Note: Descriptions are shown in the official language in which they were submitted.
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ELECTROMAGNETIC RELAY ASSEMBLY
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The disclosed invention generally relates to an electromagnetic relay assembly
incorporating a uniquely configured armature assembly. More particularly, the
disclosed
invention relates to an electromagnetic relay assembly having a magnetically
actuable
rotor assembly for linearly displacing a switch actuator.
BRIEF DESCRIPTION OF THE PRIOR ART
Generally, the function of an electromagnetic relay is to use a small amount
of
power in the electromagnet to move an armature that is able to switch a much
larger
amount of power. By way of example, the relay designer may want the
electromagnet to
energize using 5 volts and 50 milliamps (250 milliwatts), while the armature
can support
120 volts at 2 amps (240 watts). Relays are quite common in home appliances
where
there is an electronic control turning on (or off) some application device
such as a motor
or a light. The present teachings are primarily intended for use as a single
pole, 120-amp
passing electromagnetic relay assembly. It is contemplated, however, that the
essence of
the invention may be applied in multi-pole relay assemblies, having unique
construction
and functionality as enabled by the teachings of the single pole embodiment
set forth in
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this disclosure. Several other electromagnetic relay assemblies reflective of
the state of
the art and disclosed in United States patents are briefly described
hereinafter.
United States Patent No. 6,046,660 (`660 Patent), which issued to Gruner,
discloses a Latching magnetic relay assembly with a linear motor. The '660
Patent
teaches a latching magnetic relay capable of transferring currents of greater
than 100
amps for use in regulating the transfer of electricity or in other
applications requiring the
switching of currents of greater than 100 amps. A relay motor assembly has an
elongated
coil bobbin with an axially extending cavity therein. An excitation coil is
wound around
the bobbin. A generally U shaped ferromagnetic frame has a core section
disposed in and
extending through the axially extending cavity in the elongated coil bobbin.
Two contact
sections extend generally perpendicularly to the core section and rises above
the motor
assembly. An actuator assembly is magnetically coupled to the relay motor
assembly.
The actuator assembly is comprised of an actuator frame operatively coupled to
a first
and a second generally U-shaped ferromagnetic pole pieces, and a permanent
magnet. A
contact bridge made of a sheet of conductive material copper is operatively
coupled to the
actuator assembly.
United States Patent No. 6,246,306 ('306 Patent), which issued to Gruner,
discloses an Electromagnetic Relay with Pressure Spring. The '306 Patent
teaches an
electromagnetic relay having a motor assembly with a bobbin secured to a
housing. A
core is adjacently connected below the bobbin except for a core end, which
extends from
the bobbin. An armature end magnetically engages the core end when the coil is
energized. An actuator engages the armature and a plurality of center contact
spring
assemblies. The center contact spring assembly is comprised of a center
contact spring
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which is not pre bent and is ultrasonically welded onto a center contact
terminal. A
normally open spring is positioned relatively parallel to a center contact
spring. The
normally open spring is ultrasonically welded onto a normally open terminal to
form a
normally open outer contact spring assembly. A normally closed outer contact
spring is
vertically positioned with respect to the center contact spring so that the
normally closed
outer contact spring assembly is in contact with the center contact spring
assembly, when
the center contact spring is not being acted upon by the actuator. The
normally closed
spring is ultrasonically welded onto a normally closed terminal to form a
normally closed
assembly. A pressure spring pressures the center contact spring above the
actuator when
the actuator is not in use.
United States Patent No. 6,252,478 (`478 Patent), which issued to Gruner,
discloses an Electromagnetic Relay. The '478 Patent teaches an electromagnetic
relay
having a motor assembly with a bobbin secured to a frame. A core is disposed
within the
bobbin except for a core end which extends from the bobbin. An armature end
magnetically engages the core end when the coil is energized. An actuator
engages the
armature and a plurality of movable blade assemblies. The movable blade
assembly is
comprised of a movable blade ultrasonically welded onto a center contact
terminal. A
normally open blade is positioned relatively parallel to a movable blade. The
normally
open blade is ultrasonically welded onto a normally open terminal to form a
normally
open contact assembly. A normally closed contact assembly comprised of a third
contact
rivet and a normally closed terminal. A normally closed contact assembly is
vertically
positioned with respect to the movable blade so that the normally closed
contact
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assembly is in contact with the movable blade assembly when the movable blade
is not
being acted upon by the actuator.
United States Patent No. 6,320,485 ('485 Patent), which issued to Gruner,
discloses an Electromagnetic Relay Assembly with a Linear Motor. The '485
Patent
teaches an electromagnetic relay capable of transferring currents of greater
than 100 amps
for use in regulating the transfer of electricity or in other applications
requiring the
switching of currents of greater than 100 amps. A relay motor assembly has an
elongated
coil bobbin with an axially extending cavity therein. An excitation coil is
wound around
the bobbin. A generally U shaped ferromagnetic frame has a core section
disposed in and
extending through the axially extending cavity in the elongated coil bobbin.
