CN116417295A - Contactor - Google Patents

Abstract

A contactor (100) includes a housing (110) and first and second fixed contacts (120, 122) connected to the housing, the first and second fixed contacts having mating ends (144, 146) received in cavities (112) of the housing and terminating ends (130) external to the housing. The movable contact (124) is movable within the cavity between a mated position in which it engages the mating end of the second fixed contact and a unmated position in which it is separated from the second fixed contact. A flexible busbar (140) is coupled to the first mating end and coupled to the movable contact. The flexible bus electrically connects the first fixed contact and the movable contact in both the mated position and the unmated position. A coil assembly (190) in the cavity operates to move the movable contact between the unmated position and the mated position.

Description

Contactor

Cross Reference to Related Applications

The subject matter of the present application claims the benefit of the indian application No. 202241000915 filed on 7, 1, 2022, is incorporated herein by reference in its entirety.

Technical Field

The subject matter herein relates generally to high power electrical contactors.

Background

Certain electrical applications, such as HVAC, power supply, locomotive, elevator control, motor control, aerospace applications, hybrid electric vehicles, fuel cell vehicles, charging systems, and the like, utilize electrical contactors having normally open (or separated) contacts. The contacts close (or engage) to power a particular device. When the contactor receives an electrical signal, the contactor is energized to induce a magnetic field to drive the movable contact into engagement with the fixed contact. During the mating and unmating of the movable contact with the fixed contact, arcing may occur, which may lead to contact damage, such as oxidation of the contact surface, leading to failure of the contactor over time. In addition, at the interface between the fixed contact and the movable contact, the contact resistance is high. In some high power applications, the magnetic force may cause the movable contact to tend to separate from the fixed contact, resulting in undesirable vibration and noise. There is a need for a contactor that overcomes the above-mentioned problems and solves other problems encountered in the prior art.

Disclosure of Invention

In one embodiment, a contactor is provided that includes a housing having an outer wall defining a cavity. A contactor is provided that includes a first stationary contact coupled to a housing. The first stationary contact has a first mating end received in the cavity and a first end portion located outside the housing. A contactor is provided that includes a second stationary contact coupled to a housing. The second stationary contact has a second mating end received in the cavity and a second terminating end located outside the housing. A contactor is provided that includes a movable contact movable within a cavity between a mated position and a unmated position. The movable contact engages the second mating end in the mated position. In the disengaged position, the movable contact is separated from the second fixed contact. A contactor is provided that includes a flexible busbar coupled to a first mating end and coupled to a movable contact. The flexible bus electrically connects the first fixed contact and the movable contact in both the mated position and the unmated position. The coil assembly in the cavity operates to move the movable contact between the unmated position and the mated position.

Drawings

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

fig. 1 shows a contactor according to an exemplary embodiment.

Fig. 2 is a cross-sectional view of a contactor according to an exemplary embodiment.

Fig. 3 is a top perspective view of a movable contact assembly according to an exemplary embodiment.

Fig. 4 is a top perspective view of a movable contact holder according to an exemplary embodiment.

Fig. 5 is a bottom perspective view of a portion of the contactor of the exemplary embodiment, showing the movable contact assembly in a disengaged position relative to the fixed contact.

Fig. 6 is a cross-sectional view of a portion of the contactor of the exemplary embodiment, showing the movable contact in a disengaged position.

Fig. 7 is a top perspective view of a portion of the contactor of the exemplary embodiment, showing the contact holder in an exploded state.

Fig. 8 is a top perspective view of a portion of the contactor of the exemplary embodiment, showing the contact holder in an assembled state.

Fig. 9 is a cross-sectional view of a contactor according to an exemplary embodiment.

Fig. 10 is a cross-sectional view of a contactor according to an exemplary embodiment, showing the internal components of the contactor.

Fig. 11 is a top perspective view of a movable contact assembly according to an exemplary embodiment.

Fig. 12 is a bottom perspective view of a portion of the contactor of the exemplary embodiment, showing the movable contact assembly in a mated position relative to the fixed contact.

Fig. 13 is a side view of a portion of the contactor of the exemplary embodiment, showing the movable contact assembly in a mated position relative to the fixed contact.

Fig. 14 is a cross-sectional view of a portion of the contactor of the exemplary embodiment, showing the movable contact in a disengaged position.

Fig. 15 is an exploded view of a contactor according to an exemplary embodiment.

Detailed Description

Fig. 1 illustrates a contactor 100 according to an exemplary embodiment. Fig. 2 is a cross-sectional view of the contactor 100 according to an exemplary embodiment, illustrating internal components of the contactor 100. The contactor 100 is an electrical switch or relay that safely connects and disconnects one or more circuits to protect the flow of electrical power through the system. The contactor 100 may be used in a variety of applications, such as HVAC, power supply, locomotive, elevator control, motor control, aerospace applications, hybrid electric vehicles, fuel cell vehicles, charging systems, and the like.

