US3182382A - Method of making sealed switches - Google Patents

Method of making sealed switches Download PDF

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Publication number
US3182382A
US3182382A US136590A US13659061A US3182382A US 3182382 A US3182382 A US 3182382A US 136590 A US136590 A US 136590A US 13659061 A US13659061 A US 13659061A US 3182382 A US3182382 A US 3182382A
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Prior art keywords
terminal
armature
housing
magnetic
terminals
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US136590A
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Juptner Wilhelm
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IXYS Integrated Circuits Division Inc
Arris Technology Inc
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IXYS Integrated Circuits Division Inc
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Priority claimed from US678236A external-priority patent/US3033956A/en
Application filed by IXYS Integrated Circuits Division Inc filed Critical IXYS Integrated Circuits Division Inc
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Assigned to GENERAL INSTRUMENT CORPORATION reassignment GENERAL INSTRUMENT CORPORATION MERGER (SEE DOCUMENT FOR DETAILS). Assignors: C.P. CLARE & COMPANY
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H5/00Snap-action arrangements, i.e. in which during a single opening operation or a single closing operation energy is first stored and then released to produce or assist the contact movement
    • H01H5/02Energy stored by the attraction or repulsion of magnetic parts
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00Electromagnetic relays
    • H01H51/28Relays having both armature and contacts within a sealed casing outside which the operating coil is located, e.g. contact carried by a magnetic leaf spring or reed
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00Electromagnetic relays
    • H01H51/28Relays having both armature and contacts within a sealed casing outside which the operating coil is located, e.g. contact carried by a magnetic leaf spring or reed
    • H01H51/287Details of the shape of the contact springs
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49105Switch making
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49204Contact or terminal manufacturing

Definitions

  • FIG.4 Hg 5 v 44 44 56 ,I m 5 so 45 48 4o 57 as I I as I 68--- 34 I 84 5 a: J 62 M en/me G- WM 04,3,
  • This invention relates to a method of making switching devices and, more particularly, to a method of assembling a sealed switch unit having a pivotally mounted armature.
  • the present application is a division of a copending application Serial No. 678,23 6, filed August 14, 1957, now Patent No. 3,033,956.
  • One object of the present invention is to provide a new and improved method of assemblying sealed switch units.
  • Another object is to provide a method of making a sealed switch unit having a magnetic armature pivotally mounted on one of a plurality of magnetic terminals sealed Within a dielectric housing.
  • a switching unit comprising as its principal elements a balanced, pivotally mounted armature and two or more electrically conductive terminal members which extend from the switching unit, at least two of the terminals being ferromagnetic so as to function as pole pieces as well as electric terminals.
  • This sealed switch is constructed by sealing one magnetic terminal in one end of an elongated dielectric housing, inserting the armature and pivotally mounting it on the one terminal, and then mounting another terminal in the open end of the housing and sealing this other terminal in the housing.
  • FIG. 1 is a side elevational view, partially in section, of a relay embodying certain aspects of the present invention
  • FIG. 2 is a perspective View showing the switching unit of the relay illustrated in FIG. 1;
  • FIG. 3 is a fragmentary perspective view of a switching unit embodying the present invention.
  • FIGS. 4 and 5 are fragmentary side elevational views of switching units embodying other aspects of the present invention.
  • FIG. 6 is a fragmentary side elevational view of the upper portion of a relay embodying certain aspects of the present invention.
  • FIG. 7 is a side elevational view of a relay switching unit embodying certain aspects of the present invention.
  • a complete relay 10 which comprises as its principal elements a generally cylindrical housing or can 12 in which is. mounted a control Winding or coil 13 and a hermetically sealed switching unit or cartridge 14.
  • a ferromagnetic electrically conductive terminal and heel piece 15 protrudes from the top of a hermetically sealed glass housing 16 from the bottom of which extend two terminal members 17 and 18.
  • the terminal 17 is ferromagnetic so that it also functions as a heel piece.
  • the members 15 and 17 thus cooperate with the can 12 and a tubular ferromagnetic sleeve 21 to provide a stator having an air gap in which a balanced ferromagnetic and electrically conductive armature 22 is pivotally mounted for selectively connecting the terminal member 15 to either the terminal member 17 or the terminal member 18.
  • the terminals 17 and 18 are respectively connected through conductors 23 and 24, to two terminal pins 25 and 26. These terminal pins are conventionally mounted in a disk-shaped header 27 which is formed of insulating material and is secured in place, as shown, to close the bottom opening in the can 12.
  • a third terminal pin 28 extends through the header 27 and is electrically connected to the upper terminal member 15 by means of a resilient wave shaped connector 31 of rectangular cross-section, which also functions to bias the switching unit 14 against the opposite side of the inner wall ot the coil 13, thereby to eliminate any radial play between the switching unit 14 and the coil 13.
  • Radial play between the coil 13 and the housing 12 is prevented by means of a plurality of elongated resilient and folded inserts 32 which are positioned between the coil 13 and the inner wall of the housing 12.
  • Axial movement of the coil 13 with respect to the housing 12 is prevented by means of a washer 33 which is interposed between the sleeve 21 and the lower end of the coil 13 and has one or more resilient pretensioned crimps therein for resiliently biasing the coil 13 upward against the bottom surface of the oil-turned portion or the terminal 15.
  • the terminal 15 is thus resiliently urged against an insulating disk 34 positioned at the top of the housing 12.
  • the flanged sleeve 21 is supported within the housing 12 by means of a tubular sleeve 35 which is interposed between the sleeve 21 and the header 27.
  • the pretensioned washer 33 thus not only acts to force the terminal member 15 to the top of the can 12 but also acts to bias the sleeve 21 and the sleeve 35 toward the header 27, thereby to prevent relative movement of the switching unit 14 either with respect to the winding 13 or with respect to the can 12.
