Direct current contactor with improved air exhaust channel

Abstract

In a particular embodiment, a direct current contactor with an improved air extraction channel is described, the contactor including a welded plate with a port. The contactor also includes an arc chamber and a plunger tube having a cavity interconnected with the port and the arc chamber by an air passage. In this embodiment, the contactor also includes an upper fixed core disposed at least partially within the plunger tube and a shaft assembly coupled to a shaft disposed within the upper fixed core. The contactor also includes an arc shield within the arc chamber, and one or more vent channels in one or more of the arc shield, the shaft assembly, or the upper stationary core. In this embodiment, one or more of the air passages interconnect the port, the arc chamber, and the plunger tube.

Description

Technical Field

[0001] The invention relates to a DC contactor. Background Art

[0002] Electromechanical switching devices, such as contactors and relays, play a vital role in managing and distributing power within various systems by allowing the controlled connection and disconnection of high-current circuits. These devices are particularly important in electric vehicles, where they contribute to efficient power management and safety. In a typical electric vehicle, one or more high-voltage battery packs provide power to the electric motor via a main contactor that connects the battery to the vehicle's power distribution network. This main contactor operates as an electromechanical switch that is able to open or close a high-current channel, thereby regulating the flow of power from the battery pack to the electric motor and other vehicle components.

[0003] Because main contactors must reliably handle large electrical loads, they are designed to withstand high currents and maintain stable connections over long periods of use. However, the internal components of the contactor, such as metal contacts, are susceptible to degradation due to corrosion if exposed to air and moisture. To mitigate this, the inner chamber of the contactor is evacuated to remove air and water vapor to create a sealed environment. This not only extends the life of the contactor, but also ensures consistent performance by reducing the risk of contact resistance changes or short circuits due to corrosion. Summary of the invention

[0004] Embodiments of the present disclosure describe a direct current (DC) contactor with an improved evacuation channel, which is specifically designed to optimize the vacuum flow rate for rapid evacuation and reduce contact resistance. These improvements include ventilation channels placed in one or more key components such as arc shields, shaft assemblies, and upper fixed cores. By speeding up the evacuation speed, these design improvements achieve a more cost-effective manufacturing process. In addition, the reduced contact resistance minimizes heat generation during operation, thereby improving efficiency. For example, a cavity or orifice within a component can be used to implement a ventilation channel to promote these benefits.

[0005] In a particular embodiment, a DC contactor with an improved evacuation channel is described, the contactor comprising a welded plate having a port. The contactor also includes an arc chamber and a plunger tube, the plunger tube having a cavity, the cavity being interconnected with the port and the arc chamber through an air channel. In this embodiment, the contactor also includes an upper fixed core at least partially disposed within the plunger tube and a shaft assembly coupled to a shaft disposed within the upper fixed core. The contactor also includes an arc shield within the arc chamber, and one or more ventilation channels in one or more of the arc shield, the shaft assembly, or the upper fixed core. In this embodiment, one or more ventilation channels in the air channel interconnect the port, the arc chamber, and the plunger tube.

[0006] In another embodiment, a method of manufacturing a direct current (DC) contactor assembly with an improved exhaust passage is described, the method comprising at least partially incorporating an upper fixed core within a plunger tube. The method also comprises coupling the plunger tube to a welding plate having a port, and coupling a shaft assembly to the welding plate such that an axis of the shaft assembly is disposed within the upper fixed core. In this embodiment, the method also comprises forming an arc chamber around the welding plate such that a cavity of the plunger tube is interconnected with the port and the arc chamber via an air passage. The method also comprises placing an arc shield within the arc chamber. In this embodiment, at least one of the arc shield, the shaft assembly, or the upper fixed core comprises one or more ventilation passages positioned within an air passage interconnecting the port, the arc chamber, and the plunger tube.

[0007] These and other features, aspects and advantages of the present disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, wherein like reference numerals refer to like parts throughout the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1A A cross section of a conventional DC contactor is shown.

