Electrical device with guided contact member

Abstract

A contactor device includes a movable contact configured to selectively open / close an electrical circuit. The switch device can include a shaft coupled to the movable contact via a coupler. The coupler can include a first alignment feature configured to move with the coupler and the movable contact. The first alignment feature is configured to cooperate with a second alignment feature relative to which the movable contact moves. The first alignment feature and the second alignment feature cooperate to control rotation of the shaft and the movable contact.

Description

ELECTRICAL DEVICE WITH GUIDED CONTACT MEMBERFIELD OF THE TECHNOLOGY

[0001] The subject disclosure relates to electrical switching devices, such as contactor devices and electrical fuse devices, and more particularly to improved contactor devices with a guided movable contact element.BACKGROUND OF TECHNOLOGY

[0002] Many conventional devices are known to selectively power on or off electrical devices. Electrical contactors, e.g., high-voltage DC contactors, and fuses, e.g., electrical fuses and / or pyrotechnic fuses, are conventionally available and used in electrical systems. Contactors may be configured to interrupt or complete a circuit to control electrical power to and / or from a device.

[0003] In many conventional systems, a contactor is configured as a switch, e.g., to selectively allow / disallow current flow. In some examples, one or more movable contacts may be coupled to a shaft. In these examples, the shaft may be movable, e.g., by an actuator, to selectively move the movable contact(s) into and out of contact with one or more fixed contacts. In some examples, the shaft (and the movable contact(s)) may be biased away from the fixed contact(s), e g., to “open” the contactor and prevent current flow through the contactor. For example, a return spring may bias the shaft to an open position. In some conventional examples, the shaft may be subject to rotation about its axis and in some examples the rotation can be great enough to cause misalignment of the movable contact and the fixed contacts. This misalignment can lead to nonfunctioning of the contactor, arcing, and / or other undesirable results.

[0004] Accordingly, there is a need in the art for improved switching devices and methods of making such devices. There also is a need in the art for improved devices with increased life spans and / or reduced complexity and / or cost.SUMMARY OF THE TECHNOLOGY

[0005] The subject technology relates to improved electrical devices and methods of making and using those devices. In examples, aspects of this disclosure relate to improved switching devices with features for guiding a movable contact. For example, aspects of this disclosure can relate to features and / or systems that reduce and / or prohibit rotation of the movable contact during cycling. This reduced rotation may result in improved alignment of the movable contact with fixed contacts, e.g., to ensure proper functioning of the contactor. In other examples, aspects of this disclosure may relate to reducing wear on housings and / or other components of electrical devices, e.g., caused by rotation of the movable contact. This reduced wear may result in longer life of the contactor, thereby requiring less frequent maintenance and / or replacement.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] So that those having ordinary skill in the art to which the disclosed systems and techniques pertain will more readily understand how to make and use the same, reference may be had to the following drawings.

[0007] FIG. 1 is a perspective, section view of an electrical device, including a housing and electrical components, in accordance with aspects of this disclosure.

[0008] FIG. 2A is a partial cross-sectional view of portions of the electrical device of FIG. 1, in accordance with aspects of this disclosure.

[0009] FIG. 2B is a perspective view of aspects of an actuator assembly integrating a first alignment member and used with the electrical device 100, in accordance with aspects of this disclosure.

[0010] FIG. 3 is a perspective view of an arc shield integrating a second alignment member for cooperating with the first alignment member and used with the electrical device 100, in accordance with aspects of this disclosure.DETAILED DESCRIPTION

[0011] The subject technology overcomes many of the prior art problems associated with electrical devices. In brief summary, the subject technology provides improved electrical devices including a contactor design that may have improved performance and / or longer functional life compared to other conventional electrical devices. In examples, the electrical device may have two discrete operation states, including a first operating state and a second operating state. In the first operation state, the device is open, e.g., such that no voltage or current flows through the device. In the second operating state, the device is closed. In examples, the electrical device can include a coil that is energized to cause one or more movable contacts to move into contact with one or more fixed or stationary contacts, thereby completing a circuit, e.g., to configure the device in the second operating state. In the second operating state, current, e.g., from a high voltage source, may flow through the device.

[0012] In aspects of this disclosure, the electrical device can include an actuator assembly that cooperates with a coil to selectively configure the electrical device in the first or second operating state, e.g., by cycling the movable contact relative to the fixed contact(s). For example, the actuator assembly may include the movable contact(s), a shaft, and a coupler that couples themovable contact(s) to the shaft. The coupler can also include one or more posts or protrusions that extend, e.g., laterally, from the coupler.

