CN116417295A - Contactor - Google Patents

Abstract

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

Description

contactor

Cross References to Related Applications

This application claims the benefit of Indian Application No. 202241000915 filed on January 7, 2022, the subject matter of which is hereby incorporated by reference in its entirety.

technical field

The subject matter of this article relates generally to high power electrical contactors.

Background technique

Certain electrical applications, such as HVAC, power supplies, locomotives, elevator controls, motor controls, aerospace applications, hybrid electric vehicles, fuel cell vehicles, charging systems, etc., utilize electrical contactors with 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 introduce a magnetic field to drive the movable contact to cooperate with the fixed contact. During the mating and unmating of the movable contacts with the stationary contacts, arcing can occur which can lead to contact damage, such as oxidation of the contact surface, causing the contactor to fail over time. In addition, at the interface between the fixed and movable contacts, the contact resistance is high. In some high power applications, the magnetic force may cause the movable contact to tend to separate from the stationary contact, causing unwanted vibration and noise. There is a need for a contactor that overcomes the above problems and solves other problems encountered in the prior art.

Contents of the 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 fixed contact coupled to a housing. The first stationary contact has a first mating end received in the cavity and a first terminating end external to the housing. A contactor is provided that includes a second fixed contact coupled to a housing. The second stationary contact has a second mating end received in the cavity and a second terminating end external to the housing. A contactor is provided that includes a movable contact movable within a cavity between a mated position and an unmated position. The movable contact engages the second mating end in a mated position. In the disengaged position, the movable contact is separated from the second fixed contact. A contactor is provided that includes a flexible bus bar coupled to a first mating end and to a movable contact. The flexible bus electrically connects the first fixed contact and the movable contact in both the mating position and the disengaging position. The coil assembly in the cavity operates to move the movable contact between a disengaged position and a mated position.

Description of 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.

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

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

5 is a bottom perspective view of a portion of an example embodiment contactor showing the movable contact assembly in a dismated position relative to the stationary contacts.

6 is a cross-sectional view of a portion of an example embodiment contactor showing the movable contacts in a dismated position.

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

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

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

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

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

12 is a bottom perspective view of a portion of an example embodiment contactor showing the movable contact assembly in a mated position relative to the stationary contacts.

13 is a side view of a portion of an example embodiment contactor showing the movable contact assembly in a mated position relative to the stationary contacts.

14 is a cross-sectional view of a portion of an example embodiment contactor showing the movable contacts in a dismated position.

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

Detailed ways

FIG. 1 shows a contactor 100 according to an exemplary embodiment. FIG. 2 is a cross-sectional view of the contactor 100 showing internal components of the contactor 100 according to an exemplary embodiment. Contactor 100 is an electrical switch or relay that safely connects and disconnects one or more electrical circuits to protect the flow of power through the system. Contactor 100 may be used in various applications such as HVAC, power supplies, locomotives, elevator controls, motor controls, 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 ) having an outer wall 111 surrounding a cavity 112 . In various embodiments, 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 couple to another component. For example, base 114 may include mounting brackets for securing 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, a cover 118 may be coupled to the top of the head 116 . Optionally, cap 118 may be sealed to head 116 . In various embodiments, the outer wall 111 along the head 116 may be cylindrical defining a cylindrical cavity 112 . Cavity 112 may be at least partially filled with epoxy for sealing housing 110 and internal components.