  • the winding 13 is provided with a pair of input leads 36 which extend through a suitable slot 37 in the sleeve 21 and are respectively connected to terminal pins (not shown) which extend through and are supported by the header 27.
  • the armature 22 is normallybiased by means not visible in the drawing into engagement with a nonmagnetic contact member 38 which is welded to the terminal member 18 so that when no current is supplied to the coil 13 the armature is positioned in the manner illustrated in FIG. 1 and electrically connects the terminal 15 to the terminal 18. Accordingly, the terminal pins 26 and 28 are interconnected within the relay 10.
  • this unit comprises a hermetically sealed housing 41, preferably formed of glass, which may either be evacuated or filled with a suitable arc suppressing gaseous medium at a desired pressure through a tube 42 which opens into the housing and is pinched off at its upper end 43 after the desired atmosphere has been established in the housing 41.
  • a set of ferromagnetic, electrically conductive terminals 44, 45 and 48 respectively extend through the upper and lower ends of the housing 41 and facilitate connection of the unit 40 in the electrical and magnetic circuits of the relay.
  • a balanced armature 46 is pivotally mounted on the terminal 44 and selectively connects it to either of the terminals 45 and 48.
  • the armature 46 is pivotally mounted on a ferromagnetic and electrically conductive supporting structure 47 which is attached to the lower end of the terminal 44.
  • the support 47 comprises a pair of side members 50 which are received in suitable recesses at the sides of the terminal member 44 andbetween the ends of which extends a cylindrical pivot bar 51.
  • the armature 46 is attached to the support 47 by means of a cantilever type of spring or spring element 52 which has its lower end secured, as by welding or the like, to the armature 46 and may be provided with a semi-cylindrical upper end portion 53 which is adapted to engage the bar 51 and which is positioned opposite a semi-cylindrical recess 49 in the armature 46.
  • the lefthand surface of the armature 46 is slid along the right-hand edge of the pivot bar 51 so that as the off-turned upper end 54 of the spring 52 engages the bar 51 the upper end of the spring 52 moves toward the left away from the body of the armature 46 to cause the spring to ride over the bar 51 until the depression 53 and the recess 49 are aligned with the bar, at which time the spring 52 snaps toward the right, thereby pivotally to attach the armature 4-6 to the support 47.
  • the supporting posts 50 and the bar 51 are formed of ferromagnetic material, they are magnetically connected to the terminal 44. Therefore, when a magnetic field is established between the terminals 44 and 45, the armature 46 pivots clockwise into engagement with the upper portion of the terminal 45 thereby to establish a conductive path between the terminals 44 and 45.
  • the armature 46 is biased into engagement with the terminal 48 by means of a small cylindrically shaped permanent magnet 57 which is mounted in a recess 58 in the rear surface of a nonmagnetic contact 56 supported upon the terminal 48.
  • the nonmagnetic contact 56 such, for example, as silver, is welded to the upper end of the terminal 48.
  • the spacing between the contact portions of the terminals 45 and 48 is established by means of a nonmagnetic insulating spacer sleeve 60 which partially surrounds a cylindrical boss on the front side of the nonmagnetic contact member 56. The length of the spacer 60 thus determines the length of the air gap between the armature 46 and the terminal 45 and thus the air gap flux density required to operate the relay against the attractive force of the permanent magnet 57.
  • the magnet 57 biases the armature 46 in its limiting counterclockwise position as shown in FIG. 2.
  • a magnetic yoke 62 may be attached to the back of the magnet 57 so that the upper portion of the yoke 62 is in proximity to the lower end of the terminal 44 thereby to provide a low reluctance magnetic circuit for the biasing magnet 57 which extends through the yoke 62 across the gap to the terminal 44, through the support 47 and back to the opposite pole of the magnet 57 through the lower half of the armature.
  • Bounce suppression during snap return of the armature to its biased position is obtained by the magnetic attraction of armature 46 to the permanent magnet 57.
  • the relay operates and the armature rotates clockwise to strike the terminal 45, bounce is prevented by the strong magnetic field which exists between the armature'46 and the contact 45 to which it is directly connected.
  • the terminal 44 with the support 47 mounted thereon and the tube 42 are first sealed into the upper end of the tubular glass housing 43. This assembly operation is performed with the lower end .of the housing fully open.
  • the armature 46 is next inserted into the housing through the open lower end thereof and pivotally mounted upon the pivot bar 51 of the support 47 in the manner described above.
  • the terminal 43 with the parts 56, 57 and 62 mounted thereon, and the terminal 45 are next inserted into the open lower end of'the housing 41 until they are brought into the desired positions relative to the terminal 44 and the armature 46.
  • the terminals 45 and 48 are fixedly held in their desired relative positions with the spacer 60 positioned therebetween.
  • the lower end of the tubular housing 41 is sealed 01f. to complete the assembly.
  • the interior of the housing is evacuated or filled with a suitable arc suppressing gas through the tube 42 after which this tube is pinched off and sealed.
  • FIG. 4 an alternative embodiment of a portion of the switching unit is there shown, wherein a spring or resilient element 64 is used to bias the armature into engagement with the nonmagnetic contact member 56. Since this embodiment is a modification of the switching unit '46, similar parts are designated by like reference numbers.
  • the armature 46 is magnetically and electrically mounted on the common terminal 44 by means of the support 47 and the spring 52. The armature 46 is shown in its normal position in engagement with the forward face of the nonmagnetic contact member 56 which is spaced from the magnetic terminal member 45 by means of the spacer sleeve 60.
  • a preformed spring 64 having a pretensioned resilient oilturned end portion 65 is secured at its lower end, as by spot welding or the like, to the armature 46 and the upper end thereof bears against the forward face of the terminal 44 to bias the armature 46 in a counterclockwise direction into engagement with the contact member 56. It should be noted that as the armature 46 is released and pivots counterclockwise, the off-turned portion 65 of the spring 64 slides downwardly against the face of the terminal 44 as the armature 46 moves into contact with contact 56 on terminal 48.