Two contact
sections extend generally perpendicularly to the core section and rises above
the motor
assembly. An actuator assembly is magnetically coupled to the relay motor
assembly.
The actuator assembly is comprised of an actuator frame operatively coupled to
a first
and a second generally U-shaped ferromagnetic pole pieces, and a permanent
magnet. A
contact bridge made of a sheet of conductive material copper is operatively
coupled to the
actuator assembly.
United States Patent No. 6,563,409 ('409 Patent), which issued to Gruner,
discloses a Latching Magnetic Relay Assembly. The '409 Patent teaches a
latching
magnetic relay assembly comprising a relay motor with a first coil bobbin
having a first
excitation coil wound therearound and a second coil bobbin having a second
excitation
coil wound therearound, both said first excitation coil and said second
excitation coil
being identical, said first excitation coil being electrically insulated from
said second
excitation coil; an actuator assembly magnetically coupled to both said relay
motor, said
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actuator assembly having a first end and a second end; and one or two groups
of contact
bridge assemblies, each of said group of contact bridge assemblies comprising
a contact
bridge and a spring.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an electromagnetic relay
assembly having certain means for damping contact vibration intermediate
contacts of the
switching assembly. It is a further object of the present invention to provide
an armature
assembly having an axis of rotation and which rotates under the influence of
the magnetic
field created or imparted from an electromagnetic coil assembly. The armature
assembly
linearly displaces a switch actuator for opening and closing the switch
assembly of the
relay. To achieve these and other readily apparent objectives, the
electromagnetic relay
assembly of the present disclosure comprises an electromagnetic coil assembly,
an
armature bridge assembly, and a switch assembly, as described in more detail
hereinafter.
The coil assembly essentially comprises a coil, a C-shaped yoke assembly, and
a
coil axis. The coil is wound around the coil axis, and the yoke assembly
comprises first
and second yoke arms. Each yoke arm comprises an axial yoke portion that is
coaxially
alignable with the coil axis and together form the back of the C-shaped yoke
assembly.
Each yoke arm further comprises a yoke terminus, which yoke termini are
coplanar and
substantially parallel to the coil axis.
The armature bridge assembly is rotatable about an axis orthogonally spaced
from
the coil axis and coplanar with the yoke termini. The armature bridge assembly
thus
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comprises a bridge axis of rotation, a bridge, and an actuator arm. The bridge
comprises
a medial field pathway relative closer in proximity to the coil axis, a
lateral field pathway
relatively further in proximity to the coil axis, and longitudinally or
axially spaced
medial-to-lateral or lateral-to-medial field pathways (or transverse field
pathways)
extending intermediate the medial and lateral pathways. The actuator arm is
cooperable
with the lateral field pathway via a first end thereof and extends laterally
away from the
lateral field pathway.
The switch assembly essentially comprises switch terminals and a spring
assembly between the switch terminals. The spring assembly is attached a
second end of
the actuator arm. The yoke termini are received intermediate the medial and
lateral
pathways. As is standard and well-established in the art, the coil receives
current and
creates or imparts a magnetic field, which magnetic field is directable
through the bridge
assembly via the yoke termini for imparting bridge rotation about the bridge
axis of
rotation and linearly displacing the actuator arm. The displaceable actuator
arm functions
to actuate the spring assembly intermediate an open contact position and a
closed contact
position, which closed contact position enables current to pass through the
switch
assembly via the switch termini.
Certain peripheral features of the essential electromagnetic relay assembly
include
certain means for enhancing spring over travel, which means function to
increase contact
pressure intermediate the switch terminals when the spring assembly is in the
closed
position. The means for enhancing spring over travel further provide means for
contact
wiping or contact cleansing via the enhanced contact or increased contact
pressure. In
other words, the enhanced conduction path through the contact interface may
well
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function of burn off residues and/or debris that may otherwise come to rest at
the contact
surfaces. The means for enhancing spring over travel may well further function
to provide
certain means for damping contact bounce or vibration intermediate the first
and second contacts
when switching from the open position to the closed position.
In one embodiment, an electromagnetic relay assembly for selectively enabling
current to
pass through switch termini is provided. The electromagnetic relay assembly
comprises: an
electromagnetic coil assembly; an armature assembly; and a switch assembly.
The coil assembly
comprises a current conductive coil, a yoke assembly, and a coil axis. The
coil is wound around
the coil axis and comprises first and second electromagnet-driving termini.
The yoke assembly
comprises first and second yoke arms. The yoke arms each comprise an axial
yoke portion and a
yoke terminus. The armature assembly comprises a rotor assembly and a rotor
axis of
rotation. The rotor assembly comprises first and second rotor magnets, a rotor
plate, and an
actuator assembly. The actuator assembly comprises a rotor bracket and an
actuator. The rotor
bracket comprises a terminal end extending laterally from the rotor assembly
substantially
parallel to the rotor plate. The rotor magnets have like orientation and
extend intermediate the
rotor plate and the rotor bracket opposite the rotor axis of rotation. The
switch assembly
comprises first and second switch terminals and a triumvirate spring assembly.