[0009] Figure 1B Shows Figure 1A A detailed view of the components of a conventional DC contactor is shown.

[0010] Figure 2A A DC contactor with an improved air extraction channel according to at least one embodiment of the present disclosure is shown.

[0011] Figure 2B Shows Figure 2A Detailed view of the components of a DC contactor.

[0012] Figure 2C Shows Figure 2A Detailed view of a DC contactor.

[0013] Figure 3 A flow chart of an example method of increasing the vacuuming speed on a DC contactor is presented in accordance with at least one embodiment of the present disclosure.

[0014] Figure 4 A flow chart of another example method of increasing the vacuuming speed on a DC contactor according to at least one embodiment of the present disclosure is presented.

[0015] Figure 5 A flow chart of an example method of manufacturing a DC contactor with an improved air extraction channel according to at least one embodiment of the present disclosure is presented.

[0016] Figure 6A flow chart of another exemplary method for manufacturing a DC contactor having an improved air extraction channel according to at least one embodiment of the present disclosure is presented. DETAILED DESCRIPTION

[0017] The terms used to describe specific examples herein are not intended to limit other examples. Whenever singular forms such as "a", "an", and "the" are used, and only using a single element is neither explicitly nor implicitly defined as mandatory, other examples may also use multiple elements to implement the same function. Similarly, when a function is subsequently described as being implemented using multiple elements, other examples may use a single element or processing entity to implement the same function. It should also be understood that the terms "comprise", "comprising", "including", and / or "including" specify the presence of the features, wholes, steps, operations, processes, actions, elements, and / or parts when used, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, processes, behaviors, elements, parts, and / or any groups thereof.

[0018] It is understood that when an element is referred to as being "connected" or "coupled" to another element, the elements may be directly connected or coupled through one or more intermediate elements. If two elements A and B are combined using "or", it should be understood that all possible combinations are disclosed, i.e., only A, only B, and A and B. An alternative wording for the same combination is "at least one of A and B". The same applies to combinations of more than two elements.

[0019] Therefore, although other examples are capable of various modifications and alternative forms, some specific examples thereof are shown in the figures and will be described in detail later. However, this detailed description does not limit further examples to the specific forms described. Further examples may encompass all modifications, equivalents, and alternatives falling within the scope of the present disclosure. Throughout the description of the accompanying drawings, the same numbers refer to the same or similar elements, which, when compared to each other, may be implemented identically or in a modified form while providing the same or similar functions.

[0020] Direct current (DC) contactors undergo a purge process during manufacturing to remove (e.g., via a pump) oxygen and water vapor from the contactor before sealing it. This prevents oxidation of the conductive copper elements, thereby maintaining low contact resistance over the life of the product. Low contact resistance is one of the defining features of electrical contactors. An economically viable purge process allows the removal of residual oxygen and water vapor from the contactor at high speed. This is achieved using a combination of vacuum and nitrogen purges; however, the total purge time is primarily determined by the vacuum process. Vacuum behaves very differently from pressure because the evacuation time and the minimum achievable vacuum level are strongly affected by the size and length of the vacuum channel within the product.

[0021] DC contactors are typically constructed of two major internal volumes: the arc chamber and the plunger tube. Optimal product performance is achieved by removing all oxygen and water vapor from these two volumes. The passageway connecting them is internal to the product, and conventional designs do not attempt to maximize the size of this passageway. The shaft assembly typically covers the opening of the plunger tube. The arc shield also typically blocks or traps a cavity of ambient air within the arc chamber. The small passageway severely restricts vacuum flow and results in long pump-down times and higher residual levels of oxygen and water vapor.

