Description:TECHNICAL FIELD
[0001] The embodiments of the present disclosure generally relate to molded case circuit breakers, and particularly to a load terminal cover for molded case circuit breakers. More specifically, it relates to the terminal shield for high voltage high arcing capacity applications with supplementary wire routing and ground fault protection shield.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] The trend in the circuit protection industry is currently toward complete circuit protection which is accomplished by the addition of supplemental protection apparatus to standard overcurrent protective devices, such as molded case circuit breakers. In the past, when such auxiliary protection apparatus or other circuit breaker accessories were combined with a standard circuit breaker, the accessories were usually custom-installed at the point of manufacture. The combined protective device, when later installed in the field, could not be externally accessed for inspection, replacement or repair without destroying the integrity of the circuit breaker interior.
[0004] When one of such accessories is field-installed within the integrated protection unit cover, it is important that the accessory components are not removed or tampered with once the integrated protection unit is installed within an electric circuit. One purpose of the instant invention accordingly, is to provide field access facility to an integrated protection unit to allow selected accessory features to be readily installed before the integrated protection unit is connected within an electric circuit while later preventing access to such accessory components when the integrated protection unit is connected within the electric circuit.

SUMMARY
[0005] The present invention relates to molded case circuit breakers and more particularly to a terminal cover/shield which is assembled on the load and line side termination to provide enhanced ingress protection, avoid electric shock to users during service and maintenance and channelized gas exhaustion from the circuit breaker during a short-circuit interruption.
[0006] The invention intends to solve the problem of providing terminal shields with proper fitment for arc venting and locking the shield with access control. Fail safe rear plate shielding arrangement to avoid ground fault arcing. Interphase barrier arrangement to ensure longer length insulation between bare cables in incoming and outgoing termination
[0007] Molded case circuit breakers have terminals and provisions for wiring connectors at each end (Line/Load) of the circuit breaker. A removable terminal cover/shield is provided so as to provide ease of access to the technician to the breaker terminals for assembling, tightening, or inspecting the electrical connections.
[0008] When the terminal cover/shield is reassembled, the shield/cover provides higher ingress protection enabling solid objects from entry or falling into the unit, helps prevent accidental contact with the live terminals from the front of the circuit breaker and prevents hot, ionized gases caused by short circuit interruption from exiting from the front of the circuit breaker.
[0009] In some cases terminal shield helps in avoiding gases striking grounded metal on the front of the equipment enclosure and cause an electrical ground fault.
[0010] In multi-pole circuit breakers, during short-circuit interruption typically, hot, ionized gases from short circuit interruption entering into the arc chamber of the circuit breaker has to tendency to flow out in all directions.
[0011] In few cases where sufficient boundary or exit path is not defined, the exhaust from the different poles of the breaker, which are at different electrical potentials may cross each other.
[0012] This crossing can result in a phase-to-phase arcing fault across the terminals of the circuit breaker.
[0013] Additionally, there exists a concern of phase-to-ground arcing leading to circuit breaker inoperable or causing damage to human or equipment.
[0014] The problem of phase-to-phase arcing in a circuit breaker is addressed by providing raised overlap with MCCB on termination side and guided arc exhaust design. Further, as the gases flow out, it is expected that the pressure on the terminal shields should be borne by the shield and should aid in dissipating the gases without creating external arcing.
[0015] The LOAD and/or LINE terminals thereof protected by a multifunctional terminal shield arrangement provides interphase barriers for the terminals and associated wiring.
[0016] The Terminal shield provides wire channels for lower voltage supplemental wiring. These terminal shields are designed to integrate insulated base plate for high voltage applications >500V. In normal cases where customer is expected to use a protective insulating sheet according to application. This terminal shield arrangement makes the shield part of ground insulation hence, avoiding safety risk posed by customer to low.
[0017] This Terminal shield also provides relevant cutting feasibilities to accommodate vents provided for DC MCCB’s hence harmonizing and reducing the need to develop multiple tools and offering multiple solution feasibility with one component according to application needs.
[0018] These Terminal shields are provided with screw fitments on the MCCB. These screw fitments are to be covered and access controlled to avoid mis-use and accidental removal during operation or maintenance.
[0019] Terminal shield screw locks are provided through a flap cover which can be tagged-out with a one-time lock, specifically designed for this purpose. This ensures safety of operation.
[0020] These flaps are self-hinged in the Terminal shield as well as covering the screw even when Tag-out is not present. Absence of mis-place of flap covers are avoided by making it quick snap self-retaining design.
[0021] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, which are incorporated herein, and constitute a part of this invention, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that invention of such drawings includes the invention of electrical components, electronic components or circuitry commonly used to implement such components.
[0023] FIGs. 1-6 illustrates the construction of the terminal cover and its various features.
[0024] The foregoing shall be more apparent from the following more detailed description of the invention.

