan assembly in the interior
compartment. The back pan assembly has at least one latch,
typically plurality of longitudinally spaced apart latches, each
latch with a leg that extend through the aperture of the aligned
lance to attach the back pan assembly to the backwall.
Inventors: |
Benson; Tony Ray;
(Monticello, IL) ; Lanter, JR.; Roger Wayne;
(Auburn, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Eaton Intelligent Power Limited |
Dublin |
|
IE |
|
|
Family ID: |
63582954 |
Appl. No.: |
16/167871 |
Filed: |
October 23, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15467870 |
Mar 23, 2017 |
10141723 |
|
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16167871 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02B 1/30 20130101; H02B
1/20 20130101; H02B 1/056 20130101; H02B 1/04 20130101; H02B 3/00
20130101 |
International
Class: |
H02B 1/30 20060101
H02B001/30; H02B 1/20 20060101 H02B001/20; H02B 1/04 20060101
H02B001/04; H02B 3/00 20060101 H02B003/00 |
Claims
1. A loadcenter comprising: an enclosure having an interior
compartment and a back wall, wherein the back wall comprises a
plurality of lances, wherein each lance has an inwardly extending
projection that extends toward a front of the enclosure, and
wherein each lance comprises an aperture provided by the inwardly
extending projection; and at least one cover, wherein each of the
at least one cover is sized and configured to couple to a
respective one of the lances.
2. The loadcenter of claim 1, wherein the at least one cover has a
body with a long dimension and a short dimension that correspond to
a long dimension and a short dimension of an aligned lance of the
lances to define a solid, closed surface in front of or behind the
aperture of the aligned lance.
3. The loadcenter of claim 1, wherein there are more lances than
covers.
4. The loadcenter of claim 1, wherein the at least one cover
comprises a three-dimensional shape with a cavity that can slidably
receive the lance projection.
5. The loadcenter of claim 4, wherein the cavity is
rectangular.
6. The loadcenter of claim 1, wherein the at least one cover
comprises an internal segment that extends through the aperture of
an aligned one of the lances.
7. The loadcenter of claim 1, wherein the at least one cover is
polymeric or elastomeric.
8. The loadcenter of claim 1, wherein one or more of the at least
one cover resides inside a cavity of the inwardly extending
projection of the lance on a rear surface of the back wall of the
enclosure.
9. The loadcenter of claim 8, wherein the one or more of the at
least one cover partially or totally plugs the cavity.
10. The loadcenter of claim 1, wherein an outer surface of the at
least one cover can be planar and extend across a cavity of the
cover.
11. The loadcenter of claim 1, wherein one or more of the at least
one cover comprises an internal segment that projects outwardly
toward the back wall and the one or more of the at least one cover
resides over the inwardly extending projection of an aligned lance
of the lances.
12. The loadcenter of claim 1, wherein one or more of the at least
one cover comprises an internal segment that projects inwardly
toward the interior compartment and the one or more of the at least
one cover resides over a cavity of the inwardly extending
projection of an aligned lance of the lances.
13. The loadcenter of claim 1, further comprising a back pan
assembly in the interior compartment, wherein the back pan assembly
comprises a plurality of latches, wherein each latch comprises a
rearwardly extending leg that extends through the aperture of an
aligned lance to attach the back pan assembly to the back wall.
14. The loadcenter of claim 1, the lances are arranged as a
plurality of longitudinally and/or laterally spaced apart
lances.
15. The loadcenter of claim 1, wherein the back wall comprises a
rear outer facing planar surface with a plurality of spaced apart
inwardly extending cavities, each cavity under a corresponding
inwardly extending projection, with the aperture at an innermost
surface of the projection of the lance.
16. The loadcenter of claim 1, wherein the aperture of at least
some of the lances resides in a medial location of a corresponding
inwardly extending projection, and wherein the inwardly extending
projection comprises longitudinally spaced apart upper and lower
end portions that taper in a longitudinal direction toward an inner
surface of the back wall.
17. The loadcenter of claim 1, wherein the aperture is rectangular,
and wherein the at least one cover is rectangular.
18. The loadcenter of claim 13, wherein the aperture is elongate
and extends in a lateral or longitudinal direction, wherein the leg
comprises an elongate lip, and wherein the elongate lip extends
through the aperture of the aligned lance and engages a wall about
one side the aperture.
19. The loadcenter of claim 13, wherein the at least one latch
further comprises upper and lower longitudinally spaced apart
angled ribs that slidingly receive longitudinally or laterally
tapered spaced apart inwardly facing ends of the lances to help
guide a cooperating latch and lance into proper position for
locking engagement.