[0022] Additionally, residual oxygen and water vapor within the contactor can cause oxidation of the unplated copper static terminals and moving contacts. Oxidized copper has a higher resistance than bare copper and generates more heat during operation. It is very important to remove as much oxygen and water vapor as possible before sealing the contactor to ensure that the contact resistance and heat generated remain low over the life of the product. If the internal design of the contactor is not appropriate, the vacuum pumping time will be long (resulting in higher manufacturing costs) and the residual gas levels will be higher (resulting in reduced product performance).

[0023] According to an embodiment of the present disclosure, a DC contactor is provided, which combines a ventilation channel in one or more of an upper fixed core, a shaft assembly or an arc shield to provide a wide air channel for vacuuming. Increasing the width of the air channel increases the vacuum capacity and shortens the vacuuming time, thereby improving the contactor performance.

[0024] To further illustrate, Figure 1A and Figure 1B Components of a DC contactor 100 are shown. The contactor 100 includes stationary contacts 102, 104 and a movable contact 106. The contactor 100 also includes an actuator (i.e., movable) assembly including a plunger 108 disposed within a plunger tube 124, a solenoid or coil ( Figure 1A to Figure 1BThe contactor 100 also includes a shaft 110 driven by the plunger during power-on (not shown in the figure), a plunger spring 111, a contact spring 112, and a shaft assembly 114, the shaft assembly 114 driving the moving contact 106 to contact the stationary contacts 102, 104 when the DC contactor is powered on. The contactor 100 also includes an arc chamber 116 formed by a housing 118 and a welding plate 120. The arc chamber 116 includes an arc shield 122 in contact with the welding plate 120 at the bottom of the arc chamber 116. The contactor 100 also includes an upper fixed core 126 located above the plunger tube 124. The shaft extends through the plunger tube 124, the upper fixed core 126 and into the arc chamber 116, and the shaft 110 is attached to the shaft assembly 114 in the arc chamber 116. During the manufacturing process of the contactor 100, a vacuum is generated in the contactor using a port 128. The air passage for the vacuum passes through port 128, under the arc shield 122, under the shaft assembly 114, and between the shaft 110 and the upper fixed core 126. In this example, the air passage connecting the arc chamber and the cavity of the plunger tube is located inside the DC contactor and is restricted. The shaft assembly covers the opening of the plunger tube, and the arc shield blocks or traps the cavity of ambient air in the arc chamber. As described above, the small passage severely restricts the vacuum flow and results in long vacuum times, as well as higher residual amounts of oxygen and water vapor.

[0025] To further illustrate, Figure 2A and Figure 2B A schematic diagram of a DC contactor with an improved air extraction channel according to at least one embodiment of the present disclosure is shown. Figure 2A shows a perspective view of a DC contactor 200, Figure 2B A component diagram of a DC contactor 200 is shown. Figure 2A and Figure 2B The contactor 200 is similar to Figure 1A and Figure 1B The contactor 100, wherein the contactor 200 further comprises a plurality of components, such as a plunger tube 223, a shaft 210, an upper fixed core 226, a shaft assembly 224, a welding plate 220, a port 228, an arc chamber 299, an arc shield 216 and a housing 298, which perform the same Figure 1A to Figure 1B However, in Figure 2A and Figure 2BIn the contactor of FIG. 20 , a vent channel 260 is added to the underside of the arc shield 216 near the weld plate 220 to facilitate air flow between the underside of the arc shield 216 and the weld plate 220 to the port 228. The shaft assembly 224 also includes a vent channel 262 added to the underside of the shaft assembly 224 to facilitate air flow between the underside of the arc shield 216 and the weld plate 220 to the port 228. In the DC contactor 200 , the upper stationary core 226 includes a vent channel 264 added to the shaft opening to facilitate air flow between the shaft 210 and the upper stationary core 224.

