Electrical device with arc chamber assembly

Abstract

An electrical device includes a switching assembly and an arc chamber housing. The arc chamber housing includes a housing body, one or more magnets arranged along one or more sides of the housing body, and one or more brackets disposed over the magnets to retain the magnets coupled to the housing body. The arc chamber housing can also include a cover, and the cover can include one or more catch features for retaining a movable contact in an open position, e.g., to prevent the flow of electricity through the electrical device.

Description

Electrical Device with Arc Chamber AssemblyFIELD 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 housings and fabrication techniques for housings.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. Many conventional contactors include a housing that defines an interior volume, also called an arc chamber. In manufacturing and assembly of conventional devices, the requirements for such housings can vary greatly. Often, aspects of the sensing device are fabricated to meet the most taxing industry standards, e g., for high power systems, but these devices are over engineered and inefficient in lower power systems.

[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 modularity that can be used across several applications having varied requirements.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 a modular arch chamber housing. For example, aspects of this disclosure can relate to features and / or systems that provide a housing assembly for use with many different electrical devices, e.g., to meet the requirements of those devices. The modularity and simplicity provide aspects of this disclosure may result in improved safety outcomes, e.g., by ensuring that the arc chamber is suited for the particular system, device, and / or application. In other examples, aspects of this disclosure may relate to providing systems and components that are more efficiently assembled and / or tested and / or that are more cost effective.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 view of an electrical device, including an arc chamber housing and a switching assembly, in accordance with aspects of this disclosure.

[0008] FIG. 2 is an exploded perspective view of the arc chamber housing shown in FIG. 1, in accordance with aspects of this disclosure.

[0009] FIG. 3 is a perspective view of the arc chamber housing of FIG. 2, in accordance with aspects of this disclosure.

[0010] FIGS. 4A and 4B are cross-sectional views of an example implementation of the electrical device of FIG. 1, taken along the section line 4-4, showing the electrical device in a closed configuration and in a locked-open configuration, respectively, in accordance with aspects of this disclosure.

[0011] FIGS. 5 A and 5B are cross-sectional views of an alternative implementation of the electrical device of FIG. 1, taken along the section line 4-4, showing the electrical device in a closed configuration and in a locked-open configuration, respectively, in accordance with aspects of this disclosure.DETAILED DESCRIPTION

[0012] 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 enables the functionalities of a high voltage switching device, a low voltage switching device, and / or a fast disconnect device. In examples, the device may facilitate three discrete operation states, including a first operating state in which a switch is open, e g., in normal operation. The first operating state may be a default operating state. In the first operating state, no voltage or current flows through the device. A second operating state may be a state in which the switch is closed. For example, in the second operating state, a coil may be energized to cause one or more movable contacts to move into contact with one or more stationary contacts, thereby completing a circuit. In the second operating state, current, e.g., from a voltage source, may flow through the device. A third operating state may be a triggered or disconnectedstate. For example, the third operating state may be a state in which the switch is fully opened to provide insulation, e.g., by preventing current flow through the device. For example, and as detailed herein, the third state may be a permanent disconnection of components within the device, e.g., to prevent current flow between those components.

[0013] In aspects of this disclosure, the electrical device may be formed as a modular device, e.g., including a switching assembly and an arc chamber assembly. In examples, the switching assembly can include features associated with the contactor (e.g., a movable contact, fixed contacts, an actuator assembly, and / or the like) and / or with the fast disconnect component (e.g., a pyrotechnic element).

[0014] The arc chamber assembly according to aspects of this disclosure can include a housing body generally configured to define an arc suppression volume, e.g., within which some of the switching components can operate. The housing body can support one or more arcsuppression magnets. The arc chamber assembly can also include one or more brackets configured to retain the arc suppression magnet(s) on the housing body. The arc chamber assembly can also include a cover coupled to the housing body to at least partially define the arc suppression volume. In some examples, the cover can incorporate one or more catch features. The catch feature(s) can be configured to configure the electrical device in the third operating state described above.

[0015] In examples, electrical devices according to this disclosure may be used normally in the first and second operating states, with the third operating state resulting from an over- current / fault condition.

[0016] In aspects of this disclosure the arc chamber assembly may be a modular assembly, e.g., readily configured for use in different electrical devices. For example, aspects of thisdisclosure provide for a housing body that can facilitate use of different magnets and / or different covers. For example, high power applications may require certain types of rare earth magnets to suppress faults, whereas lower power applications may safely mitigate faults using cheaper and / or more readily available magnets. Similarly, some high performance applications may require insulative materials such as glass-reinforced plastic, whereas other applications are adequately insulated using different, e.g., cheaper polymers. Aspects of this disclosure provide for an arc chamber assembly that can be readily modified or configured for a given use case, which may obviate the need for expensive and time consuming engineering, re-engineering, testing, and / or the like for different applications.

[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. Moreover, while aspects of this disclosure may be particularly useful in certain application, like high voltage automotive systems, the systems and techniques, the systems and techniques described herein may be useful with any electrical devices that require an arc suppression chamber.

