ELECTROMAGNETIC RELAY ASSEMBLY WITH LINEAR MOTOR

Abstract: The present invention is an electromagnetic relay (9) capable of transferring currents of greater than 100 amps for use in regulating the transfer of electricity or in other applications requiring the switching of currents of greater than 100 amps. A relay motor assembly (10) has an elongated coil bobbin (11). A generally U- shaped ferromagnetic frame (52) has a core section (52) disposed in and extending through the axially extending cavity (12) in the elongated coil bobbin (11). Two contact sections (53, 56) extend generally perpendicularly to the core section (52) and rises above the motor assembly (10). An actuator assembly (51) is magnetically coupled to the relay motor assemlby (10). The actuator assembly (51) is comprised of an actuator frame (62) operatively coupled to a first and a second generally U-shaped ferromagnetic pole pieces (59, 60) and a permanent magnet (61). A contact bridge (70) made of a sheet of conductive material copper is operatively coupled to the actuator assembly (10).

Description: ELECTROMAGNETIC RELAY ASSEMBLY WITH LINEAR MOTOR BACKGROUND OF THE INVENTION Prior History This application is a Continuation-In-Part application of U.S. Patent Application No 09/287.469 filed on 04/07/99. Field of the Invention The present invention relates to an electromagnetic relay assembly with a linear motor capable of handling current transfers of up to and greater than 100 amps. Description of the Prior Art There are a few designs for electromagnetic relay assemblies currently in the prior art. These electromagnetic relay assemblies typically include a relay motor assembly that is magnetically coupled to an actuation assembly. The actuation assembly is then operatively coupled to a contact spring that is positioned opposite a pair of conductively isolated contact points. The relay motor typically drives the actuation assembly which in turn drives the contact spring into contact with a pair of contact points positioned directly across from it. The contact springs typically serve a dual purpose. They ensure good contact with the contact points, and they form a conductive pathway between the contact points. Contact springs are typically made of copper or a copper alloy, the copper alloys typically have lower conductivity than plain copper. Plain copper can typically sustain less than 20 amps per square millimeter without causing excess heat build up in the copper. Excess heat build up in the contact springs will cause the contact springs to lose there spring property. This results in a loss of contact pressure which leads to increased contact resistance which in turn causes the relay to fail. Consequently, most electromagnetic relays can only sustain currents of less than 20 amps per square millimeter through their copper contact springs. In order to increase current density while minimizing the heat generated by higher currents only two options are currently available. One is to make the contact springs wider, requiring an increase in the size of the relay and increasing the bending force needed by the actuator assembly and the relay motor. The other option is to increase the thickness of the spring which will also increase the bending force needed by the actuator assembly and the relay motor. Consequently, typical electromagnetic relays are not particularly suited for applications which require higher current flows of up to 100 amps. Also, current relay motors typically have relay motors which generate a rotational movement. Contact springs typically require only a linear movement in the actuator assembly to bring it into contact with the contact points. Consequently additional pieces are required in the actuation assembly in order to convert the rotational movement generated by the relay motor into a linear movement required by most contact springs, adding to the expense of producing and assembling the electromagnetic relay. Accordingly, there is a need for an electromagnetic relay which is capable of handling currents of up to 100 amps. Accordingly there is also a need for an electromagnetic relay with a motor that generates a linear movement to accommodate contact assemblies which require only a linear movement. The present invention is an electromagnetic relay assembly with a linear motor capable of transferring currents of up to 100 amps for use in regulating the transfer of electricity or in other applications requiring the switching of currents of up to 100 amps. As will be described in greater detail hereinafter, the present invention solves the aforementioned and employs a number of novel features that render it highly advantageous over the prior art. SUMMARY OF THE INVENTION Accordingly it is an object of this invention to provide an electromagnetic relay that is capable of safely transferring currents of greater than 100 amps. A further object of the present invention is to provide an electromagnetic relay with a relay motor that generates a linear movement. To achieve these objectives, and in accordance with the purposes of the present invention the following electromagnetic relay is presented. A relay motor assembly has an elongated coil bobbin with an axially