The contactor 100 includes a housing 110 (removed in fig. 2 to show the internal components of the contactor 100), the housing 110 having an outer wall 111 surrounding a cavity 112. In various embodiments, the housing 110 may be a multi-piece housing. Housing 110 includes a base 114 and a head 116 extending from base 114. Alternatively, base 114 may be configured to be coupled to another component. For example, the base 114 may include mounting brackets for securing the contactor 100 to other components. In the illustrated embodiment, the base 114 is disposed at the bottom of the contactor 100 and the head 116 is positioned above the base 114; however, in alternative embodiments, the housing 110 may have other orientations. The housing 110 includes a cover 118 (fig. 1) for enclosing the cavity 112. For example, the cover 118 may be coupled to the top of the head 116. Optionally, a cap 118 may be sealed to the head 116. In various embodiments, the outer wall 111 along the head 116 may be cylindrical defining a cylindrical cavity 112. The cavity 112 may be at least partially filled with epoxy for sealing the housing 110 and the internal components.

The contactor 100 includes a first fixed contact 120 and a second fixed contact 122 housed in the cavity 112, and a movable contact 124 movable within the cavity 112 between a mated position and a unmated position. The movable contact 124 electrically connects the fixed contacts 120, 122 in the mated position. The fixed contacts 120, 122 are fixed to the housing 110. For example, the fixed contacts 120, 122 may be coupled to the head 116 and/or the cover 118. In an exemplary embodiment, the contact holder 126 is used to hold the stationary contacts 120, 122. The contact holder 126 is received in the cavity 112 and is coupled to the housing 110. When the cap 118 is removed from the head 116, the contact holder 126 may be removed from the cavity 112. The contact holder 126 defines a surrounding portion 128. The fixed contacts 120, 122 extend into the surrounding portion 128. The movable contact 124 is located in the surrounding portion 128. The outer wall 111 surrounds the enclosure 128.

Each of the fixed contacts 120, 122 includes an outer end defining a terminating end 130 and an inner end defining a mating end 132. The fixed contacts 120, 122 each have a transition portion 134 with one or more bends 136. In the illustrated embodiment, the fixed contacts 120, 122 are S-shaped with a terminating end 130 parallel to a mating end 132. In alternative embodiments, other shapes are possible. The terminating end 130 is configured to be terminated to another component, such as a wire or terminal, such as a line input or line output wire. In an exemplary embodiment, the terminating end 130 is exposed outside of the contactor 100 for termination to another component. The terminating end 130 may be threaded to receive a nut. In the illustrated embodiment, the terminating end 130 extends through the cover 118 and is located above the cover 118. The mating end 132 is located within the cavity 112 for connection with the movable contact 124, such as when the contactor 100 is energized. In the illustrated embodiment, the mating end 132 is generally planar or planar, for example, for engaging the movable contact 124. However, in alternative embodiments, the mating end 132 may have other shapes.

In an exemplary embodiment, the contactor 100 includes a flexible bus 140 electrically connecting the first fixed contact 120 and the movable contact 124. As the movable contact 124 moves between the mated and unmated positions, the flexible bus 140 flexes. In the exemplary embodiment, flexible bus 140 includes a flexible braid 142 having braided conductors. The first mating end 144 of the flexible bus 140 is connected to the first stationary contact 120. The second mating end 146 of the flexible bus 140 is connected to the movable contact 124. The first mating end 144 and the second mating end 146 may be welded to the first fixed contact 120 and the movable contact 124, respectively. As the movable contact 124 moves between the mated and unmated positions, the movable contact 124 remains connected to the first fixed contact 120 by the flexible bus 140.

The contactor 100 includes a coil assembly 190 in the cavity 112 that is operable to move the movable contact 124 between the unmated and mated positions. The coil assembly 190 includes windings or coils 192 wound around a core 194 to form an electromagnetic field. The coil assembly 190 includes a plunger (not shown) coupled to a core 194. The movable contact 124 is coupled to the plunger and is movable therewith when the coil assembly 190 is operated. The coil assembly 190 includes a spring 198, the spring 159 being configured to return the movable contact 124 to the disengaged position when the coil assembly 190 is de-energized. Optionally, the contactor 100 may include an arc suppressor (not shown) for suppressing arcing of the circuit. The arc suppressor may be located in the cavity 112 of the housing 110. In an exemplary embodiment, the arc suppressor includes a magnet that generates a magnetic field in the housing 128 for suppressing an arc generated between the movable contact 124 and the fixed contacts 120, 122. In an exemplary embodiment, the contact holder 126 may be sealed, for example using epoxy, and may be filled with an inert gas for arc suppression.

Fig. 3 is a top perspective view of a movable contact assembly 150 according to an exemplary embodiment. The movable contact assembly 150 includes a movable contact 124 and a movable contact holder 152. The movable contact holder 152 is used to position the movable contact 124 in the housing 110 of the contactor 100 (as shown in fig. 2). For example, as the movable contact 124 moves within the housing 110, the movable contact holder 152 may hold the movable contact 124 in a planar orientation, such as a horizontal orientation.

