Electromechanical switching device assembly with a glass to metal seal module for a low-voltage auxiliary switch

Abstract

In one embodiment, an electromechanical switching device assembly is disclosed that includes a main switch and an auxiliary switch having a first set of terminals and a module having vertical pins sealed with a glass to metal seal (GTMS). The vertical pins have a first side coupled to the first set of terminals and a second side configured for coupling to a second set of terminals. The auxiliary switch also includes an aux-pusher coupled to the movable assembly such that the aux-pusher moves in response to movement of the movable assembly. Movement of the pin is configured to open or close a connection between the first set of terminals. When the connection between the first set of terminals is closed, the auxiliary switch provides a signal that indicates a state of the movable contact.

Description

ELECTROMECHANICAL SWITCHING DEVICE ASSEMBLY WITH A GLASS TO METAL SEAL MODULE FOR A LOW-VOLTAGE AUXILIARY SWITCHFIELD OF THE TECHNOLOGY

[0001] The subject disclosure relates to apparatus, systems, methods, and devices that include an electromechanical switching device assembly with a glass to metal seal module for a low- voltage auxiliary' switch.BACKGROUND

[0002] Electromechanical switching devices, such as contactors and relays, are crucial components within electrical systems, tasked with efficiently managing the flow of electrical current between fixed contacts. In a typical configuration, a contactor includes a main switch having a movable assembly configured to create or break the connection between the fixed contacts in response to movement of the actuate r / plung er assembly. High-voltage contactors often include a hermetically sealed arc chamber that aids in the arc breaking characteristics of the contactor.

[0003] Contactors and other similar devices sometimes also include an auxiliary switch to confirm the state of the main switch (open / closed). The auxiliary switch is typically mechanically coupled to the actuator, which is located inside the contactor's hermetically sealed arc chamber. In order to pass a low voltage signal from the inside to the outside of the hermetic chamber, this signal is often transferred using pins sealed with a glass to metal seal (GTMS). This GTMS is often done on large metal weld plates commonly found on hermetically sealed contactors. GTMS are created at high temperature, and the size of the header directly influences process throughput. GTMS pins are also prone to damage and must be carefully handled, which is especially difficult when small pins are sealed to a large plate.SUMMARY

[0004] The following summary is meant to help one skilled in the art understand the various presently disclosed combinations of features. It is not meant to unduly limit the scope of any pending or future claims relating to the disclosure.

[0005] This disclosure presents apparatuses, systems, and devices that include an electromechanical switching device assembly with a glass to metal seal (GTMS) module for a low-voltage auxiliary switch. Embodiments of the present disclosure replace the use of a large sealing piece for a smaller GTMS module (header) that is welded into the larger structure. This reduces the cost and complexity of the overall assembly because theprocessing and material selection is on a small plate instead of the larger plate. Furthermore, this removes the risk of handling damage since the plates are smaller relative to the pins and more can be fit on trays and more easily handled. In a particular embodiment, components of the auxiliary switch are constructed on the small GTMS module (header) before it is placed into the contactor. This embodiment allows the same GTMS module (header) to be used in multiple applications with more optimal processing and handling. This design simplifies the auxiliary switch assembly by allowing it to occur off the main contactor line, allowing for better optimization of a contactor assembly process (fewer custom processes). This saves cost, is less complex, and allows modularity, i.e. the auxiliary switch can be pushed in place. This auxiliary' switch assembly could also be overmolded to further improve strength and assembly characteristics.

[0006] In a particular embodiment, an electromechanical switching device assembly is disclosed that includes a main switch having at least two main stationary contacts and a movable contact for opening and closing a connection between the at least two stationary' contacts. The main switch also includes a movable assembly configured to move the movable contact into an open state in which the connection between the at least two stationary contacts is open and a closed state in which the connection between the at least two stationary' contacts is closed. The device assembly also includes an auxiliary' switch having a first set of terminals and a module having vertical pins sealed with a glass to metal seal (GTMS). The vertical pins have a first side coupled to the first set of terminals and a second side configured for coupling to a second set of terminals. The auxiliary’ switch also includes an aux-pusher coupled to the movable assembly such that the aux-pusher moves in response to movement of the movable assembly. In this embodiment, movement of the aux-pusher is configured to open or close a connection between the first set of terminals. When the connection between the first set of terminals is closed, the auxiliary switch provides a signal that indicates a state of the movable contact.

[0007] In another embodiment, a glass-to-metal seal (GTMS) module apparatus for an electromechanical switching device is disclosed that includes a module having a plurality of vertical oriented pins, each vertically oriented pin sealed with a glass-to-metal seal and having a first side and a second side. The GTMS module apparatus also includes a first set of terminals electrically coupled to the first side of the vertical pins. In this embodiment, the first set of terminals is configured to interface with a movable aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device.

[0008] In another embodiment, a method of assembling an electromechanical switching device is disclosed that includes providing a glass-to-metal seal module assembly. In this embodiment, the GTMS module assembly includes a GTMS module having a plurality of vertical pins each sealed with a glass-to-metal seal. In this example, the vertical pins have a first side and a second side. In this embodiment, the GTMS module assembly includes a first set of terminals electrically coupled to the first side of the vertical pins. The first set of terminals are configured to interface with an aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device. The GTMS module assembly also includes a second set of terminals electrically coupled to the second side of the vertical pins.

[0009] The foregoing and other objects, features and advantages of the invention will be apparent from the follow ing more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts of exemplary embodiments of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] One or more aspects of the present disclosure are discussed below with reference to the accompanying Figures. It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn accurately or to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element.

[0011] Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. For purposes of clarity, however, not every component may be labeled in every drawing. The Figures are provided for the purposes of illustration and explanation and are not intended to be limiting. In the Figures:

[0012] FIG. 1 is a diagram illustrating a cross-sectional view of an electromechanical switching device assembly with a known design.