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

Each stationary contact 120 , 122 includes an outer end defining a terminating end 130 and an inner end defining a mating end 132 . The stationary contacts 120 , 122 each have a transition portion 134 with one or more bends 136 . In the illustrated embodiment, the stationary contacts 120 , 122 are S-shaped with terminating ends 130 parallel to mating ends 132 . In alternative embodiments, other shapes are possible. The terminating end 130 is configured to terminate to another component, such as a wire or a terminal, such as a line-in or line-out wire. In the exemplary embodiment, the termination end 130 is exposed on the exterior of the contactor 100 for termination to another component. 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 to the movable contact 124, eg, when the contactor 100 is energized. In the illustrated embodiment, the mating end 132 is generally flat or planar, such as 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 bar 140 electrically connecting the first stationary contact 120 and the movable contact 124 . As the movable contact 124 moves between the mated and unmated positions, the flex bus 140 flexes. In the exemplary embodiment, flexible busbar 140 includes a flexible braid 142 having braided conductors. The first mating end 144 of the flexible bus bar 140 is connected to the first stationary contact 120 . The second mating end 146 of the flexible bus bar 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 stationary contact 120 and the movable contact 124 , respectively. As the movable contact 124 moves between the mated position and the unmated position, the movable contact 124 remains connected to the first stationary contact 120 via the flexible bus 140 .

The contactor 100 includes a coil assembly 190 within the cavity 112 that is operated to move the movable contact 124 between the disengaged position and the mated position. Coil assembly 190 includes a winding or coil 192 wound around a core 194 to form an electromagnetic field. Coil assembly 190 includes a plunger (not shown) coupled to core 194 . The movable contact 124 is coupled to the plunger and is movable with the plunger when the coil assembly 190 is operated. The coil assembly 190 includes a spring 198 for returning 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. An arc suppressor may be located in cavity 112 of housing 110 . In the exemplary embodiment, the arc suppressor includes magnets that generate a magnetic field in the housing 128 for suppressing arcing between the movable contact 124 and the stationary contacts 120 , 122 . In an exemplary embodiment, the contact holders 126 may be sealed, such as with epoxy, and may be filled with an inert gas for arc suppression.

FIG. 3 is a top perspective view of the 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 retainer 152 is used to position the movable contact 124 within the housing 110 of the contactor 100 (shown in FIG. 2 ). For example, the movable contact holder 152 may maintain the movable contact 124 in a planar orientation, such as a horizontal orientation, as the movable contact 124 moves within the housing 110 .

The movable contact 124 is made of conductive material, such as metal material. The movable contact 124 may be stamped or cut to a predetermined size and shape, which may affect the amount of electrical current passing through the movable contact 124 and the amount of resistance of electrical current delivered through the movable contact 124 . The movable contact 124 includes a 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 . 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 . Movable contact holder 152 is coupled to mounting tab 180 at first side 174 and second side 178 . In the illustrated embodiment, the movable contact 124 is I-shaped, wherein the movable contact 124 is wider at the first plate 162 and the second plate 166 (between the sides 174, 178 ) and extends along the The center portion of the main body 160 is narrow. The plates 162, 166 provide a greater surface area for mating with the flex bus 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, flex bus 140 is coupled to lower surface 184 of first plate 162 at first end 164 . However, in alternative embodiments, flex bus 140 may be coupled to upper surface 182 . In the exemplary embodiment, the movable contact 124 includes a mating contact pad 186 at the upper surface 182 at the second end 168 along the second plate 166 . The mating contact pad 186 is configured to mate and unmating with the second stationary contact 122 . Each mating contact pad 186 includes a mating interface 188 forming a point of contact with the second stationary contact 122 . An electrical path is formed between the movable contact 124 and the second stationary contact 122 through mating contact pads 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 a different orientation. In an exemplary embodiment, mating contact pads 186 may be located near the perimeter of movable contact 124 , such as at first side 174 and second side 178 and at second end 168 , such as to increase the distance between mating contact pads 186 . spacing between.

FIG. 4 is a top perspective view of the movable contact holder 152 according to an exemplary embodiment. In the exemplary embodiment, movable contact holder 152 is a stamped and formed component. A movable contact retainer 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 during mating and unmating (as shown in FIG. 2 ).

The base 200 is provided at the bottom of the movable contact holder 152 . The base 200 includes an opening 206 that can 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 the four corners of the movable contact 124 .