The first switch
terminal comprises a first contact and a first switch terminus. The second
switch terminal
comprises a second switch terminus. The spring assembly comprises a second
contact and three
spring elements. The first spring element comprises a first C-shaped aperture.
The first C-
shaped aperture defines a first semi-circular aperture-defining extension and
is concentric about
the first contact-receiving aperture. The second spring element comprises a
second contact-
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, .
receiving aperture and terminates in a second semi-circular aperture-defining
extension. The
third spring element comprises a third contact-receiving aperture and a second
C-shaped
aperture. The second C-shaped aperture defines a third semi-circular aperture-
defining extension
and is concentric about the second contact receiving aperture. The first and
second C-shaped
apertures are symmetrical about the longitudinal axes of the first and third
spring elements. The
second spring element is sandwiched intermediate the first and third spring
elements via the
second contact such that the first, second, and third semi-circular aperture-
defining extensions
are uniformly stacked. The first and second contacts are juxtaposed adjacent
one another. The
spring assembly is attached to the actuator. The yoke termini are received
intermediate the rotor
plate and the rotor bracket. The rotor axis of rotation is coplanar with the
yoke termini. The
rotor bracket and terminal end extend non-radially relative to the rotor axis
of rotation. The coil
is for creating a magnetic field, the magnetic field being directable through
the yoke termini via
the rotor assembly to impart armature rotation about the rotor axis of
rotation. The rotor bracket
with the terminal end is for displacing the actuator. The actuator is for
actuating the spring
assembly intermediate an open position and a closed position. The closed
position enables
current to pass through the switch assembly via the first and second contacts
and the switch
termini.
In another embodiment, an electromagnetic relay for enabling current to pass
through
switch termini is provided. The electromagnetic relay comprises: an
electromagnetic coil
assembly; and armature bridge assembly; and a switch assembly. The coil
assembly comprises a
coil, a C-shaped yoke assembly, and a coil axis. The coil is wound around the
coil axis. The
yoke assembly comprises first and second yoke arms, the yoke arms each
comprising an axial
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4
yoke portion and a yoke terminus. The armature bridge assembly comprises a
bridge axis of
rotation, a bridge, and an actuator assembly. The bridge comprises a medial
field pathway, a
lateral field pathway, and longitudinally spaced transverse field pathways.
The actuator
assembly comprises a rotor bracket. The rotor bracket comprises a terminal
end. The terminal
end zigzag extends laterally from the bridge assembly non-orthogonally
relative to the medial
and lateral field pathways. The switch assembly comprises switch terminals and
a spring
assembly. The spring assembly is attached to the actuator assembly and extends
intermediate the
switch terminals. The yoke termini are received intermediate the medial and
lateral field
pathways. The bridge axis of rotation is coplanar with the yoke termini. The
coil receives
current and creates a magnetic field, the magnetic field being directable
through the bridge
assembly via the yoke termini to impart bridge rotation about the bridge axis
of rotation to
displace the actuator assembly via the terminal end. The displaceable actuator
assembly actuates
the spring assembly intermediate an open contact position and a closed contact
position, the
closed contact position enables current to pass through the switch assembly
via the switch
termini.
In another embodiment, an electromagnetic relay for enabling current to pass
through
switch termini is provided. The electromagnetic relay comprises: a coil
assembly, a bridge
assembly, and a switch assembly. The coil assembly comprises a coil, a coil
axis, and a C-
shaped core. The coil is wound round the coil axis. The coil axis extends
through the core. The
core comprises core termini which are parallel to the coil axis. The bridge
assembly comprises
an axis of rotation, a bridge, and an actuator assembly. The bridge comprises
a medial field
pathway, a lateral field pathway, and spaced transverse field pathways. The
actuator assembly
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. . .
comprises a rotor bracket, the rotor bracket comprising a terminal end. The
terminal end zigzag
extending from the bridge assembly relative to the lateral field pathway. The
core termini are
coplanar with the axis of rotation and received intermediate the medial and
lateral field
pathways. The actuator assembly is cooperable with the switch assembly. The
coil creates a
magnetic field, the magnetic field being directable through the bridge
assembly via the core
termini to impart bridge rotation about the axis of rotation via magnetically
induced torque, the
bridge rotation displacing the actuator assembly. The displaceable actuator
assembly opens and
closes the switch assembly. The closed switch assembly enables current to pass
therethrough.