[0013] FIG. 2A is a diagram illustrating an isometric view of an electromechanical switching device assembly with a glass to metal seal module for a low-voltage auxiliary switch.

[0014] FIG. 2B is a diagram illustrating another isometric view of the electromechanical switching device assembly of FIG. 2 A.

[0015] FIG. 2C is a diagram illustrating an isometric view- of the electromechanical switching device assembly of FIG. 2A in a disassembled state.

[0016] FIG. 3A is a diagram illustrating an isometric view of an electromechanical switching device assembly with a glass to metal seal module for a low-voltage auxiliary switch.

[0017] FIG. 3B is a diagram illustrating another isometric view of the electromechanical switching device assembly of FIG. 3 A.

[0018] FIG. 3C is a diagram illustrating an isometric view of the electromechanical switching device assembly of FIG. 3 A in a disassembled state.

[0019] FIG. 4A is a diagram illustrating an isometric view of an electromechanical switching device assembly with a glass to metal seal module for a low-voltage auxiliary switch in which the main switch / movable contact is in a closed state.

[0020] FIG. 4B is a diagram illustrating another isometric view of the electromechanical switching device assembly of FIG. 4A in which the main switch / movable contact is in an open state.

[0021] FIG. 4C is a diagram illustrating an isometric view of the electromechanical switching device assembly of FIG. 4A in the disassembled state.

[0022] FIG. 4D is a diagram illustrating another isometric view of the electromechanical switching device assembly of FIG. 4A in the disassembled state.

[0023] FIG. 4E is a diagram illustrating an isometric view of the glass to metal seal module of FIG. 4A with an overmolding.

[0024] FIG. 5A is a diagram illustrating an isometric view of an electromechanical switching device assembly with a glass to metal seal module for a low-voltage auxiliary switch in which the main switch / movable contact is in a closed state.

[0025] FIG. 5B is a diagram illustrating another isometric view of the electromechanical switching device assembly of FIG. 5 A in which the main switch / movable contact is in an open state.

[0026] FIG. 5C is a diagram illustrating an isometric view of the electromechanical switching device assembly 500 of FIG. 5 A in a disassembled state.

[0027] FIG. 5D is a diagram illustrating another isometric view of the electromechanical switching device assembly of FIG. 5 A in the disassembled state.

[0028] FIG. 6 sets forth a diagram illustrating a method of assembling an electromechanical switching device.

[0029] FIG. 7 sets forth a diagram illustrating another method of assembling an electromechanical switching device.DETAILED DESCRIPTION

[0030] In the following detailed description, various combinations of embodied features are disclosed to provide one skilled in the art an understanding of the aspects and implementations of the present disclosure. It will be understood by those of ordinary skill in the art that those may be practiced without some of the specific details that are set forth. In some instances, well-known methods, procedures, components and structures may not be described in detail so as not to obscure the details of the implementations of the present disclosure. The following detailed description is not meant to unduly limit any present or future claim scope in this or subsequent related applications. This disclosure may use different names, or different numerical identifiers, to describe the same feature or partially the same part. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. For purposes of clarity, however, not every component may be labeled in every drawing.

[0031] The terminology used herein for the purpose of describing particular examples is not intended to be limiting for further examples. Whenever a singular form such as “a”, “an” and “the” is used and using only a single element is neither explicitly nor implicitly defined as being mandatory, further examples may also use plural elements to implement the same functionality. Likewise, when a functionality is subsequently described as being implemented using multiple elements, further examples may implement the same functionality using a single element or processing entity. It will be further understood that the terms “comprises”, “comprising”, “includes” and / or “including”, when used, specify the presence of the stated features, integers, steps, operations, processes, acts, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, processes, acts, elements, components and / or any group thereof.

[0032] It will be understood that when an element is referred to as being “connected” or “coupled” to another element, the elements may be directly connected or coupled or via one or more intervening elements. If two elements A and B are combined using an “or”, this is to be understood to disclose all possible combinations, i.e., only A, only B, as well as A and B. An alternative wording for the same combinations is “at least one of A and B”. The same applies for combinations of more than two elements.

[0033] Accordingly, while further examples are capable of various modifications and alternative forms, some particular examples thereof are show n in the figures and will subsequently be described in detail. However, this detailed description does not limit further examples to the particular forms described. Further examples may cover all modifications, equivalents, and alternatives falling within the scope of the disclosure. Like numbers refer tolike or similar elements throughout the description of the figures, which may be implemented identically or in modified form when compared to one another while providing for the same or a similar functionality.

[0034] This disclosure presents apparatuses, systems, methods, and devices that include an electromechanical switching device assembly with a glass to metal seal (GTMS) module for a low-voltage auxiliary switch. Embodiments of the present disclosure replace the use of a large sealing piece for a smaller GTMS module (header) that is welded into the larger structure. This reduces the cost and complexity of the overall assembly because the processing and material selection is on a small plate instead of the larger plate. Furthermore, this removes the risk of handling damage since the plates are smaller relative to the pins and more can be fit on trays and more easily handled. In a particular embodiment, components of the auxiliary switch are constructed on the small GTMS module (header) before it is placed into the contactor. This embodiment allows the same GTMS module (header) to be used in multiple applications with more optimal processing and handling. This design simplifies the auxiliary switch assembly by allowing it to occur off the main contactor line, allowing for better optimization of a contactor assembly process (fewer custom processes). This saves cost, is less complex, and allows modularity, i.e. the auxiliary switch can be pushed in place. This auxiliary7switch assembly could also be overmolded to further improve strength and assembly characteristics.