extending cavity therein. An excitation coil made of a conductive material, preferably copper is wound around the bobbin. Coil terminals are conductively attached to the excitation coil and mounted on the bobbin providing a means for sending a current through the excitation coil. A ferromagnetic frame is partially disposed within the axially extending cavity within the bobbin. The ferromagnetic frame has a first contact section with a first tongue portion extending generally perpendicularly from a first contact section and above the bobbin, and a second contact section having a second and third tongue portions extending generally perpendicularly from the second contact section and above the bobbin, the second tongue portion lying below the third tongue portion. An actuator assembly has a first and second pole piece made of sheets of ferromagnetic material and a permanent magnet sandwiched in between the pole pieces. An actuator frame made of a nonconductive material is operatively coupled to the first and second ferromagnetic pole pieces, and the permanent magnet. The actuator assembly is positioned so that a portion of the first and second pole pieces are located in between the second and third tongue portion on the second contact section and that the first tongue portion of the first contact section is positioned in between the first and second pole pieces. The first and second pole pieces are magnetically coupled to a tongue portion on opposing contact sections. A lever assembly is comprised of a housing, a plurality of levers, and a plurality of contact arms. The levers are preferably L-shaped levers. The L-shaped levers are rotatably mounted onto a lever attachment point. The L-shaped lever has a first portion and a second portion. The first portion operatively engaged to the actuator frame and the second portion operatively engaged to the contact arm. A contact bridge assembly is comprised of a plurality of contact springs, preferably 2, a pair of contact buttons, and a contact bridge made of a sheet of conductive material, preferably copper. The contact bridge is operatively coupled to the contact arm. The contact bridge serves as a conductive pathway between a pair of contact points generally positioned across from the contact bridge. The conductive bridge is connected to the contact spring. The contact spring provides a force on the contact bridge sufficient to ensure good contact between the contact bridge and the contact points lying across from the contact bridge. A pair of contact buttons are also conductively connected to the contact bridge the contact buttons further ensuring that good contact is made between the contact bridge and the two contact points lying across from the contact bridge. A relay housing encloses the components of the present invention. The relay housing is preferably made of a nonconductive material and has contact terminal assemblies attached thereto and extending through a wall of the relay housing. The contact terminal assemblies typically have isolated contact points positioned across from the contact bridge. The present invention is driven by the movement of the pole pieces in response to the polarity of a current running through the excitation coil. A linear movement occurs when the polarity of the current running through the excitation coil causes the magnetic flux to induce the first and second pole pieces to magnetically couple to the contact sections opposite the contact section that they were previously magnetically coupled to. This linear movement of the pole pieces drive the movement of the actuator assembly. The two directional movement of the actuator assembly is then translated by the L- shaped lever onto the contact arm in only one direction. Consequently, the movement of the actuator assembly will either cause the L-shaped lever either to apply a force on the contact arm or else the movement of the actuator assembly will cause the L-shaped lever to apply no force to the contact arm. When the L-shaped lever applies a force onto the contact arm, the contact arm is pulled from its previous position causing the contact bridge to break contact with the contact points positioned opposite to it and compressing the contact springs. When there is no force applied to the contact arm, the contact springs are allowed to decompress, driving the contact bridge into the contact points positioned opposite to it. Other objects, features, and advantages of the invention will become more readily apparent upon reference to the following description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1. An overhead planar view of the preferred embodiment of my electromagnetic relay assembly with the upper lever housing removed in order to show details. Figure 2. An overhead planar view of a second embodiment of my electromagnetic relay assembly with upper lever housing removed in order to show details. Figure 3. An exploded view of the preferred embodiment of my electromagnetic relay assembly revealing details. Figure 4. An isometric view of the contact bridge assembly. Figure 5. A side view of the orientation of the pole piece with respect to the ferromagnetic frame in a first position in the preferred embodiment of