Abstract: A multiphase circuit interrupter includes a plurality of power phase sections for establishing and interrupting electrical power carrying paths for a plurality of phases Each power phase section includes first and second conductive regions which contact one another to complete the current carrying path for the phase. The second conductive region is movable to an interrupted position to interrupt the path. An interphase current carrying path is established between the power phase sections to conduct electrical energy between the sections following a trip event in any one of the sections. The interphase current carrying path may be established by a conductive element extending between the power phase sections. Channels may be formed in the interrupter housing between the power phase sections to communicate conductive plasma generated during separation of the contact regions from one another between the power phase sections.

Abstract: A multilayer circuit board or laminated circuit board for use in a motor controller is described. The multilayer circuit board is preferably utilized as a power substrate module. The power substrate module includes a mounting area provided in a recess, window or portion of the circuit board where the circuit board is only a single layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The single circuit board layer at the mounting area provides a heat conductive yet highly electrically insulated mounting area for receiving a heat sink. The heat sink can be mounted on a side opposite the electrical device. The heat sink may be standard heat sink or a copper coil directly soldered to the circuit board. The multilayer circuit board includes an enhanced conductive layer for receiving the surface mount device. The enhanced conductive layer preferably includes an insulative frame which holds copper slugs.

Abstract: An electrical contactor includes an electromagnetic operator which may be powered by either AC or DC power. For use with AC power, a rectifier circuit converts AC waveforms to DC waveforms and applies the converted power to DC one or more DC coils. The rectifier circuitry applies DC power directly to a bus. A pair of coils may be used, such as separate pickup and holding coils. The pickup coil may be de-energized after an initial phase of operation. To permit rapid release of the holding coil, a control circuit interrupts an induced current path through the coil upon removal of power from the bus.

Abstract: A movable contact assembly for contactors and similar devices includes a movable spanner or conductive element biased toward a conducting position by a biasing element. A housing partially surrounds the conductive element and the biasing element. The biasing element and exerts compressive forces against the housing and the conductive element. The assembly may be installed as a modular unit on a carrier which is displaced during operation of the contactor. The housing shields the biasing element from plasma, arcs and debris during operation of the device. Multiple conductive elements and corresponding biasing elements may be includes in each assembly.

Abstract: A solid state motor starter, commonly referred to as a soft starter, is constructed in a manner to be easily manufacturable while at the same time combining all the required components in a relatively small package. A solid state power switch is clamped between a pair of bus bars in an offset manner to accommodate a discrete switching relay mounted in an inverted manner between the line input and the bus bar in communication with the load outputs. When in a motor run node, current is shunted away from the solid state power switching device and through the switching relay, a substantially linear current path is achieved to reduce power loss and heat buildup. The arrangement allows for a heat sink mounted to one of the bus bars with adequate spacing between the heat sink and the discrete relay for insertion of a cooling fan. Current sensing is achieved with a Hall effect sensor mounted to the bus bar in a small current sensing region that is created by having a pair of slots in the bus bar to direct current.

Abstract: An electromagnetic starter with an overload relay having magnetic flux shielding is disclosed for use in industrial contactor applications. The starter includes a multi-pole DC controlled contactor which is interlockingly coupled to an overload relay. The overload relay has a simplified interlocking connection to the contactor, which when made, corresponds to an abutting electrical connection between the contactor and the overload relay also being made. The contactor further has a guiding pin that promotes even contact closure within the contactor.

Abstract: A multilayer circuit board or laminated circuit board includes an insulated mounting area for a surface mount package. The mounting area is provided in a recess or portion of the circuit board where the circuit board is only a single layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The insulating medium associated with the single layer provides a heat conductive yet highly electrically insulative mounting area for a heat sink. The heat sink may be mounted on a side opposite the electrical device. The heat sink may be a standard heat sink or a copper coil directly soldered to the circuit board. The heat sink mounting advantageously eliminates the need for bolts, nuts, brackets, and an additional insulating layer necessary to insulate power semiconductor components.