[0026] According to an embodiment of the present disclosure, the ventilation channel can be implemented as a cavity, a through hole or an orifice of the arc shield, the shaft assembly and the upper fixed core. Figure 2B The ventilation passage 260 is located on the top side 215 of the arc shield 216 (at Figure 2A ) and bottom side 217 (in Figure 2B 2 and 3. An orifice having an opening (visible in FIG. 2 ) allows airflow through the arc shield 216. As another example, the vent channel 262 below the shaft assembly 224 is a cavity that creates a space between the shaft assembly and the weld plate.

[0027] exist Figure 2B In the example of, three variations of the ventilation channel 264 of the upper fixed core 226A, 226B, 226C are shown. In one configuration 226C, the three through holes are positioned outside the central axis opening of the upper fixed core 226 without expanding the central axis opening. In another configuration 226A, the two through holes are separated and parallel to the central axis opening of the upper fixed core. In the third configuration 226B, the three through holes are separated and parallel to the central axis opening of the upper fixed core. In all of these configurations, the circumference of the central axis opening is not expanded. As described above, a larger shaft opening in the upper fixed core is not ideal because it lowers the position of the shaft 210 within the shaft opening. The ventilation channel 264 allows air to flow while keeping the shaft axis aligned with the axis of the shaft opening.

[0028] The vent passages 260, 262, 264 facilitate air flow between the port 228, the arc chamber 299, and the cavity 296 of the plunger tube 223 for faster and more complete evacuation. The increased vacuum level results in a shorter evacuation time and a reduced residual amount of oxygen and water vapor in the DC contactor 200. Thus, the purification process of removing oxygen and water vapor from the contactor before sealing the contactor during the manufacturing process is shortened. In addition, the vent passages 260, 262, 264 increase the removal of oxygen and water vapor, which reduces oxidation of the conductive copper elements and maintains low contact resistance over the life of the product. Thus, an improved air passage 297 (indicated by arrows) is formed from the port 228 to below the arc shield 216 to below the shaft assembly 224, and then between the shaft 210 and the upper fixed core 226. Those skilled in the art will recognize that in other embodiments, only one or more of the arc shield, shaft assembly, or upper stationary core includes one or more vent passages in the air passage interconnecting the port, arc chamber, and plunger tube. After removing gas from the inner chamber of the DC contactor 500 to a vacuum, the port 228 is sealed, thereby forming a sealed closure for the arc chamber and plunger tube.

[0029] To explain further, Figure 2C A partial view of a DC contactor 200 for increasing the vacuuming speed on the DC contactor according to at least one embodiment of the present disclosure is given. In conventional DC contactors, the welding plate is disposed on top of the upper fixed core. According to the present invention, the upper fixed core 226 extends through the welding plate 220. In this way, the air flow through the ventilation channel 264 in the upper fixed core 226 is increased.

[0030] To explain further, Figure 3 A flow chart of an example method for increasing the vacuum pumping speed on a DC contactor according to the present disclosure is presented. Figure 3 The method includes placing 302 an upper fixed core in a plunger tube, wherein the upper fixed core includes one or more first ventilation channels. For example, the upper fixed core may be FIG. 2A to FIG. 2C The upper fixed core 226 shown in FIG. 304 may be the same or similar to the upper fixed core 226 shown in FIG. 304. The upper fixed core may be placed 302 in the plunger tube by, for example, Figure 2A and Figure 2C This is accomplished by inserting the upper fixed core into the plunger tube as shown.

[0031] Figure 3 The method further includes securing 304 the welding plate to the plunger tube, wherein the plunger tube includes a port. FIG. 2A to FIG. 2C The weld plate is shown secured 304 to a plunger tube, wherein the plunger tube includes a port.

[0032] Figure 3The method further includes securing 306 a shaft assembly to the shaft, wherein the shaft assembly includes one or more second ventilation channels. For example, the shaft assembly may be connected to FIG. 2A to FIG. 2C The shaft assembly 224 shown in FIG. may be the same or similar to the shaft assembly 224 shown in FIG. FIG. 2A to FIG. 2C A shaft assembly is shown secured 306 to the shaft, wherein the shaft assembly includes one or more second vent passages.

