Arc fault circuit breaker

Abstract

Abstract of the Disclosure A method for assembling an arc fault circuit breaker such that electrical interconnections, i.e., electrical connections between compartments, are made without disassembling any previously assembled compartment. The arc fault circuit breaker comprises housings having compartments within. Electrically connected components having interconnecting components, i.e., components which provide electrical interconnections between compartments, are disposed within the compartments. The housings are assembled together to enclose the compartments. Interconnecting components within an enclosed compartment extend through openings in the housings to provide electrical interconnections to the next compartment to be assembled. Therefore, no disassembly of the enclosed compartment is necessary to make the interconnections.

Claims 
     
         1. A method of assembling a circuit breaker, comprising: 
       connecting electrically a first plurality of components disposed within a first compartment of a first housing, said first plurality of components including a first interconnecting component; 
       assembling a second housing to said first housing to enclose said first compartment, said second housing defining a second compartment; 
       extending said first interconnecting component through a first opening of said second housing into said second compartment; 
       connecting electrically a second plurality of components disposed within said second compartment; 
       interconnecting electrically said first interconnecting component to said second plurality of components disposed within said second compartment; 
       assembling a third housing to said second housing to enclose said second compartment, said third housing defining a third compartment; 
       disposing a third plurality of components within said third compartment; 
       interconnecting electrically through a second opening of said third housing a second interconnecting component of said third plurality of components to one component of said third plurality of components disposed within said third compartment; 
       connecting electrically a fourth plurality of components disposed within a fourth compartment, said fourth compartment defined by a fourth housing; 
       assembling said fourth housing to said third housing to enclose said third compartment; 
       extending one end of said second interconnecting component of said third plurality of components through a third opening of said fourth housing into said fourth compartment; 
       aligning said one end of said second interconnecting component with a terminal of said fourth plurality of components disposed within said fourth compartment; and 
       securing mechanical and electrical engagement between said terminal and said one end of said second interconnecting component from outside of said fourth housing. 
     
     
         2. The method of  claim 1  further comprising: 
       fixedly securing said second interconnecting component to said third compartment. 
     
     
         3. The method of  claim 2  further comprising: 
       configuring said third compartment to retain an intermediate portion of said second interconnecting component in said third compartment. 
     
     
         4. The method of  claim 1  wherein said securing includes threading a screw engaged with one wall of said terminal against said extension of said third interconnecting component and an opposite wall of said terminal. 
     
     
         5.  The method of  claim 1  wherein said circuit breaker is an arc fault circuit breaker. 
     
     
         6.  The method of  claim 5  wherein said first plurality of components further comprises a bi-metal resistor. 
     
     
         7.  The method of  claim 5  wherein said second plurality of components further comprises a current sensing transformer. 
     
     
         8.  The method of  claim 5  wherein extending said second interconnecting component further comprises extending a second single load current carrying interconnecting component. 
     
     
         9.  The method of  claim 5  wherein said fourth plurality of components further comprises a bi-metal resistor. 
     
     
         10.  The method of  claim 1  wherein said first housing, said second housing, and said first plurality of components further comprise a separate subassembly. 
     
     
         11. The circuit breaker of  claim 1  wherein said fourth housing and said fourth plurality of components further comprise a separate subassembly. 
     
     
         12.  The method of  claim 1  wherein said extending said first interconnecting component further comprises extending a single load current carrying interconnecting component. 
     
     
         13.  The method of  claim 1  wherein said second plurality of components include a neutral lug. 
     
     
         14.  The method of  claim 1  wherein said third plurality of components further comprises a load lug. 
     
     
         15.  The method of  claim 1  wherein electrically interconnecting said first interconnecting component further comprises welding, bolting or crimping said first interconnecting component. 
     
     
         16.  The method of  claim 1  wherein electrically interconnecting said second interconnecting component further comprises welding, bolting or crimping said second interconnecting component in said third compartment.