The movable contact 124 is made of a conductive material, such as a metal material. The movable contact 124 may be stamped or cut to a predetermined size and shape, which may affect the amount of current passing through the movable contact 124 and the amount of resistance of the current transmitted through the movable contact 124. The movable contact 124 includes a body 160, the body 160 having a first plate 162 at a first end 164 of the movable contact 124 and a second plate 166 at a second end 168 of the movable contact 124. The movable contact 124 includes an opening 170 in the body 160. The opening 170 may be coupled to a coil assembly 190, such as a plunger. The movable contact 124 includes a first recess 172 along a first side 174 of the movable contact 124 and a second recess 176 along a second side 178 of the movable contact 124. The movable contact 124 includes a mounting tab 180 that extends into the recesses 172, 176. The movable contact holder 152 is coupled to a mounting tab 180 at a first side 174 and a second side 178. In the illustrated embodiment, the movable contact 124 is I-shaped, with the movable contact 124 being wider at the first and second plates 162, 166 (between the sides 174, 178) and narrower along a central portion of the body 160. The plates 162, 166 provide a greater surface area for mating with the flexible bus bar 140 and the second stationary contact 122 (shown in fig. 2). In alternative embodiments, the movable contact 124 may have other shapes, such as a rectangular shape with a constant width.

The movable contact 124 includes an upper surface 182 and a lower surface 184. In the exemplary embodiment, flexible bus 140 is coupled to a lower surface 184 of first plate 162 at first end 164. However, in alternative embodiments, the flexible bus 140 may be coupled to the upper surface 182. In the exemplary embodiment, movable contact 124 includes a mating contact pad 186 at upper surface 182 along second plate 166 at second end 168. The mating contact pads 186 are configured to mate and un-mate with the second fixed contacts 122. Each mating contact pad 186 includes a mating interface 188, the mating interfaces 188 forming points of contact with the second fixed contact 122. An electrical path is formed between the movable contact 124 and the second fixed contact 122 by the mating contact pad 186. In the illustrated embodiment, the mating interface 188 is generally planar. However, in alternative embodiments, the mating contact pad 186 may have other shapes, such as a bump having a convex shape. In the exemplary embodiment, movable contact 124 includes three mating contact pads 186 arranged in a triangular orientation. In alternative embodiments, more or fewer mating contact pads 186 may be provided. In alternative embodiments, the mating contact pads 186 may be arranged in different orientations. In an exemplary embodiment, the mating contact pads 186 may be located near the perimeter of the movable contact 124, such as at the first side 174 and the second side 178 and at the second end 168, such as to increase the spacing between the mating contact pads 186.

Fig. 4 is a top perspective view of a movable contact holder 152 according to an exemplary embodiment. In an exemplary embodiment, the movable contact holder 152 is a stamped component. The movable contact holder 152 may be coupled to a coil assembly 190, such as a plunger, to position the movable contact 124 as the movable contact 124 moves between the mated and unmated positions.

The movable contact holder 152 includes a base 200, a mounting arm 202 extending from the base 200, and a support arm 204 extending from the base 200. The mounting arm 202 is used to secure the movable contact holder 152 to the movable contact 124. The support arm 204 is used to position the movable contact 124 within the housing 110 of the contactor 100 (as shown in fig. 2) during mating and unmating.

The base 200 is disposed at the bottom of the movable contact holder 152. The base 200 includes an opening 206, which opening 206 may receive a plunger. The base 200 extends between a first end 210 and a second end 212. The base 200 extends between a first side 214 and a second side 216. In the illustrated embodiment, the movable contact holder 152 includes a pair of mounting arms 202 disposed on opposite sides 214, 216. The mounting arm 202 is configured to engage the movable contact 124 at the center of the body 160 of the movable contact 124. In the illustrated embodiment, the movable contact holder 152 includes four support arms 204 disposed at opposite ends 210, 212 and opposite sides 214, 216. The support arm 204 is configured to engage the movable contact 124 at four corners of the movable contact 124.

In the exemplary embodiment, each mounting arm 202 includes side walls 220 and a top wall 222 that extends between side walls 220. Mounting arm 202 includes an opening 224 surrounded by side walls 220 and a top wall 222. The opening 224 is configured to receive the mounting tab 180 (shown in fig. 3). The mounting arm 202 is configured to clip onto the movable contact 124. In alternative embodiments, other types of mounting features may be used.

In the exemplary embodiment, support arm 204 is cantilevered from base 200. Each support arm 204 extends from the base 200 to a tip 230 at the distal end of the support arm 204. The tip 230 is configured to engage a lower surface of the movable contact 124. Alternatively, support arm 204 may be curved at end 230. In an exemplary embodiment, the support arm 204 is deflectable and is configured to be spring biased against the movable contact 124 to maintain the movable contact 124 in a particular orientation, such as a horizontal orientation.