In the exemplary embodiment, each mounting arm 202 includes side walls 220 and a top wall 222 extending between side walls 220 . The mounting arm 202 includes an opening 224 surrounded by side walls 220 and a top wall 222 . Opening 224 is configured to receive 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 cantilevers 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 . Tip 230 is configured to engage the lower surface of movable contact 124 . Optionally, support arm 204 may be bent at end 230 . In an exemplary embodiment, support arm 204 is deflectable and is configured to be spring biased against movable contact 124 to maintain 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 . The support arm 204 is located on the outside of the mounting arm 202 . The support arm 204 engages the lower surface 184 of the movable contact 124 to press upwardly 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 the four outer corners of the movable contact 124 . As the movable contact 124 moves between the mated position and the unmated position, 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 dismated position relative to the stationary contacts 120 , 122 . FIG. 5 shows the flexible bus bar 140 between the first stationary contact 120 and the movable contact 124 . The movable contact 124 is disengaged from the second fixed contact 122 .

In the exemplary embodiment, the second stationary contact 122 includes a mating tab 136 at the mating end 132 . The mating tab 136 is 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 tab pads 138 at the bottom of the mating tab 136 . The mating pads 138 are configured to mate and unmate with the mating contact pads 186 of the movable contact 124 . Each mating wafer pad 138 includes a mating interface that forms a point of contact with a corresponding mating contact pad 186 . An electrical path is formed between the movable contact 124 and the second stationary contact 122 through the mating contact pad 186 and the mating blade pad 138 . Providing multiple mating contact pads 186 and mating blade pads 138 creates multiple electrical paths and multiple points of contact through the second stationary contact 122 and the movable contact 124 . For example, parallel electrical paths may be created, such as a first electrical path through the second stationary contact 122 and a second electrical path through the movable contact 124 . The parallel electrical paths create a magnetic attraction that tends to hold the movable contacts 124 in the mated position and reduces the risk of undesired separation or vibration in the contacts. In the illustrated embodiment, the mating interface is generally planar. However, in alternative embodiments, the mating pad 138 may have other shapes, such as a bump having a convex shape.

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

The movable contact pad 186 is spaced apart from the mating blade pad 138 when the movable contact 124 is in the unmated position.

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

In an exemplary embodiment, flex bus 140 has a generally rectangular cross-section. For example, the flex bus 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 . The 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 . Optionally, width 250 may be approximately equal to length 248 . The flex bus 140 has a thickness 252 between the upper surface 240 and the lower surface 242 . In an exemplary embodiment, flex bus 140 is wide and thin. For example, width 250 may be at least ten times greater than thickness 252 . In this manner, the flex bus 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 bus 140 changes.

6 is a cross-sectional view of a portion of contactor 100 showing movable contact 124 in a dismated position. In the disengaged position, the movable contact 124 is spaced apart from the first stationary contact 120 and the second stationary contact 122 . The flexible bus bar 140 extends between the movable contact 124 and the first stationary 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 stationary contact 120 and the second stationary contact 122 are positioned in a fixed position within the surrounding portion 128 by the contact retainer 126 . Transition portions 134 of the stationary contacts 120 , 122 extend from the contact holder 126 through the cover 118 . The terminating ends 130 of the stationary contacts 120, 122 are located on the exterior of the contactor 100, for example for terminating to wires or terminals. The contact retainer 126 retains the mating ends 132 of the stationary 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 stationary contacts 120 , 122 . The flex bus 140 moves together with the movable contact 124 . Mating contact pads 186 are driven into electrical contact with mating pads 138 to complete the circuit.

