CROSS-REFERENCE TO RELATED APPLICATION This application claims priority from and claims the benefit of U.S. Provisional Patent Application Serial No. 61/915,078, filed December 12, 2013, which is incorporated by reference herein.

BACKGROUND

Field

The disclosed concept relates generally to electrical switching apparatus and, more particularly, to a hybrid switchgear module.

Background Information

Electrical systems generate, regulate and/or distribute power.

Power distribution assemblies, for example, generally include an enclosure, a number of input and output connectors, internal electrical bussing, electrical conductors, a number of electrical switching apparatus, such as contactors, circuit breakers, relays and the like and/or fuses. More specifically, in aircraft or aerospace electrical systems, for example, relatively small circuit breakers, commonly referred to as subminiature or aircraft circuit breakers, are often used to protect electrical circuitry from damage due to an over current condition, such as an overload condition or a relatively high level short circuit or fault condition. Such circuit breakers also often serve as switches for turning equipment on and off, and are grouped together as part of a circuit protection module with the circuit breakers/switches being accessible on an outer panel of the enclosure.

It is sometimes desirable to control the power distribution assembly function remotely. Solid-state power controllers (SSPCs) have been used for this purpose. However, SSPCs can be adversely effected by the heat sometimes generated in aircraft electrical systems. SSPCs also exhibit increased resistance compared to circuit breakers and are prone to frequent short circuit failure, and require expensive semiconductor materials, controllers and algorithms to program the SSPCs to emulate circuit breakers, all of which leads to increased cost and complexity.

There is room, therefore, for improvement in switchgear modules. SUMMARY OF THE INVENTION

In one embodiment, a hybrid switchgear module is provided that includes a faceplate including a plurality of apertures, a backplane including a first side, a second side disposed opposite the first side, a plurality of electrical conductors at least partially embedded within the backplane, and a plurality of sockets, a first switchgear assembly and a second switchgear assembly. The first switchgear assembly includes a plurality of first electrical switching apparatus disposed on the first side of the backplane, each of the first electrical switching apparatus including a first end having a manual operating member and a second end opposite and distal the first end and including a plurality of electrical connectors, the manual operating member being disposed in a corresponding one of the apertures of the faceplate, at least one of the electrical connectors being electrically connected to a corresponding one of the electrical conductors at least partially embedded within the backplane. The second switchgear assembly includes a plurality of second electrical switching apparatus disposed on the second side of the backplane, each of the second electrical switching apparatus being electrically connected to a corresponding one of the first electrical switching apparatus through the backplane. Each of the second electrical switching apparatus is electrically connected to at least one of the electrical conductors at least partially embedded within the backplane through a corresponding at least one of the sockets in the backplane.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

Figure 1 is an isometric view of a hybrid switchgear module in accordance with an embodiment of the disclosed concept;

Figure 2 is a partially exploded isometric view of the hybrid switchgear module of Figure 1;

Figure 3 is a side elevation partially in section view of a portion of the hybrid switchgear module of Figure 2; Figure 4 is a side elevation view of the hybrid switchgear module in accordance with another embodiment of the disclosed concept;

Figure 5 is a top isometric view of the hybrid switchgear module of

Figure 4;

Figure 6 is a bottom isometric view of the hybrid switchgear module of

Figure 5; and

Figure 7 is another bottom isometric view of the hybrid switchgear module of Figure 6, modified to show one relay exploded away from the rest of the hybrid switchgear module.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of illustration, the disclosed concept is described herein in association with aircraft or aerospace power distribution assemblies and systems employing subminiature or aircraft circuit breakers and other electrical apparatus (e.g., without limitation, relays; contactors), although it will become apparent that the disclosed concept is applicable to a wide range of different applications. For example and without limitation, the disclosed concept can be employed in aircraft alternating current (AC) systems having a typical frequency of about 400 Hz, but can also be used in direct current (DC) systems. It will also become evident that the disclosed concept is applicable to other types of electrical systems including, for example and without limitation, circuit breaker panels or circuit protection modules used in AC systems operating at other frequencies; to larger circuit breakers, such as miniature residential or commercial circuit breakers; and to a wide range of circuit breaker applications, such as, for example, residential, commercial, industrial, aerospace, and automotive.

