1 Field of the Invention
The present invention relates generally to the field of electrical switches, and, more particularly, to a resettable thermostatic switch capable of automatically moving to an open condition responsive to an elevated temperature.
While the invention is subject to a wide range of applications, it is particularly well suited for use as a safety device to disconnect power to an electric water heater when the maximum temperature set-point has been exceeded.
2. Related Art
Devices such as hot water heaters, furnaces, and other appliances commonly include a thermostat, which incorporates a temperature limit switch for deactivating the device responsive to an undesirably elevated temperature condition. Such thermostats often include a bimetallic disc, a portion of which is designed to change position when a predetermined threshold temperature is reached, thereby providing an indication of some type. Such bimetallic discs generally include a high expansion material having a relatively large coefficient of thermal expansion on one side and a low expansion material having a relatively low coefficient of thermal expansion on an opposite side. As is known in the art, as the temperature increases, the high expansion side expands more rapidly than the low expansion side and eventually causes the disc to snap from one position to a second position (i.e., from a concave shape to a convex shape). It is therefore possible to have the disc snap back and forth between two known temperatures, which are determined by the materials used and other factors, as are well known in the art.
The back and forth snapping action takes place with some hysteresis involved. This means that if the disc will snap from a first to a second position at a predetermined high temperature, it will not snap back to its first position until a predetermined low temperature is reached. Accordingly, if the ambient temperature is between the predetermined high and low temperatures, the disc will operate bi-stably and not return to its first position unless the ambient temperature is dropped to below the predetermined low temperature where the disc may then be physically forced back to the first position. More specifically, if the disc is initially in a first position, it will be caused to snap by, for example, reaching of the predetermined high temperature. The disc may then be reset by physically pushing the disc back to the original first position. Generally, thermostats of the above-described type, when operated in the bi-stable condition, are returned to the original first or reset position by means of a manual reset device.
Generally speaking, the purpose of the thermostat is to operate in response to a high temperature alarm condition (the predetermined high temperature) to open a switch and maintain the switch open until it is manually reset after the alarm condition has abated. Many known thermostats, however, have no provision for preventing override thereof by manually operating the reset device, preventing the disc from snapping, or physically maintaining the switch closed by continual operation of the reset mechanism, regardless of whether the alarm condition has abated or not. As a result, thermostats on hot water heaters, furnaces, and other appliances are often manually overridden and the devices controlled by such thermostats are allowed to operate during an alarm condition (at temperature exceeding the safe temperature threshold). Because of, among other things, numerous accidents resulting from such unsafe operation, regulations have now been implemented to require that thermostats be fitted with “trip-free” high temperature limit control switches.
The Underwriters Laboratories, Inc. regulations applicable to the design and operation of a high temperature limit control switch are as follows:
11. Reset Mechanism—Limiting Control
11.1 A control shall not reset or be resettable manually or otherwise so that operation of the controlled appliance can be resumed until after a safe operating condition is restored. For example, pressure or temperature returned to a value at or below a control set point.
11.3 A manually reset device shall be trip-free; that is, the automatic tripping shall be independent of the manipulation or position of the reset button, handle, lever, or the like.
Since the implementation of the above-mentioned regulations, numerous approaches have been employed to manufacture thermostats, and specifically high temperature limit switches, that comply with UL regulations. Many of these approaches are difficult to manufacture, require a number of moving components, and require complex assembly procedures. In addition, many such devices incorporate one or more coil springs, which have a tendency to fail over time.
What is needed therefore, but seemingly unavailable in the art, is a manually resettable high temperature limit switch for thermostats that overcomes these and other shortcomings known in the art. Such a resettable high temperature limit switch should be easy to manufacture, occupy a limited amount of space, incorporate relatively few moving components, and be less expensive than other resettable high temperature limit switches presently available in the art. It is to the provision of such a manually resettable high temperature limit switch that the present invention is primarily directed.
In one aspect, the present invention is directed to a switch. The switch includes a resettable temperature responsive mechanism movable between a non-tripped position and a tripped position, a reset member movable between a position of rest and a reset position, a non-movable fixed contact, and a pivotable contact support member including a contact movable with respect to the non-movable fixed contact.
The contact support member is configured to prevent the movable contact from engaging the fixed contact while the resettable temperature responsive mechanism is urged from the tripped position to the non-tripped position in response to force applied to the reset member until the reset member is returned toward the position of rest.
In another aspect, the present invention is related to a high temperature limit switch. The high temperature limit switch includes a resettable temperature responsive mechanism movable between a non-tripped position and a tripped position, a movable actuator constructed and arranged to cooperate with the resettable temperature responsive mechanism, a reset member movable between a position of rest and a reset position, a fixed pivot point, a non-movable fixed contact and a pivotable contact support member having a contact movable with respect to the non-moveable fixed contact. The contact support member is configured to cooperate with the fixed pivot point to prevent the movable contact from engaging the non-movable fixed contact while the resettable temperature responsive mechanism is urged from the tripped position to the non-tripped position in response to force applied to the reset member.
In yet another aspect, the present invention is directed to a method of resetting a high temperature limit switch. The method includes the steps of moving a reset member from a position of rest toward a reset position to exert force on a contact support member having a contact movable with respect to a non-movable fixed contact, and depressing an actuator in response to the moving step to move a resettable temperature responsive mechanism from a tripped position to a non-tripped position without allowing the movable contact to engage the non-movable fixed contact until the reset member is returned toward the position of rest.
A further aspect of the present invention is directed to a method of resetting a high temperature limit switch. The method includes the steps of moving a reset member from a position of rest toward a reset position to exert force on a contact support member having a fixed end and a first contact remote from the fixed end, and pivoting the contact support member at a fixed pivot point disposed between the fixed end and the first contact in response to the moving step to prevent the first contact from engaging a second contact while a resettable temperature responsive mechanism is urged from a tripped position to a non-tripped position.