20. The loadcenter of claim 13, wherein an innermost wall segment
of the at least one lance comprises the aperture and resides a
distance in a range of 0.1 inches and 1 inch in front of a primary
surface of the back wall, wherein the enclosure and the lances are
metallic, wherein the at least one cover is elastomeric and/or
polymeric, and wherein the at least one latch is electrically
non-conductive or less conductive than the enclosure or the lances.
Description
RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 15/467,870, filed Mar. 23, 2017, the
contents of which are hereby incorporated by reference as if
recited in full herein.
FIELD OF THE INVENTION
[0002] The present disclosure relates to distribution load
centers.
BACKGROUND OF THE INVENTION
[0003] Electrical loadcenters are well known. Electrical
loadcenters include electrical busses that comprise conductors
permitting electrical current to be carried throughout the
electrical load center. Electrical busses may contain features
permitting attachment of fuses, relays, switches, wires, breakers,
and other electrical elements. Loadcenters may contain one or more
electrical busses in close proximity to one another, and insulating
material or insulation may be used to avoid an arcing or shorting
event occurring between the busses. Busses are electrically
insulated from each other to avoid a phase-to-phase short circuit.
Busses are also electrically insulated from the electrical load
center enclosure to avoid a phase-to-ground short circuit. Some
loadcenters also include branch circuit breakers connected to the
electrical busses at specific points within the load centers. The
location, orientation, and spacing of the bus elements and
insulation elements within the load are arranged so as to prevent
an arcing, overcurrent, or short circuit event once the busses are
placed under load. The loadcenters typically include a backpan
assembly with a backpan holding a bus structure attached to the
back of the enclosure. See, e.g., U.S. Pat. No. 9,112,336, the
contents of which are hereby incorporated by reference as if
recited in full herein.
[0004] Known conventional loadcenters with backpan assemblies
locate and hold the backpan to the back of the enclosure with a two
direction motion to assemble which can complicate the assembly
process for both mechanical function and fastening and can result
in increased assembly time and cost.
SUMMARY OF EMBODIMENTS OF THE INVENTION
[0005] Embodiments of the present invention provide backpan to case
(enclosure back wall) fasteners that allow decreased assembly time
for mounting the backpan assembly to the back of the enclosure.
[0006] Embodiments of the invention are directed to loadcenters
that include an enclosure having an interior compartment and a back
wall. The back wall has at least one lance that projects inwardly
toward a front of the enclosure. The at least one lance has an
aperture. The enclosure also has a back pan assembly in the
interior compartment. The back pan assembly has at least one latch
and the at least one latch has a rearwardly extending leg. The leg
extends through a corresponding aperture of an aligned lance to
attach the back pan assembly to the back wall.
[0007] The at least one lance can be a plurality of longitudinally
and/or laterally spaced apart lances and the at least one latch is
a plurality of longitudinally and/or laterally spaced apart
latches.
[0008] Embodiments of the invention are directed to loadcenters
that include an enclosure having an interior compartment and a back
wall. The back wall has a plurality of longitudinally spaced apart
lances that project inwardly toward a front of the enclosure. Each
lance has an aperture. The loadcenters also include a back pan
assembly in the interior compartment. The back pan assembly has a
plurality of longitudinally spaced apart latches, each latch with a
rearwardly extending leg. Each leg extends through a corresponding
aperture of an aligned one of the lances to attach the back pan
assembly to the backwall.
[0009] The plurality of spaced apart lances can include at least
three lances on a right side of the back wall and at least three on
a left side of the back wall.
[0010] The plurality of spaced apart lances can be provided as a
first plurality of lances longitudinally aligned on a right side of
the enclosure and a second plurality of lances longitudinally
aligned on a left side of the enclosure. Pairs of the first
plurality and the second plurality of lances can be laterally
aligned. The plurality of spaced apart latches can be provided as a
first plurality of latches longitudinally aligned on a right side
of a rear of the back pan assembly and a second plurality of
latches longitudinally aligned on a left side of the rear of the
back pan assembly. Pairs of the first plurality and the second
plurality of latches can also be laterally aligned.
[0011] The back wall can have a rear outer facing surface with
inwardly extending cavities behind the lances.
[0012] The lances can have a rectangular inner facing projection
with longitudinally spaced apart upper and lower end portions that
taper in a longitudinal direction toward an inner surface of the
back wall.
[0013] The apertures can be rectangular.
[0014] The apertures can be elongate and extend in a lateral or
longitudinal direction.
[0015] The legs of the latches can include an elongate lip. The
elongate lip can extends through an aligned one of the apertures to
engage a surface of a wall about one side of the aligned one of the
apertures.
[0016] The leg of the latch can have an elongate lip that engages a
wall of an aligned one of the lances on one side of the aperture.