In another embodiment, an electromagnetic relay assembly for selectively
enabling
current to pass through switch termini is provided. The electromagnetic relay
assembly
comprises: an electromagnetic coil assembly; an armature assembly; and a
switch assembly. The
coil assembly comprises a current-conductive coil, a yoke assembly, and a coil
axis. The coil is
wound around the coil axis and comprises first and second electromagnet-
driving termini. The
yoke assembly comprises first and second yoke arms, the yoke arms each
comprising an axial
yoke portion and a yoke terminus. The armature assembly comprises a rotor
assembly and a
rotor axis of rotation. The rotor assembly comprises first and second rotor
magnets, a rotor plate,
a rotor bracket, and a return spring. The rotor bracket comprises an actuator.
The rotor magnets
have like orientation and extend intermediate the rotor plate and the rotor
bracket opposite the
rotor axis of rotation. The switch assembly comprises first and second switch
terminals and a
triumvirate spring assembly. The first switch terminal comprises a first
contact and a first switch
terminus. The second switch terminal comprises a second switch terminus. The
spring assembly
comprises a second contact and three spring elements. The first spring element
comprises a first
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.. . . -
C-shaped aperture. The first C-shaped aperture is concentric about the first
contact-receiving
aperture. The second spring element comprises a second contact-receiving
aperture. The third
spring element comprises a third contact-receiving aperture and a second C-
shaped
aperture. The second C-shaped aperture is concentric about the second contact-
receiving
aperture. The second spring element is sandwiched intermediate the first and
third spring
elements via the second contact. The first and second contacts are juxtaposed
adjacent one
another. The spring assembly is attached to the actuator. The yoke termini are
received
intermediate the rotor plate and the rotor bracket, the rotor axis of rotation
is coplanar with the
yoke termini. The coil creates a magnetic field, the magnetic field is
directable through the yoke
termini via the rotor assembly to impart armature rotation about the rotor
axis of rotation. The
rotor bracket displaces the actuator, the actuator actuating the spring
assembly intermediate an
open position and a closed position. The closed position enables current to
pass through the
switch assembly via the first and second contacts and the switch termini. The
return spring
enhances the return of the spring assembly to the open position when the coil
is dormant.
Other objects of the present invention, as well as particular features,
elements, and
advantages thereof, will be elucidated or become apparent from, the following
description and
the accompanying drawing figures.
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BRIEF DESCRIPTION OF THE DRAWINGS
Other features of our invention will become more evident from a consideration
of
the following brief description of patent drawings:
Figure No. 1 is a top plan view of the electromagnetic relay assembly of the
present
invention with the switch assembly in an open position.
Figure No. 2 is a top plan view of the electromagnetic relay assembly of the
present
invention with the switch assembly in a closed position.
Figure No. 3 is a top perspective exploded type depiction of the
electromagnetic
relay assembly of the present invention with showing an optional housing
cover.
Figure No. 4 is an exploded perspective view of a first terminal assembly of
the
switch assembly of the electromagnetic relay assembly.
Figure No. 5 is an exploded perspective view of a second terminal assembly of
the
switch assembly of the electromagnetic relay assembly.
Figure No. 6 is an exploded perspective view of a coil assembly of the
electromagnetic relay assembly of the present invention.
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Figure No. 7 is an exploded fragmentary perspective view of a rotor assembly
of the
armature assembly of the electromagnetic relay assembly.
Figure No. 8 is an exploded perspective view of the triumvirate spring
assembly and
a contact button of the switch assembly of the electromagnetic relay assembly.
Figure No. 9 is a fragmentary side view depiction of the triumvirate spring
assembly, the contact buttons, and the armature arm of the present invention
showing the
contact buttons in a closed position with the triumvirate spring assembly in a
substantially
coplanar position.
Figure No. 10 is a fragmentary side view depiction of the triumvirate spring
assembly, the contact buttons, and the armature arm of the present invention
showing the
contact buttons in a closed position with the triumvirate spring assembly in
an over travel
position for enhancing contact pressure intermediate the contact buttons.
Figure No. 11 is an enlarged fragmentary side view depiction of the junction
at the
triumvirate spring assembly and the upper contact button otherwise shown in
Figure No. 10
depicting the triumvirate spring assembly in the over travel position for
enhancing contact
pressure intermediate the contact buttons.
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Figure No. 12 is a diagrammatic depiction of the flux flow through the C-
shaped
core assembly and the rotor assembly of the electromagnetic relay assembly
depicting a
diverted and divided field flow through the rotor assembly.
Figure No. 13 is a side view depiction of a switch terminal assembly as
operatively
connected to a triumvirate spring assembly and a contact button, the
triumvirate spring
assembly showing first and second springs with centrally located C-shaped
folds, and a
third spring with an end-located bend.
Figure No. 14 is an enlarged fragmentary sectional view as taken from Figure
No.
13 depicting the end-located bend of the third spring in rater detail.