[0013] Also in examples of this disclosure, the electrical device may include a guide relative to which the actuator assembly moves. The guide is positioned to cooperate with the posts or protrusions, e.g., to limit or prevent rotation of the actuator assembly relative to the guide. In some examples, the guide may be an arc shield member. In examples, the guide may be fixed relative to a housing member of the electrical device, and may define a slot, groove, or track, e.g. a vertical slot or track, with which the posts or protrusions cooperate. For instance, as the actuator assembly is cycled, the slot / track may allow for unimpeded motion of the posts in an axial (e.g., vertical) direction, but restrict lateral (e.g., rotational) movement. In other examples, the track or slot can impart some rotation on the movable contact, e.g., to further distance the movable contact from the fixed contacts.

[0014] In other examples of this disclosure, the guide may alternatively include a post or protrusion and the coupler and / or other portion of the actuator assembly may define a slot or groove. In this example, the pin will remain stationary during cycling, with the groove or track moving relative thereto.

[0015] Aspects of this disclosure also include a contact guide that is configured to reduce or prevent contact of the movable contact with alignment components. For example, some conventional systems may include ribs or other protrusions disposed proximate the movable contact member. For example, in some conventional arrangements, the ribs may extend from an inner surface of a housing of the electrical device toward the movable contact member. In this example, the ribs may be contacted by an outer edge of the movable contact member. For instance,the ribs may act to maintain a desired orientation of the movable contact member as the movable contact member is cycled and / or when the movable contact member is in a position contacting the fixed contact member(s). In some conventional arrangements, the ribs may be made of ceramic. However, ceramic is difficult to control dimensionally, and ceramic ribs are prone to create high friction and wear on the movable contact member. Such wear can result in undesirable conductive debris inside the device. Other conventional arrangements may use plastic ribs. However, when a high voltage current passes through the movable contact member, the movable contact member can heat up, often reaching temperatures of 150-degrees Celsius or more. When the ribs are made of a malleable material, e.g., plastic, the ribs can be undesirably deformed by contact with the movable contact member, especially at high heats. Moreover, when the movable contact member is made from a malleable material, like copper, contact with the ribs can act to deform the movable contact, especially at high heats.

[0016] In aspects of this disclosure, an alignment of the movable contact may be achieved using a pin and slot arrangement, as noted above. As the pin and slot are spaced from the movable contact member, the movable contact member does not contact (and is not contacted by) any alignment feature, thereby obviating some shortcomings associated with the described conventional arrangements.

[0017] Without limitation, the devices and techniques described herein may provide improved electrical devices, which may be less complex, may be cheaper to manufacture and / or use, and / or that may have improved safety and / or result in improved system protection, when compared to similar conventional systems. For instance, as discussed above, the use of the movable contact guide as detailed herein may result in reduced destruction and failure caused by rubbing of the movable contact with alignment ribs. In some examples, inclusion of the movablecontact guide can also or alternatively allow for use of a simpler or cheaper components. For example, because dimensionally-precise ceramic ribs may be unnecessary, simpler housing components may be used.

[0018] While aspects of this disclosure may be particularly useful in certain applications, like DC contactors for use in high voltage electrical systems, the systems and techniques described herein may be useful with any electrical devices that incorporate movable contact members.

[0019] Aspects of the disclosure will now be explained in more detail with reference to the Figures.

[0020] FIG. 1 is a cross-sectional view of an electrical device 100. In examples of this disclosure, the electrical device 100 may be a switch or contactor assembly, such as a DC contactor. In other examples, the electrical device may be a hybrid device, e.g., that includes a fuse or disconnect (such as a pyrotechnic disconnect). As will be appreciated from this disclosure, aspects of this disclosure may be used with any device that incorporates a return spring to bias one or more movable contacts from a fixed contact.