The latches can have a latch body with first and second segments
that extend laterally and longitudinally about the leg and reside
against an inner surface of the back wall at locations adjacent but
spaced apart from the lances.
[0017] The legs of the latches can have an elongate lip that
extends in a longitudinal direction and engages a wall of the lance
adjacent one side of the aperture.
[0018] The latches can upper and lower longitudinally spaced apart
and longitudinally extending angled ribs that slidingly receive
longitudinally or laterally tapered spaced apart inwardly facing
ends of the lances to help guide a cooperating latch and lance into
proper position for locking engagement.
[0019] An innermost wall of the lances can provide the apertures to
reside a distance in front of a primary surface of the back wall a
distance that is between 0.1 inches and 1 inch.
[0020] The enclosure and the lances can be metallic. The latches
can be electrically non-conductive or less electrically conductive
than the enclosure or lances.
[0021] Other embodiments are directed to a metallic enclosure for
an electrical apparatus, optionally a loadcenter. The enclosure
includes a back wall with a plurality of lance projections that
face inward, the projections having an innermost wall with
apertures extending therethrough. A rear outer facing surface of
the back wall has inwardly extending cavities behind the lance
projections.
[0022] The plurality of spaced apart lances can include at least
three lances on a right side of the back wall and at least three on
a left side of the back wall.
[0023] The plurality of spaced apart lances can include a first
plurality of lances longitudinally aligned on a right side of the
enclosure and a second plurality of lances longitudinally aligned
on a left side of the enclosure. Pairs of the first plurality and
the second plurality of lances can be laterally aligned.
[0024] The lances can have a rectangular inner facing projection
shape with longitudinally spaced apart upper and lower end portions
that taper in a longitudinal direction toward an inner surface of
the back wall.
[0025] The apertures can be rectangular.
[0026] The apertures can be elongate and extend in a lateral or
longitudinal direction. The apertures can have a length dimension
that is between 0.5 inches and 1 inch.
[0027] The enclosure and lances can be metallic.
[0028] An innermost wall of the lance projections can position the
lance apertures a distance in front of a primary surface of the
back wall a distance that is between 0.1 inches and 1 inch.
[0029] Other embodiments are directed to methods of installing a
backpan assembly to a back wall of an enclosure. The methods can
include: providing an enclosure with a back wall having at least
one forwardly projecting lance; providing a backpan assembly with
at least one latch; aligning the at least one latch with the at
least one lance; and then pushing the backpan assembly straight
inward with a single motion to lock the backpan assembly into
position and attached to the backwall of the enclosure.
[0030] The at least one latch and the at least one lance are both a
plurality of spaced apart lances and latches.
[0031] The latches and lances can be arranged as right and left
side lance and latch pairs. An outer surface of the back wall of
the enclosure can have cavities corresponding to the positions of
the lances.
[0032] Other methods can include: providing an enclosure with a
back wall having a plurality of forwardly projecting aligned sets
of right and left side lances; providing a backpan assembly with a
plurality of sets of left and right side latches; aligning the
latches with lances; and then pushing the backpan assembly straight
inward with a single motion to lock the backpan assembly into
position and attached to the backwall of the enclosure.
[0033] An outer surface of the back wall of the enclosure can have
inwardly facing cavities corresponding to the positions of the
lances.
[0034] Optionally: (a) the lances can have through apertures that
receive legs of the latches and engage lips that extend
perpendicular to the legs and parallel to a wall of the lance;
and/or (b) the lances can be elongate with elongate apertures and
the lips extend in a longitudinal and/or a lateral direction under
the projecting surface of the lances.
[0035] Further features, advantages and details of the present
invention will be appreciated by those of ordinary skill in the art
from a reading of the figures and the detailed description of the
preferred embodiments that follow, such description being merely
illustrative of the present invention.
[0036] It is noted that aspects of the invention described with
respect to one embodiment, may be incorporated in a different
embodiment although not specifically described relative thereto.
That is, all embodiments and/or features of any embodiment can be
combined in any way and/or combination. Applicant reserves the
right to change any originally filed claim or file any new claim
accordingly, including the right to be able to amend any originally
filed claim to depend from and/or incorporate any feature of any
other claim although not originally claimed in that manner. These
and other objects and/or aspects of the present invention are
explained in detail in the specification set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a front view of an exemplary enclosure (also
referred to as a "case") of a load center with a back pan assembly
according to embodiments of the present invention.
[0038] FIG. 2A is a side, front perspective view of the loadcenter
shown in FIG. 1 with the backpan assembly aligned for fastening to
the backwall of the enclosure according to embodiments of the
present invention.
[0039] FIG. 2B is a top, side perspective view of the back pan
assembly assembled to the backwall of the enclosure according to
embodiments of the present invention.