DETAILED DESCRIPTION
[0025] Various example embodiments will now be described more fully with reference to the accompanying drawings in which only some example embodiments are shown. Specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. The present invention, however, may be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.
[0026] Accordingly, while example embodiments of the invention are capable of various modifications and alternative forms, embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments of the present invention to the particular forms disclosed. On the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of the invention. Like numbers refer to like elements throughout the description of the figures.
[0027] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments of the present invention. As used herein, the term “and/or,” includes any and all combinations of one or more of the associated listed items.
[0028] 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. In contrast, when an element is referred to as being “directly connected,” or “directly coupled,” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between,” versus “directly between,” “adjacent,” versus “directly adjacent,” etc.).
[0029] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the,” are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the terms “and/or” and “at least one of” include any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used herein, 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.
[0030] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0031] 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, term such as “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein are interpreted accordingly.
[0032] The present invention relates to molded case circuit breakers and more particularly to a terminal cover/shield which is assembled on the load and line side termination to provide enhanced ingress protection, avoid electric shock to users during service and maintenance and channelized gas exhaustion from the circuit breaker during a short-circuit interruption.
[0033] The invention intends to solve the problem of providing terminal shields with proper fitment for arc venting and locking the shield with access control. Fail safe rear plate shielding arrangement to avoid ground fault arcing. Interphase barrier arrangement to ensure longer length insulation between bare cables in incoming and outgoing termination.
[0034] Molded case circuit breakers have terminals and provisions for wiring connectors at each end (Line/Load) of the circuit breaker. A removable terminal cover/shield is provided so as to provide ease of access to the technician to the breaker terminals for assembling, tightening, or inspecting the electrical connections.
[0035] As shown in FIGs. 1-6 the construction of the terminal cover and its various features are shown.
[0036] Component A and Component B (also interchangeably referred to as “Part A” and “Part B” respectively) constitute an integrated Terminal shield solution tailored for circuit breakers. This comprehensive system is engineered to provide a robust and versatile approach to circuit breaker protection and functionality. Following provides the key features and benefits of these components:
[0037] Combined Solution: Component A and Component B are thoughtfully paired together, offering a holistic Terminal shield solution that addresses various aspects of circuit breaker safety and performance. This synergistic pairing ensures that all necessary elements are in place to safeguard the system and enhance its functionality.
[0038] Arc Flash Prevention: Component A and Component B are meticulously designed to overlap in specific grooves, strategically marked for this purpose. This overlapping configuration serves a crucial role in preventing arc flashes from escaping the fitment. Furthermore, it provides the system with the ability to withstand gas pressure that may result from fault conditions, bolstering safety.
[0039] Fitment Locations: Component A boasts designated fitment locations that seamlessly interface with the Molded Case Circuit Breaker (MCCB). This integration ensures a snug and secure fit, optimizing the performance of the circuit breaker. Additionally, Component A incorporates fitment overlaps with Component B, a feature that can be utilized for grounding the entire Terminal shield when necessary. This grounding capability adds an extra layer of safety to the system.
[0040] Interphase Barrier: One standout feature of Component A is its interphase barrier projections. These projections are intentionally designed to be sufficiently long, meeting the stringent busbar length requirements mandated by industry standards. This meticulous attention to detail ensures that the circuit breaker operates within the prescribed safety parameters.
[0041] Accommodation for DC MCCB: Recognizing the diverse requirements of different circuit breakers, Component A is equipped with grooves and cuts specifically engineered to accommodate DC MCCB needs. These grooves are vital for accommodating arc vents located between phases, a critical component of DC MCCBs. By seamlessly integrating these features, Component A ensures that the Terminal shield solution is adaptable to a wide range of circuit breaker applications.
[0042] Arc Gas Escape and Venting: Safety is paramount in circuit breaker design. Component A incorporates sophisticated design elements that facilitate the safe escape of arc gases during fault conditions. Additionally, the system provides ample venting to release excess pressure, preventing potential hazards and protecting the integrity of the circuit breaker.
[0043] Termination Options: Component A is incredibly versatile, with grooves designed to accommodate various types of terminations. This adaptability caters to the unique needs and requirements of different markets and applications. Whether it's ring terminals, spade connectors, or other termination methods, Component A can seamlessly integrate them into the system.
[0044] Component B as Ground Shield: Component B extends up to the midpoint of the MCCB, serving as a reliable ground shield. This innovative design eliminates the need for multiple tools and additional costs by allowing Component B to be assembled on both the Line and Load sides of the circuit breaker. This reversibility simplifies installation and enhances overall efficiency.
[0045] In summary, Component A and Component B represent a state-of-the-art Terminal shield solution for circuit breakers. Their combined capabilities encompass arc flash prevention, fitment optimization, interphase barrier compliance, DC MCCB adaptability, arc gas management, termination flexibility, and cost-effective grounding solutions. These components exemplify the commitment to safety, functionality, and versatility in circuit breaker design, providing a comprehensive solution for a variety of market needs and applications.
[0046] Terminal shield covers are ordered and used in pair of 2 for incoming and outgoing termination side. As shown, terminal shields are assembled and tagged-out to avoid mis-use condition.
[0047] FIG. 6 represents the way Terminal shield and locking flap is assembled on to MCCB and locking is done and the same is indigenously adopted in lowest rating to highest rating MCCB.
[0048] To elaborate:
[0049] Arc Flash Prevention Design: The integration of Components A and B with overlapping grooves (A6, A7, B1, B2, B3) is a Innovative approach to prevent dangerous arc flashes. This design enhancement and its modified version for different sizes and ranges, significantly raises safety standards in electrical systems.
[0050] Streamlined Fitment Optimization: Component A's precisely engineered fitment locations (A6, B7) not only ensure a secure interface with MCCBs but also simplify installation. This novel approach is tweaked according to the size and circuit breaker capacity for which terminal shield is used and eliminates potential installation errors and non-compliance issues, enhancing overall system reliability.
