CLIAMS:We Claim:
1. A communication module comprising:
a PCB;
one or more connectors; and
a housing and a cover configured to house the PCB and the one or more connectors, wherein the housing and the cover are configured for use on different modular devices, and wherein housings and covers of the different modular devices have common features and specific features that are manufactured using common molding tools that use replaceable inserts for specific features and common features are in-built into the common molding tools.

2. The communication module of claim 1, wherein the housing and the cover are held together by click fit arrangement.

3. The communication module of claim 1, wherein the communication module incorporates Poka-yoke features.
,TagSPECI:TECHNICAL FIELD
[0001] The present disclosure generally relates to the field of power supply equipment. In particular it pertains to common design for housing and cover used in mechanism-independent modular communication devices used in a distribution box.

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] A distribution board (or distribution box or panel-board or breaker panel) is a panel that houses the fuses, circuit breakers, and earth leakage protection units. The board typically has a single incoming power source and it distributes electrical power to numerous individual circuits or consumer points. It follows the basic principles of “distributing” a single supply to various individual points while ensuring safety and control for each. The core function of any distribution board is to allow individual circuits to draw power from correctly rated circuit breakers and for those circuits to be isolated without causing a disruption to the rest of the supply. The distribution board offers protection to users and equipment from electrical shock or fire resulting from ground faults.
[0004] Distribution box connects multiple devices to the control system and are a great way to increase flexibility. It is used in larger systems that help to regulate the flow of electricity through a distribution board. The concept behind the box is to provide for the orderly flow of current so that circuitry is not overloaded, leading to potentially dangerous situations.
[0005] Distribution boxes incorporate a number of control assemblies such as miniature circuit breaker (MCB) that automatically switches off the electrical circuit when the network develops a fault; Residual Current Device (RCD) or Residual Current Circuit Breaker (RCCB) that disconnect a circuit whenever it detects that the electric current is not balanced between the energized conductor and the return neutral conductor. RCCBs are designed to disconnect quickly enough to prevent shock injury to a person who is grounded and accidentally comes in contact with the energized part of the circuit. Residual Current Breakers with Over-current Protection (RCBO) combines the functions of RCD and MCB and are commonly used in applications where there is a need to combine protection against over-currents (overload and short-circuit) and earth leakage currents. These and other devices within a distribution box provide measuring, control and regulating arrangement. Collectively the whole system is called switchgear that is responsible for the controlling and protection of the power system and plays a vital role in modern power system network, right from generation through transmission to distribution end.
[0006] In smart distribution networks, communication modules are used as connectors for sending different electric signals from intelligent units, e.g., switchgear, to a control centre which forms a fully functional protection system, e.g., PLC, operating in a wide area network. Converters can extend the communication distance significantly or can increase the number of communication node by a given factor. It also improves the speed and performance of device in data transmission.
[0007] Each communication device has different size and profile requiring large space in distribution box along with the primary protective switchgears. The disadvantages caused by the varied profile means that different types of housings and their covers need to be made for each of those devices, requiring separate manufacturing tools, require production in separate batches (mostly uneconomical on account of small quantities increasing cost). Besides, non-uniform appearance of the complete arrangement of the devices in a distribution box gives an appearance that they don’t belong to the same modular product family. It is a costly affair to have a large variety of tools for molding (also referred to as molds) these housings and covers for devices whose market requirement is not justified by the investment done.
[0008] There is, therefore, a need for a common housing and cover which can be used for a number of (if not all) modular communication devices in spite of their different sizes and profiles so that there variety could be reduced with resultant reduction in molds and cost.
[0009] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0010] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0011] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0012] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0013] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

OBJECTS OF THE INVENTION
[0014] An object of the present disclosure is to overcome problems associated with the housings of communication devices in a distribution box when each of them has different sizes and profiles.
[0015] Another object of the present disclosure is to provide a common housing and cover which can be used for all communication modular devices in spite of their different applications.
[0016] Another object of the present disclosure is to provide common tools for cover and housing of different modular devices.
[0017] Another object of the present disclosure is to provide common tools for cover and housing to be used for different modular devices with replaceable inserts for uncommon features.
[0018] Another object of the present disclosure is to provide a screw-less and rivet-less assembly.
[0019] Another object of the present disclosure is to provide easy assembly of housing and cover with click fit feature rather than riveting.
[0020] Another object of the present disclosure is to provide a Poka-yoke arrangement feature for replaceable inserts.

