The subject matter herein relates generally to electromechanical switches (e.g., contactors or relays) that control a flow of electrical power through a circuit.
Electromechanical switches may be used in a number of application in which it is desirable to selectively control the flow of electrical power. Electromechanical switches, such as contactors or relays, may include a movable contact and a plurality of stationary contacts. The movable contact is selectively moved to engage or disengage the stationary contacts. When the movable contact is engaged to the stationary contacts, electrical power may flow through the contacts.
For certain applications, an audible noise is generated along the interfaces between the movable contact and the stationary contacts. For example, an electric vehicle uses an electric vehicle battery (EVB) or a traction battery to power the vehicle. Such batteries may include individual cells having one or more contactors. When an individual presses the accelerator pedal, the movable contact of the contactor is moved to engage the stationary contacts. If the individual rapidly and/or deeply presses the accelerator pedal to accelerate the vehicle more quickly, a surge of current flows through the movable contact and the stationary contacts. This surge of current may cause the movable contact to oscillate and generate the audible noise. The audible noise can be distracting or annoying to drivers. In addition to the audible noise, a large amount of thermal energy may be generated within the contacts that has undesirable effects.
Accordingly, a need remains for an electromechanical switch in which the movable contact and the stationary contacts reduce the audible noise and, optionally, reduce an amount of thermal energy generated within the contacts.
In at least one embodiment, an electromechanical switch is provided that includes first and second stationary contacts. Each of the first and second stationary contacts has a respective mating end. The electromechanical switch also includes a movable contact having first and second contact zones. The first and second contact zones are separate regions of the movable contact that are operable to be covered by the respective mating ends of the first and second stationary contacts, respectively. Each of the first and second contact zones has a mating surface and a corresponding recess that divides at least a portion of the mating surface. Each of the respective mating ends is configured to extend across the corresponding recess and engage the corresponding mating surface on opposite sides of the corresponding recess. The corresponding recess has a depth that extends only partially into the movable contact.
In some aspects, the movable contact includes opposite mating and mounting sides and first and second contact ends in which each of the mating and mounting sides extends between the first and second contact ends. The mating side includes the first and second contact zones. Optionally, the movable contact has a center of mass (COM) that is closer to the mounting side than the mating side.
In some aspects, the movable contact is symmetrically shaped with respect to a first plane that extends through the COM and between the first and second contact zones and with respect to a second plane that extends through the COM between the first and second contact ends.
In some aspects the mounting side extends away from the mating side as the movable contact extends from the first contact end toward a center of the movable contact and extends away from the mating side as the movable contact extends from the second contact end toward the center of the movable contact.
In some aspects, the movable contact has a thickness measured between the mating and mounting sides. The thickness of the movable contact is greater at a center of the movable contact.
In some aspects, the movable contact also includes opposite broad sides that extend between the first and second contact ends and between the mounting and mating sides. The mounting side is shaped to center a mass of the movable contact.
In some aspects, the mating side includes a pair of gutters and a platform surface defined between the gutters. The platform surface includes the first and second contact zones. Optionally, the platform surface has a platform width defined between the gutters. The platform width is sized relative to the respective mating ends such that the respective mating ends clear the platform surface and extend over at least one of the gutters. Optionally, the platform surface extends continuously across the mating side between the first and second contact ends.
In some aspects, the corresponding recess is the only recess that is entirely covered by the respective mating end.
In some aspects, the corresponding recess of the first contact zone opens to a first contact end of the movable contact and the corresponding recess of the second contact zone opens to a second contact end of the movable contact.
In at least one embodiment, a power circuit is provided that includes an electromagnetic driving unit and a switch operably coupled to the electromagnetic driving unit. The power circuit also includes an electromechanical switch having first and second stationary contacts and a movable contact. Each of the first and second stationary contacts have a respective mating end. The movable contact has first and second contact zones. The first and second contact zones are separate regions of the movable contact that are operable to be covered by the respective mating ends of the first and second stationary contacts, respectively. The movable contact includes opposite mating and mounting sides and also includes first and second contact ends in which each of the mating and mounting sides extends between the first and second contact ends. The mating side includes the first and second contact zones. Each of the first and second contact zones has a corresponding mating surface and a corresponding recess that divides at least a portion of the corresponding mating surface. Each of the respective mating ends is configured to extend across the corresponding recess and engage the corresponding mating surface on opposite sides of the corresponding recess. The corresponding recess has a depth that extends only partially into the movable contact. The switch is operably coupled to the movable contact. The electromagnetic driving unit is operable to move the switch between at least two different positions to connect and disconnect a power supply.
The electromechanical switch 102 also includes a linkage assembly 105 that mechanically interconnects the circuit switch 108 and a movable contact 132. The linkage assembly 105 includes one or more rods 122 and a hinge 124 that is connected to the one or more rods 122. The hinge 124 is operable to rotate about a hinge axis that may be parallel to the rotational axis 120. As shown, the electromechanical switch 102 also includes a contact carrier 130, the movable contact 132, and a pair of stationary contacts 134, 136. The contact carrier 130 has one or more supporting portions 140.