Returning to fig. 3, fig. 3 shows the movable contact holder 152 coupled to the movable contact 124. The mounting arm 202 is secured to the mounting tab 180 at the first side 174 and the second side 178 of the movable contact 124. Support arm 204 is located outside of mounting arm 202. The support arm 204 engages the lower surface 184 of the movable contact 124 to press upward against the lower surface 184. In the exemplary embodiment, support arm 204 engages movable contact 124 near first end 164 and second end 168 and near first side 174 and second side 178. For example, the support arm 204 may engage the movable contact 124 near four outer corners of the movable contact 124. As the movable contact 124 moves between the mated and unmated positions, the support arm 204 of the movable contact 124 is in a horizontal orientation.

Fig. 5 is a bottom perspective view of a portion of the contactor 100 showing the movable contact assembly 150 in a disengaged position relative to the fixed contacts 120, 122. Fig. 5 shows a flexible busbar 140 between the first fixed contact 120 and the movable contact 124. The movable contact 124 is disengaged from the second fixed contact 122.

In an exemplary embodiment, the second fixed contact 122 includes a mating tab 136 at the mating end 132. The mating tabs 136 are oriented parallel to the movable contact 124. For example, mating tabs 136 may be oriented horizontally. The second stationary contact 122 includes one or more mating pad 138 located at the bottom of the mating pad 136. The mating patch pads 138 are configured to mate and un-mate with the mating contact pads 186 of the movable contact 124. Each mating patch pad 138 includes a mating interface that forms a contact point with a corresponding mating contact pad 186. An electrical path is formed between the movable contact 124 and the second fixed contact 122 by the mating contact pad 186 and the mating pad 138. Providing a plurality of mating contact pads 186 and mating patch pads 138 creates a plurality of electrical paths and a plurality of contact points through the second fixed contact 122 and the movable contact 124. For example, parallel electrical paths may be created, such as a first electrical path through the second fixed contact 122 and a second electrical path through the movable contact 124. The parallel electrical paths create magnetic attraction forces that tend to hold the movable contact 124 in the mated position and reduce the risk of undesired separation or vibration in the contact. In the illustrated embodiment, the mating interface is generally planar. However, in alternative embodiments, the mating pads 138 may have other shapes, such as bumps having a convex shape.

In one exemplary embodiment, the second stationary contact 122 includes three mating patch pads 138 arranged in a triangular orientation. In alternative embodiments, more or fewer mating pads 138 may be provided. In alternative embodiments, the mating patch pads 138 may be arranged in different orientations. In an exemplary embodiment, the mating patch pads 138 may be located near the edges of the second fixed contact 122, such as at opposite sides and ends, for example, to increase the spacing between the mating patch pads 138.

When the movable contact 124 is in the disengaged position, the movable contact pad 186 is spaced apart from the mating patch pad 138.

The movable contact pad 186 and the mating pad 138 define a separable interface between the movable contact 124 and the second fixed contact 122. However, the movable contact 124 remains electrically connected to the first fixed contact 120 by the flexible bus 140. The flexible bus 140 forms a permanent connection between the movable contact 124 and the first fixed contact 120. The flexible busbar 140 is connected to the movable contact 124 and the first fixed contact 120 in the mated position, and the flexible busbar 140 is connected to the movable contact 124 and the first fixed contact 120 in the unmated position.

In one exemplary embodiment, the flexible bus bar 140 has a generally rectangular cross section. For example, the flexible bus bar 140 is plate-like or sheet-like having an upper surface 240 and a lower surface 242 extending between a first side 244 and a second side 246. Sides 244, 246 extend between the first and second mating ends 144, 146. The flexible bus bar 140 has a length 248 between the mating ends 144, 146 and a width 250 between the sides 244, 246. Alternatively, the width 250 may be approximately equal to the length 248. Flexible bus 140 has a thickness 252 between upper surface 240 and lower surface 242. In an exemplary embodiment, the flexible bus 140 is wide and thin. For example, width 250 may be at least ten times greater than thickness 252. As such, the flexible bus bar 140 is configured to move and flex as the movable contact 124 moves between the mated and unmated positions. As the movable contact 124 moves between the mated and unmated positions, the shape of the flexible busbar 140 changes.

Fig. 6 is a cross-sectional view of a portion of the contactor 100 showing the movable contact 124 in a disengaged position. In the unmated position, the movable contact 124 is spaced apart from the first and second fixed contacts 120, 122. The flexible bus 140 extends between the movable contact 124 and the first fixed contact 120.