[0018] Aspects of the disclosure will now be explained in more detail with reference to the Figures.

[0019] FIG. 1 is a perspective view of an electrical device 100, which may be a contactor device, a fuse device, a pyrotechnic fuse, or the like.

[0020] More specifically, FIG. 1 shows that the electrical device 100 includes an arc chamber assembly 102 and a switching assembly 104. In the example orientation, the switchingassembly 104 is secured to an upper or top surface of the arc chamber assembly 102. In examples, the switching assembly 104 can include components that perform one or more fuse functionalities. For instance, FIGS. 4A and 4B, discussed below, show details of an example implementation in which the electrical device 100 is embodied as a fuse. In other examples, the switching assembly 104 can also or alternatively include components that perform one or more contactor functionalities. For instance, FIGS. 5A and 5B, discussed below, show details of an example implementation in which the electrical device 100 is embodied as a contactor. Although not illustrated herein, the arc chamber assembly 102 may be further configured for coupling to a driving or actuating assembly, e.g., which may include a coil or other actuator that facilitates movement of components of the switching assembly 104, such as when the electrical device 100 is a contactor, as detailed further herein.

[0021] As illustrated in FIG. 1, the switching assembly 104 generally includes a body or housing 106. As detailed further herein, in particular further below with reference to FIGS. 4A - 5B, the switching assembly 104 can include a number of features or components disposed within the housing 106. FIG. 1 shows that the switching assembly may include two fixed contacts 108. The fixed contacts 108 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 108 may be terminals configured to facilitate connection of first electrical leads (not shown) from a voltage source to second electrical leads (also not shown) of a load to be powered by the voltage source. For example, the first leads may be electrically coupled to one of the fixed contacts 108 and the second leads may be electrically coupled to the other of the fixed contacts 108. The switching assembly 104 can include a movable contact the selectively electrically couples or decuples the two fixed contacts 108. The switchingassembly 104 can include components that facilitate selectively opening or closing the electrical device.

[0022] The housing 106 can include any suitable material that can support the structure and function of the switching assembly 104. For example, the housing 106 is illustrated as being a substantially rectangular receptacle sized to retain the two fixed contacts 108 in a side-by-side arrangement. However, the size, shape, and configuration of the switching assembly 104 is for example only. As noted above, the arc chamber assembly 102 may be modular, and thus may define a size and / or one or more features of the housing 106 that will facilitate attachment to and / or cooperation with the arc chamber assembly 102. As noted above, because the arc chamber assembly is modular, the arc chamber assembly 102 may be used with a number of switching assemblies. That is, although FIG. 1 shows the switching assembly 104, any number of switching assemblies may be configured to cooperate with the arc chamber assembly 102. For example, the switching assembly 104 is configured as a fuse device in the example of FIG. 1, but in other examples the switching assembly 104 can include a contactor device, such as a pyrotechnic contactor device, a trigger, an interrupter, and / or the like. FIGS. 5A and 5B show an example contactor that incorporates features of this disclosure.

[0023] The housing 106 may be formed of one or more components. For instance, FIG. 1 shows that the housing 106 includes a sidewall 110 and a top 112. In examples, during assembly or manufacture, the two fixed contacts 108 may be coupled to the top 112, and the top 112 may subsequently be coupled to the side 110. In the illustrated example, a coupler 116 is configured to selectively couple the top 112 to the sidewall 110 and / or to a bottom 114 of the housing 106. A second coupler, opposite the coupler 118 may also be present (but is obscured by the fixed contact 108 in the illustration). In the example, the coupler 116 includes a post 118 with a tab or head 120that is configured to interact with, or catch, a retention surface 122 on the top 1 12 of the switching assembly 104. In examples, an end of the post 118 opposite the head 120 may be fixed to the bottom 114 of the housing 106. The illustrated coupler 116 is for example only and may be provided to position or otherwise configure aspects of the housing 106 relative to each other and / or to other features.

[0024] The electrical device 100 also includes features that facilitate operable attachment of the switching assembly 104 to the arc chamber assembly 102. For instance, FIG. 1 shows a plurality of receptacles 124 formed around a periphery of a top of the arc chamber assembly 102. The receptacles 124 are configured to receive cooperating protrusions 126 extending from the bottom 114 of the housing 106. In examples, the receptacles 124 may be slightly deformable, e.g., to facilitate a snap fit engagement of the switching assembly 104 via the protrusions 126. Of course, this coupling arrangement is for example only. Other fastening means will be appreciated by those having ordinary skill in the art with the benefit of this disclosure. For instance, the post 118 may be fixed to the arc chamber assembly 102.

[0025] Aspects of this disclosure are particularly useful to provide a modular solution, e.g., in which aspects of the arc chamber assembly 102 may be configured or reconfigured, e.g., by changing magnet specifications, cover specifications, material specifications, and / or the like. Specific details of the arc chamber assembly 102 are detailed further below, including with reference to FIGS. 2 and 3.