the present invention. Figure 6. A side view of the orientation of the pole piece with respect to the ferromagnetic frame in a second position in the preferred embodiment of the present invention. Figure 7. A side view of the orientation of the pole piece with respect to the ferromagnetic frame in a first position in the second embodiment of the present invention. Figure 8. A side view of the orientation of the pole piece with respect to the ferromagnetic frame in a second position in the second embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to Figures 1,2 and 3, the present invention is an electromagnetic relay 9 capable of transferring currents of greater than 100 amps for use in regulating the transfer of electricity or in other applications requiring the switching of currents of greater than 100 amps. Referring to Figure 1 and 3, in the preferred embodiment of the present invention, a relay motor assembly 10 has an elongated coil bobbin 1 1 with an axially extending cavity 12 therein. The bobbin 1 1 is made of a light, nonconductive material, preferably plastic. An excitation coil 13 made of a conductive material, preferably copper, is wound around the bobbin. Coil terminals 14 are conductively attached to the excitation coil 13 and mounted on the bobbin providing a means for sending a current through the excitation coil 13. In the preferred embodiment of a relay motor, a ferromagnetic frame 52 is partially disposed within the axially extending cavity 12 within the bobbin 11 and has a first contact section 53 with a first tongue portion 54 extending generally perpendicularly from a first contact section 53 and above the bobbin 11, and a second contact section 56 having a second 57 and third 58 tongue portions extending generally perpendicularly from the second contact section and above the bobbin 11, the second tongue portion 57 lying below the third tongue portion 58. The ferromagnetic frame can be a single piece or broken into several different sections so long as continuity is maintained through all the pieces upon assembly. In the preferred embodiment, an actuator assembly 51 has a first 59 and second pole pieces 60 made of sheets of ferromagnetic material and a permanent magnet 61 sandwiched in between the pole pieces. An actuator frame 62 made of a nonconductive material, preferably plastic is operatively coupled to the first 59 and second 60 ferromagnetic pole pieces, and a permanent magnet 61. In the preferred embodiment, the coupling is achieved through a pair of clip portions 63 which secure the first 59 and second 60 ferromagnetic pole pieces and the permanent magnet 61 to the actuator frame 62. Referring to Figure 1,2 and 3. the actuator assembly is positioned so that a portion of the first 59 and second 60 pole pieces are located in between the second 57 and third 58 tongue portion on the second contact section 56 and that the first tongue portion 54 of the first contact section 55 is positioned in between the first 59 and second 60 pole pieces. The first 59 and second 60 pole pieces are magnetically coupled to a tongue portion on opposing contact sections. Referring to Figure 2, in a second embodiment, the third tongue portion is removed from the second contact section, leaving only the second tongue portion 57 in place. Since the relay motor will only latch when the first 59 and second 60 pole pieces are magnetically coupled to a tongue portion on opposing contact sections, the removal of the third tongue portion prevents the relay motor from latching in two positions. Referring to Figures 1, 2. and 3, a lever assembly is comprised of a housing, a plurality of levers, and a plurality of contact arms. In the preferred embodiment, the housing is comprised of an upper lever housing 90 and a lower lever housing 91. The upper lever housing 90 overlaying the lower lever housing 91. A first channel 92 and a second channel 93 extends through the upper and lower lever housing. The upper lever housing 90 and the lower lever housing 91 are overlaid so that the first channel 92 and the second channel 93 align. A contact arm is disposed within the first channels 92 and the second channels 93. The lower lever housing has a plurality of attachment points 95 located atop the lower lever housing straddling the first 92 and second 93 channels. The levers are preferably L-shaped levers 96. The L-shaped levers 96 are rotatably mounted onto a lever attachment point 95. The L-shaped lever 96 has a first portion 96a and a second portion 96b. The first portion 96a operatively engaged to the actuator frame 62 and the second portion operatively engaged to the contact arm 94. Referring to Figure 1,2, 3 and 4, in the preferred and second embodiment of the present invention, a contact bridge assembly 74 comprising a plurality of contact springs 72, preferably 2 coiled springs, a pair of contact buttons 73, and a contact bridge 70 made of a sheet of conductive material, preferably copper, is operatively coupled to the contact arm 95. In the preferred embodiment and the second embodiment, a contact bridge assembly is located on opposite ends of both the lower lever housing 91 and the upper lever housing 90. The contact bridge 70 serves as a conductive