Note: Descriptions are shown in the official language in which they were submitted.
CA 02751585 2011-09-21
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 at least one 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. While the present teachings essentially support a single pole, 120-
amp passing
electromagnetic relay assembly, it is contemplated that the essence of the
invention may
be applied in multi-pole relay assemblies (e.g. double pole relay assemblies),
having
unique construction and functionality as enabled by the basic teachings as
applied to a
single pole embodiment as exemplified or set forth in 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
1
CA 02751585 2011-09-21
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
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
2
CA 02751585 2011-09-21
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
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
3
CA 02751585 2011-09-21
. .
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
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.
4
CA 02751585 2011-09-21
. .
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 switch actuators for opening and closing each 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 at least one 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
comprises a bridge axis of rotation, a bridge, and at least one 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)
5
CA 02751585 2011-09-21
. ,
extending intermediate the medial and lateral pathways. Each actuator arm is
cooperable
with the lateral field pathway via a first end thereof and extends laterally
away from the
lateral field pathway.
Each switch assembly essentially comprises switch terminals and a spring
assembly between the switch terminals. Each 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 each actuator arm. Each 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
each 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
function to 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.
6
CA 02751585 2014-06-26
'
,
In one embodiment, an electromagnetic relay for enabling current to pass
through
switch termini is provided. The electromagnetic relay comprises: an
electromagnetic coil
assembly; an armature bridge assembly; and two switch assemblies. 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
comprise an axial yoke portion and a yoke terminus. The armature bridge
assembly
comprises a bridge axis of rotation, a bridge, and opposing actuator arms. The
bridge
comprises a medial field pathway, a zigzagged lateral field pathway, and
longitudinally
spaced transverse field pathways. The actuator arms extend from terminal
portions of the
lateral field pathway. The switch assemblies each comprise switch terminals
and a spring
assembly. The spring assemblies are attached to the actuator arms and extend
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
actuator arms
and zigzagged lateral field pathway extend non-radially relative to the bridge
axis of
rotation. The coil receives current to create 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 and displace the actuator arms. The displaceable
actuator arms
actuate the spring assemblies intermediate an open contact position and a
closed contact
position. The closed contact position enables current to pass through the
switch assemblies
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 first and second switch assemblies. The coil assembly comprises
a coil, a coil
axis, and a C-shaped core. The coil is wound around the coil axis. The coil
axis extends
through the core. The core comprises core termini that are parallel to the
coil axis. The
bridge assembly comprises an axis of rotation, a bridge, and opposing
actuators. The bridge
comprises a medial field pathway, a zigzagged lateral field pathway, and
spaced transverse
field pathways. The actuators extend from terminal portions of the lateral
field
pathway. The core termini are coplanar with the axis of rotation and received
intermediate
6a
CA 02751585 2014-06-26
_
the medial and lateral field pathways. The first and second switch assemblies
are cooperable
with the actuators.
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 actuators. The
displaceable
actuators open and close the switch assemblies, the closed switch assemblies
enable current
to pass therethrough.
In another embodiment, an electromagnetic relay for enabling current to pass
through
switch termini is provided. The electromagnetic relay comprises: a coil
assembly for
selectively creating a coil-emanating magnetic field; a rotatable bridge
assembly comprising
opposing switch actuators and a bridge based magnetic field; and first and
second switch
assemblies cooperable with the switch actuators. The coil-emanating magnetic
field is
directable through the bridge assembly to impart bridge rotation via the
bridge based
magnetic field. The bridge rotation displaces the switch actuators about a
bridge axis of
rotation. The displaceable switch actuators opening and closing the switch
assemblies. The
closed switch assemblies enable current to pass therethrough. The switch
assemblies
comprise spring-based aperture over travel means to enhance spring over travel
and enhance
the closed switch position. The switch assemblies each comprise a spring
assembly, the
spring assemblies each comprising three spring elements. The first of the
three spring
elements comprises a first C-shaped aperture defining a first semi-circular
aperture-defining
extension. The first C-shaped aperture is concentric about the first contact-
receiving
aperture. The second of the three spring elements comprises a second contact-
receiving
aperture and terminates in a second semi-circular aperture-defining extension.
The third of
the three spring elements 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. The second C-shaped aperture 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,
6b
CA 02751585 2014-06-26
. . .
second and third semi-circular aperture defining extensions are uniformly
stacked. The three
spring elements are configured to provide the spring-based aperture means for
enhancing
spring over travel.