[0035] For further explanation, FIG. 1 sets forth a diagram illustrating a cross-sectional view of an electromechanical switching device 100 with a known design. The switching device100 includes an upper coil yoke 108 and a lower coil yoke 196 that surround a coil assembly 193 that includes a plunger tube 194 and a coil enclosure 195. A lower static core 190 is positioned between the plunger tube 194 and the coil enclosure 195. The coil enclosure 195 surrounds a coil 166 and the plunger tube 194 surrounds a plunger assembly having a plunger101 coupled to a plunger shaft 102. The upper coil yoke 108 is coupled to upper static core 103 and a plunger spring 104 is coupled between the upper static core 103 and the plunger 101. The switching device 100 also includes fixed contacts 122, 124 and a movable contact 120. The movable contact 120 is configured to create or break the connection between the fixed contacts 122, 124 in response to movement of the plunger assembly.

[0036] In the open state, the movable contact 120 is not in contact with the fixed contacts 122, 124. such that no current flows between the fixed contacts 122, 124. In this open state, a plunger spring 104 is configured to apply a pre-load force on the plunger 101 to prevent the plunger assembly from moving to a closed state. In the closed state, the movable contact 120is in contact with the fixed contacts 122. 124 such that current flows between the fixed contacts 122. 124 through the movable contact 120.

[0037] The coil consists of windings of conductive material such as copper or aluminum. When the coil 166 is connected to a low-voltage power source and current flows through the windings a strong magnetic field is generated that flows through the magnetic circuit pathways of the electromechanical switching device assembly. This magnetic field is guided and amplified by the coil yoke and static core(s) which are made of ferromagnetic materials such as low-carbon steel. This path that the magnetic field travels on is known as the magnetic circuit. The magnetic field is guided to the plunger 101, which resides within the enclosed plunger tube 194, and magnetizes it. The magnetized plunger 101 is then attracted by a magnetic force to the upper coil yoke 108. The magnetic field forces the plunger 101 with upper direction. When enough magnetic force is generated, the plunger 101 will overcome any retaining spring forces (pre-load force from the plunger spring 104) and begin to move thus closing the gap between the coil yoke / upper static core. The plunger 101 and the plunger shaft 102 drive the movable contact 120 toward the fixed contacts 122. 124 until the movable contact 120 is in a closed position in which contact is established between the movable contact 120 and the fixed contacts 122, 124, thus transitioning the switching device 100 from the open state to the closed state. When the movable contact touches the stationary' contacts, the high-voltage circuit is completed. During this operation, the movement of the plunger 101 towards the fixed contacts 122. 124 compresses the plunger spring 104.

[0038] When the coil 166 is disconnected from the low-voltage power source, the ferromagnetic components lose their magnetization and the magnetic force on the plunger decreases. The plunger spring 104 returns the plunger to its original position. That is, when the coil 166 is de-energized, the plunger 101 is driven downward from the force of the energy stored in the compressed plunger spring 104, and the plunger assembly pulls the movable contact 120 downw ard until the movable contact 120 is in an open position, thus breaking contact between the movable contact 120 and the fixed contacts 122, 124. In this example, the plunger spring 104 provides sufficient force load that prevents all movable parts from moving. The high holding force is needed to achieve high shock resistance in the open state.

[0039] A typical contactor, such as the one illustrated in FIG. 1, may include an auxiliary switch that is mechanically coupled to the actuator and configured to provide a signal used as confirmation of the main switch state (opened / closed). In current designs, the repeatability' of the auxiliary switch is negatively affected by conductive and non-conductive particles. Theseparticles are naturally generated by the opening and closing of the contactor over life and can also be introduced into the device during the assembly process.

[0040] For further explanation, FIG. 2A sets forth a diagram illustrating an isometric view of an electromechanical switching device assembly 200 with a glass to metal seal module 210 for a low-voltage auxiliary switch. FIG. 2B sets forth a diagram illustrating another isometric view of the electromechanical switching device assembly 200 of FIG. 2A. FIG. 2C sets forth a diagram illustrating an isometric view of the electromechanical switching device assembly 200 of FIG. 2A in a disassembled state. For ease of explanation and illustration, not all components of the assembly 200 are visible or referenced in each of the FIGs 2A-C.

[0041] Although not depicted entirely in FIG. 2A-C, the electromechanical switching device assembly 200 is part of an electromechanical switching device that includes a main switch wi th at least two stationary contacts and a movable contact for opening and closing connections with the two stationary contacts. The main switch of this said electromechanical switching device includes a movable assembly 281 (depicted in FIG. 2A) configured to move the movable contact into an open state in which the connection between the two stationary contacts is open and a closed state in which the connection between the two stationary contacts is closed.

[0042] The assembly 200 also includes an auxiliary' switch having a first set of terminals 220, a second set of terminals 230, and a module 210 having vertical pins 215 sealed with a glass to metal seal (GTMS). The vertical pins 215 have a first side and a second side. In FIG. 2A, the first side of the vertical pins 215 are coupled to the first set of terminals 220. In FIG. 2B, the second side of the vertical pins 215 are coupled to the second set of terminals 230.

[0043] Although not pictured in FIG. 2A-C, the auxiliary switch of the device assembly 200 may also include an aux-pusher coupled to the movable assembly 281 of the main switch such that the aux-pusher moves in response to movement of the movable assembly 281. Movement of the aux-pusher is configured to open or close a connection between the first set of terminals 220. When the connection between the first set of terminals 220 is closed, the second set of terminals 230 provides a signal that indicates a state of the movable contact.

[0044] The electromechanical switching device assembly 200 also includes an upper coil yoke 299 having an opening 288. In FIGs. 2A-B, the module 210 is inserted into the opening 288 of the upper coil yoke 299 and in FIG. 2C, the module 210 is separated from the opening 288 of the upper coil yoke 299. In a particular embodiment, the GTMS module 210 is welded to the upper coil yoke 299.