[0040] FIG. 2C is a top, rear perspective view of the loadcenter
shown in FIG. 1 according to embodiments of the present
invention.
[0041] FIG. 2D is an enlarged partial rear view of a portion of the
rear of the loadcenter shown in FIG. 2C.
[0042] FIG. 2E is a front perspective view of a backpan assembly
according to embodiments of the present invention.
[0043] FIG. 2F is a back perspective view of the backpan assembly
shown in FIG. 2E according to embodiments of the present
invention.
[0044] FIG. 3A and FIG. 3B are front perspective view of alternate
embodiments or lance orientations of the enclosure according to
embodiments of the present invention.
[0045] FIG. 4A is a section view taken along line 4A-4A of FIG. 7
of a backpan assembly latch aligned with a case lance according to
embodiments of the present invention.
[0046] FIG. 4B is a section view taken along line 4B-4B of FIG. 5
showing the backpan assembly latch attached to the case lance
according to embodiments of the present invention.
[0047] FIG. 5 is an enlarged partial front view of the enclosure
and backpan assembly shown in FIG. 1 illustrating a region of one
of the latch and case lance positions according to embodiments of
the present invention.
[0048] FIG. 6 is a section view taken along line 6-6 of FIG. 5
illustrating the latch attached to an aligned lance according to
embodiments of the present invention.
[0049] FIG. 7 is an enlarged partial front view of the enclosure
and backpan assembly shown in FIG. 1 illustrating a region of one
of the latch and case lance positions, aligned but prior to
attachment according to embodiments of the present invention.
[0050] FIG. 8 is a section view taken along line 8-8 of FIG. 7
illustrating the latch aligned with a corresponding lance according
to embodiments of the present invention.
[0051] FIG. 9 is a top side perspective view of the enclosure shown
in FIG. 1, but shown without the backpan assembly.
[0052] FIG. 10 is a top view of the enclosure with the assembled
back pan assembly and a primary circuit breaker according to
embodiments of the present invention.
[0053] FIG. 11 is a partial rear perspective view of the enclosure
with the assembled back pan assembly shown in FIG. 1 according to
embodiments of the present invention.
[0054] FIG. 12A is a partial front, side perspective view of a
backpan latch and cooperating case lance according to embodiments
of the present invention.
[0055] FIG. 12B is a partial cutaway, front, side perspective view
of the backpan latch and cooperating case lance according to
embodiments of the present invention.
[0056] FIG. 13 is a front perspective view of an exemplary
loadcenter according to embodiments of the present invention.
[0057] FIG. 14 is flow chart of exemplary assembly operations that
can be used to mount a backpan assembly to an enclosure according
to embodiments of the present invention.
[0058] FIG. 15A is a partial side exploded view of an internal
cover for a lance projection of an enclosure according to
embodiments of the present invention.
[0059] FIG. 15B is a section assembled view of the cover and back
wall of the enclosure shown in FIG. 15A.
[0060] FIG. 16A is a partial exploded view of an external cover for
a lance of an enclosure according to embodiments of the present
invention.
[0061] FIG. 16B is an enlarged partial section view of the cover
and back wall shown in FIG. 16A with a cover shown aligned prior to
assembly and further comprising a latch engaging the lance with the
cover in position according to embodiments of the present
invention.
[0062] FIG. 16C is a section assembled view of the cover and back
wall of the enclosure shown in FIG. 16A.
[0063] FIG. 17A is a partial exploded view of another external
cover for a lance of an enclosure according to embodiments of the
present invention.
[0064] FIG. 17B is a section assembled view of the cover and back
wall of the enclosure shown in FIG. 17A and also shows the cover in
exploded view.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0065] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which
illustrative embodiments of the invention are shown. Like numbers
refer to like elements and different embodiments of like elements
can be designated using a different number of superscript indicator
apostrophes (e.g., 10, 10', 10'', 10''). The terms "Fig." and
"FIG." may be used interchangeably with the word "Figure" as
abbreviations thereof in the specification and drawings. In the
figures, certain layers, components or features may be exaggerated
for clarity, and broken lines illustrate optional features or
operations unless specified otherwise.
[0066] In the drawings, the relative sizes of regions or features
may be exaggerated for clarity. This invention may, however, be
embodied in many different forms and should not be construed as
limited to the embodiments set forth herein; rather, these
embodiments are provided so that this disclosure will be thorough
and complete, and will fully convey the scope of the invention to
those skilled in the art.
[0067] It will be understood that, although the terms first,
second, etc. may be used herein to describe various elements,
components, regions, layers and/or sections, these elements,
components, regions, layers and/or sections should not be limited
by these terms. These terms are only used to distinguish one
element, component, region, layer or section from another region,
layer or section. Thus, a first element, component, region, layer
or section discussed below could be termed a second element,
component, region, layer or section without departing from the
teachings of the present invention.