Figure No. 15 is a diagrammatic depiction of a threshold current path directed
through the relay terminals as disposed in adjacency to the rotatable armature
assembly
and depicting a terminal-sourced magnetic field greater in magnitude than an
armature-
sourced magnetic field for rotating the armature assembly toward a circuit-
opening
position.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the preferred embodiment of the present
invention
concerns an electromagnetic relay assembly 10 as illustrated and referenced in
Figure
Nos. 1 ¨ 3. The electromagnetic relay assembly 10 of the present invention
essentially
functions to selectively enable current to pass through switch termini 11 as
illustrated and
referenced in Figure Nos. 1 ¨ 5. To achieve these and other readily apparent
functions,
the electromagnetic relay assembly 10 of the present invention preferably
comprises an
electromagnetic coil assembly 12 as generally illustrated and referenced in
Figure Nos. 1
¨ 3, and 6; a rotatable armature assembly 13 as generally illustrated and
referenced in
Figure Nos. 1 ¨ 3; and a switch assembly 14 as generally illustrated and
referenced in
Figure Nos. 1 ¨ 5.
The coil assembly 12 of the present invention preferably comprises a current-
conductive coil 15 as illustrated and referenced in Figure Nos. 1 ¨ 3, and 6;
a C-shaped
core or yoke assembly 16 as illustrated and referenced in Figure Nos. 3, 6,
and 12; and a
coil axis 100 generally referenced and depicted in Figure Nos. 1, 2, 6, and
12. It may be
seen or understood from an inspection of the noted figures that the current-
conductive
coil 15 is wound around the coil axis 100 and comprises first and second
electromagnet-
driving termini 17 as illustrated and referenced in Figure Nos. 1 ¨ 3, and 6.
The yoke
assembly or C-shaped core assembly 16 of the present invention is axially
received
within the coil 15 and preferably comprises first and second yoke arms 18, one
of which
is illustrated and referenced in Figure Nos. 1 ¨ 3, and both of which are
illustrated and
referenced in Figure No. 6. It may be seen from an inspection of Figure No. 6
that yoke
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arms 18 each comprise an axial yoke portion 19 and a substantially planar yoke
terminus
20, which yoke termini 20 are preferably parallel to the coil axis 100 as
further referenced
and depicted in Figure No. 12.
It is contemplated that the rotatable armature assembly 13 of the present
invention
may be described as preferably comprising a rotor assembly 21 as generally
illustrated
and referenced in Figure Nos. 1 ¨ 3, and 7; an actuator or actuator arm 22 as
generally
illustrated and referenced in Figure Nos. 1 ¨ 3, 9, and 10; and an armature
axis of rotation
101 as depicted and referenced at a point in Figure Nos. 1, 2, 12, and 15, and
as a line in
Figure Nos. 3 and 7. The rotor assembly 21 preferably comprises first and
second
uniformly directed or polarized rotor magnets 23 as illustrated and referenced
in Figure
Nos. 7 and 12; a rotor plate 25 as illustrated and referenced in Figure Nos. 1
¨ 3, 7, and
12; a rotor bracket 26 as illustrated and referenced in Figure Nos. 1 ¨ 3, 7,
and 12; a rotor
housing 27 as illustrated and referenced in Figure Nos. 1 ¨ 3, and 7; a return
spring 28 as
illustrated and referenced in Figure Nos. 3 and 7; a rotor pin 29 as
illustrated and
referenced in Figure Nos. 1 and 3; and a rotor mount 30 as illustrated and
referenced in
Figure Nos. 1 ¨ 3.
It may be seen from an inspection of the noted figures that the rotor bracket
26 is
attached or otherwise cooperatively associated with a first end of the
actuator arm 22, and
that the rotor plate 25 and the rotor bracket 26 (or portions thereof) are
preferably
oriented parallel to one another by way of the rotor housing 27. In this
regard, it may be
further seen that the first and second rotor magnets 23 are equally
dimensioned and
extend intermediate the rotor plate 25 and the rotor bracket 26 for
simultaneously and
equally spacing the rotor plate 25 and the rotor bracket 26 and for further
providing a
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guide way or pathway for so-called Lorenz current or magnetic flux to be
effectively
transversely directed across the rotor or bridge assembly 21 as
diagrammatically depicted
in Figure No. 12.
In this last regard, it is contemplated that the armature assembly 13 may be
thought of as an armature bridge assembly, which bridge assembly comprises a
bridge
axis of rotation (akin to the armature axis of rotation 101) and a bridge in
cooperative
association with the armature arm 22. In this context, the bridge may be
thought of or
described as preferably comprising a medial pathway (akin to the rotor plate
25), a lateral
pathway (akin to the rotor bracket 26), and longitudinally or axially spaced
medial-to-
lateral or transverse pathways (akin to the first and second rotor magnets 23.
The
armature arm 22 may thus be described as extending laterally away from the
lateral
pathway or rotor bracket 26 for engaging the switch assembly 14.