The contact holder 126 holds the first fixed contact 120 and the second fixed contact 122. The mating ends 132 of the first and second fixed contacts 120, 122 are positioned in a fixed position within the surrounding portion 128 by the contact holder 126. The transition portions 134 of the fixed contacts 120, 122 extend from the contact holder 126 through the cover 118. The terminating ends 130 of the fixed contacts 120, 122 are located outside of the contactor 100, for example, for termination to wires or terminals. The contact holder 126 holds the mating ends 132 of the fixed contacts 120, 122 relative to the movable contact 124. The movable contact 124 is movable within the contactor 100 from a disengaged position to a mated position. For example, when the coil assembly 190 is activated, the plunger drives the movable contact holder 152 and/or the movable contact 124 upward toward the fixed contacts 120, 122. The flexible busbar 140 moves with the movable contact 124. The mating contact pads 186 are driven into electrical contact with the mating patch pads 138 to complete the circuit.

In an exemplary embodiment, the movable contact holder 152 facilitates positioning the movable contact 124 within the contactor 100 as the movable contact 124 moves to the mated position. For example, the support arm 204 is spring biased against the bottom of the movable contact 124. The support arms 204 are spaced apart from one another to maintain the movable contact 124 in a horizontal orientation. The support arm 204 orients the movable contact 124 parallel to the mating blade 136 to ensure that the mating contact pad 186 engages the mating blade pad 138.

Fig. 7 is a top perspective view of a portion of the contactor 100 showing the contact holder 126 in an exploded state. Fig. 8 is a top perspective view of a portion of the contactor 100 showing the contact holder 126 in an assembled state. In an exemplary embodiment, the contact holder 126 is a multi-piece structure. The contact holder 126 may be assembled around the fixed contacts 120, 122. For example, the components of the contact holder 126 may snap or otherwise couple together around the fixed contacts 120, 122.

In the exemplary embodiment, contact holder 126 includes a first holder element 260 and a second holder element 262. The first and second retainer elements 260, 262 are coupled together and meet at a seam 264. Alternatively, the first and second retainer elements 260, 262 may have different dimensions, e.g., the first retainer element 260 is larger than the second retainer element 262. Alternatively, the first and second retainer elements 260, 262 may have similar dimensions. Alternatively, the first and second retainer elements 260, 262 may be mirror image halves of each other. The first and second retainer elements 260, 262 are coupled together, such as by a snap-fit coupling or interference fit. Alternatively, the first and second retainer elements 260, 262 may be secured using latching features, fasteners, or other securing means.

In the exemplary embodiment, contact holder 126 includes an end wall 266 and a side wall 268 that extends from end wall 266. Seam 264 extends along end wall 266 and side wall 268. In the illustrated embodiment, the contact holder 126 is cylindrical; however, in alternative embodiments, the contact holder 126 may have other shapes. The end wall 266 is disc-shaped and is disposed atop the contact holder 126. The side wall 268 is annular and extends from the bottom of the end wall 266 to form a chamber 270 below the end wall 266. In the exemplary embodiment, first and second retainer elements 260 and 262 engage and support first and second fixed contacts 120 and 122. The first and second fixed contacts 120, 122 pass through the contact holder 126 at a seam 264. The fixed contacts 120, 122 extend into the cavity 270. Alternatively, the first and second fixed contacts 120, 122 may be sealed to the first and second holder elements 260, 262, such as where the first and second fixed contacts 120, 120 pass through the contact holder 126. The sealing may occur inside the chamber 270 or outside the contact holder 126. The seal may be provided by a gasket, epoxy, or other sealing member.

In the exemplary embodiment, contact holder 126 includes a first channel 272 that holds first stationary contact 120 and a second channel 274 that holds second stationary contact 122. The first retainer element 260 forms at least a portion of the first channel 272 and at least a portion of the second channel 274. The second retainer element 262 forms at least a portion of the first channel 272 and at least a portion of the second channel 274. The first channel 272 and the second channel 274 span the seam 264. The first and second retainer elements 260, 262 are coupled together around the first and second fixed contacts 120, 122. For example, the first retainer element 260 may be side-loaded onto the first and second fixed contacts 120, 122 and/or the second retainer element 262 may be side-loaded onto the first and second fixed contacts 120, 122. In various embodiments, the assembly may include loading the first and second fixed contacts 120, 122 into the first and second channel portions of the first retainer element 260, and then coupling the second retainer element 262 to the first retainer element 260 to retain and capture the first and second fixed contacts 120, 122 in the first and second channels 272, 274. In the exemplary embodiment, first retainer element 260 includes a shroud wall 276 that surrounds and forms a channel portion of first channel 272 and second channel 274, and second retainer element 262 includes a shroud wall 278 that surrounds and forms a channel portion of first channel 272 and second channel 274.

In the exemplary embodiment, second retainer element 262 includes a connector portion 280. The connector portion 280 may hold contacts and/or wires configured to electrically connect to the coil assembly 190. For example, the coil assembly connector 282 may be inserted into the connector portion 280 when the contact holder 126 is assembled within the contactor 100.