  • FIG. 5 an alternative embodiment of the invention is there shown which constitutes a modification of the spring biased armature arrangement shown in FIG. 4.
  • the unit of FIG. 5 is particularly suitable for use in handling heavy switching currents and thus includes a relatively large area contact 67 which is attached as by spot welding to the lower end of the principal body portibn of an armature 68.
  • the armature 68 is pivotally supported on the terminal 44 by means of the support .47 and the spring 52 and the contact 67 is biased against the nonmagnetic contact member 56 by means of a biasing spring or resilient element 76 which is attached at its lower end to the armature 68.
  • the armature 68 is pivoted at a point approximately at its center of gravity, thus providing a balanced armature which requires a minimum of current in the control winding to effect operation of the relay.
  • a large area contact button 71 is mounted on the terminal member 45 for electrical engagement with the contact member 67 of the armature 68 when the relay is operated. The thickness of the contact member 71 exceeds that of the armature 63 so that a residual gap is provided between the armature 68 and the terminal 45 when the relay is operated.
  • FIG. 6 there is shown the upper portion of a relay embodying an alternative aspect of the invention and which includes a permanent magnet 73 disposed in the upper portion of a ferromagnetic housing or can 74 to provide a permanent magnetic field across the air gap in the associated switching unit (not shown).
  • the magnet '73 is wedged between an upper terminal 75 and the top of the can 74 and since the terminal member 75 is both a part of the magnetic circuit and an electrical conductor connected in the external switching circuit, an insulating disk 76 is positioned between the magnet 73 and the terminal member 75 to maintain the can '74 isolated from the electrical circuits. Therefore, by using the cartridge 40 in the embodiment of FIG. 6, the relay may be biased toward an operate or release position depending upon the polarity of the magnet 73.
  • a bistable, polar switching unit 89 is there shown.
  • This unit comprises a set of ferromagnetic terminal members 81 and 82 which extend through and are sealed to the bottom of the housing 83 and are spaced apart by a nonconductive spacer sleeve 84 located within the housing.
  • the unit 8%) also includes an armature 35 pivotally mounted on a support 86 which is attached to a common terminal member and heel piece 87.
  • the terminal 87 is electrically and magnetically connected to a ferromagnetic and conductive tube 95 which extends from the upper end of the housing 83 and which is pinched off and bent over at its upper end 91 to seal the housing and to provide the oil-turned upper end of the terminal for use in conjunction with the coil and associated structure as shown, for example, in FIG. 1.
  • a permanent magnet 93 is disposed outside the housing 83 between the lower portions of the terminals 81 and 82 and is insulated from the terminal 82 by means of a nonmagnetic insulating spacer 94. The magnet is polarized in a direction from right-to-left and serves to bias the armature 85 in either of its limiting positions in contact with either of the terminals 81 or $2.
  • the unit 8% may be used in a side stable relay by using it in conjunction with the embodiment shown in FIG. 6 which includes the permanent magnet 73.
  • the flux densities produced by each across the air gaps between the armature 85 and the terminals 81 and 82 will be in opposition in one instance and in aiding relationship in the other. Consequently, the armature 35 is biased so as to close the latter air gap.
  • properly polarized current in the relay winding overcomes the magnetic field of the magnets 73 and 93, thereby causing the relay to operate. There is thus provided a side stable polar relay from which the biasing spring has been eliminated.
  • a method of assembling a switching unit of the type comprising a plurality of terminals respectively extending from opposite ends of a tubular housing and a magnetic armature pivotally secured to one of said terminals, the armature and at least one of the terminals including contact portions selectively movable into and 6 out of engagement with each other, which comprises sealing said one terminal in one end of said housing, inserting the armature into said housing and pivotally securing it to said one terminal, thereafter inserting the other of said terminals into the end of said housing opposite said one end with a portion of the other terminal overlapping and spaced from a portion of the armature, and sealing said other terminal to said housing.
  • a method of making a sealed switch unit from a length of glass tubing, two magnetic terminals, and a magnetic armature, the armature and at least one of the terminals having contact portions movable into and out of engagement with each other comprises disposing a first magnetic terminal in the opening at one end of said tubing, heating said tubing to close said one end of said tubing and to rigidly mount said first terminal on said tubing, inserting said magnetic armature into said tubing through the open other end thereof, pivotally mounting the magnetic armature on said one terminal, disposing the second of said magnetic terminals in the open other end of said tubing with a portion of the second magnetic terminal overlapping but spaced from a portion of the magnetic armature, and heat sealing the other end of said tubing to seal said other end of said tubing and rigidly mount said second terminal on said housing.
  • a method of making a sealed switch unit including an elongated dielectric housing having an axially extending opening with opposite open ends, first and second magnetic terminals, a magnetic armature, a spring element, and a pivot structure, the armature and the second terminal having contact portions movable into and out of engagement with each other, which method comprises the steps of securing the pivot structure to one end of said first terminal, disposing the first terminal in the opening at one end of said housing with the pivot structure located within the housing and projecting toward the center of said opening, heat sealing said one end of said housing to close said end and rigidly mount said first terminal on said housing, securing said spring element to said armature, inserting said armature into said opening through the other open end, moving said armature to force said pivot structure between said armature and said spring element to pivotally mount said armature on said first terminal, disposing said second terminal in said other open end of said housing with at least a portion of the second terminal in an overlapping but normally spaced relation with at least a portion of the first
  • step of disposing the first terminal in the opening at one end of said housing includes disposing said first terminal to one side of the axis of said opening
  • steps of inserting and moving said armature includes disposing said armature generally at a position extending along the axis of said opening
  • step of disposing said second terminal in the opening at the other open end of said housing includes positioning said second terminal on the other side of the axis of said opening opposite said one side.