[0021] In the illustrated example, the electrical device 100 includes an electrical device housing 102. The housing 102 includes a housing base 104 disposed between an upper housing portion 106 and a lower housing portion 108. In the example of FIG. 1, the upper housing portion 106 is configured to cooperate with the housing base 104. In examples, the switch assembly housing base 104 and portions of the upper housing portion 106 may be metal parts, e.g., steel parts, welded to each other. The upper housing portion 106 defines, at least in part, an upper housing volume 110. In some examples, the upper housing volume 110 may be a hermetically- sealed volume. An electronegative gas may be contained in the upper housing volume 110. Thishermetically sealed configuration can help mitigate or prevent electrical arcing between adjacent conductive elements, and in some embodiments, helps provide electrical isolation between conductive contacts, as detailed further herein. In some examples, the upper housing volume 110 can be under vacuum conditions, and can be hermetically sealed using known means of generating hermetically sealed electrical devices.

[0022] Features of the electrical device 100 are disposed in the upper housing volume 110. For example, the view of FIG. 1 shows two fixed contacts 112 coupled to the upper housing portion 106. The fixed contacts 112 are disposed partially in the upper housing volume 110 and are configured to electrically connect internal components (detailed further herein) of the electrical device 100 to external circuitry, for example, to an electrical system or device. For example, the fixed contacts 112 may be terminals configured to facilitate connection of first electrical leads (not shown) from a voltage source to second electrical leads (also not shown) associated with a load to be powered by the voltage source, the fixed contacts 112, e.g., as fixed, or stationary contacts.

[0023] The electrical device 100 also includes a movable contact 114. As detailed further herein, the movable contact 114 is movable between a first position spaced from the fixed contacts 112 and a second position contacting the fixed contacts 112. The first position is shown in FIG. 1, and the movable contact 114 may be moved upward (in the orientation of FIG. 1) from the illustrated position to the second position. In the illustrated example, the movable contact 114 is a generally elongate member that, in the second position, not illustrated but just described, can simultaneously contact both of the fixed contacts 112. Accordingly, the movable contact 114 can selectively couple the two fixed contacts 112, to facilitate current flow between the fixed contacts 112 and thus through the electrical device 100.

[0024] The electrical device 100 also includes an actuator assembly 116 configured to, among other functions, facilitate selective opening and closing of the electrical device 100, e.g., by facilitating selective movement of the movable contact 114 into and out of contact with the fixed contacts 112. In examples, the actuator assembly 116 can include the movable contact 114 and / or may be operatively coupled to the movable contact 114.

[0025] As illustrated in FIG. 1., the actuator assembly 116 is illustrated as including a shaft 118, a coupler 120, and a plunger 122.

[0026] In the example, the shaft 118 is disposed such that a first end 124 (e g., an upper end in the orientation of FIG. 1) is positioned in the upper housing volume 110 defined by the upper housing 106 and the base 104. The first end 124 is coupled to the movable contact 114, e.g., via the coupler 120. An opposite, second end 126 of the shaft 118 extends through the base 104 into a lower housing volume 128 defined at least in part by the lower housing portion 108. The second end 126 of the shaft 118 is coupled to the plunger 122.

[0027] In more detail, FIG. 1 shows that the coupler 120 that includes a base 130 and opposing spaced sides 132 extending upward (in the orientation of FIG. 1) from the base 130. In this example, the opposing sides 132 define openings 134 through which portions of the movable contact 114 extend. Specifically, the movable contact 114 is a substantially elongate or bar-shaped member extending from a first end 136 to a second end 138. The movable contact 114 extends through the openings 134 in the spaced sides 132 such that the first end 136 and the second end 138 are disposed on opposite sides of the spaced sides 132 of the coupler 120 (and generally aligned vertically with the fixed contacts 112).

[0028] In the illustrated example, the base 130 of the coupler is secured to the first end 124 of the shaft 118. In examples, the base 130 may be molded onto the first end 124 of the shaft 118.For instance, the base 130 may be a polymeric material formed on the shaft 118 via an overmolding process or the like. In examples, the polymeric material may configure the base to electrically isolate the movable contact 114 from the remaining actuator components (e.g., the shaft 118) and / or portions of the housing 102 (e.g., the base 104). As detailed further herein, the base 130 can also incorporate one or more alignment features for maintaining a desired rotational orientation of the movable contact 114 and / or other aspects of the actuator assembly 116.

[0029] In the illustrated examples, the sides 132 of the coupler 120 may be integrated with the base 130. For example, the base 130 may be overmolded over a bottom portion of the sides 132. However, the sides 132 may be otherwise coupled, secured, or attached to the base 130 in other examples. In the illustrated example, the sides 132 may approximate an inverted U-shape to define the openings 134 which provide clearance for the ends 136, 138 of the movable contact 114, as noted above. The movable contact 114 may be movable in the openings 134 relative to the sides 132 and the base 130.