Fig. 9 illustrates a contactor 300 according to an exemplary embodiment. Fig. 10 is a cross-sectional view of a contactor 300 according to an exemplary embodiment, illustrating internal components of the contactor 300. The contactor 300 is similar to the contactor 100; however, the contactor 300 is shaped differently and includes differently shaped contacts. The contactor 300 may be an electrical switch or relay.

The contactor 300 includes a housing 310 (removed in fig. 10 to show the internal components of the contactor 300), the housing 310 having an outer wall 311 surrounding a cavity 312. In various embodiments, the housing 310 may be a multi-piece housing. In various embodiments, the outer wall 311 may have a rectangular cross-section.

The contactor 300 includes first and second fixed contacts 320, 322 received in the cavity 312, and a movable contact 324 movable within the cavity 312 between a mated position and a unmated position. The movable contact 324 electrically connects the fixed contacts 320, 322 in the mated position. The fixed contacts 320, 322 are fixed to the housing 310. In the exemplary embodiment, a contact retainer 326 is used to retain the stationary contacts 320, 322. The contact holder 326 is received in the cavity 312 and is coupled to the housing 310.

Each fixed contact 320, 322 includes an outer end defining a terminating end 330 and an inner end defining a mating end 332. In the illustrated embodiment, the fixed contacts 320, 322 are generally planar and may be oriented parallel to one another. In alternative embodiments, other shapes are possible. The terminating end 330 is configured to be terminated to another component, such as a wire or terminal, such as a line input or line output wire. In an exemplary embodiment, the terminating end 330 is exposed outside of the contactor 300 for termination to another component. In the illustrated embodiment, the terminating end 330 extends outside of the contact holder 326. The mating end 332 is positioned within the cavity 312 for connection with the movable contact 324. In the illustrated embodiment, the mating end 332 is located inside the contact holder 326.

In one exemplary embodiment, the contactor 300 includes a flexible bus 340 electrically connecting the first fixed contact 320 and the movable contact 324. As the movable contact 324 moves between the mated and unmated positions, the flexible busbar 340 flexes. In the exemplary embodiment, flexible busbar 340 includes a flexible braid 342 having braided conductors. The first mating end 344 of the flexible busbar 340 is connected to the first stationary contact 320. The second mating end 346 of the flexible busbar 340 is connected to the movable contact 324. The first and second mating ends 344, 346 may be welded to the first fixed contact 320 and the movable contact 324, respectively. As the movable contact 324 moves between the mated and unmated positions, the movable contact 324 remains connected to the first fixed contact 320 by the flexible bus 340. The contactor 300 includes a coil assembly 390 in the cavity 312, the coil assembly 390 being operated to move the movable contact 324 between the unmated and mated positions.

Fig. 11 is a top perspective view of a movable contact assembly 350 according to an exemplary embodiment. The movable contact assembly 350 includes a movable contact 324 and a movable contact holder 352. The movable contact holder 352 is used to position the movable contact 324 in the housing 310 of the contactor 300 (as shown in fig. 9). For example, as the movable contact 324 moves within the housing 310, the movable contact holder 352 may hold the movable contact 324 in a planar orientation, such as a horizontal orientation.

The movable contact 324 is made of a conductive material, such as a metal material. The movable contact 324 includes a body 360 having a first plate 362 at a first end 364 of the movable contact 324 and a second plate 366 at a second end 368 of the movable contact 324. The movable contact 324 includes a connecting beam 369 between the plates 362, 366. The body 360 may be coupled to a coil assembly 390. The movable contact 324 includes a first recess 372 along a first side 374 of the movable contact 324 and a second recess 376 along a second side 378 of the movable contact 324. The movable contact 324 includes a mounting tab 380 that extends into the recesses 372, 376. The movable contact retainer 352 is coupled to the mounting tab 380 at a first side 374 and a second side 378.

The movable contact 324 includes an upper surface 382 and a lower surface 384. In the exemplary embodiment, movable contact 324 includes a mating contact pad 386 at upper surface 382. The mating contact pads 386 are configured to mate and un-mate with the second stationary contact 322. Each mating contact pad 386 includes a mating interface 388, and the mating interfaces 188 form points of contact with the second stationary contact 322. In the illustrated embodiment, the mating interface 388 is generally planar. However, in alternative embodiments, the mating contact pads 386 may have other shapes, such as bumps having a convex shape. In the exemplary embodiment, movable contact 324 includes three mating contact pads 386 arranged in a triangular orientation. In alternative embodiments, more or fewer mating contact pads 386 may be provided. In alternative embodiments, the mating contact pads 386 may be arranged in different orientations. In an exemplary embodiment, the mating contact pads 386 may be located near the perimeter of the movable contact 324 to increase the spacing between the mating contact pads 386.