Abstract: A multilayer circuit board or laminated circuit board includes an insulated mounting area for a surface mount package. The mounting area is provided in a recess or portion of the circuit board where the circuit board is only a single layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The insulating medium associated with the single layer provides a heat conductive yet highly electrically insulative mounting area for a heat sink. The heat sink may be mounted on a side opposite the electrical device. The heat sink may be a standard heat sink or a copper coil directly soldered to the circuit board. The heat sink mounting advantageously eliminates the need for bolts, nuts, brackets, and an additional insulating layer necessary to insulate power semiconductor components.

Abstract: A multiphase circuit interrupter includes a plurality of power phase sections for establishing and interrupting electrical power carrying paths for a plurality of phases. Each power phase section includes first and second conductive regions which contact one another to complete the current carrying path for the phase. The second conductive region is movable to an interrupted position to interrupt the path. An interphase current carrying path is established between the power phase sections to conduct electrical energy between the sections following a trip event in any one of the sections. The interphase current carrying path may be established by a conductive element extending between the power phase sections. Channels may be formed in the interrupter housing between the power phase sections to communicate conductive plasma generated during separation of the contact regions from one another between the power phase sections.

Abstract: A method for retaining a movable contact in a circuit interrupter is applicable to interrupters including first and second contacts, at least one of the contacts being movable. A movable element supporting the movable contact is displaceable between a conducting position wherein the movable contact abuts a cooperating contact to complete a current carrying path through the device, and a non-conducting position wherein the movable contact is electrically separated from the cooperating contact. In accordance with the method, the movable contact is displaced by an interrupt initiation device, and a carrier or retainer is displaced by gas pressure resulting from arcs generated by movement of the contact. The carrier is guided in its displacement within the device housing from a normal operating position to a retaining position. The carrier includes an abutment element that physically contacts the movable element to prevent it from rebounding into contact with the cooperating contact.

Abstract: A method an apparatus is disclosed for preventing contact welding during fault conditions. This fault current tolerable contactor includes two magnetic components, one in operable association with the movable contacts, and the other fixable attached above the movable contacts such that when a fault condition occurs, a high magnetic force is created to draw the two magnetic components together thereby opening the contacts. The magnetic force keeps the contacts open at least until current zero, and preferably a defined time thereafter to provide enough time for the contacts to cool and prevent welding upon the closure of the contacts.

Abstract: A multilayer circuit board system or laminated circuit board system for use in a motor controller includes a motherboard, at least one power substrate circuit board, and a capacitor circuit board. The mother board includes mounting areas for receiving the power substrate board and capacitor circuit board at a 90.degree. angle. The capacitor circuit board, power substrate circuit board, and mother circuit board can be interconnected without the use of external connectors or wires. A fan can be disposed at a front edge of the power substrate circuit boards to provide air flow across their planar surfaces.

Abstract: A multilayer circuit board system or laminated circuit board system for use in a motor controller includes at least two motherboards, at least one power substrate circuit board, and a capacitor circuit board. The circuit boards are mounted in an aperture or trench within each mother board. The power substrate module circuit board includes a mounting area provided in a recess, window or portion of the circuit board where the circuit board is only a single layer thick. The single circuit board layer at the mounting area provides a heat conductive yet highly electrically insulated mounting area for receiving a heat sink. The heat sink can be mounted on a side opposite the electrical device. The capacitor circuit board, power substrate circuit board, and mother circuit boards are interconnected without the use of external connectors or wires. The use of two mother boards increases the rigidity of the circuit board system.

Abstract: A circuit interrupter provides a conducting path between two conductors and interrupts the conducting path in response to overcurrent conditions in the conductors. The interrupter includes a magnetic core around which the conductors are disposed. Each conductor is electrically coupled to an arc runner and a spanner is biased into contact with the arc runners to compete a conducting path between the conductors. A secondary response mechanism is provided adjacent to the core and includes arms extending around the core and a magnetic body. In response to overcurrent conditions of a first magnitude the body of the secondary response mechanism is attracted to the core causing the arms to displace the spanner out of contact with the arc runners. In response to overcurrent conditions of a second magnitude, such as due to direct short circuits, the spanner is repelled rapidly to a non-conducting position and the secondary response mechanism is attracted to the core to hold the spanner in the non-conducting position.