  • a method of making a sealed switch unit from a length of glass tubing, two magnetic terminals, a magnetic armature, and a generally U-shaped pivot structure, the magnetic armature and at least one of the magnetic terminals having contact portions selectively movable into and out of engagement with each other comprises securing the U-shaped pivot structure to a first magnetic terminal adjacent one end of the first magnetic terminal, disposing the first magnetic terminal in one end of the tubing with the pivot structure within the tubing, heating the one end of the tubing to seal the first terminal, inserting the magnetic armature into the tubing through the other open end and pivotally mounting it on the pivot structure with the armature disposed between the bight of the U-shaped pivot structure and the adjacent portion of the first terminal, positioning the second magnetic terminal in the other end of the tubing, and heating the other end of the tubing to seal the second terminal.
  • a method of making a sealed switch unit from a length of dielectric tubing, a magnetic armature, and two magnetic terminals, one of which carries a pivot structure, the magnetic armature and at least one of the magnetic terminals including contact portions selectively movable into and out of engagement with each other comprises disposing the first magnetic terminal in one end of the tubing with the pivot structure within the tubing, sealing the one end of the tubing to rigidly support the first terminal, inserting the magnetic armature into the tubing through the other open end and mounting it on the pivot structure with at least a portion of the armature disposed adjacent the first tominal, positioning the second magnetic terminal in the other end of the tubing with a portion of the second terminal spaced from and overlapping at least a portion of the armature, and sealing the other end of the tubing to rigidly support the second terminal.
  • the magnetic armature and at least one of the magnetic terminals including contact portions movable into and out of engagement with each other, which method comprises mounting the pivot structure on a first magnetic terminal adjacent one end of the first magnetic terminal, disposing the first magnetic terminal in one end of the housing with the pivot structure within the housing, sealing the first terminal in the one end' of the housing, mounting the resilient spring means on the armature, inserting the magnetic armature into the housing through the other open end and pivotally mounting it on the pivot structure with the resilient spring means interposed between the armature and the first terminal to bias the armature, positioning the second magnetic terminal in the other end of the housing with a portion of the second terminal spaced from and overlapping at least a portion of the armature, and sealing the second terminal in the other end of the housing.
  • a method of making a sealed switch unit from a length of glass tubing, two magnetic terminals, a magnetic armature, a resilient spring means, and a generally U-shaped pivot structure, the magnetic armature and at least one ofthe magnetic terminals having contact portions movable into and out of engagement comprises securing the U-shaped pivot structure to a first magnetic terminal adjacent one end of the first magnetic terminal, disposing the first magnetic terminal in one end of the tubing with the pivot structure within tubing, heating the one end of the tubing to seal the first terminal, securing one end of the resilient spring means to the armature, inserting the magnetic armature into the tubing through the other open end and pivotally mounting it on the pivot structure with the armature disposed between the night portion of the U-shaped pivot structure and the adjacent portion of the first terminal and with the resilient spring means engaging the first terminal, positioning the second magnetic terminal in the other end of the tubing with a portion spaced from and overlapping part of the armature, and heating the other end of the tubing to seal the

Description

1, 1965 w. JUPTNER 3,182,382
METHOD OF IAKING SEALED SIH'GHBS Original Filod Aug. 14, 1957 2 Shuts-Shut. 1
y 11, 1965 W.JUPTNER 3,182,382
METHOD OF MAKING SEALED SWITCHES Original Filed Aug 14, 1957 2 Sheets-Sheet 2 FIG.4 Hg 5 v 44 44 56 ,I m 5 so 45 48 4o 57 as I I as I 68--- 34 I 84 5 a: J 62 M en/me G- WM 04,3,
arrom/evs,
United States Patent 3,182,382 METHOD OF MAKING SEALED SWITCHES Wilhelm Juptner, Costa Mesa, Caliii, assignor to C. P. Clare & Company, Chicago, Ill., a corporation of Delaware Original application Aug. 14, 1957, Ser. No. 678,236, now Patent No. 3,033,956, dated May 8, 1962. Divided and this application Sept. 7, 1961, Ser. No. 136,590 9 Claims. (Cl. 29155.55)
This invention relates to a method of making switching devices and, more particularly, to a method of assembling a sealed switch unit having a pivotally mounted armature. The present application is a division of a copending application Serial No. 678,23 6, filed August 14, 1957, now Patent No. 3,033,956.
One object of the present invention is to provide a new and improved method of assemblying sealed switch units.
Another object is to provide a method of making a sealed switch unit having a magnetic armature pivotally mounted on one of a plurality of magnetic terminals sealed Within a dielectric housing.
Briefly, the above and further objects are realized in accordance with the present invention by providing a switching unit comprising as its principal elements a balanced, pivotally mounted armature and two or more electrically conductive terminal members which extend from the switching unit, at least two of the terminals being ferromagnetic so as to function as pole pieces as well as electric terminals. This sealed switch is constructed by sealing one magnetic terminal in one end of an elongated dielectric housing, inserting the armature and pivotally mounting it on the one terminal, and then mounting another terminal in the open end of the housing and sealing this other terminal in the housing.
The invention, both as to its organization and method of operation, together with further objects and advantages thereof, will best be understood by reference to the following detailed description taken in connection with the accompanying drawings, in which:
FIG. 1 is a side elevational view, partially in section, of a relay embodying certain aspects of the present invention;
FIG. 2 is a perspective View showing the switching unit of the relay illustrated in FIG. 1;
FIG. 3 is a fragmentary perspective view of a switching unit embodying the present invention;
FIGS. 4 and 5 are fragmentary side elevational views of switching units embodying other aspects of the present invention;
FIG. 6 is a fragmentary side elevational view of the upper portion of a relay embodying certain aspects of the present invention; and
FIG. 7 is a side elevational view of a relay switching unit embodying certain aspects of the present invention.