In the exemplary embodiment, the movable contact retainer 152 facilitates positioning the movable contact 124 within the contactor 100 as the movable contact 124 is moved into 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 each other to maintain the movable contact 124 in a horizontal orientation. Support arm 204 orients movable contact 124 parallel to mating tab 136 to ensure mating contact pad 186 engages mating tab 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 the exemplary embodiment, the contact holder 126 is a multi-piece construction. Contact holders 126 may be assembled around the stationary contacts 120 , 122 . For example, the components of the contact holder 126 may snap or otherwise couple together around the stationary contacts 120 , 122 .

In the exemplary embodiment, the contact holder 126 includes a first holder element 260 and a second holder element 262 . First retainer element 260 and second retainer element 262 are coupled together and meet at seam 264 . Optionally, the first retainer element 260 and the second retainer element 262 may have different sizes, for example the first retainer element 260 is larger than the second retainer element 262 . Alternatively, the first retainer element 260 and the second retainer element 262 may have similar dimensions. Alternatively, the first holder element 260 and the second holder element 262 may be mirror-image halves of each other. The first retainer element 260 and the second retainer element 262 are coupled together eg by a snap coupling or an interference fit. Alternatively, first retainer element 260 and second retainer element 262 may be secured using latch features, fasteners, or other securing means.

In the exemplary embodiment, the contact holder 126 includes an end wall 266 and a side wall 268 extending from the end wall 266 . Seam 264 extends along end wall 266 and side wall 268 . In the illustrated embodiment, the contact holders 126 are cylindrical; however, in alternative embodiments, the contact holders 126 may have other shapes. End wall 266 is disc-shaped and is disposed on top of contact holder 126 . The side wall 268 is annular and extends from the bottom of the end wall 266 to form a cavity 270 below the end wall 266 . In the exemplary embodiment, the first retainer element 260 and the second retainer element 262 engage and support the first stationary contact 120 and the second stationary contact 122 . The first stationary contact 120 and the second stationary contact 122 pass through the contact holder 126 at the seam 264 . The stationary contacts 120 , 122 extend into the cavity 270 . Optionally, the first stationary contact 120 and the second stationary contact 122 may be sealed to the first retainer element 260 and the second retainer element 262, for example after the first and second stationary contacts 120, 120 pass through the contacts. head holder 126 in place. The sealing may occur inside the chamber 270 or outside the contact holder 126 . Sealing may be provided by gaskets, epoxy or other sealing components.

In the exemplary embodiment, the contact holder 126 includes a first channel 272 that retains the first stationary contact 120 and a second channel 274 that retains the 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 . First channel 272 and second channel 274 span seam 264 . The first retainer element 260 and the second retainer element 262 are coupled together around the first stationary contact 120 and the second stationary contact 122 . For example, the first retainer element 260 can be side loaded onto the first stationary contact 120 and the second stationary contact 122, and/or the second retainer element 262 can be side loaded onto the first stationary contact 120 and the second stationary contact. Contact 122 on. In various embodiments, assembly may include loading the first stationary contact 120 and the second stationary contact 122 into the first channel portion and the second channel portion of the first holder element 260, and then placing the second holder Element 262 is coupled to first retainer element 260 to retain and capture first stationary contact 120 and second stationary contact 122 in first channel 272 and second channel 274 . In the exemplary embodiment, the first retainer element 260 includes a housing wall 276 surrounding and forming the channel portions of the first channel 272 and the second channel 274, and the second retainer element 262 includes a housing wall 276 surrounding and forming the first channel 272. and the housing wall 278 of the channel portion of the 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 be electrically connected 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 shows a contactor 300 according to an exemplary embodiment. FIG. 10 is a cross-sectional view of the contactor 300 showing internal components of the contactor 300 according to an exemplary embodiment. Contactor 300 is similar to contactor 100; however, contactor 300 is shaped differently and includes differently shaped contacts. Contactor 300 may be an electrical switch or a relay.