[0026] FIG. 2 shows aspects of the arc chamber assembly in more detail. Specifically,FIG. 2 is an exploded perspective view of the arc chamber assembly 102. As shown, the arc chamber assembly 102 generally includes a housing body 202, a first magnet 204, a second magnet206, a first magnet bracket 208, a second magnet bracket 210, and a cover 212. These features will be described individually herein.

[0027] The housing body 202 is illustrated as a generally polyhedral shape, having a first end wall 214 and an opposite, second end wall 216 (generally obscured in the view of FIG. 2). The housing body 202 also includes a first sidewall 218 and a second sidewall 220 (obscured in FIG. 2) extending between the end walls 214, 216. The end walls 214, 216 and the sidewalls 218, 220 generally define the sides of an arc chamber volume 222. Although the example of FIG. 2 includes the end walls 214, 216 and the sidewalls 218, 220 the housing body is not limited to the illustrated shape or configuration. In other examples, the housing body can have more or fewer walls, one or more walls may be arcuate, and / or the like. Any configuration that allows the housing body 202 to define the arc chamber volume 222 may be used. The arc chamber volume 222 is a volume inside the arc chamber assembly 102 that may be configured for containing, suppressing and / or otherwise mitigating arc- or over-current-related events.

[0028] As also shown in FIG. 2, the housing body 202 also has an upper surface 224. As illustrated in FIG. 1, the switching assembly 104 may be configured for placement on the upper surface 224. As also illustrated, a contoured protrusion 226 may be provided on the upper surface 224. In some examples, the contoured protrusion 226 can be integrated into the upper surface 224 or may be provided as a separate member, such as a gasket. The contoured protrusion 226 circumscribes an opening in the upper surface 224 that accesses the arc chamber volume 222. When the contoured protrusion is a gasket, a channel may be provided in the upper surface 224 for seating or accepting a portion of the gasket. In operation, when the switching assembly 104 is secured to the arc chamber assembly 102, the contoured protrusion 226 may form a seal between the two assemblies, e.g., such that a volume inside the switching assembly 104 and the arc chambervolume 222 are connected, but are sealed relative to the ambient environment. Moreover, the contoured protrusion 226 may be configured to be received in a corresponding channel formed in a bottom surface of the switching assembly 104, e.g., to aid in alignment of the arch chamber assembly 102 relative to the switching assembly 104.

[0029] The first magnet 204 is configured for coupling to an outside of the first end wall 214 of the housing body 202 and the second magnet 206 is configured for coupling to an outside of the second end wall 216 of the housing body 202. In examples, the magnets 204, 206 may be disposed to oppose each other, e.g., on opposite ends of a conductive member, and / or may be otherwise positioned to facilitate arcing elongation during a short circuit event. Although the magnets 204, 206 are illustrated as being disposed on the end wall 214, 216 in other examples, magnets may be disposed on the first and second sidewalls 218, 220, instead or in addition.

[0030] In examples of this disclosure, the housing body 202 includes a magnet locating feature 228 formed as a protrusion extending from the first end wall 214. Although the second end wall 216 is not visible in FIG. 2, the second end wall 216 may include one or more instances of the magnet locating feature 228. The magnet locating feature 228 defines a planar (top) surface 230 that extends generally perpendicular to the end wall 214. The magnet locating feature 228 can also include a tab 232 at an end of the planar surface 230. The tab 232 extends generally perpendicular to the end wall 214 and to the planar surface 230. Accordingly, the magnet locating feature 228 may be substantially L-shaped.

[0031] When assembled, a bottom or lower edge 234 of the first magnet 204 may be supported on the planar surface 230, e.g., to position the first magnet 204 relative to the housing body 202 in a vertical dimension (in the orientation of FIG. 2). Moreover, a side or side edge 236of the first magnet 204 may contact the tab 232, e.g., to position the first magnet 204 relative to the housing body 202 in a horizontal dimension. A back of the magnet 204 may then abut the end wall 214, thus positioning the first magnet 204 in three dimensions. In the example just described, a corner defined by the lower edge 234 and the side 236 are disposed in the angle formed by the surface 230 and the tab 232. Although not visible in FIG. 2, a similar magnet locating feature 228 may be located proximate the top surface 224 of the housing body 202. For example, when the magnet is substantially rectangular, as in the illustrated example, it may be desirable to have an instance of the magnet locating feature 228 at more than one comer, e.g., at opposite corners, at all four corners, or the like.

[0032] In another example, the first magnet 204 can include a notch 238 formed in the lower edge 234. For example, the notch 238 may be sized to receive the tab 232 therein, e.g., via a clearance fit, an interference fit, or the like. As will be appreciated, the use of the notch 238 may better locate the first magnet 204 in the horizontal dimension.