The electromechanical switch 102 is shown in an open position in which the movable contact 132 is not engaged with the stationary contacts 134, 136 such that an electrical connection is not established. The power circuit 100 also includes a power supply 142 and an electrical sub-assembly 144. The power supply 142 may be a battery for an electric vehicle. In
The first and second stationary contacts 204, 206 have respective mating ends 205, 207. The movable contact has first and second contact zones 215, 217. The first and second contact zones 215, 217 are separate regions of the movable contact 202 that are configured to be covered by the mating ends 205, 207, respectively, when the movable contact 202 and the first and second stationary contacts 204, 206 are engaged. The movable contact 202 may be similar or identical to the movable contact 300 (
Also shown in
The electromechanical switch 200 includes a contact carrier 211. The contact carrier 211 includes a pair of supporting portions 213 that are spaced apart to define a contact space 222 therebetween. The contact carrier 211 also includes one or more alignment projections 224. The alignment projections 224 may be, for example, ribs that engage the movable contact 202 if the movable contact 202 rotates about the support rod 210.
With respect to
As shown, the movable contact 300 is oriented with respect to mutually perpendicular X, Y, and Z axes. The movable contact 300 includes a mating side 302 and a mounting side 304. The mating side 302 is operable to engage and disengage stationary contacts, such as the stationary contacts 204, 206 (
The mating side 302 has first and second contact zones 330, 332. The first and second contact zones 330, 332 are separate regions of the movable contact 300 that are configured to be covered by mating ends of corresponding stationary contacts. For example, the first contact zone 330 may be aligned with and engage or be spaced apart from the mating end 205 (
As shown in
With respect to
With respect to
The mating side 302, the mounting side 304, or both may be shaped to center a mass of the movable contact. More specifically, the mating side 302, the mounting side 304, or both may be shaped to increase a proportion of the total mass of the movable contact 300 that is closer to the center 342 or the axis 212 (
The movable contact 300 may also be characterized as having a plurality of planar exterior surfaces 351-358. The planar exterior surface 351 corresponds to the mating side 302. The planar exterior surfaces 352, 354 correspond to the contact ends 312, 314, respectively. The planar exterior surfaces 353, 355 correspond to the opposite broad sides 316, 318, respectively.
With respect to
The planar exterior surfaces 356, 358 are oriented so that the thickness 324 increases as the planar exterior surfaces 356, 358 extend toward the planar exterior surface 357. More specifically, as the movable contact 300 extends from the first contact end 312 or the second contact end 314 toward the center 342, the mounting side 304 extends away from the mating side 302 in a direction along the Z axis.
In particular embodiments, the movable contact 300 may be configured to have a center of mass (COM) 303 that aligns with an axis of the support rod, such as the axis 212 (
For embodiments in which the thickness 324 is greater toward the center 342, the movable contact 300 has more material toward the center 342 compared to other known movable contacts. The additional material may absorb more thermal energy that is generated during operation. The larger surface areas of the broad sides 316, 318 proximate to the center 342 may also permit a greater rate of heat dissipation. In such embodiments, the amount of thermal energy dissipated proximate to the first and second contact ends 312, 314 may be reduced, thereby reducing damage or wear to the surrounding environment that may be caused by excessive heat. For example, the alignment projections 224 (
Optionally, the movable contact 300 may be symmetrically-shaped. For example, as shown in
As shown, the recess 336 divides at least a portion of the mating surface 334. The recess 336 is a depression that extends only partially into the movable contact 300. The mating end of the stationary contact is configured (e.g., sized and shaped relative to the contact zone) to extend entirely across the recess 336 and engage the corresponding mating surface 334 on opposite sides of the recess 336. More specifically, the mating end may engage a first sub-area 382 and a second sub-area 384 that are on opposite sides of the recess 336. Optionally, the mating end may also engage a third sub-area 386. The third sub-area 386 represents a portion of the mating surface 334 that is not divided by the recess 336. The third sub-area 386 is positioned between the border 380 and an end 388 of the recess 336.
The mating side 402 has first and second contact zones 430, 432. The first and second contact zones 430, 432 are separate regions of the movable contact 400 that are configured to be covered by mating ends of corresponding stationary contacts. As shown, each of the first and second contact zones 430, 432 has a mating surface 434 and a corresponding recess 436 that divides at least a portion of the mating surface 434. Each of the mating ends of the stationary contacts is configured to extend entirely across the corresponding recess 436 and engage the corresponding mating surface 434 on opposite sides of the recess 436. The recess 436 has a depth 438 (
Also shown, the mating side 402 includes a pair of gutters 450, 452 and a platform surface 454 defined between the gutters 450, 452. In the illustrated embodiment, the platform surface 454 extends continuously across the mating side 402 between the first and second contact ends 412, 414. The platform surface 454 includes the first and second contact zones 430, 432. The platform surface 454 has a platform width 456 defined between the gutters 450, 452. The platform width 456 is less than a width 455 of the movable contact 400 that is defined between opposite broad sides 416, 418. The platform width 456 is sized relative to the respective mating ends such that the respective mating ends clear the platform surface 454 and extend over at least one of the gutters 450, 452.
Similar to the movable contact 300 (
It should be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
As used in the description, the phrase “in an exemplary embodiment” and/or the like means that the described embodiment is just one example. The phrase is not intended to limit the inventive subject matter to that embodiment. Other embodiments of the inventive subject matter may not include the recited feature or structure. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
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