Referring now to the drawings and more particularly to FIG. 1 thereof, there is shown a complete relay 10 which comprises as its principal elements a generally cylindrical housing or can 12 in which is. mounted a control Winding or coil 13 and a hermetically sealed switching unit or cartridge 14. In the unit 14, a ferromagnetic electrically conductive terminal and heel piece 15 protrudes from the top of a hermetically sealed glass housing 16 from the bottom of which extend two terminal members 17 and 18. The terminal 17 is ferromagnetic so that it also functions as a heel piece. The members 15 and 17 thus cooperate with the can 12 and a tubular ferromagnetic sleeve 21 to provide a stator having an air gap in which a balanced ferromagnetic and electrically conductive armature 22 is pivotally mounted for selectively connecting the terminal member 15 to either the terminal member 17 or the terminal member 18.
The terminals 17 and 18 are respectively connected through conductors 23 and 24, to two terminal pins 25 and 26. These terminal pins are conventionally mounted in a disk-shaped header 27 which is formed of insulating material and is secured in place, as shown, to close the bottom opening in the can 12. A third terminal pin 28 extends through the header 27 and is electrically connected to the upper terminal member 15 by means of a resilient wave shaped connector 31 of rectangular cross-section, which also functions to bias the switching unit 14 against the opposite side of the inner wall ot the coil 13, thereby to eliminate any radial play between the switching unit 14 and the coil 13.
Radial play between the coil 13 and the housing 12 is prevented by means of a plurality of elongated resilient and folded inserts 32 which are positioned between the coil 13 and the inner wall of the housing 12. Axial movement of the coil 13 with respect to the housing 12 is prevented by means of a washer 33 which is interposed between the sleeve 21 and the lower end of the coil 13 and has one or more resilient pretensioned crimps therein for resiliently biasing the coil 13 upward against the bottom surface of the oil-turned portion or the terminal 15. The terminal 15 is thus resiliently urged against an insulating disk 34 positioned at the top of the housing 12. The flanged sleeve 21 is supported within the housing 12 by means of a tubular sleeve 35 which is interposed between the sleeve 21 and the header 27. The pretensioned washer 33 thus not only acts to force the terminal member 15 to the top of the can 12 but also acts to bias the sleeve 21 and the sleeve 35 toward the header 27, thereby to prevent relative movement of the switching unit 14 either with respect to the winding 13 or with respect to the can 12. The winding 13 is provided with a pair of input leads 36 which extend through a suitable slot 37 in the sleeve 21 and are respectively connected to terminal pins (not shown) which extend through and are supported by the header 27.
Considering the operation of the relay of FIG. 1, let it be assumed that the armature 22 is normallybiased by means not visible in the drawing into engagement with a nonmagnetic contact member 38 which is welded to the terminal member 18 so that when no current is supplied to the coil 13 the armature is positioned in the manner illustrated in FIG. 1 and electrically connects the terminal 15 to the terminal 18. Accordingly, the terminal pins 26 and 28 are interconnected within the relay 10.
When a current of suflicient value is supplied to the windig-13 to operate the relay 10, a magnetic field is establishd which causes flux traversal of the magnetic circuit. This circuit extends from the top portion of the winding 13 through the bent-over portion 15:: of the terminal member '15, through the terminal member 15 to the armature 22 across the air gap between the lower portion of the armature 22 and the upper portion of the terminal member \17, through the terminal member 17, across the relatively short gap to the sleeve 21, through the sleeve .21 and the walls of the can 12 back to the bent-over portion 15a of the terminal member 15. The magnetic flux which is thus caused to traverse the gap between the armature 22 and the terminal 17 causes the armature 22. to pivot clockwise so that the amature 22 engages the terminal 17. When this occurs, the terminal pins 25 and 28 are interconnected and the terminal pin 26 is disconnected from the terminal pin 28. Upon termination of the supply of current to the winding 13, the
armature 22 pivots counterclockwise under the influence of the biasing force exerted thereon to its normal position in which the terminal pins 26 and 28 are connected.
Referring now more particularly to FIGS. 2 and 3, the details of a sealed switching unit or cartridge 40 of the side stable type are there illustrated. Briefly, this unit comprises a hermetically sealed housing 41, preferably formed of glass, which may either be evacuated or filled with a suitable arc suppressing gaseous medium at a desired pressure through a tube 42 which opens into the housing and is pinched off at its upper end 43 after the desired atmosphere has been established in the housing 41. A set of ferromagnetic, electrically conductive terminals 44, 45 and 48 respectively extend through the upper and lower ends of the housing 41 and facilitate connection of the unit 40 in the electrical and magnetic circuits of the relay. A balanced armature 46 is pivotally mounted on the terminal 44 and selectively connects it to either of the terminals 45 and 48.
As best shown in FIGS. 2 and 3, the armature 46 is pivotally mounted on a ferromagnetic and electrically conductive supporting structure 47 which is attached to the lower end of the terminal 44. The support 47 comprises a pair of side members 50 which are received in suitable recesses at the sides of the terminal member 44 andbetween the ends of which extends a cylindrical pivot bar 51. The armature 46 is attached to the support 47 by means of a cantilever type of spring or spring element 52 which has its lower end secured, as by welding or the like, to the armature 46 and may be provided with a semi-cylindrical upper end portion 53 which is adapted to engage the bar 51 and which is positioned opposite a semi-cylindrical recess 49 in the armature 46. In initially mounting the armature 46 upon the support 47, which has previously been attached to the terminal 44, the lefthand surface of the armature 46, as viewed in FIG. 2, is slid along the right-hand edge of the pivot bar 51 so that as the off-turned upper end 54 of the spring 52 engages the bar 51 the upper end of the spring 52 moves toward the left away from the body of the armature 46 to cause the spring to ride over the bar 51 until the depression 53 and the recess 49 are aligned with the bar, at which time the spring 52 snaps toward the right, thereby pivotally to attach the armature 4-6 to the support 47. Since the supporting posts 50 and the bar 51 are formed of ferromagnetic material, they are magnetically connected to the terminal 44. Therefore, when a magnetic field is established between the terminals 44 and 45, the armature 46 pivots clockwise into engagement with the upper portion of the terminal 45 thereby to establish a conductive path between the terminals 44 and 45.