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

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

Each stationary 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 stationary 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 terminate to another component, such as a wire or a terminal, such as a line-in or line-out wire. In the exemplary embodiment, the termination end 330 is exposed on the exterior of the contactor 300 for termination to another component. In the illustrated embodiment, the terminating end 330 extends to the exterior of the contact holder 326 . The mating end 332 is located 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 an exemplary embodiment, the contactor 300 includes a flexible bus bar 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 flex bus 340 flexes. In the exemplary embodiment, flexible bus bar 340 includes a flexible braid 342 having braided conductors. The first mating end 344 of the flexible bus bar 340 is connected to the first stationary contact 320 . The second mating end 346 of the flexible bus bar 340 is connected to the movable contact 324 . The first mating end 344 and the second mating end 346 may be welded to the first stationary contact 320 and the movable contact 324 respectively. As the movable contact 324 moves between the mated position and the unmated position, the movable contact 324 remains connected to the first stationary contact 320 through the flexible bus bar 340 . Contactor 300 includes a coil assembly 390 within cavity 312 that is operated to move movable contact 324 between an unmated position and a mated position.

FIG. 11 is a top perspective view of 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 retainer 352 is used to position the movable contact 324 within the housing 310 of the contactor 300 (shown in FIG. 9 ). For example, the movable contact holder 352 may maintain the movable contact 324 in a planar orientation, such as a horizontal orientation, as the movable contact 324 moves within the housing 310 .

The movable contact 324 is made of conductive material, such as 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 main 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 . Movable contact holder 352 is coupled to mounting tab 380 at first side 374 and 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 pad 386 is configured to mate and unmating with the second stationary contact 322 . Each mating contact pad 386 includes a mating interface 388 forming a point 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 pad 386 may have other shapes, such as a bump 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, mating contact pads 386 may be arranged in a different orientation. 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, mounting arm 402 may clip onto 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 during mating and unmating (as shown in FIG. 9 ). 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 provided 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 the 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 . The support arm 404 is located on the outside of the mounting arm 402 . The support arm 404 engages the lower surface 384 of the movable contact 324 to press upwardly 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, the support arm 404 may engage the movable contact 324 near the four outer corners of the movable contact 324 . The support arm 404 maintains the movable contact 324 in a horizontal orientation as the movable contact 324 moves between the mated position and the unmated position.

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 stationary contacts 320 , 322 . 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 stationary contacts 320 , 322 . 12 and 13 illustrate the flexible bus bar 340 between the first stationary contact 320 and the movable contact 324 . The movable contact 324 cooperates with the second fixed contact 322 .

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

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

In the exemplary embodiment, flexbus 340 has a generally 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 extending between first and second sides 444, 446 (FIG. 12). The sides 444 , 446 extend between the first and second mating ends 344 , 346 . The flexible bus bar 340 has a length between mating ends 344 , 346 and a width between sides 444 , 446 . Alternatively, the width may be approximately equal to the length. The flexible bus bar 340 has a thickness between an upper surface 440 and a lower surface 442 . In an exemplary embodiment, flex bus 340 is wide and thin. For example, the width may be at least ten times the thickness. In this manner, the flex bus 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 bus 340 changes.

14 is a cross-sectional view of a portion of contactor 300 showing movable contact 324 in a dismated position. In the disengaged position, the movable contact 324 is spaced apart from the first stationary contact 320 and the second stationary contact 322 . The flexible bus bar 340 extends between the movable contact 324 and the first stationary contact 320 .

The contact holder 326 supports the first and second stationary contacts 320 , 322 . The mating ends 332 of the first and second stationary contacts 320 , 322 are held by the contact holder 326 in a fixed position inside the contact holder 326 . The terminating ends 330 of the fixed contacts 320, 322 are located on the exterior of the contactor 300, for example for terminating to wires or terminals. The contact retainer 326 retains the mating ends 332 of the stationary 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 upwardly toward the stationary contacts 320 , 322 . The flex bus 340 moves together with the movable contact 324 . Mating contact pads 386 are driven into electrical contact with mating pads 338 to complete the circuit.

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

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