[0033] The illustrated magnet locating feature 228 is for example only. In other examples, other protrusions, surfaces, and / or feature may be provided to locate the magnets 204, 206 on the housing body 202. In another non-limiting example, a magnet locating feature 228 may include a number of planar surfaces, like the planar surface 230, defining the positions of the lower edge 234, on or both of the sides, and / or the top edge of the magnet 204.

[0034] The housing body 202 can also include one or more switch assembly locating features. For example, FIG. 2 shows four arcuate tabs 240 extending (upward) from the upper surface 224. The arcuate tabs may be positioned and sized to receive corners of a switch assembly, like the switching assembly 104 discussed above. Moreover, one or more locating holes 242,which may be threaded holes, are formed in the top surface 224. Without limitation, the holes 242 may be configured for attachment of the coupler 114.

[0035] The first magnet bracket 208 and the second magnet bracket 210 are configured to retain the magnets 204, 206 on the housing body 202 and / or to provide a magnetic circuit. For example, and as illustrated, each of the magnet brackets 208, 210 is substantially U-shaped, including a central portion 244 and end portions 246 angled relative to the central portion 244. In the illustrated example, the end portions 246 are angled at substantially right angles relative to the central portion 244. In examples, the end portions 246 are spaced a distance to extend outside the magnets 204, 206, e.g., to sandwich the magnets 204, 206 between the housing body 202 and the associated end portion 246. In examples, the brackets 208, 210 may be made of a magnetic material, e.g., such that the end portions 246 are magnetically coupled to the magnets 204, 206. For example, the brackets 208, 210 may be made of a metallic material, such as sheet metal. In some specific examples, the brackets 208, 210 may be made of a low carbon steel to provide a magnetic circuit.

[0036] As will be appreciated, the magnetic coupling of the brackets 208, 210 to the magnets 204, 206 will maintain the brackets and the magnets on the housing body 202. As also shown in FIG. 2, the housing body 202 may have one or more bracket locating features. The bracket locating feature(s) are configured to ensure proper positioning of the brackets relative to the housing body 202. In the illustrated example, the bracket locating features include a ledge 248 formed on the first sidewall 218. When assembled, a bottom edge 250 of the bracket 208 contacts the ledge 248 to position the bracket 208 vertically on the sidewall 218. Although obscured in FIG. 2, the second sidewall 220 may have a similar ledge for similarly positioning the second bracket 210. As will be appreciated, the ledge 248 is but one example of a bracketlocating feature. Other features that facilitate positioning of the bracket(s) will be appreciated by those having ordinary skill in the art with the benefit of this disclosure.

[0037] The cover 212 is configured to be attached to a bottom of the housing body 202. For example, and although not visible in FIG. 2, the housing body 202 can have an opening in a bottom surface. The cover 212 may be received in the opening, e.g., to provide a bottom of the arc chamber volume 222. In the illustrated example, side edges 252 of the cover 212 include protrusions 254. The periphery of the cover 212 may be sized and shaped for placement into the opening in the bottom of the housing body 202, and the protrusions 254 may be received in cooperating receptacles or indentations formed at lower edges of the housing body 202. In examples, the cover 212 may be sealed relative to the housing body 202, e.g., via a gasket or the like, to seal the arc chamber volume 222.

[0038] The cover 212 is also illustrated as including a plurality of retention members or catch features 256. The catch features 256 are configured to facilitate retention of a movable contact in a position spaced from the fixed contacts 108, e.g., to retain the electrical device 100 in an open position. In the illustrated example, the catch features 256 each comprise a contoured protrusion 258 extending from the cover 212 and having a distal end 260 disposed in a path of travel of the movable contact (better illustrated in FIGS. 4A and 4B, discussed below). The contoured protrusions 258 or tabs are angled, e.g. relative to a travel path (the vertical direction in the example) and resilient. For example, the retention members are configured to allow one-way travel of the movable contact, e.g., in a first (downward) direction, but to inhibit or prevent motion of the movable contact in the opposite direction. In examples, the movement of the movable contact resulting from contact by a pyrotechnic device or other interrupter is sufficient such that the movable contact pushes the protrusions 258 out of the travel path, e.g., toward the sidewalls218, 220, until the movable contact clears the distal ends 260 of the catch features 256. Once the movable contact clears the catch features 256, the catch features 256 are no longer contacted by the movable contact. Without the force applied by the movable contact, the catch features 256 “spring” back to their angled positions (the position illustrated in FIG. 2 and FIG. 4B, shown below), with the distal ends 260 being disposed above (e.g., over) a top surface of the movable contact. With the distal ends 260 of the catch features 256 over the movable contact, upward motion (in the orientation of FIG. 2) is precluded by the catch features 256.

[0039] In non-limiting examples, the cover 212 may be a molded part, e.g., injection molded or the like from a rigid polymer. The catch features 256 are illustrated as being supported on a base of the cover 212.