[0068] Spatially relative terms, such as "beneath", "below",
"lower", "above", "upper" and the like, may be used herein for ease
of description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the figures.
For example, if the device in the figures is turned over, elements
described as "below" or "beneath" other elements or features would
then be oriented "above" the other elements or features. Thus, the
exemplary term "below" can encompass both an orientation of above
and below. The device may be otherwise oriented (rotated 90.degree.
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly.
[0069] The term "about" refers to numbers in a range of +/-20% of
the noted value.
[0070] As used herein, the singular forms "a", "an" and "the" are
intended to include the plural forms as well, unless expressly
stated otherwise. It will be further understood that the terms
"includes," "comprises," "including" and/or "comprising," when used
in this specification, specify the presence of stated features,
integers, steps, operations, elements, and/or components, but do
not preclude the presence or addition of one or more other
features, integers, steps, operations, elements, components, and/or
groups thereof. It will be understood that when an element is
referred to as being "connected" or "coupled" to another element,
it can be directly connected or coupled to the other element or
intervening elements may be present. As used herein, the term
"and/or" includes any and all combinations of one or more of the
associated listed items.
[0071] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of this specification and the relevant art
and will not be interpreted in an idealized or overly formal sense
unless expressly so defined herein.
[0072] Embodiments of the invention are particularly suitable for
electrical devices such as load centers. The terms "loadcenter" and
"electrical distribution load center" refer to the collective
components of an electrical distribution system and its respective
housing that supplies electrical power to one or more subsidiary
circuits. The terms "bus," "bus element," "electrical distribution
bus," or "bus bar" refers to components in an electrical
distribution system that conducts electricity within the load
center. However, the latch attachments and lances may also be
useful for other devices such as devices comprising circuit
breakers, for example.
[0073] Referring now to FIGS. 1 and 2, an exemplary enclosure 10
suitable for a load center is shown. The term "enclosure" is used
interchangeably herein with the terms "case" and "housing". The
enclosure 10 includes sidewalls 11, a top 13 and bottom 14 attached
to a back wall 12 and providing an interior compartment 15.
[0074] As shown, the enclosure holds a backpan assembly 50, which
includes a back pan 25 and an interior assembly 40 (sometimes
referred to as an "interior"). The interior assembly 40 comprises a
bus structure 45 with one or more bus bars 45b. The interior
assembly 40 can be either detachably or permanently fastened to the
back pan 25. The interior assembly 40 (also sometimes just referred
to as "the interior") can refer to the internal components of the
load center 10 including the insulating barrier, i.e., sheet, film
or layer (which can optionally comprise mylar), the bus 45, the
retaining clips (the hook part) and the stabs (the bent-up parts)
and the like. The interior assembly 40 can include or be connected
to a main breaker 35 (FIG. 10). The main breaker 35 may be
connected to an external power supply via collars or lugs 35c that
connect to cables/power cords that connect to an external power
supply.
[0075] Referring to FIGS. 1 and 10, the one or more bus bars 45b
may have substantially flat portions that extend longitudinally
within, and lie in a plane parallel to a trough formed by the back
pan 25. The bus bars 45b may contain stabs 48, such as branch
circuit breaker stabs, that can be exposed within an insulation
element so as to conduct electricity to branch circuit breakers
when connected. The stabs 48 may extend upwardly to contact desired
components such as a branch circuit breaker when connected.
[0076] The one or more bus bars 45b can be designed to electrically
couple to the main breaker as well any branch circuit breakers. The
one or more bus bars 45b can remain electrically insulated from
other electrically conducting elements thus avoiding the occurrence
of a shorting event.
[0077] The backpan assembly 50 and/or the interior assembly 40 may
comprise either electrically conducting or electrically insulating
(i.e., non-electrically conducting) material adjacent the back pan
25. In some embodiments, an electrically insulating barrier such as
a polyester sheet or film which may comprise a mylar or BoPET
(biaxially-oriented polyethylene terephthalate) sheet or film, may
be provided under and/or on the substantially flat surfaces of the
bus bars 45b to electrically insulate the one or more bus bars 45b
from other conducting elements, such as the back pan 25, if the
back pan 25 is made of a conductive material such as metal.
[0078] In some embodiments, the one or more bus bars 45b can
maintain electrical insulation from other conducting elements based
only on physical separation from the other conducting elements
without requiring electrically insulating material.
[0079] In some embodiments, if the back pan 25 comprises an
electrically insulating material such as a ceramic, polymer and/or
plastic, the bus bars 45b do not need to be physically separated
from the back pan 25.