[0045] As illustrated in FIGs. 2A-2B, the first set of terminals 220 is connected perpendicular to the vertical pins 215 and mechanically coupled to the housing 290 of the electromechanical switching device assembly. This configuration allows the auxiliary switch terminals to be rigidly supported by the housing while maintaining electrical continuity through the vertical pins sealed within the glass-to-metal seal (GTMS) module 210. The GTMS module itself is compact and discrete and is welded into an opening in the larger structure — specifically, the upper coil yoke — rather than forming the GTMS directly on a large metal plate or panel integral to the entire device. This structural arrangement enables the GTMS to be processed and sealed on a small, thermally manageable plate, which simplifies the sealing process and reduces thermal stress on the surrounding components.

[0046] This design offers significant improvements over prior configurations in which GTMS pins were sealed directly into large, welded plates that formed part of the contactor housing. Those earlier designs required complex thermal processing of large assemblies, introduced greater risk of damage to the fragile GTMS pins during handling, and limited production throughput due to size and handling constraints. By reducing the GTMS to a modular, prewelded header, the assembly process becomes more flexible, efficient, and scalable. The technical effect is improved manufacturing yield, lower cost, and enhanced reliability through reduced mechanical stress and simplified assembly operations. This modular approach also supports better process control and allows for off-line functional testing of the GTMS and auxiliary switch before integration, improving quality assurance and enabling standardized use across multiple device platforms.

[0047] For further explanation, FIG. 3A sets forth a diagram illustrating an isometric view of an electromechanical switching device assembly 300 with a glass to metal seal module 310 for a low-voltage auxiliary switch. FIG. 3B sets forth a diagram illustrating another isometric view of the electromechanical switching device assembly 300 of FIG. 3 A. FIG. 3C sets forth a diagram illustrating an isometric view of the electromechanical switching device assembly 300 of FIG. 3A in a disassembled state. For ease of explanation and illustration, not all components of the assembly 300 are visible or referenced in each of the FIGs 3 A-C.

[0048] Although not depicted entirely in FIG. 3A-C, the electromechanical switching device assembly 300 is part of an electromechanical switching device that includes a main switch with at least two stationary' contacts and a movable contact for opening and closing connections with the two stationary contacts. The main switch of this said electromechanical switching device includes a movable assembly configured to move the movable contact intoan open state in which the connection between the two stationary contacts is open and a closed state in which the connection between the two stationary contacts is closed.

[0049] The assembly 300 also includes an auxiliary switch having a first set of terminals 320, a second set of terminals 330, and a module 310 having vertical pins 315 sealed with a glass to metal seal (GTMS). The vertical pins 315 have a first side and a second side. In FIG. 3A, the first side of the vertical pins 315 are coupled to the first set of terminals 320. In FIG. 3B, the second side of the vertical pins 315 are coupled to the second set of terminals 330.

[0050] Although not pictured in FIG. 3A-C, the auxiliary switch of the device assembly 300 may also include an aux-pusher coupled to the movable assembly of the main switch such that the aux-pusher moves in response to movement of the movable assembly. Movement of the pin is configured to open or close a connection between the first set of terminals 320. When the connection between the first set of terminals 320 is closed, the second set of terminals 330 provides a signal that indicates a state of the movable contact.

[0051] The electromechanical switching device assembly 300 also includes an upper coil yoke 399 having an opening 388. In FIGs. 3A-B, the module 310 is inserted into the opening 388 of the upper coil yoke 399 and in FIG. 3C, the module 310 is separated from the opening 388 of the upper coil yoke 399. In a particular embodiment, the module 310 is welded to the upper coil yoke 399. The proposed embodiment replaces the use of a large sealing piece for a smaller GTMS module (header) that is welded into the larger structure.

[0052] For further explanation, FIG. 4A sets forth a diagram illustrating an isometric view of an electromechanical switching device assembly 400 with a glass to metal seal module 470 for a low-voltage auxiliary' switch. Although not depicted entirely in FIG. 4A, the electromechanical switching device assembly 400 is part of an electromechanical switching device that includes a main switch with at least two stationary’ contacts and a movable contact for opening and closing connections with the two stationary’ contacts. The main switch of this said electromechanical switching device includes a movable assembly 488 configured to move the movable contact into an open state in which the connection between the two stationary’ contacts is open and a closed state in which the connection between the two stationary contacts is closed. In the example of FIG. 4A, the main switch / movable contact is a closed state. FIG. 4B sets forth a diagram illustrating another isometric view of the electromechanical switching device assembly 400 of FIG. 4A in which the main switch / movable contact is in an open state. FIG. 4C sets forth a diagram illustrating an isometric view of the electromechanical switching device assembly 400 of FIG. 4A in a disassembled state. FIG. 4D sets forth a diagram illustrating another isometric view of theelectromechanical switching device assembly 400 of FIG. 4A in the disassembled state. FIG. 4E sets forth a diagram illustrating an isometric view of the glass to metal seal module 470 of FIG. 4A with an overmolding 495. For ease of explanation and illustration, not all components of the assembly 400 are visible or referenced in each of the FIGs 4A-E.

[0053] The assembly 400 also includes an auxiliary switch having a first set of terminals 452 and the module 470 having vertical pins 460 sealed with a glass to metal seal (GTMS). The vertical pins 460 have a first side and a second side. The first side of the vertical pins 460 are coupled to the first set of terminals 452. Although not pictured, the second side of the vertical pins 460 may be coupled to a second set of terminals.

[0054] The auxiliary switch of the device assembly 400 also includes an aux-pusher 450 coupled to the movable assembly 488 of the main switch such that the aux-pusher 450 moves in response to movement of the movable assembly 488. Movement of the aux-pusher 450 is configured to open or close a connection between the first set of terminals 452. When the connection between the first set of terminals 452 is closed, the auxiliary switch provides (via a second set of terminals or the second side of the vertical pins) a signal that indicates a state of the movable contact.