[0033] Figure 3 The method also includes placing 308 an arc shield on the weld plate, wherein the arc shield includes one or more third ventilation channels. For example, the arc shield may be disposed with FIG. 2A to FIG. 2C The arc shield 216 shown in FIG. FIG. 2A to FIG. 2C An arc shield is shown placed 308 on the weld plate, wherein the arc shield includes one or more third ventilation channels.

[0034] To explain further, Figure 4 A flow chart of an example method for increasing the vacuum pumping speed on a DC contactor according to the present disclosure is presented. Figure 4 The method includes connecting 402 a pump to a port of a DC contactor. Figure 4 In an example, a DC contactor includes a welding plate having a port, a housing coupled to a first side of the welding plate and defining a chamber, and a plunger tube coupled to a second side of the welding plate. The DC contactor also includes an upper fixed core at least partially disposed within the plunger tube, a shaft assembly coupled to the shaft and disposed above the upper fixed core, an arc shield disposed on the welding plate within the chamber, and one or more ventilation channels in one or more of the arc shield, the shaft assembly, and the upper fixed core. Figure 4 In an example of the invention, one or more ventilation channels provide air passage to the port.

[0035] Figure 4 The method also includes evacuating 404 gas from the interior of the DC contactor through the port. Evacuating 402 gas from the interior of the DC contactor through the port involves connecting a vacuum pump to the evacuation port and safely delivering the gas to a recovery tank or closed system. The pump creates a vacuum, thereby extracting the gas while ensuring that no leaks occur during the process.

[0036] also, Figure 4The method also includes forming 406 an airtight sealed closure for the arc chamber and the plunger tube by sealing the port after evacuating the gas from the inside of the DC contactor through the port. Depending on the design requirements and materials involved, the ports of the DC contactor can be sealed after evacuating the gas by a variety of methods. For example, the port can be sealed using a precision welding process, such as laser welding or TIG (tungsten inert gas). As another example, a welding or brazing material can be melted and applied to the port to form a seal. In another example, a high-strength, airtight epoxy resin or adhesive is applied to seal the port. As another example, a special plug or cover can be inserted into the port and mechanically fastened (e.g., by crimping or threading) or bonded using a sealing material. In some cases, a glass-to-metal seal can be used, wherein a glass material is melted and bonded to a metal port to form an airtight seal. As another example, a crimping process can be used to mechanically compress a metal collar or seal around a port opening.

[0037] To explain further, Figure 5 A flow chart of an example method for manufacturing a DC contactor with an improved air extraction channel according to the present disclosure is presented. Figure 5 The method includes at least partially incorporating 502 an upper stationary core within the plunger tube. For example, the upper stationary core may be FIG. 2A to FIG. 2C The plunger tube may be the same as or similar to the upper fixed core 226 shown in FIG. FIG. 2A to FIG. 2C The upper fixed core 502 may be at least partially incorporated into the plunger tube by, for example, FIG. 2A to FIG. 2C This is shown being achieved by inserting the upper fixed core into the plunger tube.

[0038] Figure 5 The method also includes coupling 504 the plunger tube to a welding plate having a port. For example, the welding plate may be connected to FIG. 2A to FIG. 2C The illustrated welding plate 220 is the same or similar. Coupling 504 the plunger tube to the welding plate having ports may be accomplished by welding the plunger tube to the welding plate.

[0039] also, Figure 5 The method also includes coupling 506 a shaft assembly to the welding plate such that the shaft of the shaft assembly is disposed within the upper fixed core. FIG. 2A to FIG. 2C The shaft assembly 224 shown in FIG. 506 is connected to the welding plate so that the shaft of the shaft assembly is disposed in the upper fixed core portion by welding the shaft assembly to the welding plate.