[0080] Referring now to FIGS. 1, 2A, 2B, 2C, 2E, 2F, 4A and 4B, the
backpan assembly 50 can comprise a plurality of longitudinally
spaced apart latches 60. The latches 60 engage lances 20 in the
back wall 12 of the enclosure 10. The term "lance" is used herein
to refer to a feature and/or member that faces and engages a
corresponding latch 60 to lock the latch 60 of the backpan assembly
50 to the back wall 12 of the enclosure 10.
[0081] As shown in FIG. 2A, the backpan assembly 50 can be aligned
with the enclosure 10 and a locking engagement can be carried out
with a single inward pressing action to concurrently lock the
latches 60 to the corresponding lances 20 which fastens the backpan
assembly 50 to the backwall 12 in its final assembly position.
[0082] As shown in FIGS. 2C, 2D, 4A, 4B, 5-8, 9 and 10, the lances
20 can project inwardly and can be provided as a plurality of
longitudinally spaced apart lances 20. The lances 20 can be
provided as a set of longitudinally aligned right side lances and a
set of longitudinally aligned left side lances. Pairs of right and
left side lances 20 may also be horizontally aligned. The lances 20
can include apertures 21 that face inward and extend through the
projecting portion 20p of the lances 20.
[0083] The latches 60 can be provided as a set of longitudinally
aligned right side latches and a set of longitudinally aligned left
side latches. Pairs of right and left side latches 60 may also be
horizontally aligned.
[0084] Referring to FIG. 2, FIG. 9 and FIG. 11, the apertures 21 of
the lances 20 can be rectangular with a long dimension L
corresponding to a longitudinal dimension of the enclosure 10 and
with the long dimension L greater than a width dimension W. In some
particular embodiments, the long dimension can be in a range of 0.5
inches to 2 inches, typically between about 0.5 inches and 1 inch,
more typically about 0.625 inches. The shorter dimension, i.e., a
width W dimension, can be about half the long dimension L. The
width W can be, for example, in a range of about 0.25 inches to
about 0.5 inches, typically about 0.31 inches.
[0085] As shown in FIG. 3A and 3B, the lances 20 and respective
apertures 21 that receive the latches 60 can be oriented
horizontally instead of vertically or combinations of vertical and
horizontal lances as shown in FIG. 3B. The legs 160 and lips161 of
the latches 60 can be oriented in a corresponding direction.
[0086] The lip 161 of the leg 160 of the latch 60 can have a
smaller length and width than a corresponding aperture 21, and is
typically between 75%-95% of the length L of the aperture 21. In
some particular embodiments, the lip 161 has a longitudinal length
L of between 0.5 inches and 1 inch, such as, for example, about
0.59 inches and a width W that is less than the length L (FIG. 11),
typically between about 0.5 and 0.3.times. the width W.
[0087] Referring to FIG. 2C, 2D and 11, the back wall 12 of the
enclosure 10 can have a rear and/or externally facing surface 12r
with cavities 12c (i.e., inward indentations or recesses)
corresponding to the projection surfaces 20p of the lances 20. The
apertures 21 can extend through the back wall 12. The cavities 12c
can have a rectangular perimeter extending about the apertures 21.
In some embodiments, the back wall 12 can comprise a monolithic
single piece of sheet metal member that can be formed to provide
inward integral indentations or recesses to provide the lance
peaks. In some embodiments, the projections 20p of the lances 20
can be welded or brazed onto the back panel 12.
[0088] Referring to FIGS. 4A, 4B and 11, the latches 60 can include
a leg 160 that extends toward the back wall 12, aligned with a
respective lance 20 (shown as a downwardly extending leg in the
orientation shown). The leg 160 can be perpendicular to the back
wall 12. The leg 160 can have an end portion with a lip 161. The
lip 161 can be perpendicular to the leg 160. The lip 161 can be
parallel to the back wall 12 and/or wall 20w of the projecting
portion 20p of the lance 20.
[0089] Referring to FIGS. 4A, 4B, and 5-8, the leg 160 can extend
through an aligned lance aperture 21 and position the lip 161 under
and against a surface 20s of the wall 20w of the lance 20. The lip
161 can be elongate and extend longitudinally a distance between
0.25 inches and 2 inches, more typically between about 0.5 inches
and 0.6 inches and laterally to a lesser extent.
[0090] Referring to FIG. 8, the projection of the lance 20p can
extend a distance "d" forward of a planar rear facing primary
surface 12p of the back wall 12. This distance "d" can be between
0.1 inches and 2 inches, such as between 0.1 inches and 1 inch, in
some embodiments.
[0091] Referring to FIG. 4B, the lip 161 can engage a surface 20s
of the lance wall 20w. In some embodiments, the lip161 has a
lateral engagement extent with the lance wall 20w of between about
0.05 inches to about 0.25 inches, more typically in a range of 0.06
inches to 0.1 inches, such as about 0.06 inches, about 0.065
inches, and about 0.07 inches, in some particular embodiments.