The rotor housing 27 essentially functions to receive, house, and position the
first
and second rotor magnets 23, the rotor plate 25 and the rotor bracket 26 to
form the
bridge like structure of the armature assembly 13. The rotor magnets 23 are
uniformly
directed such that like poles face the same rotor structure. For example, it
is
contemplated that the north poles of rotor magnets 23 may face the rotor
bracket 26 (the
south poles thereby facing the rotor plate 25) or that the south poles of
rotor magnets 23
may face the rotor bracket 26 (the north poles thereby facing the rotor
bracket).
The rotor housing 27 may well further comprise a pin-receiving aperture or
bore
for receiving the rotor pin 29 as may be generally seen from an inspection of
Figure Nos.
3 and 7. The pin-receiving aperture or bore of the rotor housing 27 enables
rotation of
the bridge or armature assembly 13 about the armature axis of rotation 101.
The rotor pin
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29, extending through the pin-receiving bore, may be axially anchored at a
lower end
thereof by way of a relay housing 48 as illustrated and referenced in Figure
Nos. 1 ¨ 3,
and which relay housing 48 is sized and shaped to receive, house, and position
the coil
assembly 12, the armature assembly 13, and the switch assembly 14 as may be
readily
understood from an inspection of Figure No. 3. It may be further readily
understood
from an inspection of Figure No. 3 that the relay housing 48 may, but not
necessarily,
comprise or be cooperable with a relay cover 49.
In this last regard, it will be recalled that the armature assembly 13 of
present
invention may be anchored or mounted by way of the rotor mount 30. Rotor mount
30
may be cooperatively associated with the relay housing 48 (i.e. anchored to
the relay
housing 48) for axially fixing the rotor pin 29, the fixed rotor mount 30
receiving and
anchoring an upper end of the rotor pin 29 so as to enable users of the relay
to effectively
operate the electromagnetic relay assembly 10 of the present invention without
the relay
cover 49. The rotor mount 30 or bridge mount or means for mounting the rotor
assembly
or bridge assembly may thus be described as providing certain means for
enabling open
face operation of the electromagnetic relay assembly 10. It is contemplated,
for example,
that in certain scenarios a coverless relay assembly provides a certain
benefit. For
example, the subject relay assembly may be more readily observed during
testing
procedures. In any event, it is contemplated that the rotor mount 30 of the
present
invention enables cover-free operation of the electromagnetic relay assembly
10 by
otherwise fixing the armature assembly 13 to the relay housing 48.
The switch assembly 14 of the present relay assembly 10 preferably comprises a
first switch terminal assembly 31 as generally illustrated and referenced in
Figure Nos. 1
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¨ 4; and a second switch terminal assembly 32 as illustrated and referenced in
Figure
Nos. 1 ¨3, 5, 13, and 14; and a triumvirate spring assembly 33 as illustrated
and
referenced in Figure Nos. 1 ¨ 3, 5, 8 ¨ 11, 13, and 14. From an inspection of
the noted
figures, it may be seen that the first switch terminal assembly 31 preferably
comprises a
first contact button 34 and a first switch terminus as at 11. Further, the
second switch
terminal assembly 32 preferably comprises a second switch terminus as at 11.
The triumvirate spring assembly 33 preferably comprises a second contact
button
37 as illustrated and referenced in Figure Nos. 1, 2, 9¨ 11, 13, and 14; and a
first spring
38, second spring 39, and third spring 40 as further illustrated and
referenced in Figure
Nos. 5, 8 ¨ 10, and 13. It may be further seen that the first spring 38
preferably
comprises a first contact-receiving aperture as at 41 and a first C-shaped
aperture as at 42
in Figure No. 8, as well as an end-located offset or bend as at 70 in Figure
Nos. 1.3 and
14. Notably, the first C-shaped aperture 42 is preferably concentric about the
first
contact-receiving aperture 41. The second spring 39 preferably comprises a
second
contact-receiving aperture as at 43 and a first C-shaped fold as at 44 in
Figure No. 8. It
may be seen from an inspection of Figure No. 8 that the first C-shaped fold 44
has a
certain first radius of curvature. The third spring 40 preferably comprises a
third contact-
receiving aperture as at 45, a second C-shaped aperture as at 46, and a second
C-shaped
fold as at 47.
It may be further seen that the second C-shaped aperture 46 is preferably
concentric about the third contact-receiving aperture 45, and that the second
C-shaped
fold 47 has a certain second radius of curvature, which second radius of
curvature is
greater in greater in magnitude than the first radius of curvature (of the
first C-shaped
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fold 44). The second spring 39 is sandwiched intermediate the first and third
springs 38
and 40 via the second contact button 37 as received or extended through the
contact-
receiving apertures 41, 43, and 45. The first C-shaped fold 44 is concentric
(about a fold
axis) within the second C-shaped fold 47. The first and second contact buttons
34 and 37
or contacts are spatially oriented or juxtaposed adjacent one another as
generally depicted
in Figure Nos. 1, 2, 9, and 10. In the preferred embodiment, the triumvirate
spring
assembly 33 is biased in an open contact position intermediate the first and
second switch
termini 11 and attached to (the lateral end of) the armature arm 22 as perhaps
mostly
clearly depicted in Figure Nos. 9 and 10.