[0040] Figure 5 The method also includes forming 508 an arc chamber around the welding plate so that the cavity of the plunger tube is interconnected with the port and the arc chamber through the air passage. For example, the arc chamber can be connected to FIG. 2A to FIG. 2CThe arc chamber 299 shown in FIG. 508 is formed around the welding plate so that the cavity of the plunger tube is interconnected with the port and the arc chamber through the air passage. This can be achieved by welding the housing to the welding plate.

[0041] Figure 5 The method also includes positioning 510 an arc shield within the arc chamber. For example, the arc shield may be positioned with FIG. 2A to FIG. 2C Positioning 510 the arc shield within the arc chamber may be accomplished by aligning the arc shield around the shaft assembly and over the weld plate.

[0042] exist Figure 5 In an example method, at least one of the arc shield, the shaft assembly, or the upper stationary core includes one or more vent passages positioned within an air passage interconnecting the port, the arc chamber, and the plunger tube.

[0043] To explain further, Figure 6 A flow chart of an example method for manufacturing a DC contactor with an improved air extraction channel according to the present disclosure is presented. Figure 6 The method is similar to Figure 5 method, in which Figure 6 Methods include Figure 5 In addition, Figure 6 The method also includes connecting 602 a pump to the port. For example, a suitable pump for evacuating air and water from the DC contactor chamber may be a two-stage rotary vane vacuum pump that has the ability to handle gases and small amounts of steam. This type of pump is effective for applications that require rapid evacuation and low pressure because it produces a strong vacuum that can effectively remove air and moisture from an enclosed space. Connecting 602 the pump to the port may be accomplished by connecting one end of a hose to the port and connecting the other end of the hose to the inlet of the pump.

[0044] Figure 6 The method also includes evacuating 604 gas from the interior of the DC contactor through the port. Extracting 602 gas from the interior of the DC contactor through the port can be achieved by turning on a pump and pumping gas out of the DC contactor through the port.

[0045] In view of the above, improving the evacuation speed of the DC contactor includes providing a vent channel to facilitate air flow between the ports in the DC contactor welding plate or other external surface and the arc chamber and plunger tube, thereby evacuating faster and more completely. The increased vacuum degree results in a shorter evacuation time and a lower residual amount of oxygen and water vapor in the DC contactor. Therefore, the purification process of removing oxygen and water vapor from the contactor before sealing the contactor during the manufacturing process is shortened. In addition, the vent channel increases the removal of oxygen and water vapor, which alleviates the oxidation of the conductive copper components and maintains low contact resistance over the life of the product.

[0046] The flowcharts and diagrams in the figures illustrate the architecture, functions and operations of the implementation of the apparatus and method according to various embodiments of the present disclosure. In some alternative implementations, the functions described in the blocks or steps in the method may not occur in the order shown in the figure. For example, depending on the functions involved, two blocks shown in succession may actually be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order.

[0047] The advantages and features of the present disclosure can be further described by the following statements:

[0048] 1. A direct current (DC) contactor assembly with an improved evacuation passage, the assembly comprising: a port; an arc chamber; a plunger tube having a cavity interconnected with the port and the arc chamber by an air passage; an upper fixed core at least partially disposed within the plunger tube; a shaft assembly coupled to a shaft disposed within the upper fixed core; an arc shield within the arc chamber; and one or more ventilation passages in one or more of the arc shield, the shaft assembly, or the upper fixed core, wherein the one or more ventilation passages in the air passage interconnect the port, the arc chamber, and the plunger tube.

[0049] 2. The DC contactor assembly of statement 1, wherein the arc shield comprises at least one vent channel.

[0050] 3. A DC contactor assembly according to statement 1 or 2, wherein the at least one ventilation channel is arranged on a lower side of the arc shield that is connected to the welding plate.

[0051] 4. A DC contactor assembly according to any one of statements 1-3, wherein the shaft assembly includes at least one ventilation channel.

[0052] 5. A DC contactor assembly according to any one of statements 1-4, wherein the at least one ventilation channel is provided on a lower side of the shaft assembly that interfaces with the upper stationary core.