As employed herein, the term "electrical conductor" shall mean an electrical buss member, a pin, a connector, a copper conductor, an aluminum conductor, a suitable metal conductor, or other suitable material or object that permits an electric current to flow easily.

As employed herein, the term "embedded" shall mean disposed within a material so as to be integrally formed within, surrounded by, or covered by the material. Accordingly, unless explicitly stated otherwise, an electrical conductor that is "at least partially embedded" in accordance with the disclosed concept may be either entirely embedded (e.g., integrally formed within; surrounded by; covered by) within the material, or a portion of the electrical conductor may protrude outwardly from the material.

As employed herein, the term "liquid crystalline polymer" shall mean a moldable (e.g., without limitation, by injection molding) material that is both thermally conductive and electrically non-conductive (e.g., an electrical insulator) exhibiting dielectric properties and expressly includes, but is not limited to, CoolPoly ^® D5506, which is available from Cool Polymers, Inc. having a place of business at 51 Circuit Drive, North Kingstown, Rhode Island 02852.

As employed herein, the term "managed" or "manages" shall mean handled or directed with a degree of skill, worked upon or tired to alter for a purpose, or succeeded in accomplishing or achieved a purpose.

As employed herein, the term "plug-in" refers to a connection between two components that expressly excludes the use of hardware, fasteners, or adhesives (e.g., without limitation, glue; solder; weld) and may include, for example and without limitation, connections between male and female plug-in connectors and interference or press fit plug-in connections.

As employed herein, the term "fastener" refers to any suitable connecting or tightening mechanism expressly including, but not limited to, screws, bolts and the combinations of bolts and nuts (e.g., without limitation, lock nuts) and bolts, washers and nuts.

As employed herein, the statement that two or more parts are "coupled" together shall mean that the parts are joined together either directly or joined through one or more intermediate parts. Further, as employed herein, the statement that two or more parts are "directly connected" shall mean that the parts are joined together directly.

As employed herein, the term "number" shall mean one or an integer greater than one (i.e., a plurality).

Referring now to the drawings, which are not intended to limit the scope of the disclosed concept, Figure 1 shows a hybrid switchgear module 2, which among other benefits, provides a compact modular plug-in assembly that is relatively quick and easy to install as one single component, and which advantageously has relatively low resistance or power dissipation and is suitable for operation in relatively high temperature (e.g., without limitation, up to about 120°C ambient, or more) environments. The electro-mechanical devices employed in accordance with the disclosed concept also have substantially no leakage current, and fail "open" as opposed to being shorted "closed" like prior art designs, which for example employ solid state power controllers (SSPCs). In other words, the modular design of the disclosed hybrid switchgear module provides a considerable size, depth and weight savings, as well as an overall simplified construction, compared to existing designs and methods of wiring or otherwise interconnecting the plurality of different electrical switching apparatus. That is, the hybrid switchgear module 2 essentially consolidates two separate electrical switching apparatus modules or switchgear assemblies into a singular hybrid switchgear module 2, as will now be described in greater detail.

EXAMPLE 1

The hybrid switchgear module in the non-limiting example of Figures

1 and 2 includes a faceplate 4 with a plurality of apertures 6. A backplane 8, which includes first and second opposing sides 10,12 is spaced from, and generally parallel to, the faceplate 4. A plurality of electrical conductors, such as for example and without limitation electrical bus members 14, 16, 18, are at least partially embedded within the backplane 8, as best shown in the enlarged section view of Figure 3. The backplane 8 also includes a plurality of sockets 20,22,24, also shown in Figure 3.

Particularly to the disclosed hybrid switchgear module 2 is that a first switchgear assembly 100 and a second switchgear assembly 200 are both operably coupled to the backplane 8, preferably by way of a suitable plug-in arrangement with the backplane 8.

EXAMPLE 2

The backplane 8 may, for example and without limitation, comprise a printed circuit board (PCB).