pathway between a pair of contact points 71 generally positioned across from the contact bridge 70. The conductive bridge 70 is connected to the contact springs 72. The contact springs 72, are preferably made from steel and are disposed within the upper lever housing 90 or lower lever housing 91. The contact springs provides a force on the contact bridge sufficient to ensure good contact between the contact bridge and the contact points lying across from the contact bridge. In the second embodiment, the contact springs also provides a force which drives the actuator assembly back to its starting position. A pair of contact buttons 73 are also conductively connected to the contact bridge 70, the contact buttons 73 further ensuring that good contact is made between the contact bridge and the two contact points 71 lying across from the contact bridge 70. Since the contact bridge 70 forms the conductive pathway between the two contact points 71 and not the spring 72, the contact bridge can be made thicker and wider to allow for greater current flow, without affecting the properties of the spring. In the preferred embodiment and in the second embodiment of the present invention, the contact bridge is 1 millimeter thick and 10 millimeter wide, allowing the contact bridge to safely handle up to 200 amps without significant heat build up. Referring to Figures 1, 2, and 3, in the preferred embodiment and the second embodiment, a relay housing 28 encloses the components of the present invention. The relay housing 28 is preferably made of a nonconductive material and has contact terminal assemblies 25 attached thereto and extending through a wall of the relay housing 28. The contact terminal assemblies typically have isolated contact points 71 positioned across from the contact bridge 70. An air gap of typically 1.6mm exists between the contact bridge and each contact point, with the gaps typically adding up to at least 3.0mm for safe disconnection of power. However, the air gaps can vary to accommodate different applications and different regulatory requirement. The present invention is driven by the movement of the pole pieces 59 and 60 in response to the polarity of a current running through the excitation coil 13. A linear movement occurs when the polarity of the current running through the excitation coil 13, causes the magnetic flux to induce the first 59 and second 60 pole pieces to magnetically couple to the contact sections opposite the contact section that they were previously magnetically coupled to. Figures 5 and 6 show the two positions, with respect to the ferromagnetic frame 52, in which the first 59 and second pole pieces 60 of the preferred embodiment linearly reciprocate between. Figures 7 and 8 show the two positions, with respect to the ferromagnetic frame 52, in which the first 59 and second 60 pole pieces of the second embodiment of this invention reciprocate between. In the second embodiment of the relay motor, the relay motor is capable of latching with the actuator assembly in only one position Figure 8, and capable of temporarily moving to a second position Figure 7 only as long as the polarity of the current in the relay coil is appropriate. Consequently, when the relay coil is activated to an appropriate polarity, the actuator assembly will move to the second position. Once the polarity in the coil is changed or if their is no current running in the relay coil, the actuator assembly is driven by the contact springs 72, fall back into the first position Figure 8. This linear movement of the pole pieces 59, 60 drive the movement of the actuator assembly 51. The two directional movement of the actuator assembly 51 is then translated by the L-shaped lever 96 onto the contact arm 94 in only one direction. Consequently, the movement of the actuator assembly 51 will either cause the L-shaped lever 96 either to apply a force on the contact arm 94 or else the movement of the actuator assembly 51 will cause the L-shaped lever 96 to apply no force to the contact arm 94. When the L-shaped lever 96 applies a force onto the contact arm 94, the contact arm 94 is pulled from its previous position causing the contact bridge 70 to break contact with the contact points 71 positioned opposite to it and compressing the contact springs 72. When there is no force applied to the contact arm, the contact springs 72 are allowed to decompress, driving the contact bridge into the contact points 71 positioned opposite to it. The effect of a particular movement by the actuator assembly 51 on the L-shaped lever 96 is dependent upon which attachment point 95 the L-shaped lever 96 is mounted to. Consequently, the present invention is easily configurable. The contact bridge can be easily positioned to be normally open or normally closed with respect to the contact points 71 positioned opposite to it, by simply changing the attachment point 95 of the L-shaped lever 96. The invention described above is the preferred embodiment of the present invention. It is not intended that the novel device be limited thereby. The preferred embodiment may be susceptible to modifications and variations that are within the scope and fair meaning of the accompanying claims and drawings.