[0030] In the example of FIG. 1, a biasing spring 140 is disposed between the base 130 and the movable contact 114. More specifically, the biasing spring 140 biases the movable contact 114 away from the shaft 118 and against a top edge of the openings 134 in the sides 132. Thus, in the illustrated example, the shaft 118 is secured to the coupler 120 (e.g., to the base 130 of the coupler 120) and the biasing spring 140 biases the movable contact 114 against the top edge of the openings 134 in the sides 132 of the coupler 120. Accordingly, movement of the shaft 118, e.g., along an axis 141 of the shaft 118, will cause corresponding movement of the coupler 120, the biasing spring 140, and the movable contact 114. For example, when the shaft 118 is caused tomove downward in the orientation of FIG. 1, the movable contact 114 moves away from the fixed contacts 112. Alternatively, when the shaft 118 is caused to move upward in the orientation ofFIG. 1, the movable contact 114 is moved toward, and eventually into contact with, the fixed contacts 112. Continued movement of the shaft 118 in the upward direction (in the orientation of FIG. 1) when the movable contact 114 contacts the fixed contacts 112, can result in continued travel of the coupler 120 relative to the movable contact 114, e.g., resulting from compression of the biasing spring 140. In this example, the biasing spring 140 can compensate for overtravel of the shaft 118, e.g., to prevent destructive contact of the movable contact 114 with the fixed contacts 112. In other examples, the biasing spring 140 may not be included.

[0031] As also illustrated in FIG. 1, the base 130 of the coupler 120 includes a tapered protrusion 142. In examples, the protrusion 142 may be provided to help maintain positioning and / or orientation of the biasing spring 140. For example, an outer diameter of the protrusion 142 may be similar to or slightly smaller than an inner diameter of the biasing spring 140, e.g., to limit or prevent lateral movement of the biasing spring 140 relative to the coupler 120.

[0032] FIG. 1 also shows a lower yoke 144 disposed below and in contact with the movable contact 114. In examples, the lower yoke 144 may be a metal component configured to cooperate with an upper yoke 146 to provide a metallic or conductive “ring” around the movable contact 114 when the movable contact 114 contacts the fixed contacts 112. For example, the lower yoke 144 and the upper yoke 146 may cooperate to enhance or control an electromagnetic field generated by current passing through the movable contact 114. In the example, the upper yoke 146 is coupled to the upper housing 106, e.g., such that the shaft 118, the movable contact 114, the coupler 120, and the lower yoke 144 (e.g., the actuator assembly 116) move relative to the upper yoke 146. Inother examples, however, the upper yoke 146 may be coupled to the movable contact 114 and / or to the lower yoke 144.

[0033] FIG. 1 also shows an arc shield member 148. The arc shield member 148 may be a polymeric or other insulative material that acts as an insulator or barrier, e.g., in case of arcing in the upper housing volume 110 or the like. In the illustrated example, the arc shield 148 is disposed on the housing base 104 and defines an opening that generally surrounds a portion of the actuator assembly 116, e.g., the coupler 120. As detailed further below, the arc shield member 148 may incorporate an alignment feature that cooperates with an alignment feature, on the actuator assembly 116 to resist rotation of the actuator assembly 116.

[0034] The configuration of FIG. 1 is provided for example only. For example, modifications to the actuator assembly 116 are contemplated and will be appreciated by those having ordinary skill in the art with the benefit of this disclosure. For example, the lower yoke 144 and / or the upper yoke 146 may be omitted. Also, in some examples, aspects of the coupler 120 may be omitted. For instance, the shaft 118 may be coupled directly to the movable contact 114, e.g., instead of via the coupler 120. For instance, a hole may be formed the movable contact 114 and the shaft 118 may extend through the hole in one non-limiting example. In this example, the shaft 118 may include a flanged head and the flanged head may contact an upper surface of the movable contact 114. Other example arrangements also are contemplated. Any arrangement in which movement of the shaft causes corresponding movement of the movable contact 114 may be implemented.