In the arrangement shown in FIGS. 2 and 3, the armature 46 is biased into engagement with the terminal 48 by means of a small cylindrically shaped permanent magnet 57 which is mounted in a recess 58 in the rear surface of a nonmagnetic contact 56 supported upon the terminal 48. In order to maximize the ratio ofthe flux path reluctance of the terminal 48 to that of the terminal 45, the nonmagnetic contact 56, such, for example, as silver, is welded to the upper end of the terminal 48. The spacing between the contact portions of the terminals 45 and 48 is established by means of a nonmagnetic insulating spacer sleeve 60 which partially surrounds a cylindrical boss on the front side of the nonmagnetic contact member 56. The length of the spacer 60 thus determines the length of the air gap between the armature 46 and the terminal 45 and thus the air gap flux density required to operate the relay against the attractive force of the permanent magnet 57.
It may thus be seen that the magnet 57 biases the armature 46 in its limiting counterclockwise position as shown in FIG. 2. If an increased biasing force is desired, a magnetic yoke 62 may be attached to the back of the magnet 57 so that the upper portion of the yoke 62 is in proximity to the lower end of the terminal 44 thereby to provide a low reluctance magnetic circuit for the biasing magnet 57 which extends through the yoke 62 across the gap to the terminal 44, through the support 47 and back to the opposite pole of the magnet 57 through the lower half of the armature.
Bounce suppression during snap return of the armature to its biased position is obtained by the magnetic attraction of armature 46 to the permanent magnet 57. When the relay operates and the armature rotates clockwise to strike the terminal 45, bounce is prevented by the strong magnetic field which exists between the armature'46 and the contact 45 to which it is directly connected.
In assembling the parts of the switching unit 4-6, the terminal 44 with the support 47 mounted thereon and the tube 42 are first sealed into the upper end of the tubular glass housing 43. This assembly operation is performed with the lower end .of the housing fully open. The armature 46 is next inserted into the housing through the open lower end thereof and pivotally mounted upon the pivot bar 51 of the support 47 in the manner described above. The terminal 43 with the parts 56, 57 and 62 mounted thereon, and the terminal 45 are next inserted into the open lower end of'the housing 41 until they are brought into the desired positions relative to the terminal 44 and the armature 46. During this positioning operation, the terminals 45 and 48 are fixedly held in their desired relative positions with the spacer 60 positioned therebetween. When the parts 41, 44, 45, 46, and 48 are thus correctly positioned relative to each other and while being held in their correct relative positions, the lower end of the tubular housing 41 is sealed 01f. to complete the assembly. Finally, the interior of the housing is evacuated or filled with a suitable arc suppressing gas through the tube 42 after which this tube is pinched off and sealed.
Referring now to FIG. 4, an alternative embodiment of a portion of the switching unit is there shown, wherein a spring or resilient element 64 is used to bias the armature into engagement with the nonmagnetic contact member 56. Since this embodiment is a modification of the switching unit '46, similar parts are designated by like reference numbers. As shown, the armature 46 is magnetically and electrically mounted on the common terminal 44 by means of the support 47 and the spring 52. The armature 46 is shown in its normal position in engagement with the forward face of the nonmagnetic contact member 56 which is spaced from the magnetic terminal member 45 by means of the spacer sleeve 60. A preformed spring 64 having a pretensioned resilient oilturned end portion 65 is secured at its lower end, as by spot welding or the like, to the armature 46 and the upper end thereof bears against the forward face of the terminal 44 to bias the armature 46 in a counterclockwise direction into engagement with the contact member 56. It should be noted that as the armature 46 is released and pivots counterclockwise, the off-turned portion 65 of the spring 64 slides downwardly against the face of the terminal 44 as the armature 46 moves into contact with contact 56 on terminal 48.
Referring to FIG. 5 an alternative embodiment of the invention is there shown which constitutes a modification of the spring biased armature arrangement shown in FIG. 4. The unit of FIG. 5 is particularly suitable for use in handling heavy switching currents and thus includes a relatively large area contact 67 which is attached as by spot welding to the lower end of the principal body portibn of an armature 68. The armature 68 is pivotally supported on the terminal 44 by means of the support .47 and the spring 52 and the contact 67 is biased against the nonmagnetic contact member 56 by means of a biasing spring or resilient element 76 which is attached at its lower end to the armature 68. As shown, the armature 68 is pivoted at a point approximately at its center of gravity, thus providing a balanced armature which requires a minimum of current in the control winding to effect operation of the relay. Also, a large area contact button 71 is mounted on the terminal member 45 for electrical engagement with the contact member 67 of the armature 68 when the relay is operated. The thickness of the contact member 71 exceeds that of the armature 63 so that a residual gap is provided between the armature 68 and the terminal 45 when the relay is operated.
Referring now to FIG. 6, there is shown the upper portion of a relay embodying an alternative aspect of the invention and which includes a permanent magnet 73 disposed in the upper portion of a ferromagnetic housing or can 74 to provide a permanent magnetic field across the air gap in the associated switching unit (not shown). The magnet '73 is wedged between an upper terminal 75 and the top of the can 74 and since the terminal member 75 is both a part of the magnetic circuit and an electrical conductor connected in the external switching circuit, an insulating disk 76 is positioned between the magnet 73 and the terminal member 75 to maintain the can '74 isolated from the electrical circuits. Therefore, by using the cartridge 40 in the embodiment of FIG. 6, the relay may be biased toward an operate or release position depending upon the polarity of the magnet 73. More specifically, with the magnet 73 polarized in one direction, more current of a particular polarity must flow through the winding 13 to effect operation of the armature from its released position to its operated position, whereas if the magnet 7'3 is polarized in the opposite direction, a lesser current flow of the same polarity through the winding 13 is required to overcome the normal armature bias and effect operation of the armature to its operated position.