SUMMARY
[0021] Aspects of present disclosure relate to a common housing and cover which can be used for all communication modular devices in spite of their different sizes and profiles. Besides being space saving, the common housing and cover can be flexible enough to cater to any future electronic or non-electronic components / assembly.
[0022] In another aspect of the present disclosure, the common housing and cover can provide uniform appearance for different modular devices. In an embodiment of the disclosure, common tools for housing and cover can be used for modular devices with replaceable inserts to provide for uncommon features, reducing the cost by over 30%.
[0023] In another aspect of the present disclosure, the common housing and cover can provide easy assembly of housing and cover with Poka-yoke arrangement features thereby eliminating the chances of wrong assembly due to component mixing during mass production. Further, the common housing and cover would be least cumbersome for being screw-less and rivet-less, having click-fit feature.
[0024] 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
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026] FIG. 1 illustrates an exemplary schematic diagram of common cover and housing for communication modules and converters in accordance with embodiments of the present disclosure.
[0027] FIG. 2 illustrates an exemplary schematic diagram of a communication product assembly procedure in respect of housing and cover, and Poka-yoke arrangement with different sized connectors in accordance with embodiments of the present disclosure.
[0028] FIG. 3 illustrates an exemplary diagram of a converter product assembly procedure in respect of housing and cover, and Poka-yoke arrangement with different sized connectors in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0030] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0031] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0032] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0033] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0034] Embodiments of the present disclosure relate to a common housing and cover design which can be used in mechanism-independent communication modular devices in spite of their different sizes and profiles, giving them a uniform appearance.
[0035] In an embodiment the disclosure provides same sized cover and housing for a plurality of modular devices, having similar applications, such that these cover and housing can be molded using common molding tools with replaceable inserts for uncommon features. In an aspect the common tools with replaceable inserts type construction can reduce the cost by over 30% when implemented for two devices/products. Further, common cover and housing can be extended to more than two products, increasing the cost saving potentials.
[0036] In another embodiment the disclosure provides means for easy and hassle free assembly of the devices with click fit feature rather than the riveting feature and the whole assembly is screw-less. It follows a unique tooling design using different inserts for a plurality of devices with Poka-yoke arrangement features, reducing the chances of wrong assembly due to component mixing during mass production.
[0037] In another embodiment the disclosure provides means for flexibility and compatibility whereby the disclosed common housing and cover design can cater to any future electronic or non electronic components / assembly bringing uniformity to products.
[0038] FIG. 1A through FIG. 1F illustrate exemplary schematic views, including top 140 and isometric views 120 & 130, of a common cover 110 and bottom 180 and isometric views 160 & 170 of a common housing 150 for a plurality of communication modules and converters in accordance with embodiments of the present disclosure. The housing 150 can be provided with a common Din clip area 162 that can be used when assembling the communication modules or the converters. Since the common cover 110 and the common housing 150 can be used for a plurality of communication modules and converters, the look and appearance of such devices would be uniform. Further, the view 180 shows common internal features for the communication modules and converters.
[0039] In an embodiment the common cover 110 and housing 150 for different communication modules can be manufactured using common tools i.e. molding tools for cover and housing respectively. In an aspect common tooling can reduce variety of tools, reduce investment in tools and accordingly bring corresponding economy in cost of production. It can bring in further economy in production by increasing the batch size of the cover and housing as covers and housings of a number of communication devices can be produced without dismounting the tools from the molding machine and continuing production simply by changing the replaceable inserts.
[0040] FIG. 2A through FIG. 2F illustrate exemplary schematic views of cover 205 and housing 225 of a specific product such as a communication module in accordance with an embodiment of the disclosure wherein the cover 205 and housing 225 incorporate features specific to the product. It shows the top view 220 and isometric views 210 & 215, of the cover 205; and also exemplary views, including bottom view 240 and isometric views 230 & 235, of the housing 225 for the communication module in accordance with embodiments of the present disclosure. Shown therein are exemplary special features of the cover 205 such as 212, 214, 216 & 222 and that of the housing 225 such as 232 & 236 to meet the specific requirements of the product.