[0035] As also shown in FIG. 1, the shaft 118 extends through the base plate 104, such that the second end 126 of the shaft 118 is disposed in the lower volume 128, defined at least in partby the lower housing portion 108. In the illustrated example, an opening 150 or hole is formed in the base 104, and the shaft 118 extends through the opening 150. In the illustrated example, the opening 1150 is sized to have a diameter smaller than an outer extent of the coupler 120 (e.g., the base 130 of the coupler 120) such that the coupler 120 contacts the base 104 and does not pass through the opening 150. Also in the illustrated example, an alignment plug 152 is disposed at least partially in the opening 150. The alignment plug 152 may be configured for fitting into the opening 150, e.g., via a press fit. When present, the alignment plug 152 also defines an opening through which the shaft 118 extends.

[0036] When used, the alignment plug 152 may facilitate locating one or more additional components of the electrical device 100. For example, the alignment plug 152 extends from the opening 150 (and the base 104) into the lower volume 128. In the illustrated example, a distal end (e.g., spaced from the base 104) of the alignment plug 152 is sized to extend into a plunger tube 154. For example, an inner diameter of the plunger tube 154 and an outer diameter of the alignment plug 152 may be sized to allow for the alignment plug 152 to be disposed in the plunger tube 154. In some examples, the alignment plug 152 can be press fit into the plunger tube 154 (or the plunger tube 154 can be press fit over the alignment plug 152). As detailed further below, the plunger tube 154 can house or otherwise retain the plunger 122.

[0037] As also illustrated in FIG. 1, the alignment plug 152 may also define a bore 156. The shaft 118 passes through the bore 156. Moreover, the bore 156 is sized to receive at least a portion of a return spring 158. In the example, the return spring 158 is a compression spring extending from a first end disposed in the bore 156 (and contacting an inner, bottom surface of the bore 156) of the alignment plug 152 to a second end spaced from the first end along an axis of the return spring 158. The second end of the return spring 158 contacts an upper surface 160 ofthe plunger 122. In the illustrated example, because the alignment plug 152 is fixed to the base104 of the housing 102, the return spring 158 biases the plunger 122 away from the base 104, e.g., in a downward direction in the orientation of FIG. 1. Moreover, because the second (e.g., lower) end of the shaft 118 also is coupled to the plunger 122, the return spring 158 biases the shaft 118 and the movable contact 114, e.g., away from the fixed contacts 112.

[0038] The actuator assembly 116 is driven by a coil 162, e.g., a DC coil. The coil 162 may be selectively energized. For example, and as shown in FIG. 1, the coil 162 is disposed proximate the plunger tube 154. In examples, the coil 162 is a cylindrical coil that is disposed around the plunger tube 154. The plunger 122 is disposed in the plunger tube 154, and the plunger 122 is movable relative to the plunger tube 154. In examples, the plunger tube 154 may be fixed relative to the coil 162 and the plunger 122 is free to move axially relative to the plunger tube 154 (and the coil 162) in response to activation / deactivation of the coil 162. As detailed above, the plunger 122 is coupled to the second end 126 of the shaft 118. The return spring 158 is positioned on the shaft 118 between the upper surface 160 of the plunger 122 and a lower surface of the housing base 104 (e.g., the alignment plug 152 inFIG. 1). The return spring 158 biases the plunger 122 (and thus the shaft 118) away from the base 104, e.g., in a downward direction in FIG. 1 along the axis 141. Accordingly, when the coil 162 is not charged, the return spring 158 biases the shaft 118 (via the plunger 122) to distance the movable contact 114 from the fixed contacts 112.

[0039] The example of FIG. 1 shows a normally open contactor, e.g., such that the return spring 158 biases the movable contact 114 away from the fixed contacts 112, and the plunger is actuated against a biasing force of the return spring 158 to close the circuit (e.g., by contacting the movable contact 114 to the fixed contacts 112). Aspects of this disclosure may also be applied to other contactor constructions, including normally closed contactors. In a normally closedcontactor, the return spring 158 may bias the movable contact toward the fixed contacts 112 and the plunger is actuated against the biasing force of the return spring 158 to open the circuit (e.g., by separating the movable contact 114 from the fixed contacts 112).

[0040] Regardless of the type of contactor, e.g., normally open or normally closed, the shaft 118 may be cylindrical. Accordingly, as the shaft 118 is cycled between positions, e.g., to place the movable contact 114 into and out of contact with the fixed contacts 112, the shaft 118 may be prone or able to rotate about its axis. As will be appreciated, if the shaft 118 rotates, the coupler 120 and the movable contact 114 also will rotate. Rotation of the movable contact 114 may be undesirable. For instance, rotation can lead to misregistration of the movable contact 114 and the fixed contacts 112, e.g., because the movable contact 114 is rotated relative to the fixed contacts 112. Rotation of the shaft can also cause unwanted binding, e.g., because the movable contact 114 and / or other components coming into contact with other features of the electrical device 100. This misregistration and / or binding can lead to malfunctions and / or failure of the device 100.