The movable contact holder 352 includes a base 400, a mounting arm 402 extending from the base 400, and a support arm 404 extending from the base 400. The mounting arm 402 is used to secure the movable contact holder 352 to the movable contact 324. For example, the mounting arm 402 may be clipped onto the movable contact 324. In alternative embodiments, other types of mounting features may be used. The support arm 404 is used to position the movable contact 324 within the housing 310 of the contactor 300 (as shown in fig. 9) during mating and unmating. In an exemplary embodiment, support arm 404 is deflectable and is configured to be spring biased against movable contact 324 to maintain movable contact 324 in a particular orientation, such as a horizontal orientation.

The base 400 is disposed at the bottom of the movable contact holder 352. The base 400 extends between a first end 410 and a second end 412. The base 400 extends between a first side 414 and a second side 416. In the illustrated embodiment, the movable contact holder 352 includes a pair of mounting arms 402 disposed on opposite sides 414, 416. In the illustrated embodiment, the movable contact holder 352 includes four support arms 404 disposed at opposite ends 410, 412 and opposite sides 414, 416. The support arm 404 is configured to engage the movable contact 324 at four corners of the movable contact 324.

When assembled, the mounting arm 402 is secured to the mounting tab 380 at the first and second sides 374, 378 of the movable contact 324. Support arm 404 is located outside of mounting arm 402. The support arm 404 engages the lower surface 384 of the movable contact 324 to press up against the lower surface 384. In the exemplary embodiment, support arm 404 engages movable contact 324 near first end 364 and second end 368 and near first side 374 and second side 378. For example, support arm 404 may engage movable contact 324 near four outer corners of movable contact 324. Support arm 404 maintains movable contact 324 in a horizontal orientation as movable contact 324 moves between the mated and unmated positions.

Fig. 12 is a bottom perspective view of a portion of the contactor 300 showing the movable contact assembly 350 in a mated position relative to the fixed contacts 320, 322. Fig. 13 is a side view of a portion of the contactor 300 showing the movable contact assembly 350 in a mated position relative to the fixed contacts 320, 322. Fig. 12 and 13 show a flexible busbar 340 between the first fixed contact 320 and the movable contact 324. The movable contact 324 is mated with the second fixed contact 322.

In the exemplary embodiment, second stationary contact 322 includes a mating tab 336 at mating end 332. The mating tabs 336 are oriented parallel to the movable contact 324. For example, the mating tabs 336 may be oriented horizontally. The second stationary contact 322 includes one or more mating pad 338 (fig. 13) located at the bottom of the mating pad 336. The mating patch pad 338 is configured to mate and un-mate with a mating contact pad 386 (fig. 13) of the movable contact 324. An electrical path is formed between the movable contact 324 and the second fixed contact 322 by the mating contact pads 386 and the mating blade pads 338. Providing a plurality of mating contact pads 386 and mating patch pads 338 creates a plurality of electrical paths and a plurality of contact points through the second fixed contact 322 and the movable contact 324. For example, parallel electrical paths may be created, such as a first electrical path through the second fixed contact 322 and a second electrical path through the movable contact 324. The parallel electrical paths create magnetic attraction forces that tend to hold the movable contact 324 in the mated position and reduce the risk of undesired separation or vibration in the contact.

The flexible busbar 340 forms a permanent connection between the movable contact 324 and the first fixed contact 320. The flexible busbar 340 is connected to the movable contact 324 and the first fixed contact 320 in the mated position, and the flexible busbar 340 is connected to the movable contact 324 and the first fixed contact 320 in the unmated position. When disengaged, the movable contact 324 is separated from the second fixed contact 322.

In the exemplary embodiment, flexible bus 340 has a substantially rectangular cross-section. For example, the flexible busbar 340 is plate-like or sheet-like having an upper surface 440 and a lower surface 442 (fig. 12) extending between the first and second sides 444, 446. Sides 444, 446 extend between the first and second mating ends 344, 346. The flexible bus 340 has a length between the mating ends 344, 346 and a width between the sides 444, 446. Alternatively, the width may be approximately equal to the length. Flexible bus 340 has a thickness between upper surface 440 and lower surface 442. In an exemplary embodiment, the flexible bus 340 is wide and thin. For example, the width may be at least ten times the thickness. As such, the flexible bus bar 340 is configured to move and flex as the movable contact 324 moves between the mated and unmated positions. As the movable contact 324 moves between the mated and unmated positions, the shape of the flexible busbar 340 changes.

Fig. 14 is a cross-sectional view of a portion of the contactor 300 showing the movable contact 324 in a disengaged position. In the unmated position, the movable contact 324 is spaced apart from the first and second fixed contacts 320, 322. The flexible busbar 340 extends between the movable contact 324 and the first fixed contact 320.