[0041] In an embodiment, these features on cover and housing specific to the product can be incorporated in the common molding tool as replaceable inserts. Thus the requirement of covers and housings specific to different products can be met using common molding tools.
[0042] FIG. 2G illustrates an exemplary schematic view 245 showing assembly of various parts of the communication module in accordance with embodiments of the present disclosure. View 245 shows different constituent parts of the communication module. It can incorporate a PCB 247 housed within the housing 248 with the cover 246 that sits on top. The Din Clips 249 & 250 can fit in to the common features built in the housing 248. In an embodiment the cover 246 and the housing 248 can fit to each other with click fit arrangement incorporated on the two as common feature. In an aspect the click fit assembly feature can do away with screws or rivets that are otherwise used for assembly. In another exemplary view of FIG. 2 H, the final communication assembly 255 is shown. The final assembly 255 would look similar for plurality of communication modules that use the common cover and housing giving uniform appearance and saving spaces in the power distribution network.
[0043] FIG. 2I and FIG. 2J illustrate exemplary schematic views 260 and 265 respectively wherein Poka-yoke arrangement features are shown. The PCB 262 can be housed within the housing 263 and the cover 261 and the connector 262 & 267 follow the Poka-yoke arrangement wherein different size connectors are provided to prevent mix up of components.
[0044] FIG. 3A through FIG. 3F illustrate exemplary schematic views of cover 305 and housing 325 of another specific product such as a converter in accordance with an embodiment of the disclosure wherein the cover 305 and housing 325 can incorporate features specific to the converter. It shows the top view 320 and isometric views 310 & 315 of the cover 305; and also exemplary views including bottom view 340 and isometric views 330 & 335 of the housing 325 for the converter in accordance with embodiments of the present disclosure. Shown therein are exemplary special features of the cover 305 such as 312 and 316 and that of the housing 325 such as 332 & 336 to meet the specific requirements of the converter. These features on cover 305 and housing 325 specific to the converter can be incorporated in the common molding tool as replaceable inserts. Thus the requirement of covers and housings specific to different products can be met using common molding tools.
[0045] FIG. 3G illustrates an exemplary schematic view 345 showing assembly of the various parts of the converter in accordance with embodiments of the present disclosure. View 345 shows different constituent parts of the communication module. It can incorporate a PCB 347 housed within the housing 349 and the cover 346 that sits on top. The Din Clips 348 & 350 can fit in to the common features built in the housing 349. In the same manner as for communication module, the cover 346 and the housing 349 of the converter can fit to each other with click fit arrangement incorporated on the two as common features can do away with screws or rivets that are otherwise used for assembly. In another exemplary view of FIG. 3 H, the final converter assembly 355 is shown. The final assembly 355 would look similar to communication module that used the common cover and housing giving uniform appearance and saving space in the power distribution board.
[0046] FIG. 3I and FIG. 3J illustrate exemplary schematic views 360 and 365 respectively wherein Poka-yoke arrangement features are shown in accordance with an embodiment of the present disclosure. The PCB 362 can be housed within the housing 363 and the cover 361, the connector 362 & 367 can follow the Poka-yoke arrangement wherein different size connectors are provided to prevent mix up of components.
[0047] Thus cover and housing manufactured using a common tool that can be provided with inserts to incorporate features specific to each product have been used for both the communication module 255 and the converter 355. It is apparent that the two assemblies 255 and 355 shall have uniform appearance and size. Further, the assembly process is simple and easy wherein click fit feature can be used and the assembly can be screw-less and rivet-less. Further, Poka-yoke arrangement feature greatly reduce the chances of component mixing during mass production.
[0048] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0049] The present disclosure overcomes problems associated with the housing of communication devices in a distribution box when each of them has different sizes and profiles.
[0050] The present disclosure provides a common housing and cover which can be used for all communication modular devices in spite of their different applications.
[0051] The present disclosure provides common tools for cover and housing of different modular devices.
[0052] The present disclosure provides common tools for cover and housing to be used for different modular devices with replaceable inserts for uncommon features.
[0053] The present disclosure provides a screw-less and rivet-less assembly.
[0054] The present disclosure provides easy assembly of housing and cover with click fit feature rather than riveting.
[0055] The present disclosure provides a Poka-yoke arrangement feature for replaceable inserts.