EXAMPLE 3

The backplane 8 is preferably made from a thermally conductive and electrically insulative material. At least one and preferably both of the first switchgear assembly 100 and second switchgear assembly 200, are directly connected to the thermally conductive backplane 8. In this manner, the backplane 8 can serve to thermally conduct and therefore dissipate heat while simultaneously providing the necessary electrical insulation between electrical components such that the entire assembly can be arranged in the substantially compact configuration, shown.

EXAMPLE 4

In one non-limiting example embodiment, the backplane 8 is made from a liquid crystalline polymer. It will be appreciated, however, that any known or suitable alternative type and/or configuration of backplane 8 (not shown) made from any known or suitable alternative material, could be employed without departing from the scope of the disclosed concept.

EXAMPLE 5

Continuing to refer to Figures 1-3, the first switchgear assembly 100 includes a plurality of first electrical switching apparatus, such as for example and without limitation, circuit breakers 102. The circuit breakers 102 are disposed on the first side 10 of the backplane 8. Each circuit breaker 102 includes a first end 104 having a manual operating member 106, and a second end 108 opposite and distal from the first end 104, and including a plurality of electrical connectors 110,112.

Each manual operating member 106 is disposed in a corresponding aperture 6 of the faceplate 4. At least one of the circuit breaker electrical connectors 110,112 is electrically connected to a corresponding one of the electrical conductors 14, 16, 18

(e.g., without limitation, electrical buses), which are at least partially embedded within the backplane 8, as shown in Figure 3.

The second switchgear assembly 200 includes a plurality of second electrical switching apparatus, such as for example and without limitation, relays 202, which are disposed on the second side 12 of the backplane 8. Each relay 202 is electrically connected to a corresponding one of the aforementioned circuit breakers

102 through the backplane 8, as shown in Figure 3.

Referring to the section view of Figure 3, it will be appreciated that each of the relays 202 is electrically connected to at least one of the aforementioned electrical busses 14,16,18, which are at least partially embedded within the backplane

8, through corresponding sockets 20,22,24 in the backplane 8.

EXAMPLE 6

The first switchgear assembly 100 of the example hybrid switchgear module 2, shown in Figures 1-3, includes 30 circuit breakers 102, and the second 5 switchgear assembly 200 includes 30 corresponding relays 202 therefore. It will be appreciated, however, that any known or suitable alternative number and/or configuration of first and second electrical switching apparatus could be employed in accordance with the disclosed concept. The circuit breakers 102 provide protection from relatively significant faults (e.g., without limitation short circuits) and the relays 10 202 are controlled for not only providing the ability for remote control purposes, for example and without limitation, via a number of suitable solenoids 300,302, but also for opening the power circuit in response to an arc fault detected by the circuit breaker 102.

EXAMPLE 7

15 In the example of Figures 1-3, the second switchgear assembly 200 further includes a cover 204, which is coupled to the backplane 8. In this manner, the cover 204 collectively secures all of the relays 202 between the cover 204 and the second side 12 of the backplane 8, without requiring a number of separate fasteners. In other words, the cover 204 serves to compress or otherwise secure the relays 202

20 such that separate fasteners for individually fastening each of the relays 202 to the backplane are not required. The cover 204 may be coupled to the backplane 8 in any known or suitable manner, such as for example and without limitation, using the four screws shown in Figures 1 and 2.

EXAMPLE 8

25 The first switchgear assembly 100 of the example hybrid switchgear module 2 further includes a frame 120, wherein the plurality of circuit breakers 102 are disposed within the frame 120 on the first side 10 of the backplane 8, as shown.

EXAMPLE 9

The example circuit breakers are residual current circuit breakers 30 (RCCBs), which are relatively small and therefore permit a very compact package size for the hybrid switchgear module 2. The RCCBs 102 are also remotely operable using a suitable number of solenoids 300,302, in a generally well known manner. EXAMPLE 10

Referring again to Figure 3, as previously discussed, the circuit breakers 102 preferably include a plug-in connector arrangement. In the example shown, the circuit breaker 102 includes a load pin 110 and a line pin 112 each being connected to a corresponding electrical bus 16 and 18, respectively. The relay 202 is electrically connected to the load pin 110 and/or the line pin 112 of the circuit breaker 102. The example relay 202 further includes a plurality of control pins 212,214,216. Each of the control pins 212,214,216 is disposed in a corresponding one of the aforementioned sockets 20,22,24 of the backplane 8, as shown. Accordingly, each control pin 212,214,216 is electrically connected to a corresponding one of the electrical busses 14,16,18 embedded within the backplane 8, as shown.