[0055] In the example of FIGs. 4A-D, the aux-pusher 450 has a non-conductive surface. As shown in FIG. 4A, when the main switch / movable assembly 488 is in the closed state, the aux-pusher 450 is positioned to not separate the first set of terminals 452 such that the auxiliary switch is in a closed state. FIG. 4B illustrates the main switch / movable assembly in the open state in which the aux -pusher 450 is positioned to separate the first set of terminals 452 such that the auxiliary7switch is in an open state.

[0056] The first set of terminals 452 are connected parallel to the vertical pins 460 and are not coupled to a housing of the electromechanical switching device assembly. As shown in FIG. 4C, the housing 481 includes an opening 486. The electromechanical switching device assembly 400 also includes an upper coil yoke 499 having an opening 487. In FIGs. 4A-B, the module 470 is inserted into the opening 487 of the upper coil yoke 499 and the opening 486 of the housing 481. In FIG. 4C-D, the module 470 is separated from the opening 487 of the upper coil yoke 499 and the opening 486 of the housing 481. In this embodiment, components of the auxiliary switch are constructed on a small GTMS header (module 470) before it is placed into the contactor / upper coil yoke.

[0057] As illustrated in FIG. 4C, the electromechanical switching device assembly includes a first set of terminals 452 arranged to define a first portion 479 and a second portion 477, each configured to interact differently with the aux-pusher450. When the non-conductive aux-pusher 450 is positioned between the terminals at the first portion 479, the terminals at the second portion 477 are electrically connected, resulting in a closed state for the auxiliary switch. That is, the first set of terminals is arranged such that the terminals are electrically separated in a first portion and in electrical contact in a second portion when the aux-pusher is positioned between the terminals of the first portion. However, when the aux-pusher 450 moves into the second portion 477, it separates the terminals at the second portion, transitioning the auxiliary switch to an open state. That is, the terminals of the first set are electrically separated in the second portion when the aux-pusher is positioned between the terminals of the second portion.

[0058] In the example embodiment of FIG. 4E, portions of the GTMS header module 470 are encapsulated in an overmolding material 495. Specifically, the overmolding 495 is applied to cover selected sections of the vertical pins 460 and portions of the first set of terminals 452. The overmolding serves multiple functional purposes, including providing mechanical reinforcement to the GTMS module assembly and protecting the sealed pins and terminal connections from environmental exposure, such as moisture, dust, or arc byproducts within the arc chamber. By stabilizing the interface between the terminals and the sealed pins, the overmolding also reduces the risk of mechanical fatigue or displacement during assembly or operation, which is particularly important in applications subject to vibration or thermal cycling.

[0059] The overmolding may be formed using a thermoplastic or thermoset polymer material selected for its dielectric strength, adhesion to metal surfaces, and thermal stability. This additional encapsulation helps maintain electrical isolation between conductive elements and enhances the robustness of the module within the sealed portion of the contactor. In contrast to prior designs that exposed internal terminals and connections, this integrated overmolding improves reliability by reducing the likelihood of short circuits, corrosion, or degradation over time. It also simplifies handling during assembly by providing a more rigid, protected interface, thereby contributing to a more repeatable and durable manufacturing process.

[0060] For further explanation, FIG. 5A sets forth a diagram illustrating an isometric view of an electromechanical switching device assembly 500 with a glass to metal seal module 570 for a low-voltage auxiliary switch. Although not depicted entirely in FIG. 5A, the electromechanical switching device assembly 500 is part of an electromechanical switching device that includes a main switch with at least two stationary' contacts and a movable contact for opening and closing connections with the two stationary contacts. The main switch of this said electromechanical switching device includes a movable assembly 588 configured tomove the movable contact into an open state in which the connection between the two stationary contacts is open and a closed state in which the connection between the two stationary contacts is closed. In the example of FIG. 5 A, the main switch / movable contact is a closed state. FIG. 5B sets forth a diagram illustrating another isometric view of the electromechanical switching device assembly 500 of FIG. A in which the main switch / movable contact is in an open state. FIG. 5C sets forth a diagram illustrating an isometric view of the electromechanical switching device assembly 500 of FIG. 5 A in a disassembled state. FIG. 5D sets forth a diagram illustrating another isometric view of the electromechanical switching device assembly 500 of FIG. 5 A in the disassembled state. For ease of explanation and illustration, not all components of the assembly 500 are visible or referenced in each of the FIGs 5A-D.

[0061] The assembly 500 also includes an auxiliary switch having a first set of terminals 552 and the module 570, which has vertical pins 560 sealed with a glass to metal seal (GTMS). The vertical pins 5 0 have a first side and a second side. The first side of the vertical pins 560 are coupled to the first set of terminals 552. Although not pictured, the second side of the vertical pins 560 may be coupled to a second set of terminals.

[0062] The auxiliary switch of the device assembly 500 also includes an aux -pusher 550 coupled to the movable assembly 588 of the main switch such that the aux-pusher 550 moves in response to movement of the movable assembly 588. Movement of the aux-pusher 550 is configured to open or close a connection between the first set of terminals 552. When the connection between the first set of terminals 552 is closed, the auxiliary' switch provides (via a second set of terminals or the second side of the vertical pins) a signal that indicates a state of the movable contact.

[0063] In the example of FIGs. 5A-D, the aux-pusher 450 has a conductive surface. As shown in FIG. 5 A, when the main switch / movable assembly 588 is in the closed state, the aux-pusher 550 is positioned to not form a connection between the first set of terminals 552 such that the auxiliary- switch is in an open state. FIG. 5B illustrates the main switch / movable assembly in the open state in which the aux-pusher 550 is to form a connection between the first set of terminals 552 such that the auxiliary switch is in a closed state.

[0064] The first set of terminals 552 are connected parallel to the vertical pins 560 and are not coupled to a housing 581 of the electromechanical switching device assembly. As show n in FIG. 5C. the housing 581 includes an opening 586. The electromechanical switching device assembly 500 also includes an upper coil yoke 599 having an opening 587. In FIGs. 5A-B, the module 570 is inserted into the opening 587 of the upper coil yoke 599 and theopening 586 of the housing 581. In FIG. 5C-D, the module 570 is separated from the opening 587 of the upper coil yoke 599 and the opening 586 of the housing 581. In this embodiment, components of the auxiliary switch are constructed on the small GTMS header (module 570) before it is placed into the contactor / upper coil yoke.