Claims: I claim: 1. An electromagnetic relay comprising: a relay motor comprising a bobbin having an axially extending cavity therethrough and a conductive coil wound therearound, a generally U-shaped ferromagnetic frame disposed in and extending through the axially extending cavity in the bobbin, and having a first and a second contact section extending generally perpendicularly from opposite ends of the core section and rising above the bobbin, the first contact section having a first tongue portion extending generally perpendicularly from the first contact section and above the bobbin, the second contact section having a second and third tongue portions extending generally perpendicularly from the second contact section and above the bobbin, the second tongue portion lying below the third tongue portion; an actuator assembly comprising an actuator frame operatively coupled to a first and a second ferromagnetic pole pieces, and a permanent magnet, the permanent magnet lying sandwiched in between the pole pieces, the actuator assembly positioned so a portion of the first and second pole pieces are located in between the second and third tongue portion on the second contact section and the first tongue portion of the first contact section positioned in between the first and second pole pieces, the first and second pole pieces magnetically coupled to opposing contact sections; a lever assembly, the lever assembly comprising a lever housing, an L-shaped lever and a contact arm, the lever housing having a channel running therethrough and a plurality of lever attachment points straddling the channel, the L-shaped lever rotatively mounted onto a lever attachment point on the lever housing, the L-shaped lever having a first portion and a second portion, the first portion operatively engaged to the actuator assembly and the second portion operatively engaged to the contact arm, the contact arm disposed within the channel; and a contact bridge assembly, the contact bridge assembly having a contact bridge and a plurality of contact springs, the contact springs disposed within the lever housing and connected to the contact bridge, the contact bridge operatively engaged by the contact arm, the contact bridge moving between a first position wherein the contact bridge is not in contact with two contact points positioned directly opposite the contact bridge and a second position wherein the contact bridge is in contact with the contact points, the contact bridge serving as a conductive pathway between the two contact points, the contact arm pulling the contact bridge into the first position and compressing the contact spring attached thereto, in the second position the contact arm applying no pulling force allowing the contract spring to decompress driving the contact bridge into contact with the two contact points. 2. The electromagnetic relay in claim 1 wherein the lever assembly is comprised of an upper lever housing and a lower lever housing, a pair of contact arms, and a pair of L-shaped levers, the upper lever housing overlaying the lower lever housing, a first channel and a second channel extending through the upper and lower lever housing, a contact arm disposed within the first and the second channel, the L-shaped levers rotatably mounted onto a lever attachment point located atop the lower lever housing each L-shaped lever operatively engaged to a contact arm, the lower and upper lever housing each having a pair of contact bridge assemblies attached thereto, and each contact arm operatively engaging a pair of contact bridges. 3. The electromagnetic relay in claim 1 further comprising a relay housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the actuator assembly, the lever assembly and the contact bridge assembly being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6mm separating the contact bridge and each contact point. 4. The electromagnetic relay in claim 1 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter. 5. An electromagnetic relay assembly comprising: a relay motor; an actuator assembly; a lever assembly, the lever assembly comprising a lever and a contact arm, the lever having a first portion and a second portion, the first portion operatively engaged to the actuator assembly and the second portion operatively engaged to the contact arm: and a contact bridge assembly, the contact bridge assembly comprising a contact bridge and a plurality of contact springs, the contact springs connected to the contact bridge, the contact bridge operatively engaged by the contact arm, the contact bridge moving between a first position wherein the contact bridge is not in contact with two contact points positioned directly opposite the contact bridge and a second position wherein the contact bridge is in contact with the contact points, the contact bridge serving as a conductive pathway between the two contact points, the contact arm pulling the contact bridge into the first position and compressing the contact spring attached thereto, in the second position the contact arm applying no pulling force allowing the contract spring to decompress driving the contact bridge into contact with the two contact points. 