US3146315A - Readily adjustable relay contact structure - Google Patents

Description

Aug. 25, 1964 D. R. HAZELQUIST 3,146,315

READILY ADJUSTABLE RELAY CONTACT STRUCTURE Fild May 16, 1962 "Hul 1 i 21% 54 F 9' Bomb 2 2x523 1315:- T '9 4 7% M United States Patent 3,146,315 READILY ADJUSTABLE RELAY CONTACT STRUCTURE Donald R. Hazelquist, St. Louis Park, Minn, assignor to Minneapolis-Honeywell Regulator Company, Minneapolis, Minn., a corporation of Delaware Filed May 16, 1962, Ser. No. 195,220 Claims. (Cl. 20087) The present invention is directed to an electro-magnetically operated relay, and more particularly is directed to a relay having a unique type of contact structure. The invention is further directed to a method of manufacturing the contact structure in a more economical fashion than has been previously available.

The relay art is a very highly developed art and as such is exceedingly competitive in nature. Any advantage which can be gained by the utilization of a particular type of relay structure or a method of fabricating part of a relay structure or contact structure is exceedingly important in the commercial world. In the field of control, that is the switching of relatively small currents at varying voltages, it has been desirable to provide a relay structure that is reliable in contact action and also which can be manufactured at a reasonable cost. The present relay is directed both to a relay that provides reliable contact action and also provides a method of fabricating the contact structure that is exceedingly cheap and convenient.

It is a primary object of the present application to disclose a novel contact structure for a relay and further to disclose a method of manufacturing the contact structure.

It is a further object of the present invention to disclose a contact structure that can be readily adjusted and which adjustment remains fixed after the adjustment has been made.

Still a further object of the present invention is to disclose a contact structure that is exceedingly rigid because of its form and method of manufacture thereby providing a reliable contact structure.

These and other objects will become apparent when the drawings of the present application are considered, wherein:

FIGURE 1 is a side view of a clapper type of relay utilizing the present invention;

FIGURE 2 is an end view of the relay of FIGURE 1 from the end where the contact structure is mounted;

FIGURE 3 is an elevation of a piece of the contact structure in a first step in a method of manufacturing the contact structure;

FIGURE 4 is an assembled contact means prior to its mounting on a mounting means of the relay of FIGURES 1 and 2, and;

FIGURE 5 is a partial view of the contact portion of FIGURE 4 wherein a silver overlay has been added to the contact areas for more reliable operation.

The entire relay structure is shown in FIGURES 1 and 2. This relay is formed by a solid magnetic member that has a laminated leg 11 which forms a fixed magnetic portion of the over-all magnetic circuit. The magnetic circuit is completed by an armature 12 of magnetic material that is pivoted at 13 on a frame 14. The frame 14 extends upward at 15 to form a hinge member for the armature 12 so that it can cooperate magnetically and mechanically with the laminated leg 11. The laminated leg 11 has a copper ring 16 embedded in it and ring 16 forms a conventional shading coil for the device.

Encircling the laminated leg 11 is a coil 20 that has a pair of terminals 21 and 22 to which are connected the normal leads for energizing the electric coil. The electric coil 20, when it is energized from a normal source of 3,146,315 Patented Aug. 25, 1964 electric power, provides a magnetic flux that can flow in the magnetic circuit means formed by the member 10, the laminated leg 11, and the armature 12. The structure described is conventional in the clapper type of relay and warrants little or no further explanation.

A conventional tail spring 23 is connected between an end of the armature 12 and the frame 14 at a point not shown. The frame 14 has an extension 24 that can be placed through a panel and bent over or crimped to provide a mounting means for the relay. The frame 14 has tabs 25, 26 and 27 that are bent around the magnetic member 10 to hold the device in a unitary form. A conductor 30 joins a rivet 31 electrically with the frame 14 at a point 32 so that the frame 14 becomes part of any electric circuit to which the relay is connected. This is accomplished by wrapping a conductive wire 33 around the rivet 31 and allowing the wire 33 to extend outwardly at 34 beyond the armature 12. It should be understood that the wire 33 is wrapped around the rivet 31 could be replaced by any type of elongated contact means that would project beyond the armature 12 to the point 34 and which would form a part of an electrical contact structure for the relay. The elongated contact means or wire 33 is preferably somewhat flexible in nature so that good alignment will be accomplished when the device is utilized, as will be seen later in the present disclosure.

An upstanding channel 35 is provided integrally with the frame 14 and is U-shaped in cross section. The U- shaped channel 35 has a bight portion 36 and two upstanding channel members 37 and 38. A slot 40 is cut in the bight 36 and provides a means for mounting the novel contact structure of the present relay.

