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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
First Claim
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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.

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