It is contemplated that the first and second C-shaped apertures 42 and 46, and
the
end-located offset or bend 70 may well function to provide certain means for
enhanced
over travel for increasing contact pressure intermediate the first and second
contact
buttons 34 and 37. In this regard, the reader is further directed to Figure
Nos. 9 and 10.
From a comparative consideration of the noted figures, it may be seen that the
terminal
side ends 53 of the spring assembly 33 may be actuated past the planar
portions of the
spring assembly immediately adjacent the stem 51 of contact button 37. The
planar
portions of the spring assembly immediately (and radially) adjacent the stem
51 of
contact button 37 thus form button-stackable spring portions as at 52 in
Figure Nos. 8 and
11. From an inspection of Figure Nos. 8 and 11, it may be seen that the button-
stackable
portions 52 stack upon the contact button 37 and that terminal side ends 53 of
the
elastically deform as at 50 for enabling said over travel.
In other words, the material (preferably copper) of the spring elements having
the
C-shaped apertures is more readily and elastically deformable at the termini
of the C-
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shaped apertures as at 50 in Figure No. 8. Notably, the elastic deformation of
the
material adjacent termini 50 does not result in appreciable embrittlement of
the
underlying material lattice (i.e. does not appreciably impart undesirable
lattice
dislocations) and thus the C-shaped aperture structure or feature of the
triumvirate spring
assembly provides a robust means for enhanced over travel for further
providing a certain
added pressure intermediate the contact buttons 34 and 37 for improving
conductive
contact(s) therebetween. The end-located offset or bend 70 further provides a
means for
enhanced overtravel for increasing contact pressure and reducing contact
bounce of the
contacts 34 and 37.
Conduction through the contact buttons 34 and 37 is thus improved by way of
the
C-shaped aperture-enabled and/or enhanced over travel as generally depicted in
Figure
No. 10. It is contemplated that the enhanced contact and resulting conduction
provides
certain means for improved contact wiping, the means for contact wiping or
contact
cleansing thus being further enabled by way of the enhanced over travel. In
this regard, it
is contemplated that the relay assembly 10 of the present invention inherently
has a self-
cleansing feature as enabled by the C-shaped apertures 42 and 46. Further, it
is
contemplated that the C-shaped apertures 42 and 46 (and offset or bend 70) may
well
provide certain means for reducing contact bounce or for otherwise damping
contact
vibration intermediate the contact buttons 34 and 37 when switching from an
open
contact state or open switch position (as generally depicted in Figure No. 1)
to a closed
contact state or closed switch position (as generally depicted in Figure No.
2).
From an inspection of Figure No. 12, it may be readily understood that the
core or
yoke termini 20 are loosely received intermediate the rotor plate 25 and the
rotor bracket
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26, and that the armature axis of rotation 101 is coplanar with the yoke
termini 20, which
axis of rotation 101 extends through the rotor pin 29 (not specifically
depicted in Figure
No. 20). As should be readily understood, the current-conductive coil 15
functions to
receive current and thereby creates a magnetic field as further depicted and
referenced at
vectors 102 in Figure No. 12. As may be seen from an inspection of the noted
figure, the
magnetic field 102 is directed through the yoke termini 20 via the rotor
assembly
(essentially defined by the rotor bracket 26, the rotor magnets 23, and the
rotor plate 25)
for imparting armature or bridge rotation about the armature axis of rotation
101 via a
magnetically induced torque.
The rotor bracket 26 thus functions to linearly displace the actuator arm 22,
which
displaced actuator arm 22 functions to actuate the triumvirate spring assembly
33 from a
preferred spring-biased open position (as generally depicted in Figure No. 1)
to a spring-
actuated closed position (as generally depicted in Figure No. 2). The material
construction of the relay assembly 10 (believed to be within the purview of
those skilled
in the art) and the closed position essentially function to enable 120-amp
current to pass
through the switch assembly 14 via the first and second contact buttons 34 and
37 and the
switch termini 11. When the coil assembly 12 is currently dormant and the
magnetic
field is effectively removed, the return spring 28 may well function to
enhance return of
the triumvirate spring assembly 33 to the preferred spring-biased open
position as
generally depicted in Figure Nos. 11. Should a fault current condition arise,
it is
contemplated that the electromagnetic relay 10 may preferably further comprise
certain
closed contact default means, the closed contact default means for forcing the
first and
second contact buttons 34 and 37 closed during said fault current or short
circuit
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condition(s). In this regard, it is contemplated that the path followed by the
Lorenz
current or magnetic field path as generally depicted in Figure No. 12 by
vector arrows
102.