The novel contact structure of the present relay is formed by an insulating member 41 that holds the contact means generally. The insulating member 41 is attached by rivets 42 and 43, with enlarged heads and 46, through the slot 40 along with a large frictional spacing member 44. When the rivets 42 and 43 are placed through the frictional member 44 and properly flattened with heads at 47 and 48 on the back side of the insulator 41, a unitarily mounted contact structure is provided. The insulating member 41 can he slid frictionally in the slot 40 for adjustment purposes. The frictional engagement of member 44 provides an adjustment feature. After the device is adjusted it normally will retain its adjustment without further locking means. If the particular relay is to be subjected to any unusual environmental conditions, the adjusting or frictional member 44 can be further locked by cements, ambroid, glues, or any similar material after the position of the insulator 41 has been accomplished.

The insulator 41 carries a fixed contact means for the present device and the fixed contact means is made up of two L- shaped contact members 50 and 51. The L- shaped member 50 has a plurality of tabs 52 that are crimped or bent around a portion of the insulating member 41 by passing the tabs 52 through holes 53 in the insulating member 41. Also integrally connected to the contact 50 is a terminal 54 that passes through an opening 55 in the insulated member 41.

The contact member 51 also has tabs 52 and a hole 53 in the insulator 41. The tabs 52 are bent to hold the contact 51 is position also. The contact 51 further has a terminal 54 that passes through an opening 55 in the insulator 41 as did the contact member 50.

The contact members 50 and 51 are stamped from a sheet of metal and the portions that are generally at right angles to one another are of a suflicient thickness to maintain the relationship of the parts in a fixed manner so that the contact is not subject to bending or adjustment after the tabs 52 have been crimped or bent into place. The contact 50 further has a contact surface 60 that is substantially parallel to the contact surface 61 that is formed along the top edge of the contact 51. It will be noted that the wire 33 of the elongated contact means passes between the surfaces 6% and 61 and bears against the surface 60 when the relay is in a de-energized condition. When the relay is energized the wires 33 move downward in the space between the contact members 50 and 51 to engage the surface 61 of contact 51. By adjusting the position of the insulating member 41, as previously described, the location of the opening between the surfaces 60 and 61 can be set for proper relay operation. It will thus be noted that a single pole double throw relay contact structure has been provided wherein the frame 14 of the relay is common between the contacts 50 and 51 which are electrically isolated on the insulating member 41.

The description of the relay of FIGURES 1 and 2 has been made with the discussion of the contacts 50 and 51 being separate movable contact members on a mounting means of an insulated type. In fabricating this relay the method of manufacturing the contacts 50 and 51 forms an important part of the design and construction of the relay. In order to explain this, FIGURES 3 and 4 will be considered. In fabricating the contact structure for the relay a single contact member or structure is punched or formed from a sheet of metal. This unitary contact structure is shown in FIGURE 3 with the contact 50 and the contact 51 joined at a corner 70. It will be noted that structurally the contacts 50 and 51 are interconnected when the contact structure is initially formed. The spacing and position of the contact surfaces 60 and 61 is established by the design of the die which punches the contact structure disclosed in FIG- URE 3 from the sheet of metal. The tabs 52 are integrally formed to the single contact structure member as are the terminals 54. After the contact structure shown in FIGURE 3 has been punched out of a solid sheet of conductive material, the tabs 52 and the terminals 54 are bent perpendicular to the contact members 50 and 51. It wil be noted that both the contact members 50 and 51 are generally L-shaped in their c011- figuration and that they are interconnected only at the corner 70.

The next two steps in the assembly or manufacture of the contact section of the present relay are shown in FIGURE 4. The insulating member 41 is placed over the structure disclosed in FIGURE 3 and the tabs 52 are bent over after passing through the holes 53 in the insulating member 41. After the tabs 52 are bent down or crimped, it will be obvious that the contact structure and the insulating member form a rigidly mounted single contact structure. In order to electrically separate the two contacts 50 and 51 the corner 70 is clipped off on a line 71 which passes through the corner 70 at approximately a 45 degree angle. The separation of the two contacts leaves two rigidly fixed contact members that are not subject to any type of bending or displacement after assembly. In severing the corner of the contact structure the interconnection has been removed and the two L-shaped members form two electrically independent relay contacts. The contact assembly disclosed in FIGURE 4 is then mounted by rivets 42 and 43 into place as has been previously described. The adjustment is accomplished and the relay is ready for operation.

