Integrated Contact Carrier Structure for Easier Contactor Assembly
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Solution Overview
Problem
Conventional actuator assemblies for electrical devices, such as contactors and fuses, are difficult to manufacture and assemble, leading to increased complexity and cost, and often have a limited lifespan.
Innovation Solution
An actuator assembly design that includes a carrier member coupling a movable contact to a shaft, featuring a movable contact retention member and a coupler made of insulating material, which simplifies manufacturing and assembly by allowing for a single bend operation and easy insertion of components, while enhancing insulation and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional carrier designs are used to couple movable contacts to the shaft, then the actuator assembly can provide improved performance over directly-connected arrangements, but the devices are difficult to manufacture and assemble
Solution Approach 1:
The patent combines the carrier body and carrier arm into a single integrated component formed from a single piece of conductive material. This merging eliminates the need for separate parts and complex assembly operations while maintaining the functional benefits of a carrier-based actuator assembly, directly resolving the contradiction between performance and manufacturability.
Solution Approach 2:
The integrated carrier structure performs multiple functions simultaneously: it provides mechanical coupling between the shaft and movable contact, establishes electrical conductivity paths, and serves as a structural support element. This multi-functionality reduces the number of separate components needed while maintaining actuator assembly performance.
2Ease of operation
If conventional carrier designs with multiple parts are used, then flexibility in movement is achieved, but device complexity increases
Solution Approach 1:
The integrated carrier is formed from a single piece of material that includes an integrated bend feature, creating a segmented structure within a monolithic component. This allows the carrier arm to flex relative to the carrier body, providing movement flexibility while maintaining structural integrity and reducing overall device complexity compared to multi-part assemblies.
3Ease of manufacture
If directly-connected movable contacts are used on the shaft, then assembly is simpler, but the lifespan and durability are limited
Solution Approach 1:
The integration of the carrier body and carrier arm into a single component formed from a single piece of conductive material creates a more durable structure than directly-connected arrangements. The integrated design eliminates stress concentration points at connection interfaces, thereby extending device lifespan while maintaining manufacturing simplicity.
Data Source
AI summary
A contactor device includes a movable contact configured to selectively open/close an electrical circuit. The contactor device includes an actuator assembly having a shaft, a movable contact retention member, and a coupler coupling the shaft to the movable contact retention member. The movable contact retention member may be a single piece comprising a central portion, a first side portion, and a second side portion, and the first side portion and the second side portion are angled relative to the central portion.