Electromagnetic relay with pressure spring

• US 6,246,306 B1
• Filed: 08/22/2000
• Issued: 06/12/2001
• Est. Priority Date: 02/04/1999
• Status: Expired due to Fees

• Current Assignee: Gruner, Klaus A.
• Original Assignee: Gruner, Klaus A.
• Inventors: Gruner, Klaus A.
• Primary Examiner(s): Donovan, Lincoln
• Assistant Examiner(s): Nguyen, Tuyen T.
• Application Number:
  US09/643,436
• Time in Patent Office: 294 Days
• Field of Search: 335/78-86, 335/124, 335/128, 335/133, 335/130, 335/129, 335/131
• US Class Current: 335/83
• CPC Class Codes: C22C 9/00 Alloys based on copper
• CPC Class Codes: H01H 1/025 having copper as the basic material
• CPC Class Codes: H01H 1/18 with subsequent sliding
• CPC Class Codes: H01H 1/26 with spring blade support
• CPC Class Codes: H01H 50/026 Details concerning isolation between driving and switching circuit
• CPC Class Codes: H01H 50/54 Contact arrangements
• CPC Class Codes: H01H 50/642 intermediate part being generally a slide plate, e.g. a card
• CPC Class Codes: H01H 51/2227 in which the movable part comprises at least one permanent magnet, sandwiched between pole-plates, each forming an active air-gap with parts of the stationary magnetic circuit H01H51/2209 takes precedence

Abstract

The electromagnetic relay has 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 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.

Claims

1. An electromagnetic relay device comprising:

a relay motor, the relay motor having a relay coil, the relay coil having a magnetic core disposed therein, the magnetic core having a magnetic core end extending from the relay motor;

an armature, the armature having a first armature end and a second armature end, the first armature end magnetically coupled to the magnetic core end;

an actuator, the actuator having a first actuator end and a second actuator end, the first actuator end operatively coupled to the second armature end;

a center contact spring assembly, the center contact spring assembly comprising a center contact spring, the center contact spring being formed straight without pre bending, the center contact spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu, and a center contact terminal made of pure copper, the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal, the center contact spring operatively coupled to the second actuator;

a normally open contact spring assembly, the normally open contact spring assembly being curl shaped to be sized and fitted within the electromagnetic relay, the normally open contact spring assembly having a normally open spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.%Ti, 0.02%Si, and the balance Cu and a normally open terminal made of pure copper, the normally open spring having a second contact rivet, permanently attached to the normally open spring, with a third contact surface, and a third planar shaped end, the normally open terminal having a fourth planar shaped end, the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal allowing for greater current flow between the normally open spring and the normally open terminal, the normally open spring positioned relatively parallel to the center contact spring with the second contact rivet positioned opposite the first contact surface of the first contact rivet, the normally open spring vertically positioned with respect to the center contact spring assembly so that the first contact surface of the first contact rivet touches the second contact rivet when the center contact spring is acted upon by the actuator;

a normally closed contact spring assembly, the normally closed contact spring assembly being curl shaped to be sized and fitted within the electromagnetic relay, the normally closed contact spring assembly having a normally closed spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu and a normally closed terminal made of pure copper, the normally closed spring having a third contact rivet, permanently attached to the normally closed spring with a fourth contact surface, and a fifth planar shaped end, the normally closed terminal having a sixth planar shaped end, the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal allowing for greater current flow between the normally closed spring and the normally closed terminal, the normally closed contact spring assembly is vertically positioned with respect to the center contact spring so that the third contact rivet is in contact with the second contact surface of the first contact rivet when the center contact spring is not being acted upon by the actuator;

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end, the retaining end positioned opposite of the normally open contact spring assembly for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, the pressure end applying pressure to the center contact spring for pressuring the second contact surface of the first contact rivet into contact with the fourth contact surface of the third contact rivet without pre bending the center contact spring when the center contact spring is not being acted upon by the actuator; and

a housing, the housing having the relay motor, the armature, the actuator, the center contact spring assembly, the normally open contact spring assembly, the normally closed contact spring assembly, and the pressure spring disposed therein.

2. The electromagnetic relay device defined in claim 1 wherein the center contact spring of the center contact spring assembly has a first slot therethrough, and the normally open spring of the normally open contact spring assembly has a second slot therethrough, the first slot and the second slot reducing the cross section of the center contact spring and the normally open spring, reducing the bending force of both the center contact spring and the normally open spring, and reducing the electrical power consumption of the relay coil.