[0041] Aspects of this disclosure provide systems and components that may reduce or eliminate undesirable rotation of the actuator assembly 116. Specifically, some aspects of this disclosure include a first alignment feature associated with the actuator assembly 116 that is configured to cooperate with a second alignment feature fixed in the electrical device 100. The second alignment feature can be associated with the arc shield member 148. In examples detailed further herein, the first alignment feature can be a post or slot and the second alignment feature can include the other of the post or the slot. In arrangements detailed herein, the post is disposed at least partially in the slot such that, during movement of the actuator assembly 116 in the housing 102, the post and the slot cooperate to define a travel path. For example, in examples describedherein, the slot may be substantially parallel to the axis of the shaft 118, such that movement of actuator assembly 116 is allowed in the axial direction, but rotation of the actuator assembly about the axis is reduced or prevented (because the post and sides of slot contact each other). In other examples, these systems / components can impart a desired rotation on the actuator assembly. For example, the slot may define an arcuate or angled travel path for the post. For instance, rotation of the actuator assembly may facilitate both linear displacement and rotational displacement of the movable contact from the fixed contacts.

[0042] An example implementation of the use of alignment features is illustrated in FIG. 2. More specifically, FIG. 2 shows the electrical device 100, and the view of FIG. 2 is generally the reverse of, or opposite, the view of FIG. 1. For example, some the magnified portion of FIG. 1, and the electrical device 200 may include any or all of the features of the electrical device 100. In FIG. 2, the same reference numerals used in FIG. 1 are used to identify the same features.

[0043] In more detail, the view of FIG. 2 shows additional aspects of the actuator assembly 116, including specifically the coupler 120, and of the arc shield member 148. In FIG. 2, the arc shield member 148 is illustrated as including a base 202 and a sidewall 204 extending (e.g., upward in the illustrated orientation) from the base 202. A single instance of the sidewall 204 is illustrated, but it will be understood that a second, opposite sidewall is also provided extending from the base 202, spaced from the illustrated sidewall 204.

[0044] As illustrated (and as also illustrated in FIG. 3), the coupler 120 includes a post 206 that extends or protrudes from the coupler 120. The post 206 may be any protrusion or extending feature configured to cooperate with a slot (discussed below) or similar receptacle to facilitate and / or selectively restrict relative movement of the post 206 and / or the slot. In the illustratedexample, the post 206 extends from the coupler at an angle relative to the axis 141. In the illustrated example, the post 206 protrudes from the coupler 120 in a direction away from the axis 141. Although FIG. 2 illustrates the direction along which the post 206 extends as being substantially perpendicular or normal to the axis 141, in other examples the post 204 may otherwise extend from the coupler 120.

[0045] As also illustrated in FIG. 2 (and in FIG. 4, discussed below), the arc shield member 148 includes a slot 208. The slot 208 is an elongated opening having opposing sidewalls 210 extending from a first end 212 to a second end 214 spaced from the first end 212. In the example of FIG. 2, the first end 212 and the second end 214 are aligned along a direction that is parallel to the axis 141, e.g., such that the slot 208 is vertically-oriented (in the orientation of FIG. 2). More specifically, the sidewalls 210 of the slot 208 are vertically oriented in the orientation of FIG. 2.

[0046] A width of the slot 208, e.g., a distance between the sidewalls 210 of the slot 208, is sized to accommodate a portion of the post 206. For example, an outer diameter (or other extent) of the post 206 may be less than the width of the slot 208 such that the post 206 extends at least partially into the slot 208. With the post 206 extending into the slot 208, rotational motion of the coupler 120, e.g., about the axis 141, is constrained. More specifically, a torque applied to the coupler 120 (or the shaft or some other feature of the actuator assembly 116 will cause an outer surface of the post 206 to contact one of the sidewalls 210 of the slot 208. The slot 208 may be fixed relative to the base 104, so the torque is countered by the sidewall 210 to resist rotation of the actuator assembly 116.