In another embodiment, an electromagnetic relay for enabling current to pass
through
switch termini is provided. The electromagnetic relay comprises: a coil
assembly, for
selectively creating a coil-emanating magnetic field; a rotatable bridge
assembly comprising
opposing switch actuators and a bridge-based magnetic field; and first and
second switch
assemblies cooperable with the switch actuators. The coil-emanating magnetic
field is
directable through the bridge assembly for imparting bridge rotation via the
bridge-based
magnetic field, the bridge rotation displaces the switch actuators about a
bridge axis of
rotation. The displaceable switch actuators open and close the switch
assemblies. The
closed switch assemblies enable current to pass therethrough. The
electromagnetic relay also
comprises spring-based aperture damping means for damping switch vibration
when
switching from open to closed switch positions. The switch assemblies each
comprise a
spring assembly, each comprising three spring elements. The first of the three
spring
elements comprises a first C-shaped aperture defining a first semi-circular
aperture-defining
extension. The first C-shaped-aperture is concentric about the first contact-
receiving
aperture. The second of the three spring elements comprises a second contact-
receiving
aperture and terminates in a second semi-circular aperture defining extension.
The third of
the three spring elements 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 being 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 three spring elements are
configured to
provide the spring-based aperture means for damping contact vibration.
In another embodiment, an electromagnetic relay for enabling current to pass
through
switch termini is provided. The electromagnetic relay comprises: a coil
assembly; an
armature assembly; and first and second switch assemblies. The coil assembly
comprises a
6c
CA 02751585 2014-06-26
. = . =
current-conductive coil and a coil axis. The coil is for creating a magnetic
field. The
armature assembly comprises switch actuators, a zigzagged rotor bracket having
opposing
actuator-engaging structures, and field-diversion means. The field-diversion
means to
transversely divert the magnetic field relative to the coil axis and
magnetically induce a
torque. The magnetically induced torque actuates the switch actuators via the
actuator-
engaging structures. The switch actuators are cooperable with the switch
assemblies to
enable current to pass therethrough. The first and second switch assemblies
each comprise
spring-based aperture means to damp switch vibration when switching from open
to closed
switch positions. Each switch assembly comprises a spring assembly, the spring
assemblies
each comprising three spring elements. The first of the three spring elements
comprise a first
C-shaped aperture defining a first semi-circular aperture-defining extension.
The first C-
shaped aperture is concentric about the first contact-receiving aperture. The
second of the
three spring elements comprises a second contact-receiving aperture and
terminates in a
second semi-circular aperture-defining extension. The third of the three
spring elements
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 so that the first, second and third semi-circular aperture-defining
extensions are
uniformly stacked. The three spring elements are configured to provide the
spring-based
aperture means for damping contact vibration.
30
6d
CA 02751585 2011-09-21
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.
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 first top plan view of the electromagnetic relay assembly of
the
present invention with each switch assembly in an closed position.
Figure No. 2 is a second top plan view of the electromagnetic relay assembly
of the
present invention with the switch assembly in a closed position.
Figure No. 2(a) is a fragmentary enlarged sectional view as sectioned from the
assembly depicted in Figure No. 2 showing the rotor assembly and rotor mount.
Figure No. 3 is a diagrammatic plan type depiction of the rotor assembly, each
actuator arm, and each switch assembly in a closed position as separated from
the relay
housing and coil assembly for enhancing understanding of the structural
relationship
therebetween.
Figure No. 4 is a diagrammatic plan type depiction of the rotor assembly, each
actuator arm, and each switch assembly in an open position as separated from
the relay
housing and coil assembly for enhancing understanding of the structural
relationship
therebetween.
Figure No. 5 is a top perspective exploded type depiction of the
electromagnetic
relay assembly of the present invention showing an optional housing cover.
7
CA 02751585 2011-09-21
Figure No. 6 is an exploded perspective view of a coil assembly of the
electromagnetic relay assembly of the present invention.
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 a first terminal assembly of a
first
switch assembly of the electromagnetic relay assembly.
Figure No. 9 is an exploded perspective view of a second terminal assembly of
the
first switch assembly of the electromagnetic relay assembly.
Figure No. 10 is an exploded perspective view of a first switch terminal
assembly of
a second switch assembly according to the present invention.
Figure No. 11 is an exploded perspective view of a second switch terminal
assembly
of the second switch assembly according to the present invention.
Figure No. 12 is a fragmentary side view depiction of the triumvirate spring
assembly, the contact buttons, and an 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. 13 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. 14 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. 13
8
CA 02751585 2011-09-21
. .
depicting the triumvirate spring assembly in the over travel position for
enhancing contact
pressure intermediate the contact buttons.