[0053] 6. A DC contactor assembly according to any one of statements 1 to 5, wherein the upper fixed core includes at least one ventilation channel.

[0054] 7. A DC contactor assembly according to any of Statements 1-6, wherein the at least one vent passage provides a passage between the cavity in the plunger tube and the arc chamber.

[0055] 8. A DC contactor assembly according to any of Statements 1-7, wherein the one or more vent channels are configured so that gas within the arc chamber and the plunger tube is evacuated through the one or more vent channels and the port.

[0056] 9. The DC contactor assembly of any one of Statements 1-8, wherein one or more vent passages are provided in each of the arc shield, the shaft assembly, and the upper stationary core.

[0057] 10. The DC contactor assembly according to any one of statements 1-9 further includes: at least one stationary main contact; and a moving main contact connected to the shaft, wherein the shaft causes the moving main contact to move between an open position and a closed position relative to the at least one stationary main contact.

[0058] 11. A DC contactor assembly according to any one of statements 1 to 10, further comprising: one or more springs for applying a force to separate the moving main contact from the at least one stationary main contact.

[0059] 12. A method for manufacturing a direct current (DC) contactor assembly with an improved exhaust passage, the method comprising: at least partially incorporating an upper fixed core into a plunger tube; connecting the plunger tube to a welding plate having a port; connecting an axis assembly to the welding plate so that an axis of the axis assembly is disposed within the upper fixed core; forming an arc chamber around the welding plate so that a cavity of the plunger tube is interconnected with the port and the arc chamber through an air passage; and positioning an arc shield within the arc chamber; wherein at least one of the arc shield, the axis assembly or the upper fixed core comprises one or more ventilation passages, and the one or more ventilation passages are positioned within an air passage interconnecting the port, the arc chamber and the plunger tube.

[0060] 13. The method according to statement 12 also includes: connecting a pump to the port; evacuating gas from inside the DC contactor through the port; after evacuating gas from inside the DC contactor through the port, forming a sealed closure for the arc chamber and the plunger tube by sealing the port.

[0061] 14. The method of statement 12 or 13, wherein the arc shield comprises at least one vent channel.

[0062] 15. The method of any of statements 12-14, wherein the at least one vent channel is disposed on an underside of the arc shield that interfaces with the weld plate.

[0063] 16. A method according to any of statements 12-15, wherein the shaft assembly includes at least one vent channel.

[0064] 17. A method according to any one of statements 12-16, wherein the at least one vent channel is provided on an underside of the shaft assembly that meets the upper stationary core.

[0065] 18. A method according to any of statements 12-17, wherein the upper fixed core comprises at least one ventilation channel.

[0066] 19. The method of any of Statements 12-18, wherein the at least one vent passage provides a passage between the cavity in the plunger tube and the arc chamber.

[0067] 20. The method of any of Statements 12-19, wherein one or more vent channels are provided in each of the arc shield, the shaft assembly, and the upper stationary core.

[0068] One or more embodiments may be described herein by means of method steps that illustrate the performance of specified functions and their relationships. For ease of description, the boundaries and order of these functional building blocks and method steps are arbitrarily defined herein. As long as the specified functions and relationships are properly performed, alternative boundaries and orders may be defined. Therefore, any such alternative boundaries or orders are within the scope and spirit of the claims. In addition, for ease of description, the boundaries of these functional building blocks are arbitrarily defined. As long as certain important functions are properly performed, alternative boundaries may be defined. Similarly, flow chart blocks may also be arbitrarily defined herein to illustrate certain important functions.

[0069] To the extent used, the flow diagram block boundaries and sequence could have been defined otherwise and still perform the certain significant functionality. Thus, such alternate definitions of both functional building blocks and flow diagram blocks and sequences are within the scope and spirit of the claims.