[0065] As illustrated in FIG. 5C, the electromechanical switching device assembly includes a first set of terminals 552 arranged to define a first portion 579 and a second portion 577, each configured to interact with the conductive aux-pusher550. When the conductive aux-pusher 550 is positioned between the terminals at the first portion 579, the terminals at the first portion 579 and the second portion 577 are electrically separated, preventing current flow and resulting in an open state for the auxiliary switch. The terminals of the first set remain physically separated in the second portion when the aux-pusher is positioned between the terminals of the first portion. That is, the first set of terminals is arranged such that the terminals are electrically separated in both a first portion and a second portion when the aux- pusher is positioned betw een the terminals of the first portion. How ever, w hen the aux- pusher 550 is positioned between the terminals at the second portion 577, the conductive aux- pusher 550 forms a connection between the terminals at the second portion 577, transitioning the auxiliary switch in a closed state. This arrangement ensures that electrical continuity is established only when the aux-pusher is positioned betw een the second portion, providing a controlled and repeatable switching response based on the position of the movable assembly.

[0066] For further explanation, FIG. 6 sets forth a diagram illustrating a method of assembling an electromechanical switching device. The method of FIG. 6 includes providing 602 a glass-to-metal seal module assembly. In the example of FIG. 6, the GTMS module assembly includes a GTMS module having a plurality of vertical pins each sealed with a glass-to-metal seal. In this example, the vertical pins have a first side and a second side. In this embodiment, the GTMS module assembly includes a first set of terminals electrically coupled to the first side of the vertical pins. The first set of terminals are configured to interface with an aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device. The GTMS module assembly also includes a second set of terminals electrically coupled to the second side of the vertical pins. Providing 602 a glass-to-metal seal (GTMS) module assembly may be carried out by fabricating a GTMS header that includes a metal plate with vertical conductive pins hermetically sealed using glass. The first set of terminals is attached to the interior side of the pins, configured to interface with a movable aux-pusher within the arc chamber. The second set of terminals is connected to the exterior side of the pins to enable signal transmission outside the sealedenvironment. This module may be preassembled and functionally verified prior to installation, enabling modular integration and reducing assembly complexity in the final electromechanical switching device.

[0067] The method also includes inserting 604 the GTMS module assembly into an opening defined in an upper coil yoke of the electromechanical switching device. Inserting 604 the GTMS module assembly into an opening defined in an upper coil yoke of the electromechanical switching device may be carried out by aligning the GTMS module with a pre-formed opening in the upper coil yoke. The module is then positioned such that the first set of terminals enters the interior region of the arc chamber while the second set of terminals remains accessible from the exterior. This insertion may be facilitated by mechanical features such as locating tabs or grooves to ensure proper orientation and fit. Once seated, the module may be held in place temporarily by friction or fixtures prior to welding or sealing in a subsequent step.

[0068] In addition, the method also incudes securing and sealing 606 the GTMS module to the upper coil yoke such that the first set of terminals is positioned within an arc chamber of the electromechanical switching device and the second set of terminals is positioned external to the arc chamber. Securing and sealing 606 the GTMS module to the upper coil yoke may be carried out by welding or brazing the perimeter of the GTMS module to the yoke at the interface, creating a hermetic mechanical and electrical seal. The module is positioned such that the first set of terminals extends into the arc chamber to interface with the auxiliary switch mechanism, while the second set of terminals remains accessible outside the chamber for signal routing. A sealant or overmolding material, may optionally be applied around the weld joint or pin interfaces to enhance environmental protection and mechanical robustness. This process ensures that the arc chamber remains sealed while allowing reliable electrical signal transmission from the internal switching components to external systems.

[0069] The method of FIG. 6 addresses key challenges in the manufacturing and integration of auxiliary switches within electromechanical switching devices. By enabling the use of a preassembled glass-to-metal seal (GTMS) module that can be inserted and sealed into defined structural openings, the method reduces reliance on large, complex sealing operations and minimizes the risk of damage to delicate GTMS pins during assembly. This modular approach improves manufacturing efficiency, enhances quality control through preinstallation testing, and supports greater design flexibility across product platforms. The ability to maintain a hermetic seal while simplifying signal routing from within the arcchamber to external circuits ultimately contributes to improved device reliability and reduced production cost.

[0070] For further explanation, FIG. 7 sets forth a diagram illustrating a method of assembling an electromechanical switching device. The method of FIG. 6 includes inserting 702 the GTMS module assembly into a corresponding opening defined in a housing of the electromechanical switching device, such that the GTMS module assembly extends through both the housing and the upper coil yoke. Inserting 702 the GTMS module assembly into a corresponding opening defined in a housing of the electromechanical switching device may be carried out by aligning the preassembled GTMS module with a through-hole formed in both the outer housing and the upper coil yoke. The module is guided through the housing opening and continues into the aligned opening in the upper coil yoke, ensuring that the first set of terminals extends into the arc chamber and the second set remains external. Mechanical alignment features or stops may be used to ensure correct depth and orientation during insertion. Once fully seated, the module can be secured by welding, fastening, or overmolding to create a sealed interface across both structural elements.

[0071] This method enables the integration of a preassembled glass-to-metal seal (GTMS) module into both the housing and upper coil yoke of an electromechanical switching device, rather than requiring the GTMS to be formed on a large, unitary structure. By allowing the GTMS module to be constructed separately and inserted as a discrete component, the approach reduces handling risks, improves manufacturing throughput, and simplifies material selection and thermal processing. The resulting assembly process is more modular and flexible, supporting the use of standardized components across multiple product variants. Additionally, the ability to test the GTMS module and auxiliary switch functionality prior to installation improves quality assurance and reduces the likelihood of field failures.