Figure No. 15 is a dual fragmentary side view depiction of opposed triumvirate
spring assemblies, contact buttons, and armature arm assemblies of the present
invention
showing contact buttons in a closed position, showing the respective
triumvirate spring
assemblies such that two springs are in a substantially linear configuration
and one spring is
in an offset configuration before over travel.
Figure No. 16 is an enlarged fragmentary side view depiction of the junction
at the
right most triumvirate spring assembly and the upper contact button otherwise
shown in
Figure No. 15 depicting the spring with offset before over travel.
Figure No. 17 is an enlarged fragmentary side view depiction of the junction
at the
left most triumvirate spring assembly and the upper contact button otherwise
shown in
Figure No. 15 depicting the spring with offset before over travel.
Figure No. 18 is an enlarged fragmentary side view depiction of the junction
of the
triumvirate spring assembly and the upper contact button otherwise shown in
Figure No. 16
depicting the spring with offset after over travel.
Figure No. 19 is an enlarged fragmentary side view depiction of the junction
of the
triumvirate spring assembly and the upper contact button otherwise shown in
Figure No. 17
depicting the spring with offset after over travel.
Figure No. 20 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.
9
CA 02751585 2011-09-21
Figure No. 21 is a dual side view depiction of (1) 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, and (2) an enlarged
fragmentary sectional view depicting the end-located bend of the third spring
in greater
detail.
Figure No. 22 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.
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, 2, and 5. 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, 2, 3 ¨ 5, and 8 ¨ 11. 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, 2, and 5; a rotatable armature
assembly 13 as
generally illustrated and referenced in Figure Nos. 1 ¨ 5; and switch
assemblies 14 as
generally illustrated and referenced in Figure Nos. 1, 2, 3, and 4.
CA 02751585 2011-09-21
. ,
The coil assembly 12 of the present invention preferably comprises a current-
conductive coil 15 as illustrated and referenced in Figure Nos. 1, 2, and 6; a
C-shaped
core or yoke assembly 16 as illustrated and referenced in Figure No. 6; and a
coil axis. 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 and comprises electromagnet-
driving
termini 17 as illustrated and referenced in Figure No. 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. It may be seen from an
inspection
of Figure No. 6 that yoke 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.
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 ¨ 5, 7, 15, and 17; actuator or actuator
arm(s) 22 as
generally illustrated and referenced in Figure Nos. 1, 2, 3 ¨ 5, and 13; and
an armature
axis of rotation 101 as depicted and referenced at a point in Figure Nos. 2(a)
¨ 4, 15, and
17; and as a broken line in Figure No. 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 15; a rotor plate 25 as illustrated and
referenced in Figure
Nos. 3 ¨ 5, 7, and 15; a rotor bracket 26 as illustrated and referenced in
Figure Nos. 3 -5,
7, and 15; a rotor housing 27 as illustrated and referenced in Figure No. 7; a
return spring
(not specifically illustrated); a rotor pin 29 as illustrated and referenced
in Figure No. 5;
and a rotor mount 30 as illustrated and referenced in Figure Nos. 1, 2(a), and
5.
11
CA 02751585 2011-09-21
It may be seen from an inspection of the noted figures that the rotor bracket
26 is
attached or otherwise cooperatively associated with first end(s) of the
actuator arm(s) 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
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. 15.
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(s) 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(s) 22 may thus be described as extending laterally away from the
lateral
pathway or rotor bracket 26 for engaging the switch assemblies 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
12
CA 02751585 2011-09-21
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 plate
25).
The rotor housing 27 may well further comprise a pin-receiving aperture or
bore
for receiving the rotor pin. 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 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
assemblies 14. It
may be further readily understood from an inspection of Figure No. 5 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
13
CA 02751585 2011-09-21
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 assemblies 14 of the present relay assembly 10 each preferably
comprises a first switch terminal assembly 31 as generally illustrated and
referenced in
Figure Nos. 1, 2, 3 ¨ 5, 9, 11, and 17; a second switch terminal assembly 32
as illustrated
and referenced in Figure Nos. 1, 2, 3 ¨ 5, 8, 10, 16, and 17; and a
triumvirate spring
assembly 33 as illustrated and referenced in Figure Nos. 1, 2, 3 ¨ 5, 8, 10,
12, 14, and 16.
From an inspection of the noted figures, it may be seen that each first switch
terminal
assembly 31 preferably comprises a first contact button 34 and a first switch
terminus as
at 11. Further, each second switch terminal assembly 32 preferably comprises a
second
switch terminus as at 11.