Referring now to FIG. 7, a bistable, polar switching unit 89 is there shown. This unit comprises a set of ferromagnetic terminal members 81 and 82 which extend through and are sealed to the bottom of the housing 83 and are spaced apart by a nonconductive spacer sleeve 84 located within the housing. The unit 8%) also includes an armature 35 pivotally mounted on a support 86 which is attached to a common terminal member and heel piece 87. The terminal 87 is electrically and magnetically connected to a ferromagnetic and conductive tube 95 which extends from the upper end of the housing 83 and which is pinched off and bent over at its upper end 91 to seal the housing and to provide the oil-turned upper end of the terminal for use in conjunction with the coil and associated structure as shown, for example, in FIG. 1. A permanent magnet 93 is disposed outside the housing 83 between the lower portions of the terminals 81 and 82 and is insulated from the terminal 82 by means of a nonmagnetic insulating spacer 94. The magnet is polarized in a direction from right-to-left and serves to bias the armature 85 in either of its limiting positions in contact with either of the terminals 81 or $2.
The unit 8% may be used in a side stable relay by using it in conjunction with the embodiment shown in FIG. 6 which includes the permanent magnet 73. Depending upon the polarities of the magnets 73 and 93, the flux densities produced by each across the air gaps between the armature 85 and the terminals 81 and 82 will be in opposition in one instance and in aiding relationship in the other. Consequently, the armature 35 is biased so as to close the latter air gap. In such a side stable relay, properly polarized current in the relay winding overcomes the magnetic field of the magnets 73 and 93, thereby causing the relay to operate. There is thus provided a side stable polar relay from which the biasing spring has been eliminated.
While the invention has been described in connection with particular embodiments thereof, it will be understood that various modifications may be made therein which are within the true spirit and scope of the invention as defined in the appended claims.
What is claimed as new and desired to be secured by Letters Patent of the United States is:
l. A method of assembling a switching unit of the type comprising a plurality of terminals respectively extending from opposite ends of a tubular housing and a magnetic armature pivotally secured to one of said terminals, the armature and at least one of the terminals including contact portions selectively movable into and 6 out of engagement with each other, which comprises sealing said one terminal in one end of said housing, inserting the armature into said housing and pivotally securing it to said one terminal, thereafter inserting the other of said terminals into the end of said housing opposite said one end with a portion of the other terminal overlapping and spaced from a portion of the armature, and sealing said other terminal to said housing.
2. The method set forth in claim 1 in which the one terminal carries a pivot structure and the armature carries a fiat spring secured at one end to the armature, and in which the step of pivotally securing the armature to the one terminal includes inserting the pivot structure between the armature and the free end of the fiat spring so that the flat spring forces the pivot structure and the armature together to pivotally secure these two elements.
3. A method of making a sealed switch unit from a length of glass tubing, two magnetic terminals, and a magnetic armature, the armature and at least one of the terminals having contact portions movable into and out of engagement with each other, which method comprises disposing a first magnetic terminal in the opening at one end of said tubing, heating said tubing to close said one end of said tubing and to rigidly mount said first terminal on said tubing, inserting said magnetic armature into said tubing through the open other end thereof, pivotally mounting the magnetic armature on said one terminal, disposing the second of said magnetic terminals in the open other end of said tubing with a portion of the second magnetic terminal overlapping but spaced from a portion of the magnetic armature, and heat sealing the other end of said tubing to seal said other end of said tubing and rigidly mount said second terminal on said housing.
4. A method of making a sealed switch unit including an elongated dielectric housing having an axially extending opening with opposite open ends, first and second magnetic terminals, a magnetic armature, a spring element, and a pivot structure, the armature and the second terminal having contact portions movable into and out of engagement with each other, which method comprises the steps of securing the pivot structure to one end of said first terminal, disposing the first terminal in the opening at one end of said housing with the pivot structure located within the housing and projecting toward the center of said opening, heat sealing said one end of said housing to close said end and rigidly mount said first terminal on said housing, securing said spring element to said armature, inserting said armature into said opening through the other open end, moving said armature to force said pivot structure between said armature and said spring element to pivotally mount said armature on said first terminal, disposing said second terminal in said other open end of said housing with at least a portion of the second terminal in an overlapping but normally spaced relation with at least a portion of the armature, and heat sealing said other end of said tubing to close said other end and rigidly mount said second terminal on said housing.
5. The method set forth in claim 4 in which the step of disposing the first terminal in the opening at one end of said housing includes disposing said first terminal to one side of the axis of said opening, in which the steps of inserting and moving said armature includes disposing said armature generally at a position extending along the axis of said opening, and in which the step of disposing said second terminal in the opening at the other open end of said housing includes positioning said second terminal on the other side of the axis of said opening opposite said one side.
6. A method of making a sealed switch unit from a length of glass tubing, two magnetic terminals, a magnetic armature, and a generally U-shaped pivot structure, the magnetic armature and at least one of the magnetic terminals having contact portions selectively movable into and out of engagement with each other, which method comprises securing the U-shaped pivot structure to a first magnetic terminal adjacent one end of the first magnetic terminal, disposing the first magnetic terminal in one end of the tubing with the pivot structure within the tubing, heating the one end of the tubing to seal the first terminal, inserting the magnetic armature into the tubing through the other open end and pivotally mounting it on the pivot structure with the armature disposed between the bight of the U-shaped pivot structure and the adjacent portion of the first terminal, positioning the second magnetic terminal in the other end of the tubing, and heating the other end of the tubing to seal the second terminal.