A still further aspect of the present invention relates to a high temperature limit switch. The high temperature limit switch includes a resettable temperature responsive mechanism movable between a non-tripped position and a tripped position, a reset member movable between a position of rest and a reset position, a pivotable contact support member including a fixed end and a first contact remote from the fixed end, a fixed contact configured to receive the first contact, a pivot point disposed between the first end and the first contact, and a movable actuator disposed between the pivot point and the first contact to urge the resettable temperature responsive mechanism from the tripped position to the non-tripped position in response to movement of the reset member in the direction of the reset position. The first contact is prevented from contacting the fixed contact by force applied at the pivot point until the reset member is returned toward the position of rest.
The switch and method of resetting a high temperature limit switch of the present invention provides a number of advantages over other temperature limit switches and methods known in the art. For example, the resettable high temperature limit switch of the present invention incorporates relatively few movable parts and does not include a coil spring. As a result, the switch of the present invention is not susceptible to failure, is robust, and is consistent in operation.
In addition, the limit switch of the present invention does not permit closing of the electrical circuit (i.e., engagement of the electrical contacts) until after the reset member is returned toward its position of rest (e.g., when the reset member is released following resetting of the resettable temperature responsive mechanism to the non-tripped position). As a result, the high temperature limit switch of the present invention is a “fail-safe” mechanism. More specifically, if the resettable temperature responsive mechanism does not remain in its non-tripped position when the rest member is released or otherwise moves toward its position of rest following an attempt to reset the switch, engagement of the contact members, and thus completion of the electrical circuit, cannot occur.
Additional features and advantages of the invention will be set forth in the detailed description which follows and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide further understanding of the invention, illustrate various embodiments of the invention, and together with the description serve to explain the principles and operation of the invention.
The invention can be better understood with reference to the following drawings. The elements of the drawings are not necessarily to scale relative to each other, emphasis instead being placed upon clearly illustrating the principles of the invention. Furthermore, like reference numerals designate corresponding parts throughout the several views.
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawing figures. An exemplary embodiment of a switch of the present invention is shown in
In
Generally speaking, and as depicted in
Pivotable contact support member 28 is preferably mounted to include a fixed end 32 adjacent a stationary support 34 and is preferably a flexible member made of a conductive material such as copper, brass or some other metal. The opposite end of pivotable contact support member 28, which carries movable contact 30, is preferably a free end adapted for movement into and out of contact with non-movable fixed contact 26 mounted on stationary contact member 35. As will be described in greater detail below, movement of the free end of pivotable contact support member 28, and thus movement of movable contact 30, into and out of engagement with non-movable fixed contact 26 is facilitated by an actuator 36 adapted to cooperate with resettable temperature responsive mechanism 22 to urge the free end of pivotable contact support member 28 out of engagement with stationary contact member 35. As shown by
If, however, resettable temperature responsive mechanism 22 has not sufficiently cooled to enable resettable temperature responsive mechanism 22 to be reset to its non-tripped position, resettable temperature responsive mechanism 22 will snap back to the tripped position depicted in
Although an exemplary switch 20 and method of operation has been described above with reference to
While the switch of the present invention may have several applications, it will be described hereafter as a high temperature limit control switch for a domestic hot water heater, wherein water is heated in an enclosed tank by a suitable heat source such as an electric heating element. Such a water heater, water heater tank, thermostat, and electric heating element may be of conventional design and thus are not described in detail herein.
A thermostat 44 including a preferred switch 20 in accordance with the present invention is depicted in an exploded prospective view in
Under normal operating conditions, i.e., when switch 20 is closed and the electrical circuit is complete, pivotable contact support member 58 is seated adjacent actuator guide 56 such that first end 60 is fastened to stationary support 66 while movable contact 68 adjacent second end 62 of pivotable contact support member 58 is in contact with stationary contact member 70. Reset button 72 is positioned atop of pivotable contact support members 58 and actuator 54 and is held in position by reset cover 50.
Reset button 72 is preferably constructed and arranged such that it may cooperate with both pivotable contact support members 58 and actuator 54. In a preferred embodiment, and when utilized to manually reset switch 20, central portion 74 of reset button 72 communicates with post 76 of actuator 54 while extended detents 78 communicate with reset arms 64 of pivotable contact support members 58. Although not required, reset button 72 may also include biasing tabs 80 to provide the resilient “feel” typically associated with manual reset buttons conventionally employed with thermostats. Although not readily perceptible in
Fulcrums 82, at least one of which cooperates with each pivotable contact support member 58, together with actuator 54 are depicted more clearly in
The operation of the preferred switch 20 of the present invention will now be described with reference to
As shown in
In accordance with manual reset procedures, and as depicted in
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention.
While the present invention has been described in detail, it is to be expressly understood that it will be apparent to persons skilled in the relevant art that the invention may be modified without departing from the spirit of the invention. Various changes of form, design or arrangement may be made to the invention without departing from the spirit and scope of the invention. Therefore, the above mentioned description is to be considered exemplary, rather than limiting and the true scope of the invention is that defined in the following claims.
This application is related to U.S. Provisional Application No. 60/440,659 entitled “Trip-Free Limit Switch and Reset Mechanism” and filed on Jan. 16, 2003, which is incorporated herein by reference. This application claims priority to U.S. Provisional Application No. 60/562,414 entitled “Trip-Free Limit Switch and Reset Mechanism” and filed on Apr. 15, 2004, which is incorporated herein by reference.
Number | Date | Country | |
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60562414 | Apr 2004 | US |