3. The electromagnetic relay device defined in claim 1 wherein the electromagnetic relay device has a plurality of center contact spring assemblies, normally open contact spring assemblies, normally closed contact spring assemblies and pressure springs.

4. The electromagnetic relay device defined in claim 1 wherein the relay motor can either be an all-or-nothing DC operated relay motor, or an all-or-nothing AC operated relay motor, or a magnetic latching linear operating relay motor.

5. An electromagnetic relay device comprising:

a relay motor, the relay motor having a relay coil;

an armature, the armature having a first armature end and a second armature end, the first armature end coupled to the relay motor;

an actuator, the actuator having a first actuator end and a second actuator end, the first actuator end operatively coupled to the second armature end;

a center contact spring assembly, the center contact spring assembly having a center contact spring, the center contact spring being formed straight without pre bending, the center contact spring made of a copper alloy with a conductivity which is 50% or greater of the conductivity of pure copper and a center contact terminal made of pure copper, the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal, the center contact spring operatively coupled to the second actuator allowing for greater current flow between the center contact spring and the center contact terminal, the center contact spring operatively coupled to the second actuator end; and

a normally open contact spring assembly, the normally open contact spring assembly being curl shaped, the normally open contact spring assembly having a normally open spring made of a copper alloy with a conductivity which is 50% or greater of the conductivity of pure copper and a normally open terminal made of pure copper, the normally open spring having a second contact rivet, permanently attached to the normally open spring, with a third contact surface, and a third planar shaped end, the normally open terminal having a fourth planar shaped end, the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal allowing for greater current flow between the normally open spring and the normally open terminal, the normally open spring positioned relatively parallel to the center contact spring, the normally open spring vertically positioned with respect to the center contact spring assembly so that the first contact surface of the first contact rivet touches the second rivet when the center contact spring is acted upon by the actuator; and

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end, the retaining end positioned opposite of the normally open contact spring assembly for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, pressing the center contact spring in contact with the second actuator end.

6. The electromagnetic relay device defined in claim 5 wherein the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal.

7. The electromagnetic relay device defined in claim 6 wherein the normally open spring having a second contact rivet, permanently attached to the normally open spring, with a third contact surface, and a third planar shaped end, the normally open terminal having a fourth planar shaped end, the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal allowing for greater current flow between the normally open spring and the normally open terminal.

8. The electromagnetic relay device in claim 7 wherein the center contact spring and the normally open spring is made from a copper alloy having a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu.

9. The electromagnetic relay device defined in claim 8 wherein the center contact spring of the center contact spring assembly has a first slot therethrough, and the normally open spring of the normally open contact spring assembly has a second slot therethrough, the first slot and the second slot reducing the cross section of the center contact spring and the normally open spring, reducing the bending force of both the center contact spring and the normally open spring, and reducing the electrical power consumption of the relay coil.

10. The electromagnetic relay device defined in claim 9 further comprising a normally closed contact spring assembly, the normally closed contact spring assembly being curl shaped, the normally closed contact spring assembly having a normally closed spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu and a normally closed terminal made of pure copper, the normally closed spring having a third contact rivet, permanently attached to the normally closed spring with a fourth contact surface, and a fifth planar shaped end, the normally closed terminal having a sixth planar shaped end, the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal allowing for greater current flow between the normally closed spring and the normally closed terminal, the normally closed contact spring assembly is vertically positioned with respect to the center contact spring so that the third contact rivet is in contact with the second contact surface of the first contact rivet when the center contact spring is not being acted upon by the actuator and the pressure spring.

11. An electromagnetic relay device comprising:

a relay motor, the relay motor having a relay coil;

an armature, the armature having a first armature end and a second armature end, the first armature end coupled to the relay motor;

an actuator, the actuator having a first actuator end and a second actuator end, the first actuator end operatively coupled to the second armature end;

a center contact spring assembly, the center contact spring assembly having a center contact spring, the center contact spring being formed straight without pre bending, the center contact spring made of a copper alloy with a conductivity which is 50% of the conductivity of pure copper or greater and a center contact terminal made of pure copper, the center contact spring and the center contact terminal each having end portions which are ultrasonically metal-to-metal welded to each other forming a first weld spanning the area between the end portions allowing for greater current flow between the center contact spring and the center contact terminal, the center contact spring assembly operatively coupled to the second actuator end;

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end, the retaining end positioned opposite of a normally open contact spring assembly for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, the pressure end applying pressure to the center contact spring for pressuring the second contact surface of the first contact rivet into contact with a fourth contact surface of a third contact rivet of a normally closed spring without pre bending the center contact spring when the center contact spring is not being acted upon by the actuator; and

a housing, the housing having the relay motor, the armature, the actuator, the center contact spring assembly, and the pressure spring disposed therein.