[0072] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, apparatuses, and methods, according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

[0073] Advantages and features of the present disclosure can be further described by the following statements:

[0074] 1. An electromechanical switching device apparatus comprising: a main switch that includes: at least two main stationary contacts; a movable contact for opening and closing a connection between the at least two stationary contacts; and a movable assembly configured to move the movable contact into an open state in which the connection between the at least two stationary contacts is open and a closed state in which the connection between the at least two stationary contacts is closed; and an auxiliary switch that includes: a first set of terminals; a module having vertical pins sealed with a glass to metal seal (GTMS), the vertical pins having a first side coupled to the first set of terminals and a second side configured for coupling to a second set of terminals; and an aux-pusher coupled to the movable assembly such that the aux -pusher moves in response to movement of the movable assembly; wherein movement of the aux-pusher is configured to open or close a connection between the first set of terminals; wherein when the connection between the first set of terminals is closed, the auxiliary switch provides a signal that indicates a state of the movable contact.

[0075] 2. The electromechanical switching device apparatus of statement 1, wherein the aux- pusher has a non-conductive surface; wherein when the movable assembly is in the open state, the aux-pusher is positioned to separate the first set of terminals such that the auxiliary switch is in an open state; and wherein when the movable assembly is in the closed state, the aux-pusher is positioned to not separate the first set of terminals such that the auxiliary switch is in a closed state.

[0076] 3. The electromechanical switching device apparatus of statement 1 or 2, wherein the first set of terminals is arranged such that the terminals are electrically separated in a first portion and in electrical contact in a second portion when the aux-pusher is positioned between the terminals of the first portion.

[0077] 4. The electromechanical switching device apparatus of any of statements 1-3, wherein the terminals of the first set are electrically separated in the second portion when the aux-pusher is positioned between the terminals of the second portion.

[0078] 5. The electromechanical switching device apparatus of statement 1, wherein the aux- pusher has a conductive surface; wherein when the movable assembly is in the open state, the aux-pusher is positioned to form a connection between the first set of terminals such that the auxiliary switch is in a closed state; and wherein when the movable assembly is in the closedstate, the aux-pusher is positioned to not form a connection between the first set of terminals such that the auxiliary switch is in an open state.

[0079] 6. The electromechanical switching device apparatus of any of statements 1 or 5 wherein the first set of terminals is arranged such that the terminals are electrically separated in both a first portion and a second portion when the aux-pusher is positioned between the terminals of the first portion.

[0080] 7. The electromechanical switching device apparatus of any of statements 1 and 5-6, wherein the terminals of the first set remain electrically separated in the second portion when the aux-pusher is positioned between the terminals of the second portion.

[0081] 8. The electromechanical switching device apparatus of any of statements 1-7 further comprising an upper coil yoke having an opening; wherein the module is inserted into the opening of the upper coil yoke.

[0082] 9. The electromechanical switching device apparatus of any of statements 1-8, the GTMS module is coupled to the upper coil yoke such that the first set of terminals are positioned within an arc chamber of the electromechanical switching device and the second set of terminals are positioned outside the arc chamber.

[0083] 10. The electromechanical switching device apparatus of any of statements 1-9, wherein the first set of terminals are connected perpendicular to the vertical pins and coupled to a housing of the electromechanical switching device assembly.

[0084] 11. The electromechanical switching device apparatus of any of statements 1-10, wherein the first set of terminals are connected parallel to the vertical pins and are not coupled to a housing of the electromechanical switching device assembly.

[0085] 12. The electromechanical switching device apparatus of any of statements 1-11, wherein the housing includes an opening; wherein the module is inserted into the opening of the housing.

[0086] 13. The electromechanical switching device apparatus of any of statements 1-12, wherein the module includes an overmolding.

[0087] 14. A glass-to-metal seal (GTMS) module apparatus for an electromechanical switching device, the GTMS module apparatus comprising: a module having a plurality of vertical oriented pins, each vertically oriented pin sealed with a glass-to-metal seal and having a first side and a second side; and a first set of terminals electrically coupled to the first side of the vertical pins, the first set of terminals configured to interface with a movable aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device.

[0088] 15. The GTMS module apparatus of statement 14, wherein the first set of terminals is arranged such that the terminals are electrically separated in a first portion and electrically connected in a second portion when the aux -pusher is positioned between the terminals of the first portion.

[0089] 16. The GTMS module apparatus of statement 14 or 15, wherein the first set of terminals are arranged such that the terminals are electrically separated in the second portion when the aux-pusher is positioned between the terminals of the second portion.

[0090] 17. The GTMS module apparatus of statement 14, wherein the first set of terminals are arranged such that the terminals are electrically separated in both a first portion and a second portion when the aux-pusher is positioned between the terminals of the first portion.

[0091] 18. The GTMS module apparatus of any of statements 14 and 17, wherein the terminals of the first set remain electrically separated in the second portion when the aux- pusher is positioned between the terminals of the second portion.

[0092] 19. A method of assembling an electromechanical switching device, the method comprising: providing a glass-to-metal seal module assembly that includes: a GTMS module having a plurality of vertical pins each sealed with a glass-to-metal seal, the vertical pins having a first side and a second side; a first set of terminals electrically coupled to the first side of the vertical pins, the first set of terminals configured to interface with an aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device; and a second set of terminals electrically coupled to the second side of the vertical pins; inserting the GTMS module assembly into an opening defined in an upper coil yoke of the electromechanical switching device; and securing and sealing the GTMS module to the upper coil yoke such that: the first set of terminals is positioned within an arc chamber of the electromechanical switching device; and the second set of terminals is positioned external to the arc chamber.