[0040] Of course, the catch features 256 are for example only. Modifications and alternative configurations also are contemplated. For example, other configurations that allow for movement of the movable contact to a position spaced from the fixed contacts 108, and that can retain the movable contact in this spaced position may be used. In one non-limiting example, the catch features 256 may be replaced with detents or spring-biased members that are biased into a position blocking upward movement of the movable contact when the movable contact travels a predetermined distance from the fixed contacts 116. In still further examples, one or more posts may extend upward from the cover 212, e.g., in a footprint of the movable contact. In this example, a bottom of the movable contact may have corresponding openings or bores that align with the posts, such that when the movable contact is forced into contact with the posts, the posts cooperate with the openings to retain the movable contact. For example, the posts may form an interference fit with the openings. In other examples, the posts may have a contour that expands or otherwisedeforms to create a force that retains the movable contact in a position spaced from the fixed contact 108.

[0041] FIG. 3 is a perspective view of the arc chamber assembly 102 in an assembled state. As illustrated in FIG. 3, the first magnet bracket 208 and the second magnet bracket 210 are positioned on the housing body 202 such that the lower edge 250 abuts or is arranged proximate the ledge 248. As also shown in FIG. 3, the housing body 202 also includes an upper ledge 302 configured to contact or otherwise position an upper edge of the bracket 208.

[0042] FIG. 3 also illustrates that a lower edge of the housing body 202 includes a plurality of tabs 304 configured to cooperate with the protrusions 254 of the cover 212. More specifically, each of the tabs 340 defines a slot or opening 306 configured to receive one of the protrusions 254 therein. The tabs 304 may be configured to flex, e.g., such the cover can be pressed into position and once in position, the tabs snap back into the illustrated position, with each of the protrusions 254 seated in an associated opening 306. FIG. 3 also shows one of the catch features 256 disposed in the arc chamber volume 222.

[0043] FIGS. 4A and 4B are cross-sectional views taken along the section line 4 — 4 in FIG. 1. FIGS 4A and 4B show additional aspects of the electrical device 100, including additional aspects of the switching assembly 104. More specifically, FIG. 4 A shows aspects of normal operation of the electrical device 100 and FIG. 4B illustrates a locked-out or locked-open configuration.

[0044] FIGS. 4A and 4B show the arc chamber volume 222 an upper portion 402 defined by the housing 106 of the switching assembly.

[0045] Features of the electrical device 100 are disposed in the arc chamber volume222 and / or the upper portion 402. For example, the view of FIGS. 4 A and 4B shows the two fixed contacts 108 coupled to the housing 106. The fixed contacts 108 are disposed to extend through the upper portion 402 and into the arc chamber volume 222. The fixed contacts 108 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 108 may be terminals configured to facilitate connection to a voltage source and to a load to be powered by the voltage source.

[0046] The electrical device 100 also includes a movable contact 404. In the example of FIGS. 4A and 4B, the electrical device 100 may be a normally-closed fuse device. In this example, the movable contact 404 is normally positioned in a first position contacting the fixed contacts 108 (shown in FIG. 4A). In the illustrated example, the movable contact 404 is a generally elongate member that, in the first position illustrated by FIG. 4A, can simultaneously contact both of the fixed contacts 108. Accordingly, the movable contact 404 can selectively couple the two fixed contacts 108, to facilitate current flow between the fixed contacts 108 and thus through the electrical device 100.

[0047] The electrical device 100 also includes a fuse assembly 406 configured to, among other functions, facilitate selective opening of the electrical device 100, e.g., during an overload, surge event, or the like, by facilitating selective movement of the movable contact 404 out of contact with the fixed contacts 108. In examples, the fuse assembly 406 can include the movable contact 404 and / or may be operatively coupled to the movable contact 404.

[0048] In FIGS. 4A and 4B, the fuse assembly 406 is illustrated as including a shaft 408, a biasing spring 410, a shaft retention member 412, a trigger spring 414, and a trigger spring retention member 416.

[0049] In the example, the shaft 408 is disposed through the movable contact 404, e.g., through a hole formed in the movable contact 404 such that a first end 418 (e.g., an upper end in the orientation of FIG. 4A) is positioned in the upper portion 402 and a second end 420 (e.g., a lower end in the orientation of FIG. 4A) is positioned in the arc chamber volume 222. As illustrated, the shaft 408 also includes a first flange 422 proximate a longitudinal middle of the shaft 408 and a second flange 424 proximate the second end 420.

[0050] The biasing spring 410 is positioned between the second flange 424 and a bottom surface of the movable contact 404 to bias the movable contact 404 away from the second end 418 of the shaft 408. When the shaft 408 is retained in the position illustrated in FIG. 4A, the biasing spring 410 biases the movable contact 404 against the fixed contacts 108.