The contact holder 326 supports the first and second fixed contacts 320, 322. The mating ends 332 of the first and second stationary contacts 320, 322 are positioned in a fixed position within the contact holder 326 by the contact holder 326. The terminating ends 330 of the fixed contacts 320, 322 are located outside of the contactor 300, for example, for termination to wires or terminals. The contact holder 326 holds the mating ends 332 of the fixed contacts 320, 322 relative to the movable contact 324. The movable contact 324 is movable within the contactor 300 from a disengaged position to a mated position. For example, when the coil assembly 390 is activated, the movable contact holder 352 and/or the movable contact 324 are driven upward toward the fixed contacts 320, 322. The flexible busbar 340 moves with the movable contact 324. The mating contact pads 386 are driven into electrical contact with the mating pad 338 to complete the circuit.

In an exemplary embodiment, the movable contact holder 352 facilitates positioning the movable contact 324 within the contactor 300 as the movable contact 324 moves to the mated position. For example, the support arm 404 is spring biased against the bottom of the movable contact 324. The support arms 404 are spaced apart from one another to maintain the movable contact 324 in a horizontal orientation. The support arm 404 orients the movable contact 324 parallel to the mating tab 336 to ensure that the mating contact pad 386 engages the mating tab pad 338.

Fig. 15 is an exploded view of the contactor 300 in an exemplary embodiment. In the exemplary embodiment, contact holder 326 is a multi-piece structure. The contact holder 326 may be assembled around the fixed contacts 320, 322. For example, the components of the contact holder 326 may snap or otherwise couple together around the fixed contacts 320, 322. In the exemplary embodiment, contact holder 326 includes a first holder element 460 and a second holder element 462. The first and second retainer elements 460, 462 are coupled together and meet at a seam 464. The first and second retainer elements 460, 462 are coupled together, for example, by a snap-fit coupling or an interference fit. Alternatively, the first and second retainer elements 460, 462 may be secured using latching features, fasteners, or other securing means. In the illustrated embodiment, the contact holder 326 is rectangular; however, in alternative embodiments, the contact holder 326 may have other shapes.

Claims (10)

1. A contactor (100) comprising:

a housing (110) having an outer wall (111) defining a cavity (112);

a first fixed contact (120) coupled to the housing, the first fixed contact having a first mating end (144) received in the cavity and a first terminating end (130) external to the housing;

a second fixed contact (122) coupled to the housing, the second fixed contact having a second mating end (146) received in the cavity and a second terminating end external to the housing;

a movable contact (124) movable within the cavity between a mated position in which the movable contact engages the second mating end and a unmated position in which the movable contact is separated from the second fixed contact;

a flexible busbar (140) coupled to the first mating end and connected to the movable contact, the flexible busbar electrically connecting the first fixed contact and the movable contact in both a mated position and an unmated position; and

a coil assembly (190) in the cavity is operable to move the movable contact between a disengaged position and a mated position.

2. The contactor (100) of claim 1, wherein the second mating end (146) includes a mating blade (136) having a first mating blade pad (138) and a second mating blade pad spaced apart from the first mating blade pad, the movable contact (124) engaging the first and second mating blade pads of the second fixed contact (122) in a mated position to establish a first electrical path between the first and second mating blade pads through the movable contact and a second electrical path between the first and second mating blade pads through the second fixed contact.

3. The contactor (100) of claim 1, further comprising a movable contact holder (152) coupled to the movable contact (124), the movable contact holder including a support arm (204) engaging the movable contact to hold the movable contact parallel to a mating blade (136) of the second fixed contact (122).

4. The contactor (100) of claim 1, further comprising a contact holder (126) received in the cavity (112) that holds the first and second fixed contacts (120, 122) within the housing (110), the contact holder comprising first and second holder elements (260, 262) that meet at a seam (264) where the first and second fixed contacts pass through the contact holder such that both the first and second holder elements engage and support the first and second fixed contacts.

5. The contactor (100) of claim 4, wherein the contact holder (126) includes a first channel (272) holding the first stationary contact (120) and a second channel (274) holding the second stationary contact (122), the first holder element (260) forming at least a portion of the first channel and at least a portion of the second channel, the second holder element (262) forming at least a portion of the first channel and at least a portion of the second channel.

6. The contactor (100) of claim 4, wherein the contact holder (126) includes an end wall (266) and a side wall (268) forming a cavity (270) into which the first and second fixed contacts (120, 122) extend, the seam extending along the end wall and the side wall.

7. The contactor (100) of claim 1, wherein the flexible bus bar (140) comprises a flexible braid (142).

8. The contactor (100) of claim 1, wherein the flexible bus bar (140) includes a first mating end (144) coupled to the first fixed contact (120) and a second mating end (146) coupled to the movable contact (124), the second mating end being movable relative to the first mating end as the mating contact moves between the mated position and the unmated position.

9. The contactor (100) of claim 1, wherein the flexible bus bar (140) is welded to the first fixed contact (120) to establish a fixed connection therewith, the flexible bus bar being welded to the movable contact (124) to establish a fixed connection therewith.

10. The contactor (100) of claim 1, wherein the flexible bus bar (140) has a width between the opposing first and second sides (174, 178) and a thickness between the opposing upper and lower surfaces (182, 184), the width being at least ten times the thickness.

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