Each triumvirate spring assembly 33 preferably comprises second contact
button(s) 37; and a first spring 38, second spring 39, and third spring 40 as
further
illustrated and referenced in Figure Nos. 8, 10, 12 ¨ 14, and 16. It may be
further seen
that the first spring(s) 38 each preferably comprises a first contact-
receiving aperture as at
41 and a first C-shaped aperture as at 42 in Figure Nos. 8 and 10, as well as
an end-
located offset or bend as at 70 in Figure Nos. 16, 17, and 21. Notably, the
first C-shaped
aperture 42 is preferably concentric about the first contact-receiving
aperture 41. The
second spring(s) 39 each preferably comprises a second contact-receiving
aperture as at
43 and a first C-shaped fold as at 44 in Figure Nos. 8 and 10. It may be seen
from an
inspection of Figure Nos. 8 and 10 that the first C-shaped fold 44 has a
certain first radius
14
CA 02751585 2011-09-21
of curvature. The third spring(s) 40 each preferably comprises a third contact-
receiving
aperture as at 45 and a second C-shaped fold as at 47.
It may be further seen 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 fold 44). The second
spring(s) 39
are [[is]] sandwiched intermediate the first and third springs 38 and 40 via
the second
contact button(s) 37 as received or extended through the contact-receiving
apertures 41,
43, and 45. The first C-shaped fold(s) 44 are concentric (about a fold axis)
within the
second C-shaped fold(s) 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, 3, 4, 12 ¨ 14, and 17. In the preferred embodiment, the triumvirate
spring
assemblies 33 are biased in an open contact position intermediate the first
and second
switch termini 11 and attached to (the lateral end of) the armature arm(s) 22.
It is contemplated that the first and second C-shaped apertures 42, 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. 12 ¨ 14
and 15 ¨ 19.
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 33 immediately adjacent the stem 51 of contact button 37. The
planar
portions of the spring assembly 33 immediately (and radially) adjacent the
stem 51 of
contact button 37 thus form button-stackable spring portions as at 52 in
Figure No. 14. It
may be seen that the button-stackable portions 52 stack upon the contact
button 37 and
CA 02751585 2011-09-21
that terminal side ends 53 of the spring assembly 33 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-
shaped apertures as at 50. 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 over travel
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. 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. Further, it is contemplated that the C-shaped apertures
42 (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
16
CA 02751585 2011-09-21
Figure No. 4) to a closed contact state or closed switch position (as
generally depicted in
Figure Nos. 1, 2, and 3).
From an inspection of Figure No. 15, it may be readily understood that the
core or
yoke termini 20 are loosely received intermediate the rotor plate 25 and the
rotor bracket
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. 15). 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. 15. 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(s)
22,
which displaced actuator arm(s) 22 actuate the triumvirate spring assemblies
33 from a
preferred spring-biased open position (as generally depicted in Figure No. 4)
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 assemblies 14 via the 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
17
CA 02751585 2011-09-21
may well function to enhance return of the triumvirate spring assembly 33 to
the
preferred spring-biased open position. 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
contact
buttons 34 and 37 closed during said fault current or short circuit
condition(s).
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.
22 which is a diagrammatic depiction of a threshold current path as at 71
being directed
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
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. 22.
This
feature can be calibrated by the size and strength of the magnets 23 and the
distance
between the armature and stationary contacts.
18
CA 02751585 2013-08-21
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. 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 comprises a coil assembly, a bridge
assembly, and
at least one switch assembly. The coil assembly comprises a coil, a coil axis,
and a C-
shaped core. The coil is wound around its coil axis, and the coil axis extends
through the
core as at 60 in Figure No. 15. The core 60 comprises core termini 20, which
core
termini 20 are substantially parallel to the coil axis.
The bridge assembly comprises an axis of rotation as at 101 and a bridge as at
61
in Figure No. 15; and switch actuator(s) 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(s) 22 are cooperable with,
and extend
away from, the lateral pathway 64 (not specifically depicted in Figure No.
15). 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(s) 22. Said field diversion means may be further described
as
19
CA 02751585 2013-08-21
. .
comprising certain field division means (there being two axis-opposing paths
as at 66 in
Figure No. 15) for creating a magnetic couple about the magnetically induced
torque.
The switch assemblies as at 14 are further cooperable with the actuator arm(s)
22,
which actuator arm(s) 22 are essentially a coupling intermediate the bridge
assembly 61
Each 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
function to
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
CA 02751585 2013-08-21
, .
the broadest interpretation consistent with the description as a whole. For
example, the
foregoing specifications support an electromagnetic relay assembly primarily
intended
for use as a multi-pole relay assembly, having unique construction and
functionality in its
own right, and which is enabled by the teachings of the embodiment(s) set
forth in this
disclosure.
21