[0051] The shaft retention member 412 selectively retains the shaft 408 in the position illustrated in FIG. 4A. In the illustrated example, the shaft 408 includes a reduction or channel 426 proximate the first end 418 of the shaft 408. The shaft retention member 412 includes a slot or opening that is configured to cooperate with the channel 426 to selectively prevent (or allow) axial motion of the shaft 408 as detailed further herein. In the example of FIG. 4A, a portion of the shaft retention member 412 is retained in the channel 426 to act as a catch that prevents downward movement of the shaft 408 (e.g., due to gravity and / or a force applied by the trigger spring 414, discussed below). In the example of FIG. 4A, a length of the shaft is generally received in a shaft receptacle 428 provided in the upper portion 402. In this example, the shaft receptable428 provides a clearance fit with the shaft 408, but limits lateral movement of the shaft 408, e.g., to constrain motion of the shaft 408 generally to movement along an axis of the shaft 408.

[0052] The trigger spring 414 is positioned to apply a downward force on the shaft 408. In the illustrated example, the trigger spring 414 is a compression spring disposed around the shaft 408. A first, top end of the trigger spring 414 contacts a fixed surface or feature of the upper portion 402. A second, bottom end of the trigger spring 414 contacts the trigger spring retention member 416. In the examples, the trigger spring retention member 416 comprises a cup-shaped member that is disposed on the shaft 408. Specifically, a bottom of the trigger spring retention member 416 includes a hole through which the shaft 408 extends. The hole has a diameter larger than a diameter of the shaft 408, but smaller than a diameter or other outer extent of the first flange 422 of the shaft 408. Accordingly, the bottom of the trigger spring retention member rests on or otherwise contacts a top of the first flange 422 and the trigger spring 414 applies a biasing force that pushes the bottom of the trigger spring retention member 416 against the first flange 422.

[0053] In the arrangement of FIG. 4A, the shaft retention member 412 cooperates with the shaft 408 to resist the biasing force of the trigger spring 414. Also in this position, the biasing spring 410 biases the movable contact 404 into contact with the fixed contacts 108. In this configuration, current passes between the fixed contacts 108 via the movable contact 404.

[0054] FIG. 4B shows a triggered or open configuration, which results from the disengagement of the shaft retention member 412 from the shaft 408. More specifically, in response to a triggering event, such as a power surge, an overcurrent event, or the like, the shaft retention member 412 may be moved, destroyed, or otherwise reconfigured to no longer inhibit axial movement of the shaft 408. With the shaft retention member no longer inhibiting suchmotion, the biasing force of the trigger spring 414 forces the shaft 408 downward, thereby forcing the movable contact 404 away from the fixed contacts 108, opening the electrical device and prevent flow of electricity between the fixed contacts 108.

[0055] FIGS. 4A and 4B also show two of the catch features 256. As shown in FIG. 4A, during normal operation of the electrical device 100, the movable contact 404 is generally disposed above the catch features. However, if the movable contact 404 is driven away from the fixed contacts, e.g., by the trigger spring 414, the movable contact 404 will cause the protrusion 258 to flex, e.g., outwardly, as discussed above. Continued downward movement will cause the movable contact 404 to advance below the distal ends 260 of the catch features 256. Once clear of the distal ends 260, the protrusion 258 will return to its unflexed state, and the distal ends 260 will be positioned above the movable contact 404, as shown in FIG. 4B. With the distal ends 260 above the movable contact, the movable contact 404 is prevented from moving upward, e.g., to contact the fixed contacts 108. Thus, the catch features 256 maintain the electrical device 100 in an open state.

[0056] As discussed above, the arc chamber assembly 102 may be a modular assembly that may be used with any number of switching assemblies 104 having different characteristics, components, or the like. For example, the fuse assembly 406 can be replaced or augmented with one or more additional components that otherwise facilitate reconfiguration of the electrical device 100 from the closed state to the open state.

[0057] Moreover, although the electrical device 100 is illustrated as a fuse-type device, aspects of this disclosure can also be used in other types of electrical devices. For example, FIGS. 5A and 5B are cross-sectional views generally corresponding to the view of FIGS. 4A and 4B,respectively, of the use of aspects of this disclosure in a contactor-type device. For instance, FIG.5 A shows aspects of normal operation of the electrical device 100, and FIG. 5B illustrates a locked- out or locked-open configuration.

[0058] Features of the electrical device 100 are disposed in the arc chamber volume 222 and / or the upper volume 502. For example, the view of FIGS. 5A and 5B shows the two fixed contacts 108 coupled to the housing 106. The fixed contacts 108 are disposed partially in the upper volume 502 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 108 may be terminals configured to facilitate connection to a voltage source and to a load to be powered by the voltage source.

[0059] The electrical device 100 also includes a movable contact 504. The movable contact 504 is movable between a first position spaced from the fixed contacts 108 (shown in solid lines in FIG. 5 A) and a second position contacting the fixed contacts 108 (shown in dashed lines in FIG. 5A. Specifically, the movable contact 504 may be moved upward (in the orientation of FIG. 5A) from the first position to the second position. In the illustrated example, the movable contact 504 is a generally elongate member that, in the second position as illustrated by the dashed lines, can simultaneously contact both of the fixed contacts 108. Accordingly, the movable contact 504 can selectively couple the two fixed contacts 108, to facilitate current flow between the fixed contacts 108 and thus through the electrical device 100.