EXAMPLE 11

The second switchgear assembly 200 of the example hybrid switchgear module 2 further includes a relay control connector 400, which is disposed on the first side 10 of the backplane 8. The relay control connector 400 is electrically connected to the relays 202, which are disposed on the second side 12 of the backplane 8, by way of the appropriate embedded electrical busses (e.g., without limitation 14,16,18) embedded within the backplane 8.

EXAMPLE 12

The first switchgear assembly 100 may further include a number of feeder posts, which are electrically connected to the line pins 12 of the circuit breakers 102. The example hybrid switchgear module 2 includes a first feeder post 130 and a second feeder post 132, which are also electrically connected to suitable corresponding electrical busses 14, 16, 18 embedded within the backplane 8, and which extend outwardly from the first side 10 of the backplane 8, as shown.

EXAMPLE 13

Figures 4-7 show an alternative non-limiting embodiment of a hybrid switchgear module 2', in accordance with the disclosed concept. It will be appreciated that the embodiment shown in Figures 4-7 is substantially similar to the hybrid switchgear module 2 previously discussed hereinabove with respect to Figures 1-3. Accordingly, similar features are numbered or referenced substantially similarly. Specifically, features shown in the embodiment of Figures 4-7, which can be liken to a corresponding feature in the embodiment of Figures 1-3, are labeled with the same number but include the prime symbol For example, the backplane, which was assigned reference numeral 8 for the embodiment of Figures 1-3, is referred to as backplane 8' in the embodiment of Figures 4-7.

EXAMPLE 14

The primary distinguishing feature of the hybrid switchgear module 2' of Figures 4-7 is that each relay 202' includes a number of fasteners. Specifically, in the non-limiting example shown and described herein, each relay 202' includes a first screw 204' and a second screw 206' for fastening the relay 202' to the second side 12' of the backplane 8'. This will be best appreciated with reference to the partially exploded view of Figure 7. It will also be appreciated with reference to Figure 7 that the aforementioned control pins 212',214',216' are received by, and disposed in, corresponding sockets 20',22',24', respectively, in the backplane 8'.

All of the remaining features of the hybrid switchgear module 2' are substantially similar to those previously discussed with respect to hybrid switchgear module 2 of Figures 1-3. It will, however, be appreciated that the aforementioned examples are not intended to be limiting upon the scope of the disclosed hybrid switchgear module concept, in any manner.

Accordingly, the disclosed concept provides a hybrid switchgear module 2,2' having enhanced thermal properties afforded by the unique backplane 8,8' and modular design of the first and second switchgear assemblies 100,100',200,200', which are mechanically coupled and thermally connected thereto. In this manner, the disclosed concept addresses and overcomes shortcomings and limitations associated with prior art designs. Among other benefits, the disclosed hybrid switchgear module 2,2' and switchgear assemblies 100,100',200,200' thereof, provide a much lower resistance solution versus electronic SSPCs, eliminate the power consumption required by SSPCs, provide a more desirable failure mode, and are suitable for use in relatively high temperature (e.g., without limitation, up to about 120°C ambient, or more) compared to SSPCs, which are typically limited to about 55-71°C max ambient. Furthermore, because the heat-generating devices are directly mounted to the thermally conductive and electrically insulative backplane 8,8', spacing between components can be reduced, and additional separate electrical conductors (e.g., without limitation, exposed wires) and fasteners conventionally required, are eliminated. Accordingly, the hybrid switchgear module 2,2' is not only more compact, but is also of a relatively simplified construction and affords the benefits of solid-state circuit protection.

While specific embodiments of the disclosed concept have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.