[0070] It can be understood from the above description that the various embodiments of the present disclosure may be modified and changed without departing from the true spirit of the present disclosure. The description in this specification is for illustrative purposes only and should not be interpreted as limiting. The scope of the present disclosure is limited only by the language of the appended claims.

Claims

1. A DC contactor assembly with an improved air extraction channel, the assembly comprising: port; Arc chamber; a plunger tube having a cavity interconnected with the port and the arc chamber by an air passage; an upper stationary core at least partially disposed within the plunger tube; a shaft assembly coupled to a shaft disposed within the upper stationary core; an arc shield, the arc shield being within the arc chamber; as well as One or more vent passages in one or more of the arc shield, the shaft assembly, or the upper stationary core, the one or more vent passages in the air passage interconnecting the port, the arc chamber, and the plunger tube.

2. The DC contactor assembly according to claim 1, wherein: The arc shield includes at least one vent channel.

3. The DC contactor assembly according to claim 2, wherein: The at least one ventilation channel is arranged on a lower side of the arc shield adjoining the welding plate.

4. The DC contactor assembly according to claim 1, wherein: The shaft assembly includes at least one vent passage.

5. The DC contactor assembly according to claim 4, wherein: The at least one vent passage is disposed on an underside of the shaft assembly that interfaces with the upper stationary core.

6. The DC contactor assembly according to claim 1, wherein: The upper stationary core includes at least one ventilation channel.

7. The DC contactor assembly according to claim 6, wherein: The at least one vent passage provides a passage between the cavity in the plunger tube and the arc chamber.

8. The DC contactor assembly according to claim 1, wherein: The one or more vent channels are configured such that gas within the arc chamber and the plunger tube is evacuated through the one or more vent channels and the port.

9. The DC contactor assembly according to claim 1, wherein: The one or more vent passages are disposed in each of the arc shield, the shaft assembly, and the upper stationary core.

10. The DC contactor assembly according to claim 1, further comprising: At least one static main contact; and A moving main contact is coupled to the shaft, wherein the shaft moves the moving main contact relative to the at least one stationary main contact between an open position and a closed position.

11. The DC contactor assembly according to claim 10, further comprising: One or more springs for applying a force to separate the moving main contact from the at least one stationary main contact.

12. A method for manufacturing a DC contactor assembly having an improved air extraction channel, the method comprising: Incorporating an upper stationary core at least partially within the plunger tube; coupling the plunger tube to a welding plate having a port; coupling a shaft assembly to the welding plate such that a shaft of the shaft assembly is disposed within the upper stationary core; forming an arc chamber around the welding plate such that the cavity of the plunger tube is interconnected with the port and the arc chamber through an air passage; as well as positioning an arc shield within the arc chamber; Wherein at least one of the arc shield, the shaft assembly or the upper stationary core includes one or more vent passages positioned within the air passage interconnecting the port, the arc chamber and the plunger tube.

13. The method according to claim 12, further comprising: Connect a pump to the port; evacuating gas from the interior of the DC contactor through the port; as well as After evacuating gas from the interior of the DC contactor through the port, a hermetically sealed closure for the arc chamber and the plunger tube is formed by sealing the port.

14. The method according to claim 12, wherein: The arc shield includes at least one vent channel.

15. The method according to claim 14, wherein: The at least one ventilation channel is disposed on a lower side of the arc shield adjoining the welding plate.

16. The method according to claim 12, wherein: The shaft assembly includes at least one vent passage.

17. The method according to claim 16, wherein: The at least one vent passage is disposed on an underside of the shaft assembly that interfaces with the upper stationary core.

18. The method according to claim 12, wherein: The upper stationary core includes at least one ventilation channel.

19. The method according to claim 18, wherein: The at least one vent passage provides a passage between the cavity in the plunger tube and the arc chamber.

20. The method according to claim 12, wherein: The one or more vent passages are disposed in each of the arc shield, the shaft assembly, and the upper stationary core.

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