[0060] The electrical device 100 also includes an actuator assembly 506 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 504 into and out of contact with thefixed contacts 108. In examples, the actuator assembly 506 can include the movable contact 504 and / or may be operatively coupled to the movable contact 504.

[0061] In FIGS. 5A and 5B, the actuator assembly 506 is illustrated as including a shaft 508 and a coupler 510.

[0062] In the example, the shaft 508 is disposed such that a first end (e.g., an upper end in the orientation of FIG. 1) is positioned in the arc chamber volume 222. The first end is coupled to the movable contact 504, e.g., via the coupler 510. An opposite, second end of the shaft 508 is not illustrated in the FIGS. In examples, the shaft may extend through the cover 212. In examples, and although not illustrated, an opposite, bottom end of the shaft 508 may be coupled to a plunger.

[0063] In the example of FIG. 5A and 5B, the coupler 510 includes a base 512 and opposing spaced sides 514 extending upward (in the orientation of FIG. 5A) from the base 512. In this example, the opposing sides 514 define openings through which portions of the movable contact 504 extend. Specifically, the movable contact 504 is a substantially elongate or bar-shaped member extending from a first end proximate the first end wall 214 to a second end. The movable contact 504 extends through the openings in the spaced sides 514 such that the first end and the second end are disposed on opposite sides of the spaced sides 514 of the coupler 510 (and generally aligned vertically with the fixed contacts 108).

[0064] In the illustrated example, the base 512 of the coupler 510 is secured to the upper end of the shaft 508. In examples, the base 512 may be molded onto the shaft 508. For instance, the base 512 may be a polymeric material formed on the shaft 508 via an overmolding process or the like. In examples, the polymeric material may configure the base to electrically isolate themovable contact 504 from the remaining actuator components (e.g., the shaft 508) and / or portions of the housing.

[0065] In the illustrated examples, the sides 514 of the coupler 510 may be integrated with the base 512. For example, the base 512 may be overmolded over a bottom portion of the sides 514. However, the sides 514 may be otherwise coupled, secured, or attached to the base 512 in other examples. In the illustrated example, the sides 514 may approximate an inverted U-shape to define the openings which provide clearance for the ends of the movable contact 504, as noted above. The movable contact 504 may be movable in the openings relative to the sides 514 and the base 512.

[0066] In the example of FIG. 5 A and FIG. 5B, a biasing spring 516 is disposed between the base 512 and the movable contact 504. More specifically, the biasing spring 516 biases the movable contact 504 away from the shaft 508 and against a top edge of the openings in the sides 514. Thus, in the illustrated example, the shaft 508 is secured to the coupler 510 (e.g., to the base 512 of the coupler 510) and the biasing spring 516 biases the movable contact 504 against the top edge of the openings in the sides 514 of the coupler 510. Accordingly, movement of the shaft 508, e.g., along an axis of the shaft 508, will cause corresponding movement of the coupler 510, the biasing spring 516, and the movable contact 504. For example, when the shaft 508 is caused to move downward in the orientation of FIG. 5A, the movable contact 504 moves away from the fixed contacts 108. Alternatively, when the shaft 508 is caused to move upward in the orientation of FIG. 5 A, the movable contact 504 is moved toward, and eventually into contact with, the fixed contacts 108. Continued movement of the shaft 508 in the upward direction (in the orientation of FIG. 5 A) when the movable contact 504 contacts the fixed contacts 108, can result in continued travel of the coupler 510 relative to the movable contact 504, e.g., resulting from compression ofthe biasing spring 516. In this example, the biasing spring 516 can compensate for overtravel of the shaft 508, e.g., to prevent destructive contact of the movable contact 504 with the fixed contacts 108. In other examples, the biasing spring 516 may not be included.

[0067] FIGS. 5A and 5B also show two of the catch features 256. As shown in FIG. 5A, during normal operation, e.g., normal opening and closing of the electrical device 100, the movable contact 504 is generally disposed above the catch features. However, if the movable contact 504 is driven away from the fixed contacts, e.g., by a pyrotechnic element (not shown), the movable contact 504 will cause the protrusion 258 to flex, e.g., outwardly, as discussed above. Continued downward movement will cause the movable contact 504 to advance below the distal ends 260 of the catch features 256. Once clear of the distal ends 260, the protrusion 258 will return to its unflexed state, and the distal ends 260 will be positioned above the movable contact 504, as shown in FIG. 5B. With the distal ends 260 above the movable contact, the movable contact 504 is prevented from moving upward, e.g., to contact the fixed contacts 108. Thus, the catch features 256 maintain the electrical device 100 in an open state.

[0068] Although not illustrated in FIGS. 5A and 5B, the electrical device 100, and specifically the actuator assembly 506 can include one or more additional components to move the shaft 508 as just described. For example, the actuator assembly 506 can include a plunger disposed at a lower end of the shaft 508. The plunger may be driven by a coil, e.g., a DC coil. The coil may be selectively energized.