Since one of the primary objects of the present relay is reliable switching action, it will be noted that the elongated contact structure has been shown as two wires 33. The two Wires provide redundant contact with the surfaces 60 and 61 so that exceedingly small voltages can be reliably switched without the normal effects of dirt and deposits on the contact surfaces. The elongated contact members 33 are quite flexible and thereby adjust to the surfaces 60 and 61 to provide good contact. In an improved version where exceedingly sensitive control is required, an arrangement disclosed in FIGURE 5 is utilized. The contact structure disclosed in FIGURE 3 is punched from metal stock having a silver overlay 72 that passes adjacent the surfaces 60 and 61, thereby providing a silver edge on the contact surfaces 60 and 61. It will be noted that with the arrangement of FIGURE 5 the contact wires 33 pass over the edge of the silver thereby giving an exceedingly reliable contact structure that normally accomplishes the job of a silver or similar electrical overlay but without the expense of using silver or similar contact material on the entire structure.

It will be noted in this entire discussion that the contact structure disclosed is an exceedingly rigid contact structure as far as the members 50 and 51 are concerned. The members are of sufiicient thickness and of such cross-section that they cannot be readily moved by bending the sections and therefore the control of the contact placement can readily be accomplished in the punching operation. The contact surfaces 60 and 61 can either be punched parallel to one another or in some other alignment depending upon the type of contact operation desired. While the contacts 50 and 51 could be made and aligned separately by manual means, this would defeat the advantage of the present structure. The present relay is designed for substantially automatic production in exceedingly high volume and the cost saving in assembling a single part to the insulator 41 and then severing the part to provide the two contact members is a substantial improvement in the manufacture of this type of relay. The sections of metal involved are of suificient size so that the contact surfaces 60 and 61 remain substantialy fixed throughout the life of the device and require no further adjustment in production or use. It is obvious that many of the features of the present invention could be modified by one skilled in the art and the applicant wishes to point out that only one of the preferred embodiments of the invention has been disclosed. As such, the applicant wishes to be limited in the scope of his invention only by the scope of the appended claims.

I claim as my invention:

1. In an electromagnetically actuated relay, comprising: magnetic circuit means including magnetic flux generating means for providing a controlled magnetic flux in said circuit means; said circuit means including a fixed magnetic member and a movable magnetic member which move relative to each other as said magnetic flux is controlled; elongated contact means carried by said movable magnetic member; fixed metal contact means including two contacts of rectangular cross section having adjoining contact surfaces and each further having an integral extension at generally right angles to said contact surfaces; said contact surfaces and said extensions lying in a plane perpendicular to and intersected by said elongated contact means; and an insulating member attached to said extensions to mount said contact surfaces adjoining each other; said contacts and said extensions being integrally formed of a metal of sufiicient thickness to maintain a fixed relationship between said contacts after said contact means is mounted upon said insulating member; said insulating member mounted upon said magnetic circuit means to allow said elongated contact to pass between said contact surfaces.

2. In an electromagnetically actuated relay, comprising: mounting means and magnetic circuit means including magnetic flux generating means for providing a controlled magnetic flux in said circuit means; said circuit means including a fixed magnetic member and a movable magnetic member which move relative to each other as said magnetic flux is controlled; elongated contact means carried by said movable magnetic member; fixed metal contact means including two contacts of rectangular cross section having adjoining substantially parallel contact surfaces and each further having an integral extension at generally right angles to said contact surfaces; said contact surfaces and said extensions lying in a plane perpendicular to and intersected by said elongated contact means; and an insulating member attached to said extensions to mount said contact surfaces adjoining each other; said contacts and said extensions being integrally formed of a metal of sufficient thickness to maintain a fixed relationship between said contacts after said contact means is mounted upon said insulating member to maintain said substantially parallel relationship; said insulating member mounted upon said mounting means to allow said elongated contact to pass between said contact surfaces.

3. In an electromagnetically actuated relay, comprising: a mounting frame and magnetic circuit means including an electrical coil for providing a controlled magnetic flux in said circuit means; said circuit means including a fixed magnetic member and a movable magnetic armature which move relative to each other as said magnetic flux is controlled; an elongated contact formed of at least two wires carried by said magnetic armature; fixed metal contact means including two rigid L-shaped contacts of rectangular cross section having adjoining substantially parallel contact surfaces; both said L-shaped contacts lying in a single plane perpendicular to and intersected by said elongated contact; and an insulating member attached to a lower portion of said L-shaped contacts to mount said contact surfaces adjoining each other; said contacts including said lower portions being formed of a metal of sufiicient thickness to maintatin a fixed relationship between said contact surfaces after said contact means is mounted upon said insulating member to maintain said substantially parallel relationship; said insulating member mounted upon said mounting frame to allow said elongated contact wires to pass between said contact surfaces.