[0047] However, and as illustrated, the slot 208 has a length extending between the first end 212 and the second end 214. While the slot will inhibit or reduce rotational movement of thepost 206, e.g., about the axis 141, the post 206 is free to move along the length of the slot 208.Thus, and as will be appreciated, when the movable contact 114 is moved between a first position contacting the fixed contacts 112 (not shown in FIG. 2) and a second position spaced from the fixed contacts 112, the post 206 will allow this axial movement, but will prevent rotation of the movable contact 114 about the axis 141.

[0048] Aspects of the actuator assembly 116 are shown more clearly in FIG. 3. Specifically, FIG. 3 is a perspective view of the coupler 120 disposed on an end of the shaft 118. As shown in FIG. 3, two posts 206 extend from the base 130. The posts 206 are generally coaxial and extend in opposite directions from each other. In some examples, each of the posts 206 is configured to cooperate with a different instance of the slot 208. For example, FIG. 4, discussed below, shows the arc shield member 148 including two slots 208, e.g., one in each of the sidewalls 204.

[0049] In the illustrated example of FIG. 3, each of the posts 206 is cylindrical, although in other examples, the posts 206 may have a different shape or cross-section. In some examples, the posts 206 may be formed from a different material than the base 130. For example, the posts 206 may be formed from a relatively more durable material, such as metal or the like. The durable material may be desirable because of the likelihood of repeated contact of the posts 206 with the slots 208, as discussed above. In some examples, the base 130 may be a polymeric material formed around or otherwise receiving the posts 206. Without limitation, the base 130 may be molded over the posts 206.

[0050] FIG. 4 shows aspects of the arc shield member 148. More specifically, FIG. 4 is a bottom perspective view of the arc shield member 148. FIG. 4 illustrates the base 202 and both ofthe opposing sidewalls 204. The sidewalls 204 are spaced on opposite sides of an opening 402.The opening 402 may be sized and shaped to receive an outer extent of the coupler 120, e.g., to allow the coupler to move freely in the opening 402.

[0051] As noted above, the slots 208 generally extend from a first end 212 to a second end 214. As also shown in FIG. 4, proximate the first end 212 of the slot 208, the sidewalls 210 can include a tapered portion 404. For example, the tapered portion 404 can be provided to guide or urge the post 206 into the slot 208, e .g., should the coupler 120 become rotated with the posts 206 outside, e.g., below, the slot 208.

[0052] As will be understood from the foregoing, aspects of this disclosure relate to the use of alignment members to reduce or otherwise control rotational motion of an actuator assembly including the movable contacts 114. In the examples just described, a first alignment member may be the post 206 formed on the base 130 of the coupler 120 and the second alignment member may be the groove or slot 208 formed in the arc shield member 148. However, other arrangements also are contemplated and / or will be appreciated by those having ordinary skill in the art with the benefit of this disclosure. For example, and without limitation, although two instances of the post 206 and two instances of the slot 208 are shown, in other examples more or fewer instances may be provided. Moreover, although the illustrated example shows the posts 206 as being integrated with the base 130, in other examples, the posts can be integrated with any other component that moves with the movable member 114. While it may be desirable in some applications to have the posts 206 (or other alignment members associated with the actuator assembly 116) spaced from the movable contact 114, in some examples the posts may be coupled directly to or otherwise integrated into the movable contact member 114. As will be appreciated, re-locating the posts 206 may also require a re-location of the slots 210.

[0053] Although the illustrated examples show the slots 208 being disposed in the arc shield member 148, in other examples the slots 208 may be otherwise formed, e.g., in a section of the housing 102 or the like. For example, the arc shield member 148 may not be provided. In other examples, additional structure(s) approximating the sidewalls 204 may be provided for the sole purpose of providing the slot(s) 208, e.g., independent of arc shielding functionality. For example, a guide member may be provided that includes the slot(s) 208.

[0054] Moreover, although the slots 208 are illustrated as being substantially linear, e.g., with the sidewalls 210 extending generally in a direction parallel to the axis 141, in other examples the sidewalls 210 may be otherwise contoured. Without limitation, the sidewalls 210 may be angled, arcuate, or the like. As will be understood, the slots 208 are generally provided to constrain motion of the posts 206. In the example above, the slots 208 and the posts 206 cooperate to reduce or eliminate rotation of the movable contact 114. In other examples, however, the slots 208 and the posts 206 may cooperate to impart a controlled rotation of the movable contact 114. For example, the slots 208 may be configured such that in the closed position the movable contact 114 contacts the fixed contacts 112, e.g., to close the circuit, but in the open position, the slots 208 cause the movable contact 114 to be rotated relative to the fixed contacts 112. For instance, by rotating the movable contact 114 in this manner, the movable contact 114 may be spaced both axially and rotationally from the fixed contacts 112, which may increase a separation distance between these components.