7. A method of making a sealed switch unit from a length of dielectric tubing, a magnetic armature, and two magnetic terminals, one of which carries a pivot structure, the magnetic armature and at least one of the magnetic terminals including contact portions selectively movable into and out of engagement with each other, which method comprises disposing the first magnetic terminal in one end of the tubing with the pivot structure within the tubing, sealing the one end of the tubing to rigidly support the first terminal, inserting the magnetic armature into the tubing through the other open end and mounting it on the pivot structure with at least a portion of the armature disposed adjacent the first tominal, positioning the second magnetic terminal in the other end of the tubing with a portion of the second terminal spaced from and overlapping at least a portion of the armature, and sealing the other end of the tubing to rigidly support the second terminal.
8. A method of making a sealed switch unit from a hollow dielectric housing, two magnetic terminals, a
magnetic armature, a resilient spring means, and a pivot structure, the magnetic armature and at least one of the magnetic terminals including contact portions movable into and out of engagement with each other, which method comprises mounting the pivot structure on a first magnetic terminal adjacent one end of the first magnetic terminal, disposing the first magnetic terminal in one end of the housing with the pivot structure within the housing, sealing the first terminal in the one end' of the housing, mounting the resilient spring means on the armature, inserting the magnetic armature into the housing through the other open end and pivotally mounting it on the pivot structure with the resilient spring means interposed between the armature and the first terminal to bias the armature, positioning the second magnetic terminal in the other end of the housing with a portion of the second terminal spaced from and overlapping at least a portion of the armature, and sealing the second terminal in the other end of the housing.
9. A method of making a sealed switch unit from a length of glass tubing, two magnetic terminals, a magnetic armature, a resilient spring means, and a generally U-shaped pivot structure, the magnetic armature and at least one ofthe magnetic terminals having contact portions movable into and out of engagement, which method comprises securing the U-shaped pivot structure to a first magnetic terminal adjacent one end of the first magnetic terminal, disposing the first magnetic terminal in one end of the tubing with the pivot structure within tubing, heating the one end of the tubing to seal the first terminal, securing one end of the resilient spring means to the armature, inserting the magnetic armature into the tubing through the other open end and pivotally mounting it on the pivot structure with the armature disposed between the night portion of the U-shaped pivot structure and the adjacent portion of the first terminal and with the resilient spring means engaging the first terminal, positioning the second magnetic terminal in the other end of the tubing with a portion spaced from and overlapping part of the armature, and heating the other end of the tubing to seal the second terminal.
References titted by the Examiner UNITED STATES PATENTS JOHN F. CAMPBELL, Primary Examiner.

Claims (1)

1. A METHOD OF ASSEMBLING A SWITCHING UNIT OF THE TYPE COMPRISING A PLURALITY OF TERMINALS RESPECTIVELY EXTENDING FROM OPPOSITE ENDS OF A TUBULAR HOUSING AND A MAGNETIC ARMATURE PIVOTALLY SECURED TO ONE OF SAID TERMINALS, THE ARMATURE AND AT LEAST ONE OF THE TERMINALS INCLUDING CONTACT PORTIONS SELECTIVELY MOVABLE INTO AND OUT OF ENGAGEMENT WITH EACH OTHER, WHICH COMPRISES SEALING SAID ONE TERMINAL IN ONE END OF SAID HOUSING, INSERTING THE ARMATURE INTO SAID HOUSING AND PIVOTALLY SECURING IT TO SAID ONE TERMINAL, THEREAFTER INSERTING THE OTHER OF SAID TERMINALS INTO THE END OF SAID HOUSING OPPOSITE SAID ONE END WITH A PORTION OF THE OTHER TERMINAL OVERLAPPING AND SPACED FROM A PORTION OF THE ARMATURE, AND SEALING SAID OTHER TERMINAL TO SAID HOUSING.
US136590A 1957-08-14 1961-09-07 Method of making sealed switches Expired - Lifetime US3182382A (en)

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US678236A US3033956A (en) 1957-08-14 1957-08-14 Switching device
US136590A US3182382A (en) 1957-08-14 1961-09-07 Method of making sealed switches

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3253102A (en) * 1962-09-07 1966-05-24 Siemens Ag Polarized relay
US3317869A (en) * 1965-07-06 1967-05-02 Allen Bradley Co Reed switch having large current carrying capacity
US3341926A (en) * 1964-09-02 1967-09-19 Western Electric Co Terminal assembly apparatus
US4309816A (en) * 1978-09-12 1982-01-12 Matsushita Electric Works, Ltd. Method of manufacturing gas-charged electric switches

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2397123A (en) * 1943-04-30 1946-03-26 Bell Telephone Labor Inc Contact operation
US2459306A (en) * 1944-07-21 1949-01-18 Bell Telephone Labor Inc Contact protection for mercury wetted switch contacts
US2706756A (en) * 1953-10-19 1955-04-19 Bell Telephone Labor Inc Electromechanical switch

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2397123A (en) * 1943-04-30 1946-03-26 Bell Telephone Labor Inc Contact operation
US2459306A (en) * 1944-07-21 1949-01-18 Bell Telephone Labor Inc Contact protection for mercury wetted switch contacts
US2706756A (en) * 1953-10-19 1955-04-19 Bell Telephone Labor Inc Electromechanical switch

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3253102A (en) * 1962-09-07 1966-05-24 Siemens Ag Polarized relay
US3341926A (en) * 1964-09-02 1967-09-19 Western Electric Co Terminal assembly apparatus
US3317869A (en) * 1965-07-06 1967-05-02 Allen Bradley Co Reed switch having large current carrying capacity
US4309816A (en) * 1978-09-12 1982-01-12 Matsushita Electric Works, Ltd. Method of manufacturing gas-charged electric switches

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