[0051] Efficient Grounding Solution: Component B's dual role as a grounding element (B5, B6) is a groundbreaking solution. It not only improves grounding efficiency but also eliminates customer-end non-compliance concerns, ultimately bolstering arc fault prevention and safety. This grounding component can be mirrored on both line and load side of circuit breakers.
[0052] Interphase Barrier Excellence: The adherence to industry busbar length standards by the interphase barrier projections (B4) showcases a commitment to safe and reliable operation. This standardization is a remarkable step forward in ensuring system integrity.
[0053] Versatile Compatibility with DC MCCBs: The incorporation of grooves and cuts (A8) to accommodate DC MCCB requirements, including arc vents, demonstrates remarkable adaptability. This feature makes the system suitable for various circuit breaker types, fostering versatility.
[0054] Efficient Arc Gas Management: The terminal shield's ability to facilitate the safe release of arc gases through (A2, A1) strengthen with (A10, A9) and modified according to size and rating and arc fault requirements, used during faults is a pioneering safety measure. This innovation minimizes hazards and reduces the risk of system damage, setting a new benchmark for system protection.
[0055] Tailored Termination Flexibility: The adaptability of terminal shield grooves (A3, A4) to different termination methods is a customer-centric innovation. This flexibility caters to diverse market needs, ensuring the product's broad applicability.
[0056] Cost-Efficient Ground Shield: The utilization of the terminal shield as a versatile ground shield is a cost-effective solution. This approach not only reduces expenses but also simplifies installation on both Line and Load sides, making it a game-changer in cost management.
[0057] The above features highlight the ingenuity and advancements in the design and functionality of the electrical components, emphasizing safety, efficiency, and versatility.
[0058] Arc Flash Prevention: Components A and B's overlapping design in marked grooves prevents dangerous arc flashes during faults, enhancing safety.
[0059] Fitment Optimization and Grounding: Component A's fitment locations ensure a secure interface with MCCBs, while Component B can be used for grounding. This simplifies installation and improves grounding efficiency and avoiding non-compliance from customer end, leading to arc fault and safety concern.
[0060] Interphase Barrier Compliance: Interphase barrier projections meet industry busbar length standards, ensuring safe and reliable operation.
[0061] Adaptability for DC MCCBs: Grooves and cuts in accommodate DC MCCB requirements, including arc vents, making it suitable for various circuit breaker types.
[0062] Arc Gas Management and Venting: Terminal shield facilitates the safe release of arc gases during faults, minimizing hazards and system damage.
[0063] Termination Flexibility: Terminal shield Grooves adapt to different termination methods, catering to diverse market needs.
[0064] Cost-Effective Ground Shield: Terminal shield used as a versatile ground shield, reducing costs and simplifying installation on both Line and Load sides.
[0065] In summary, these features enhance safety, compliance, adaptability, and cost-efficiency, making the Terminal shield solution a valuable innovation for the electrical industry.
[0066] Accordingly, the present invention provides a terminal cover for a molded case circuit breaker (MCCB) having a load end enclosing at least one electrical terminal and a line end enclosing at least one electrical terminal. The terminal cover includes a first part (A) with a plurality of first grooves (A6, A7) and a second part (B) with a plurality of second grooves (B1, B2, B3) removably connectable to each other to form the terminal cover. The first part (A) and the second part (B) are connected such that the plurality of first grooves (A6, A7) and the plurality of second grooves (B1, B2, B3) overlap over each other to prevent arc flashes.
[0067] The terminal cover comprises a plurality of guided arc exhaust apertures (A2, A1, A10, A9) that provides exhaustion of gas generated from the MCCB during a short-circuit interruption.
[0068] In this embodiment, each of the first part (A) and the second part (B) are dimensioned to cover at least 3 sides of the MCCB.
[0069] In this embodiment, the first part (A) comprises at least two fitment locations (A6, B7) for attaching the terminal cover to said MCCB.
[0070] In this embodiment, the second part (B) comprises one or more grounding element (B5, B6).
[0071] In this embodiment, the second part (B) comprises an interphase barrier projection (B4) to reduce cross-phase arcing.
[0072] In this embodiment, the first part (A) comprises a plurality of grooves and cuts (A8) to accommodate at least one of arc vents.
[0073] In this embodiment, he first part (A) comprises a plurality of terminal shield grooves (A3, A4) to accommodate one or more termination methods. It may be appreciated that, the termination methods include Direct termination (Cable with prepared ends, Cable with unprepared ends, Busbar), extended termination with spreader links, Rear termination with rear plugs.
[0074] In this embodiment, the first part and the second part are flanges dimensioned to cover said MCCB.
[0075] In this embodiment, the terminal cover is adapted to accommodate the lode end and the line end.
[0076] In this embodiment, the terminal cover is adapted to cover the lode end and the line end.
[0077] What are described above are merely preferred embodiments of the present invention, and are not to limit the present invention; any modification, equivalent replacement and improvement within the principle of the present invention should be included in the protection scope of the present invention.
[0078] The example embodiment or each example embodiment should not be understood as a restriction of the invention. Rather, numerous variations and modifications are possible in the context of the present disclosure, in particular those variants and combinations which can be inferred by the person skilled in the art with regard to achieving the object for example by combination or modification of individual features or elements or method steps that are described in connection with the general or specific part of the description and are contained in the claims and/or the drawings, and, by way of combinable features, lead to a new subject matter or to new method steps or sequences of method steps, including insofar as they concern production, testing and operating methods.
[0079] References back that are used in dependent claims indicate the further embodiment of the subject matter of the main claim by way of the features of the respective dependent claim; they should not be understood as dispensing with obtaining independent protection of the subject matter for the combinations of features in the referred-back dependent claims. Furthermore, with regard to interpreting the claims, where a feature is concretized in more specific detail in a subordinate claim, it should be assumed that such a restriction is not present in the respective preceding claims.
[0080] Since the subject matter of the dependent claims in relation to the prior art on the priority date may form separate and independent inventions, the applicant reserves the right to make them the subject matter of independent claims or divisional declarations. They may furthermore also contain independent inventions which have a configuration that is independent of the subject matters of the preceding dependent claims.
[0081] Further, elements and/or features of different example embodiments may be combined with each other and/or substituted for each other within the scope of this disclosure and appended claims.
[0082] Example embodiments being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the scope of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