Abstract: An apparatus for retaining a movable contact in a circuit interrupter includes a movable element that is displaced by gas pressure within the interrupter housing resulting from arcs generated during initial displacement of the movable element. The movable element may be a spanner extending between two stationary contacts. The apparatus may be configured as a three phase interrupter in which a single carrier or retainer is common to three power phase sections, and is displaced by interruption of a current carrying path for any one power phase section. The retainer may include a retaining pin which extends through the movable element. The movable element is biased into a conducting position and a head of the retaining pin contacts the movable element to hold it in a non-conducting position following a trip event.

Abstract: A power substrate module having a multilayer circuit board or laminated circuit board for use in a motor controller is described. The power substrate module includes pair of switching devices coupled across a direct current bus for converting direct current power from the bus to controlled alternating current power in response to control signals. The circuit board includes a first conductive layer, a second conductive layer and an insulative layer separating the conductive layers. The first and second conductive layers each include a conductive bus region, one of which is coupled to the first switching device and forms a high side of the direct current bus, and the other of which is coupled to the second switching device and forms the low side of the direct current bus.

Abstract: A fixture is provided for facilitating the fabrication of a motor controller of the type including a power substrate module and a control circuit board mounted to and electrically coupled to the power substrate module via a plurality of conductors. The fixture is preferably a ring-like structure made of epoxy-fiberglass laminate. Apertures for engaging and holding the conductors are provided in the fixture at locations corresponding to conducting pads on the power substrate module. For fabrication, the power substrate module and the fixture are preformed and solder is disposed on the conducting pads of the module. During fabrication, the conductors are inserted into the apertures in the fixture and the fixture and conductors are positioned over the preformed power substrate module to bring the conductors into contact with the conducting pads. The fixture and power substrate module are then passed through a reflow oven to melt the solder and complete the connection of the conductors to the module.

Abstract: A variable frequency motor drive incorporating a circuit interrupter includes a rectifying circuit for converting incoming AC power to DC power and an inverting circuit for converting the DC power to controlled AC power in response to control signals. A control circuit implements a preset control routine to control operation of the inverting circuit to drive a motor in accordance with desired operating parameters. A circuit interrupter is coupled between the source of AC power and the rectifying circuit and includes an actuator for interrupting power to the drive in response to interrupt command signals from the motor control circuit. The motor drive includes a switching circuit and a capacitive circuit for powering the circuit interrupter. The drive control circuitry monitors operation of the drive and the motor and when conditions require removal of power to the drive, the control circuitry commands the switching circuit to close, energizing the circuit interrupter and thereby removing power to the drive.

Abstract: A fixture is provided for facilitating the fabrication of a motor controller of the type including a power substrate module and a control circuit board mounted to and electrically coupled to the power substrate module via a plurality of conductors. The fixture is preferably a ring-like structure made of epoxy-fiberglass laminate. Apertures for engaging and holding the conductors are provided in the fixture at locations corresponding to conducting pads on the power substrate module. For fabrication, the power substrate module and the fixture are preformed and solder is disposed on the conducting pads of the module. During fabrication, the conductors are inserted into the apertures in the fixture and the fixture and conductors are positioned over the preformed power substrate module to bring the conductors into contact with the conducting pads. The fixture and power substrate module are then passed through a reflow oven to melt the solder and complete the connection of the conductors to the module.

Abstract: A multilayer circuit board or laminated circuit board for use in a motor controller is described. The multilayer circuit board is preferably utilized as a power substrate module. The power substrate module includes a mounting area provided in a recess, window or portion of the circuit board where the circuit board is only a single layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The single circuit board layer at the mounting area provides a heat conductive yet highly electrically insulated mounting area for receiving a heat sink. The heat sink can be mounted on a side opposite the electrical device. The heat sink may be standard heat sink or a copper coil directly soldered to the circuit board. The multilayer circuit board includes an enhanced conductive layer for receiving the surface mount device. The enhanced conductive layer preferably includes an insulative frame which holds copper slugs.