12. The electromagnetic relay device defined in claim 11 wherein the relay motor can either be an all-or-nothing DC operated relay motor, or an all-or-nothing AC operated relay motor, or a magnetic latching linear operating relay motor.

13. The electromagnetic relay device defined in claim 11 wherein the center contact spring has a first contact rivet permanently attached to the center contact spring with a first contact surface and a second contact surface.

14. The electromagnetic relay device in claim 11 wherein the center contact spring is made from a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu.

15. The electromagnetic relay device defined in claim 11 wherein the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal.

16. The electromagnetic relay device in claim 11 further comprising a normally open contact spring assembly, the normally open contact spring assembly being curl shaped, the normally open contact spring assembly having a normally open spring made of a copper alloy with a conductivity which is 50% of the conductivity of pure copper or greater and a normally open terminal made of pure copper, the normally open spring having a second contact rivet, permanently attached to the normally open spring, with a third contact surface, and a third planar shaped end, the normally open terminal having a fourth planar shaped end, the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal allowing for greater current flow between the normally open spring and the normally open terminal, the normally open spring positioned relatively parallel to the center contact spring, the normally open spring vertically positioned with respect to the center contact spring assembly so that the center contact spring contacts the normally open spring when the center contact spring is acted upon by the actuator.

17. The electromagnetic relay device in claim 16 wherein the normally open spring is made from a copper alloy having a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance.

18. The electromagnetic relay device defined in claim 11 further comprising a normally closed contact spring assembly, the normally closed contact spring assembly being curl shaped, the normally closed contact spring assembly having a normally closed spring made of a copper alloy having a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu and a normally closed terminal made of pure copper, the normally closed spring having a third contact rivet, permanently attached to the normally closed spring with a fourth contact surface, and a fifth planar shaped end, the normally closed terminal having a sixth planar shaped end, the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal allowing for greater current flow between the normally closed spring and the normally closed terminal, the normally closed contact spring assembly is vertically positioned with respect to the center contact spring so that the third contact rivet is in contact with the second contact surface of the first contact rivet when the center contact spring is not being acted upon by the actuator and the pressure spring.

19. The electromagnetic relay device defined in claim 11 wherein the center contact spring of the center contact spring assembly has a first slot therethrough, and the normally open spring of the normally open contact spring assembly has a second slot therethrough, the first slot and the second slot reducing the cross section of the center contact spring and the normally open spring, reducing the bending force of both the center contact spring and the normally open spring, and reducing the electrical power consumption of the relay coil.

20. An electromagnetic relay device comprising:

a relay motor, the relay motor having a relay coil;

an armature, the armature coupled to the relay motor;

an actuator, the actuator operatively coupled to the armature;

a center contact spring assembly, the center contact spring assembly having a center contact spring having a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal, the center contact spring operatively coupled to the actuator; and

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end, the retaining end positioned opposite of the normally open contact spring assembly for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, the pressure end applying pressure to the center contact spring for pressuring the second contact surface of the first contact rivet into contact with the fourth contact surface of the third contact rivet without pre bending the center contact spring when the center contact spring is not being acted upon by the actuator.

21. The electromagnetic relay in claim 20 wherein the center contact spring having a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal.

22. An electromagnetic relay device comprising:

a relay motor, the relay motor having a relay coil;

an armature, the armature coupled to the relay motor;

an actuator, the actuator operatively coupled to the armature;

a center contact spring assembly, the center contact spring assembly having a center contact spring the center contact spring having a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal; and

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, the pressure end applying pressure to the center contact spring without pre bending the center contact spring when the center contact spring is not being acted upon by the actuator.