[0093] 20. The method of statement 19 further comprising: inserting the GTMS module assembly into a corresponding opening defined in a housing of the electromechanical switching device, such that the GTMS module assembly extends through both the housing and the upper coil yoke.

[0094] It will be understood from the foregoing description that modifications and changes may be made in various embodiments of the present disclosure without departing from its true spirit. The descriptions in this specification are for purposes of illustration only and are not to be construed in a limiting sense. The scope of the present disclosure is limited only by the language of the following claims.

Claims

CLAIMSWhat is claimed is:

1. An electromechanical switching device apparatus comprising: a main switch that includes: at least two main stationary contacts; a movable contact for opening and closing a connection between the at least two stationary contacts: and a movable assembly configured to move the movable contact into an open state in which the connection between the at least two stationary contacts is open and a closed state in which the connection between the at least two stationary contacts is closed; and an auxiliary switch that includes: a first set of terminals; a module having vertical pins sealed with a glass to metal seal (GTMS), the vertical pins having a first side coupled to the first set of terminals and a second side configured for coupling to a second set of terminals; and an aux-pusher coupled to the movable assembly such that the aux-pusher moves in response to movement of the movable assembly; wherein movement of the aux-pusher is configured to open or close a connection between the first set of terminals; wherein when the connection between the first set of terminals is closed, the auxiliary switch provides a signal that indicates a state of the movable contact.

2. The electromechanical switching device apparatus of claim 1, wherein the aux-pusher has a non-conductive surface; wherein when the movable assembly is in the open state, the aux-pusher is positioned to separate the first set of terminals such that the auxiliary switch is in an open state; and wherein when the movable assembly is in the closed state, the aux-pusher is positioned to not separate the first set of terminals such that the auxiliary switch is in a closed state.

3. The electromechanical switching device apparatus of claim 2, wherein the first set of terminals is arranged such that the terminals are electrically separated in a first portion and in electrical contact in a second portion when the aux-pusher is positioned between the terminals of the first portion.

4. The electromechanical switching device apparatus of claim 3, wherein the terminals of the first set are electrically separated in the second portion when the aux-pusher is positioned between the terminals of the second portion.

5. The electromechanical switching device apparatus of claim 1, wherein the aux-pusher has a conductive surface; wherein when the movable assembly is in the open state, the aux-pusher is positioned to form a connection between the first set of terminals such that the auxiliary switch is in a closed state; and wherein when the movable assembly is in the closed state, the aux-pusher is positioned to not form a connection between the first set of terminals such that the auxiliary switch is in an open state.

6. The electromechanical switching device apparatus of claim 5, wherein the first set of terminals is arranged such that the terminals are electrically separated in both a first portion and a second portion when the aux-pusher is positioned between the terminals of the first portion.

7. The electromechanical switching device apparatus of claim 6. wherein the terminals of the first set remain physically separated in the second portion when the aux-pusher is positioned between the terminals of the first portion.

8. The electromechanical switching device apparatus of claim 1 further comprising an upper coil yoke having an opening; wherein the module is inserted into the opening of the upper coil yoke.

9. The electromechanical switching device apparatus of claim 8, the GTMS module is coupled to the upper coil yoke such that the first set of terminals are positioned within an arc chamber of the electromechanical switching device and the second set of terminals are positioned outside the arc chamber.

10. The electromechanical switching device apparatus of claim 1, wherein the first set of terminals are connected perpendicular to the vertical pins and coupled to a housing of the electromechanical switching device assembly.

11. The electromechanical switching device apparatus of claim 1. wherein the first set of terminals are connected parallel to the vertical pins and are not coupled to a housing of the electromechanical switching device assembly.

12. The electromechanical switching device apparatus of claim 10, wherein the housing includes an opening; wherein the module is inserted into the opening of the housing.

13. The electromechanical switching device apparatus of claim 1, wherein the module includes an overmolding.

14. A glass-to-metal seal (GTMS) module apparatus for an electromechanical switching device, the GTMS module apparatus comprising: a module having a plurality of vertical oriented pins, each vertically oriented pin sealed with a glass-to-metal seal and having a first side and a second side; and a first set of terminals electrically coupled to the first side of the vertical pins, the first set of terminals configured to interface with a movable aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device.

15. The GTMS module apparatus of claim 14. wherein the first set of terminals is arranged such that the terminals are electrically separated in a first portion and electrically connected in a second portion when the aux-pusher is positioned between the terminals of the first portion.

16. The GTMS module apparatus of claim 15. wherein the first set of terminals are arranged such that the terminals are electrically separated in the second portion when the aux-pusher is positioned between the terminals of the second portion.

17. The GTMS module apparatus of claim 14, wherein the first set of terminals are arranged such that the terminals are electrically separated in both a first portion and a second portion when the aux -pusher is positioned between the terminals of the first portion.

18. The GTMS module apparatus of claim 17, wherein the terminals of the first set remain physically separated in the second portion when the aux-pusher is positioned between the terminals of the first portion.

19. A method of assembling an electromechanical switching device, the method comprising: providing a glass-to-metal seal module assembly that includes: a GTMS module having a plurality of vertical pins each sealed with a glass-to-metal seal, the vertical pins having a first side and a second side; a first set of terminals electrically coupled to the first side of the vertical pins, the first set of terminals configured to interface with an aux-pusher that moves in response to a position of a movable assembly of the electromechanical switching device; and a second set of terminals electrically coupled to the second side of the vertical pins;inserting the GTMS module assembly into an opening defined in an upper coil yoke of the electromechanical switching device; and securing and sealing the GTMS module to the upper coil yoke such that: the first set of terminals is positioned within an arc chamber of the electromechanical switching device; and the second set of terminals is positioned external to the arc chamber.

20. The method of claim 19 further comprising: inserting the GTMS module assembly into a corresponding opening defined in a housing of the electromechanical switching device, such that the GTMS module assembly extends through both the housing and the upper coil yoke.

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