PCB connector module for plug-in circuit breakers and fuses

A connector module for mechanically mounting and providing electrical connections to a plurality of overcurrent protection devices each having first and second male electrical plugs for conducting a load current and an auxiliary signal terminal, comprising:

• a mounting substrate having a first side and a second opposed side;
• a signal terminal passageway disposed in said substrate for each overcurrent protection device, each said signal terminal passageway extending from said first side to said second side and shaped and positioned to permit the passage of the male auxiliary signal terminal of a corresponding overcurrent protection device from said first side to said second side;
• a conductive clip for each signal terminal passageway, said clips mounted to the second side of the substrate adjacent each signal terminal passageway and having contact surfaces shaped and positioned to make electrical contact with one of the auxiliary signal terminals;
• at least one electrical trace disposed on one of said sides of the substrate and electrically coupled to said clips to form at least one transmission path for signals;
• first and second plug passageways disposed in said substrate for each overcurrent protection device, said plug passageways shaped and spaced apart from each other to permit the passage of the two male plugs of each overcurrent protection device in the direction from the first side to the second side;
• a conductive load busbar member for each of the first plug passageways, each said conductive member mounted by a mechanical connector to the second side of said substrate and each having a socket shaped and positioned to mate with a friction fit with a corresponding first male plug extending through said first plug passageway;
• and
• a conductive common busbar support member mounted by a second mechanical connector to the second side of said substrate, said support member having a plurality of sockets shaped, dimensioned, and positioned to mate with a friction fit with corresponding second male plugs extending through said second plug passageways;
• wherein said substrate contains insulating surface regions on said first and second sides so that the first male electrical connector of each overcurrent protection device and their corresponding busbar members are electrically insulated from said second male plugs and from each other.

A connector module for mechanically mounting and providing electrical connections to a plurality of circuit breakers each having first and second male electrical plugs and an auxiliary signal terminal, comprising:

• a mounting substrate with a first side and a second opposed side;
• signal terminal passageway means for enabling signal terminals of each circuit breaker to extend through the substrate from the first side to the second side;
• a plurality of clips configured to provide an electrical connections to each auxiliary signal terminal of each circuit breaker to be coupled thereto;
• passageway means for enabling the male plugs of each circuit breaker to extend through the substrate from the first side to the second side;
• a plurality of busbars mounted on the second side of the substrate, said plurality of busbars, including socket means for mechanically mounting and providing electrical connections to the male plugs of each circuit breaker to be coupled thereto.

A method of fabricating a connector module for mechanically mounting and providing electrical connections to a plurality of circuit breakers each having two male current plugs and an alarm contact terminal, comprising the steps of:

• a) providing a printed circuit board substrate having a first side and a second side;
• b) forming first and second plug passageways from said first side to said second side shaped and dimensioned to permit the passage of the first and second male connector plug;
• c) forming a conductive strip composed of a malleable metal into a metal strip;
• d) forming a protruded socket in the conductive strip shaped and dimensioned to mate with the male connector with a friction fit;
• e) fastening the conductive strip to said second side of said substrate so that the protruded socket is aligned with one of the plug passageways;
• f) forming a plurality of alarm contact terminal passageways extending from said first side to said second side shaped to permit the passage of the male alarm contact terminal of each of the circuit breakers;
• g) providing a plurality of connector clips;
• h) forming a conductive trace on one of said sides of the printed circuit board;
• i) mounting one clip above each alarm contact terminal passageway;
• and
• j) forming a conductive connection to each clip and the conductive trace so that an electrical connection is made to each clip.