23. An electromagnetic relay device comprising:

a relay motor assembly, the relay motor assembly comprising an elongated coil bobbin having an axially extending cavity therein and an excitation coil wound therearound, a generally U shaped ferromagnetic frame, the ferromagnetic frame having a plurality of core sections being disposed in and extending through the axially extending cavity in the elongated coil bobbin and a first and second contact sections extending generally perpendicularly to the core section and rising above the relay motor assembly;

an actuator, the actuator comprising an actuator frame operatively coupled to a first and a second generally U shaped ferromagnetic pole pieces, and a permanent magnet, the first pole piece mounted in overlapping relation over the second pole piece, the permanent magnet lying sandwiched therebetween, the actuator positioned so the second pole piece is located in between the first and second contact sections of the ferromagnetic frame and the first pole piece is located in overlapping relation across from the two contact sections of the relay motor, the first and second pole pieces magnetically coupled to opposite contact sections;

a center contact spring assembly, the center contact spring assembly comprising a center contact spring, the center contact spring being formed straight without pre bending, the center contact spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu, and a center contact terminal made of pure copper, the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal, the center contact spring assembly operatively coupled to the actuator;

a normally open contact spring assembly, the normally open contact spring assembly being curl shaped, the normally open contact spring assembly having a normally open spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu and a normally open terminal made of pure copper, the normally open spring having a second contact rivet, permanently attached to the normally open spring, with a third contact surface, and a third planar shaped end, the normally open terminal having a fourth planar shaped end, the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal allowing for greater current flow between the normally open spring and the normally open terminal, the normally open spring positioned relatively parallel to the center contact spring with the second contact rivet positioned opposite the first contact surface of the first contact rivet, the normally open spring vertically positioned with respect to the center contact spring assembly so that the first contact surface of the first contact rivet touches the second contact rivet when the center contact spring is acted upon by the actuator;

a normally closed contact spring assembly, the normally closed contact spring assembly being curl shaped, the normally closed contact spring assembly having a normally closed spring made of a copper alloy comprising a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu and a normally closed terminal made of pure copper, the normally closed spring having a third contact rivet, permanently attached to the normally closed spring with a fourth contact surface, and a fifth planar shaped end, the normally closed terminal having a sixth planar shaped end, the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal allowing for greater current flow between the normally closed spring and the normally closed terminal, the normally closed contact spring assembly is vertically positioned with respect to the center contact spring so that the third contact rivet is in contact with the second contact surface of the first contact rivet when the center contact spring is not being acted upon by the actuator;

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end, the retaining end positioned opposite of the normally open contact spring assembly for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, the pressure end applying pressure to the center contact spring for pressuring the second contact surface of the first contact rivet into contact with the fourth contact surface of the third contact rivet without pre bending the center contact spring when the center contact spring is not being acted upon by the actuator; and

a housing, the housing having the relay motor, the actuator, the center contact spring assembly, the normally open contact spring assembly, the normally closed contact spring assembly, and the pressure spring disposed therein.

24. The electromagnetic relay device defined in claim 23 wherein the center contact spring of the center contact spring assembly has a first slot therethrough, and the normally open spring of the normally open contact spring assembly has a second slot therethrough, the first slot and the second slot reducing the cross section of the center contact spring and the normally open spring, reducing the bending force of both the center contact spring and the normally open spring, and reducing the electrical power consumption of the excitation coil.

25. The electromagnetic relay device defined in claim 23 wherein the electromagnetic relay device has a plurality of center contact spring assemblies, normally open contact spring assemblies, normally closed contact spring assemblies and pressure springs.

26. An electromagnetic relay device comprising:

a relay motor assembly, the relay motor assembly comprising an elongated coil bobbin having an axially extending cavity therein and an excitation coil wound therearound, a generally U shaped ferromagnetic frame, the ferromagnetic frame having a plurality of core sections being disposed in and extending through the axially extending cavity in the elongated coil bobbin and a first and second contact sections extending generally perpendicularly to the core section and rising above the relay motor assembly;

an actuator, the actuator comprising an actuator frame operatively coupled to a first and a second generally U shaped ferromagnetic pole pieces, and a permanent magnet, the first pole piece mounted in overlapping relation over the second pole piece, the permanent magnet lying sandwiched therebetween, the actuator positioned so the second pole piece is located in between the first and second contact sections of the ferromagnetic frame and the first pole piece is located in overlapping relation across from the two contact sections of the relay motor, the first and second pole pieces magnetically coupled to opposite contact sections;

a center contact spring assembly, the center contact spring assembly having a center contact spring, the center contact spring being formed straight without pre bending, the center contact spring made of a copper alloy with a conductivity which is 50% of the conductivity of pure copper or greater and a center contact terminal made of pure copper, the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal, the center contact spring assembly operatively coupled to the second actuator end;

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end, the retaining end positioned opposite of the normally open contact spring assembly for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, pressing the center contact spring in contact with the second actuator end; and

a housing, the housing having the relay motor, the armature, the actuator, the center contact spring assembly, and the pressure spring disposed therein.