[0069] As noted above, the example of FIGS. 5A and 5B is for example only. Modifications to the switching assembly 104 are contemplated. For instance, the switching assembly may be a normally open switching device, e.g., such that the movable contact 504 isbiased away from the fixed contacts 108 by the actuator assembly 506. Aspects of this disclosure may also be applied to other constructions, including normally closed switching device arrangements. In a normally closed arrangement, the actuator assembly 506 may bias the movable contact toward the fixed contacts 108.

[0070] As discussed above, the arc chamber assembly 102 may be a modular assembly that may be used with any number of switching assemblies 104 having different characteristics, components, or the like. The arc chamber assembly 102 can also be configured depending on an application. For example, when the electrical device 100 is to be used in a high-power application, the magnets 204, 206 may be relatively robust, rare earth magnets, such as neodymium magnets. Also in higher power applications, the housing body 202 and / or the cover 212 may be made of insulating materials such as reinforced polymers. In some examples, the housing body 202 and / or the cover 212 may be made of a polymer reinforced with glass fiber.

[0071] In other, e.g., lower power applications, the magnets may be smaller and / or made of a less expensive permanent magnet material. Also in lower power applications a polymer used for the housing body 202 and / or the cover 212 may be a less insulative and / or less expensive polymer. Without limitation, the housing body 202 and / or the cover 212 may not comprise a reinforced polymer. In examples, the modularity of the present disclosure may enable more efficient assembly by allowing functional testing and / or assembly to occur in parallel and / or as an off-line process.

[0072] 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 ofthe 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. An arc chamber assembly comprising: a housing body having a first end wall and an opposing second end wall and a first sidewall and an opposing second sidewall, the housing body defining an arc chamber volume; a first magnet proximate an outer surface of the first end wall of the housing body; a second magnet proximate an outer surface of the second end wall of the housing body; a first bracket contacting an outer surface of the first magnet and an outer surface of the second magnet and extending generally along the first sidewall; and a second bracket contacting the outer surface of the first magnet and the outer surface of the second magnet and extending generally along the second sidewall.

2. The arc chamber assembly of claim 1, wherein at least one of the first bracket or the second bracket is substantially C-shaped, having a first end and a second end angled relative to a central portion, the first end being configured for contacting the outer surface of the first magnet, the second end being configured for contacting the outer surface of the second magnet, and the central portion generally extending along the first sidewall or the second sidewall.

3. The arc chamber assembly of claim 2, wherein the at least one of the first bracket or the second bracket is magnetically coupled to the first magnet at the first end and is magnetically coupled to the second magnet at the second end.

4. The arc chamber assembly of any one of claim 1 through claim 3, further comprising: a cover coupled to the housing body to occlude an opening into the arc chamber volume.

5. The arc chamber assembly of claim 4, wherein the cover comprises one or more catch features extending into the arc chamber volume, the one or more catch features comprising a flexible protrusion extending at least partially into the arc chamber volume.

6. The arc chamber assembly of claim 1, wherein the first end wall includes at least one magnet alignment feature extending from the first end wall in a direction away from the arc chamber volume, the at least one alignment feature being configured to position the first magnet proximate the first end wall.

7. The arc chamber assembly of claim 1, wherein the first sidewall includes a support ledge configured to contact an edge of the first bracket.

8. The arc chamber assembly of claim 1, wherein the housing body is a polymeric housing body.

9. The arc chamber assembly of claim 8, wherein the polymeric housing body is reinforced with glass fiber.

10. The arc chamber assembly of claim 4, wherein the cover is a polymeric cover.

11. The arc chamber assembly of any one of claim 1, wherein at least one of the first magnet or the second magnet is a neodymium magnet.

12. An electrical device comprising: the arc chamber assembly of any one of claim 1 through claim 11; and a switching assembly coupled to the arc chamber housing, the switching assembly comprising: a switch assembly housing sealed to the housing body of the arc chamber housing, the switch assembly housing defining a second volume in communication with the arc chamber volume; one or more fixed contacts disposed at least partially in the arc chamber volume or the second volume; and a movable contact disposed at least partially in the arc chamber volume and configured to be movable relative to the fixed contacts between a first position in which the movable contact contacts the one or more fixed contacts and a second position in which the movable contact is spaced from the one or more fixed contacts.

13. The electrical device of claim 12, wherein: the arc chamber assembly includes the cover and the one or more catch features; and the one or more catch features retain the movable contact in the second position.

14. The electrical device of claim 12, wherein:the housing body of the arc chamber assembly further comprises a locating feature extending from a top surface of the housing body; and at least a portion of the switch assembly housing contacts the locating feature to position the switching assembly relative to the switch assembly.

15. The electrical device of claim 14, further comprising a contoured protrusion disposed between the housing body of the arc chamber assembly and the switch assembly housing to seal the housing body relative to the switch assembly housing.

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