Different latches 60 may have different lateral engagement extents
with a respective lance 20.
[0092] As shown in FIGS. 2D, 4B, 11, 12A and 12B, the lip 161 can
reside closer to one side of the aperture 21 than another and
engage i.e., abut, a single long side of the projecting portion 20p
of the lance 20.
[0093] FIG. 2E and 2F show an exemplary backpan assembly 50 with
the latches 60 and associated legs 160 and lips 161. The backpan
assembly 50 can comprise a planar substrate 50p that holds the
latches 60 with the legs oriented to face the lances 20 (FIG. 2C,
for example).
[0094] FIG. 9 and FIG. 11 show that the lances 20 can have
projections 20p with a rectangular shape and with upper and lower
end portions 23 that taper toward a primary inner surface 12i of
the back wall 12. The projections 20p of the lances can have closed
surfaces except for the aperture 21.
[0095] Referring again to FIGS. 4A, 4B, 12A and 12B, the latch 60
can include an outer facing longitudinally extending portion 63
that has an angular offset .beta. of about 60-120 degrees with a
free end 63f that extends above the leg 160. The outer facing
portion 63 can include at least one longitudinally extending recess
63r, shown in FIG. 12A as first and second longitudinally extending
recesses 63r, one above and one below the leg 161.
[0096] Referring to FIG. 10, in some embodiments, a foot of a
breaker 35f can engage and/or reside over the outer end portion 63
of one or more respective latches 60 to hold a breaker 35 in
position.
[0097] The latch 60 can also include a body 60b with first and
second members 65, 67, respectively, that reside on laterally and
longitudinally opposing sides of the leg 160. The members 65, 67
can have planar free ends 65f, 67f that are parallel to the inner
surface 12i of the back wall to reside against the inner surface
12i of the back wall 12 at locations that are planar with the
primary surface 12p of the back wall 12, adjacent but spaced apart
from the projections 20p and cavities 20c of the lance 20. Stated
differently, the body 60b of the latch 60 can extend in four
directions about the respective lance 20, to both lateral sides and
above and below a respective leg 160 and adjacent the lance 20.
[0098] Referring to FIGS. 4A and 4B, the leg 160 can have a tapered
surface 164 from a lower end 160e to the lip 161. Thus, the tapered
surface 164 forces the leg 160 to flex outward as it contacts the
wall 20w of the lance 20 but the leg 161 can then flex back into
its original shape (FIG. 4A) once but the leg 161 extends through
the lance aperture 21 to position the lip 161 under the wall 20w of
the lance 20.
[0099] The latches 60 and lances 20 can be easily assembled
together via a single, straight inward push motion to concurrently
lock the different latches and lances together with a single
direction motion.
[0100] As shown in FIG. 6 and FIG. 8, for example, the latches 60
can include longitudinally extending upper and lower angled ribs 66
that can contact a corresponding lance projection tapered upper and
lower end wall 23 during assembly. The ribs 66 and endwalls 23 can
cooperate to slidingly guide the latch 60 and lance 20 into a
proper orientation/position for engagement. The angled ribs 66 can
have an angle, measured from horizontal, that is between 30-60
degrees, typically about 45 degrees. The tapered end walls 23 of
the lance projection 20p can have a corresponding angle.
[0101] As shown in FIGS. 1, 2A, 2B, four sets of latch and lance
pairs 20, 60 are used to fasten the backpan assembly 50 to the back
wall 12 of the enclosure 10. However, a single pair or a plurality
of pairs (and more or less pairs than shown) may be used. Also,
where right and left side pairs are used, different numbers of
pairs may be used on different sides, i.e., one pair on the right
and two pairs on the left. The latches 60 and lances 20 may have
different sizes or configurations at different longitudinal or
lateral locations and different orientations (horizontal or
horizontal and vertical as discussed with respect to FIG. 3A and
FIG. 3B) or for different loadcenters.
[0102] In some embodiments, a single set of longitudinally spaced
apart latches 60 and lances 20 may be used and the single set may
not be aligned in a column but can be offset relative to each other
at different lateral positions (not shown).
[0103] In some embodiments, the latches 60 (and lances 20) are not
required to be aligned longitudinally and may not be aligned
laterally/horizontally where right and left side latches 60 and
lances 20 are used.
[0104] There may be a greater number of lances 20 than latches 60
leaving some lances unused (FIG. 1, FIG. 3, for example). This
allows for adjustability for assembly to position different backpan
assemblies 50 at different locations in a respective enclosure or
to use a common enclosure for different backpan assemblies.