It is further contemplated that the electromagnetic relay according to the
present
invention may comprise certain means for defaulting to an open contact
position during
threshold terminal-based current conditions. In this regard, it is noted from
classical
electromagnetic theory that streaming charge carriers develop a magnetic field
in radial
adjacency to the direction of the carrier stream. The reader is thus directed
to Figure No.
which is a diagrammatic depiction of a threshold current path as at 71 being
directed
10 through the relay terminals 31 and 32 via the contact buttons 34 and 37.
A magnetic
force vector as at 103 is depicted as terminal-sourced via the charge carrier
current
flowing through the path 71. After reaching certain threshold amperage, the
magnetic
field generated through the terminals 31 and 32 will interact with the
permanent magnets
or rotor magnets 23 of the rotatable armature assembly 13. The magnets 23 have
an
15 inherent magnetic field directed outward as referenced at vector arrow
104, the force of
which is lesser in magnitude than the force at vector arrow 103. The
difference in force
between 104 and 103 as directed causes the rotatable armature assembly 13 to
rotate
toward an open contact position as diagrammatically shown in Figure No. 15.
This
feature can be calibrated by the size and strength of the magnets 23 and the
distance
between the armature and stationary contacts,
The scope of the claims should not be limited by the preferred embodiments
herein, but should be given the broadest interpretation consistent with the
description
as a whole.
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For example, the invention may be said to essentially teach or disclose
an electromagnetic relay assembly for enabling current to pass through switch
termini,
which electromagnetic relay assembly comprising a coil assembly, a bridge
assembly,
and a switch assembly. The coil assembly comprises a coil, a coil axis, and a
C-shaped
core. The coil is wound around the coil axis 100, and the coil axis extends
100 through
the core as at 60 in Figure No. 12. The core 60 comprises core termini 20,
which core
termini 20 are substantially parallel to the coil axis 100.
The bridge assembly comprises an axis of rotation as at 101 and a bridge as at
61
in Figure Nos. 12 and 15; and a switch actuator as at 22. The bridge 61
comprises a
medial field pathway 63 (i.e. a pathway relatively closer in proximity to the
core 60), a
lateral field pathway 64 (i.e. a pathway relatively further in proximity to
the core 60), and
axially spaced transverse pathways 65 for guiding the field as at 102
intermediate the
medial and lateral field pathways 63 and 64. The actuator arm 22 is cooperable
with, and
extends away from, the lateral pathway 64 (not specifically depicted in Figure
No. 12).
The core termini 20 are preferably coplanar with the axis of rotation 101 and
received
intermediate the medial and lateral pathways 63 and 64.
It is contemplated that the transverse pathways 65 provide certain field-
diversion
means for transversely diverting the magnetic field 102 relative to the coil
axis 100 and
magnetically inducing a torque, which magnetically induced torque functions to
actuate
the switch actuator 22. Said field diversion means may be further described as
comprising certain field division means (there being two axis-opposing paths
as at 66 in
Figure No. 12) for creating a magnetic couple about the magnetically induced
torque.
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The switch assembly as at 14 is further cooperable with the actuator arm 22,
which actuator arm 22 is essentially a coupling intermediate the bridge
assembly 61 and
the switch assembly 14. The coil functions to create or impart a magnetic
field as
vectorially depicted at 102. The magnetic field 102 is directable through the
bridge
assembly 61 via the core termini 20 for imparting bridge rotation about the
axis of
rotation 101 via magnetically induced torque. The bridge rotation functions to
displace
the actuator arm 22, which displaced actuator arm 22 physically opens and
closes the
switch assembly 14. As is most readily understood in the arts, the closed
switch
assembly 14 enables current to pass theretluough.
The switch assembly 14 comprises certain spring means for enhancing spring
over travel, said means for enhancing the closed switch position by way of
increasing the
contact pressure intermediate contact buttons 34 and 37. The spring means for
enhancing
spring over travel further provide contact wiping means, and vibration damping
means.
The contact wiping means are contemplated to effectively self-cleanse the
switch
assembly 14, and the vibration damping means function to damp contact
vibration when
switching from open to closed switch positions. The spring means for enhancing
spring
over travel may thus be said to enhance the closed switch position by
increasing contact
pressure intermediate the contacts, by maintaining a residue free contact
interface, and by
damping contact vibration when closing the contacts.
Although the invention has been described by reference to a number of
preferred
embodiments, the scope of the claims should not be limited thereby, but should
be given
the broadest interpretation consistent with the description as a whole
For example, the foregoing
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specifications support an electromagnetic relay assembly primarily intended
for use as a
single pole, 120-amp passing relay assembly. It is contemplated, however, that
the
invention may be applied in multi-pole relay assemblies, having unique
construction and functionality in their own right, but which are enabled by
the teachings
of the single pole embodiment set forth in this disclosure.
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