4. In an electromagnetically actuated relay, comprising: mounting means including sliding connection means; magnetic circuit means including magnetic flux generating means for providing a controlled magnetic flux in said circuit means mounted upon said mounting means; said circuit means including a fixed magnetic member and a movable magnetic member which move relative to each other as said magnetic flux is controlled; elongated contact means carried by said movable magnetic member; fixed metal contact means including two contacts of rectangular cross section having adjoining contact surfaces and each further having an integral extension at generally right angles to said contact surfaces; said contact surfaces and said extensions lying in a plane perpendicular to and intersected by said elongated contact means; and an insulating member attached to said extensions to mount said contact surfaces adjoining each other; said contacts and said extensions being integrally formed of a metal of sufficient thickness to maintain a fixed relationship between said contacts after said contact mean-s is mounted upon said insulating member; said insulating member mounted upon said mounting means by said sliding connection means to allow said elongated contact to pass between said contact surfaces; said sliding connection means further providing for adjustment of the position of said elongated contact means with respect to said contact surfaces.

5. In an electromagnetically actuated relay, comprising: a mounting frame including sliding connection means; magnetic circuit means including an electrical coil for providing a controlled magnetic flux in said circuit means mounted upon said mounting means; said circuit means including a fixed magnetic member and a movable magnetic armature which move relative to each other as said magnetic flux is controlled; elongated contact means carried by said movable magnetic armature; fixed metal contact means including two rigid L-shaped contacts of rectangular cross section having adjoining substantially parallel contact surfaces; both said L-shaped contacts lying in a single plane perpendicular to and intersected by said elongated contact means; and an insulating member attached to a lower portion of 'said L- shaped contacts to mount said contact surfaces adjoining each other; said contacts including said lower portions being formed of a metal of suflicient thickness to maintain a fixed relationship between said contact surfaces after said contact means is mounted upon said insulating member; said insulating member mounted upon said mounting means by said sliding connection means to allow said elongated contact to pass between said contact surfaces; said sliding connection means further providing for adjustment of the position of said elongated contact means with respect to said contact surfaces.

References Cited in the file of this patent UNITED STATES PATENTS 1,669,784 Scofield May 15, 1928 2,097,335 Memrnel Oct. 26, 1937 2,292,497 Vradenburgh Aug. 11, 1942 2,757,254 Wells July 31, 1956 2,854,545 Nemeth Sept. 30, 1958 3,012,117 Bernier Dec. 5, 1961 3,015,876 Hutt Jan. 9, 1962 3,025,370 Greshel Mar. 13, 1962 3,071,844 Krause et al. Ian. 8, 1963

Claims (1)

1. IN AN ELECTROMAGNETICALLY ACTUATED RELAY, COMPRISING: MAGNETIC CIRCUIT MEANS INCLUDING MAGNETIC FLUX GENERATING MEANS FOR PROVIDING A CONTROLLED MAGNETIC FLUX IN SAID CIRCUIT MEANS; SAID CIRCUIT MEANS INCLUDING A FIXED MAGNETIC MEMBER AND A MOVABLE MAGNETIC MEMBER WHICH MOVE RELATIVE TO EACH OTHER AS SAID MAGNETIC FLUX IS CONTROLLED; ELONGATED CONTACT MEANS CARRIED BY SAID MOVABLE MAGNETIC MEMBER; FIXED METAL CONTACT MEANS INCLUDING TWO CONTACTS OF RECTANGULAR CROSS SECTION HAVING ADJOINING CONTACT SURFACES AND EACH FURTHER HAVING AN INTEGRAL EXTENSION AT GENERALLY RIGHT ANGLES TO SAID CONTACT SURFACES; SAID CONTACT SURFACES AND SAID EXTENSIONS LYING IN A PLANE PERPENDICULAR TO AND INTERSECTED BY SAID ELONGATED CONTACT MEANS; AND AN INSULATING MEMBER ATTACHED TO SAID EXTENSIONS TO MOUNT SAID CONTACT SURFACES ADJOINING EACH OTHER; SAID CONTACTS AND SAID EXTENSIONS BEING INTEGRALLY FORMED OF A METAL OF SUFFICIENT THICKNESS TO MAINTAIN A FIXED RELATIONSHIP BETWEEN SAID CONTACTS AFTER SAID CONTACT MEANS IS MOUNTED UPON SAID INSULATING MEMBER; SAID INSULATING MEMBER MOUNTED UPON SAID MAGNETIC CIRCUIT MEANS TO ALLOW SAID ELONGATED CONTACT TO PASS BETWEEN SAID CONTACT SURFACES.

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