27. The electromagnetic relay device defined in claim 26 wherein the center contact spring has a first contact rivet permanently attached to the center contact spring with a first contact surface and a second contact surface.

28. The electromagnetic relay device defined in claim 26 wherein the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal.

29. The electromagnetic relay device in claim 26 further comprising a normally open contact spring assembly, the normally open contact spring assembly being curl shaped, the normally open contact spring assembly having a normally open spring made of a copper alloy with a conductivity which is 50% of the conductivity of pure copper or greater and a normally open terminal made of pure copper, the normally open spring having a second contact rivet, permanently attached to the normally open spring, with a third contact surface, and a third planar shaped end, the normally open terminal having a fourth planar shaped end, the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the third planar shaped end of the normally open spring and the fourth planar shaped end of the normally open terminal allowing for greater current flow between the normally open spring and the normally open terminal, the normally open spring positioned relatively parallel to the center contact spring, the normally open spring vertically positioned with respect to the center contact spring assembly so that the center contact spring contacts the normally open spring when the center contact spring is acted upon by the actuator.

30. The electromagnetic relay device in claim 26 wherein the center contact spring and the normally open spring are made from a copper alloy having a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance of Cu.

31. The electromagnetic relay device defined in claim 26 further comprising a normally closed contact spring assembly, the normally closed contact spring assembly being curl shaped, the normally closed contact spring assembly having a normally closed spring made of a copper alloy having a chemical composition of 0.3% Cr, 0.1%Ti, 0.02%Si, and the balance Cu and a normally closed terminal made of pure copper, the normally closed spring having a third contact rivet, permanently attached to the normally closed spring with a fourth contact surface, and a fifth planar shaped end, the normally closed terminal having a sixth planar shaped end, the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the fifth planar shaped end of the normally closed spring and the sixth planar shaped end of the normally closed terminal allowing for greater current flow between the normally closed spring and the normally closed terminal, the normally closed contact spring assembly is vertically positioned with respect to the center contact spring so that the third contact rivet is in contact with the second contact surface of the first contact rivet when the center contact spring is not being acted upon by the actuator and the pressure spring.

32. An electromagnetic relay device comprising:

a relay motor assembly, the relay motor assembly comprising an elongated coil bobbin having an axially extending cavity therein and an excitation coil wound therearound, a generally U shaped ferromagnetic frame, the ferromagnetic frame having a plurality of core sections being disposed in and extending through the axially extending cavity in the elongated coil bobbin and a first and second contact sections extending generally perpendicularly to the core section and rising above the relay motor assembly;

an actuator, the actuator comprising an actuator frame operatively coupled to a first and a second generally U shaped ferromagnetic pole pieces, and a permanent magnet, the first pole piece mounted in overlapping relation over the second pole piece, the permanent magnet lying sandwiched therebetween, the actuator positioned so the second pole piece is located in between the first and second contact sections of the ferromagnetic frame and the first pole piece is located in overlapping relation across from the two contact sections of the relay motor, the first and second pole pieces magnetically coupled to opposite contact sections;

a center contact spring assembly, the center contact spring assembly having the center contact spring having a first contact rivet, permanently attached to the center contact spring with a first contact surface and a second contact surface, and a first planar shaped end, the center contact terminal having a second planar shaped end, the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal being ultrasonically metal-to-metal welded to each other forming a planar shaped weld spanning the area between the first planar shaped end of the center contact spring and the second planar shaped end of the center contact terminal allowing for greater current flow between the center contact spring and the center contact terminal; and

a pressure spring, the pressure spring being made of steel, the pressure spring having a retaining end for positioning the pressure spring, the pressure spring further having a pressure end, the pressure end contacting the center contact spring perpendicularly above the actuator, the pressure end applying pressure force to the center contact spring for pressuring contact on the center contact spring at an angle without pre bending the center contact spring when the center contact spring is not being acted upon by the actuator and the pressure spring.