[0055] Although examples described herein show the post(s) 206 as being associated with the actuator assembly 116 and the slot(s) 208 as being associated with the arc shield member 148 (or alternatively some other stationary feature), in other examples the post(s) 206 may be formed on the arc shield member 148 and the actuator assembly 116 may incorporate the grooves. Forexample, instead of the protrusions that are the posts 206 extending from an edge of the base 130, in other examples the slot 208 may be formed in the edge of the base 130. In this example, the slot 208 of the arc shield member 148 may be replaced with a protrusion or post that extends toward and cooperates with the slot in the edge of the base 130. Other arrangements that use alignment features to maintain a desired orientation of the movable contacts 114 can be used.

[0056] While the subject technology has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and / or modifications can be made to the subject technology without departing from the spirit or scope of the subject technology. For example, each claim may depend from any or all claims in a multiple dependent manner even though such has not been originally claimed.

Claims

WHAT IS CLAIMED IS:

1. A switching device comprising: a housing defining a volume; one or more fixed contacts disposed at least partially in the volume defined by the housing; a movable contact disposed in the volume; a shaft movable between a first position that configures the switching device in a closed configuration in which the movable contact contacts the one or more fixed contacts and a second position that configures the switching device in an open configuration in which the movable contact is spaced from the one or more fixed contacts; a coupler coupling the movable contact to the shaft, the coupler including a first alignment feature; and a second alignment feature fixed relative to the housing, the first alignment feature and the second alignment feature cooperating to guide the coupler during movement of the shaft between the first position and the second position.

2. The switching device of claim 1, wherein: the first alignment feature comprises a protrusion extending from the coupler; and the second alignment feature comprises a slot configured to receive at least a portion of the post.

3. The switching device of claim 2, wherein:the shaft is moved between the first position and the second position in an axial direction along an axis, and the post extends from the coupler at an angle relative to the axis.

4. The switching device of claim 3, wherein the slot extends from a first end to a second end along a direction that is substantially parallel to the axis to allow movement of the shaft in the axial direction but to impede rotation of the shaft about the axis.

5. The switching device of claim 3, wherein the slot extends from a first end to a second end and the first end and the second end are offset relative to each other about the axis.

6. The switching device of claim 4 or claim 5, wherein the first end of the slot includes one or more tapered sidewalls.

7. The switching device of claim 1, further comprising an arc shield disposed in the volume, wherein the second alignment feature is associated with the arc shield.

8. The switching device of claim 7, wherein the second alignment feature comprises a slot formed in the arc shield.

9. The switching device of claim 7 or claim 8, wherein: the housing comprises a base portion through which the shaft extends; and the arc shield is disposed on the base portion.

10. The switching device of any one of claim 7, wherein the arc shield comprises a base and a sidewall extending from the base generally in a direction parallel to an axis of the shaft, wherein the second alignment feature is disposed in the sidewall.

11. The switching device of claim 10, wherein the second alignment feature comprises a post extending from the sidewall or a slot formed in the sidewall.

12. An electrical device comprising: a housing defining a volume; fixed contacts coupled to the housing and extending into the volume, an actuator assembly comprising: a shaft, a movable contact, a coupler coupling the movable contact to the shaft, and a first alignment member, wherein the actuator assembly is configured to move the movable contact between a first position contacting the fixed contacts and a second position spaced from the fixed contacts; and a second alignment member configured to cooperate with the first alignment member to control a rotation of the actuator assembly relative to the fixed contacts.

13. The electrical device of claim 12, wherein:the first alignment member comprises one of a post or a slot, and the second alignment member comprises the other of the post or the slot.

14. The electrical device of claim 13, wherein: the first alignment member is the post, and the post extends from the coupler; and the second alignment member is the slot, and the slot extends from a first end to a second end; and at least a portion of the post is disposed in the slot and moves relative to the slot.

15. The electrical device of claim 12, further comprising: an arc shield disposed in the volume, wherein the second alignment feature is associated with the arc shield.

16. The electrical device of claim 15, wherein: the arc shield comprises a base and a sidewall extending from the base generally in a direction parallel to an axis of the cylinder, and the second alignment feature is disposed in the sidewall.

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