, Claims:1. A terminal cover for a molded case circuit breaker (MCCB) having a load end enclosing at least one electrical terminal and a line end enclosing at least one electrical terminal, the terminal cover comprising:
a first part (A) comprising a plurality of first grooves (A6, A7) and a second part (B) comprising a plurality of second grooves (B1, B2, B3) removably connectable to each other to form the terminal cover, wherein the first part (A) and the second part (B) are connected such that the plurality of first grooves (A6, A7) and the plurality of second grooves (B1, B2, B3) overlap over each other to prevent arc flashes; and
wherein the terminal cover comprises a plurality of guided arc exhaust apertures (A2, A1, A10, A9) that provides exhaustion of gas generated from the MCCB during a short-circuit interruption.

2. The terminal cover as claimed in claim 1, wherein each of the first part (A) and the second part (B) are dimensioned to cover at least 3 sides of the MCCB.

3. The terminal cover as claimed in claim 1, wherein the first part (A) comprises at least two fitment locations (A6, B7) for attaching the terminal cover to said MCCB.

4. The terminal cover as claimed in claim 1, wherein the second part (B) comprises one or more grounding element (B5, B6).

5. The terminal cover as claimed in claim 1, wherein the second part (B) comprises an interphase barrier projection (B4) to reduce cross-phase arcing.

6. The terminal cover as claimed in claim 1, wherein the first part (A) comprises a plurality of grooves and cuts (A8) to accommodate at least one of arc vents.
7. The terminal cover as claimed in claim 1, wherein the first part (A) comprises a plurality of terminal shield grooves (A3, A4) to accommodate one or more termination methods.

8. The terminal cover as claimed in claim 1, wherein the first part and the second part are flanges dimensioned to cover said MCCB.

9. The terminal cover as claimed in claim 1, wherein the terminal cover is adapted to accommodate the lode end and the line end.

10. The terminal cover as claimed in claim 1, wherein the terminal cover is adapted to cover the lode end and the line end.