[0105] FIG. 10 illustrates that a primary circuit breaker 35 can be
positioned over some lances 20.
[0106] FIG. 13 illustrates a loadcenter 200 with a front panel 125
and door 130 that cooperate with the enclosure 10. The loadcenters
200 can be residential or industrial loadcenters. The loadcenter
200 can include a main circuit breaker 35 (FIG. 10) and it can be
an Arc Fault Circuit Interrupter (AFCI) and/or Ground Fault Circuit
Interrupter (GFCI) which are among a variety of overcurrent
protection devices used for circuit protection and isolation. AFCIs
reduce fire hazards in electrical circuits by reducing the effects
of high current arcing faults as well as detecting persistent
low-current arcing faults. GFCIs reduce the potential of electrical
shock. Both branch feeder and combination AFCIs provide
conventional thermal and magnetic overcurrent protection. Both can
also provide high current or "parallel" arcing fault detection and
fire mitigation for installed wiring and connected cords. National
Electrical Code (NEC) revisions have increased the requirement for
sections of the home that require Arc Fault or Ground Fault
protection. The circuit breaker can be a Type BR or CH AFCI or GFCI
breaker.
[0107] FIG. 14 illustrates a single motion assembly method
according to embodiments of the present invention. An enclosure
with a back wall having a plurality of forwardly projecting aligned
sets of right and left side lances is provided (block 300). A
backpan assembly with a plurality of sets of left and right side
latches is also provided (block 310). The latches are aligned with
lances and the backpan assembly is then pushed straight inward with
a single motion to lock the backpan assembly into position and
attached to the backwall of the enclosure (block 320).
[0108] The outer surface of the back wall of the enclosure can have
a plurality of cavities corresponding to the positions of the
lances (block 302).
[0109] The lances have through apertures that receive legs of the
latches and engage lips that extend perpendicular to the legs and
parallel to a wall of the lance (block 312).
[0110] The lances can be elongate with elongate apertures and the
lips can extend in a longitudinal direction under the projecting
surface of the lances (block 315).
[0111] FIG. 15A and FIG. 15B illustrate an internal cover 400 that
can be placed over respective unused lances 20 according to some
embodiments of the present invention. The cover 400 can have a
three-dimensional shape with a cavity 401 that can slidably receive
the lance projection 20p. The cavity 401 can be rectangular. The
cover 400 can have an internal member 403 that projects outward
toward the back wall 12 and can extend through the aperture 21 of
the lance projection 20p. In some embodiments, the cover 400 can
comprise or be polymeric or elastomeric.
[0112] FIG. 16A-16C illustrate an external lance cover 500 that can
be placed inside lance cavities 12c on the rear 12r of the back
wall 12 of the enclosure 10. The external lance cover 500 can be
used with lances 20 that engage latches 60. The cover 500 can have
an inner portion 502 that resides behind (under in the orientation
shown) a leg 161 of the latch 60. The cover 500 can partially plug
the cavity 12c, leaving an open space 20g for the leg 161 of the
latch (FIG. 16B). FIG. 16A and FIG. 16C illustrate that the cover
500 can be placed on the back wall 12 prior to the backpan assembly
50 with the latches 60 being attached to the back wall 12. The
outer surface 505 of the cover 500 can be planar and extend across
the cavity 12c. In other embodiments, the cover 500 has a three
dimensional inwardly extending shape that corresponds to the shape
of the cavity 12c. In some embodiments, the cover 500 can comprise
or be polymeric or elastomeric.
[0113] FIG. 17A and 17B illustrate an external lance cover 600 that
can be placed inside lance cavities 12c on the rear 12r of the back
wall 12 of the enclosure 10. The external lance cover 600 can be
used with lances 20 that are unused (do not engage latches 60). The
external cover 600 can have an inwardly extending body 603 with a
front segment 605 that extends through the lance aperture 21. The
cover 600 can have a cavity 606 that corresponds to a shape of the
rear wall cavity 12c. The cover 600 can have a rectangular
perimeter and can have a rectangular cavity 606. The front segment
605 can have a rectangular perimeter that is smaller than that of
the body 603. In some embodiments, the cover 600 can comprise or be
polymeric or elastomeric.
[0114] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although a few
exemplary embodiments of this invention have been described, those
skilled in the art will readily appreciate that many modifications
are possible in the exemplary embodiments without materially
departing from the novel teachings and advantages of this
invention. Accordingly, all such modifications are intended to be
included within the scope of this invention. Therefore, it is to be
understood that the foregoing is illustrative of the present
invention and is not to be construed as limited to the specific
embodiments disclosed, and that modifications to the disclosed
embodiments, as well as other embodiments, are intended to be
included within the scope of the invention.
* * * * *