6. The electromagnetic relay in claim 5 wherein the lever assembly is comprised of an upper lever housing and a lower lever housing, a pair of contact arms, and a pair of L-shaped levers, the upper lever housing overlaying the lower lever housing, a first channel and a second channel extending through the upper and lower lever housing, a contact arm disposed within the first and the second channel, the L-shaped levers rotatably mounted atop the lower lever housing each L-shaped lever operatively engaged to a contact arm, the lower and upper lever housing each having a pair of contact bridge assemblies attached thereto, each contact arm operatively engaging a contact bridge on the upper lever housing and a contact bridge on the lower lever housing. 7. The electromagnetic relay in claim 5 wherein the relay motor is comprised of a bobbin having an axially extending cavity therethrough and a conductive coil wound therearound, a generally U-shaped ferromagnetic frame having a plurality of core sections disposed in and extending through the axially extending cavity in the bobbin, and having a first and a second contact section extending generally perpendicularly from opposite ends of the core section and rising above the bobbin, the first contact section having a first tongue portion extending generally perpendicularly from the first contact section and above the bobbin, the second contact section having a second and third tongue portions extending generally perpendicularly from the second contact section and above the bobbin, the second tongue portion lying below the third tongue portion. 8. The electromagnetic relay in claim 5 wherein the actuator assembly is comprised of an actuator frame operatively coupled to a first and a second ferromagnetic pole pieces, and a permanent magnet, the permanent magnet lying sandwiched in between the pole pieces, the actuator assembly positioned so a portion of the first and second pole pieces are located in between the second and third tongue portion on the second contact section and the first tongue portion of the first contact section positioned in between the first and second pole pieces, the first and second pole pieces magnetically coupled to opposing contact sections. 9. The electromagnetic relay in claim 5 wherein the lever assembly is comprised of a housing, an L-shaped lever and a contact arm, the housing having a plurality of channels running therethrough and a plurality of lever attachment points alongside the channel, the L-shaped lever rotatively mounted onto a lever attachment point, the L-shaped lever having a first portion and a second portion, the first portion operatively engaged to the actuator assembly and the second portion operatively engaged to the contact arm, the contact arm disposed within the channel. 10. The electromagnetic relay in claim 5 wherein further comprising a housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the actuator assembly, the lever assembly and the contact bridge being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6mm separating the contact bridge and each contact point. 11. The electromagnetic relay in claim 5 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter. 12. An electromagnetic relay assembly comprising: a relay motor comprising a bobbin having an axially extending cavity therethrough and a conductive coil wound therearound, a generally U-shaped ferromagnetic frame having a plurality of core sections disposed in and extending through the axially extending cavity in the bobbin, and having a first and a second contact section extending generally perpendicularly from opposite ends of the core section and rising above the bobbin, the first contact section having a first tongue portion extending generally perpendicularly from the first contact section and above the bobbin, the second contact section having a second tongue portion extending generally perpendicularly from the second contact section and above the bobbin; an actuator assembly comprising an actuator frame operatively coupled to a first and a second ferromagnetic pole pieces, and a permanent magnet, the permanent magnet lying sandwiched in between the pole pieces, the actuator assembly positioned so the first tongue portion of the first contact section is positioned in between the first and second pole pieces, the actuator assembly in a latched position when the first and second pole pieces magnetically are coupled to opposing contact sections, the actuator assembly temporarily moving to an unlatched position when a current is sent through the excitation coil and the actuator assembly is magnetically coupled to only the first tongue portion ; a lever assembly, the lever assembly comprising a housing, an L-shaped lever and a contact arm, the housing having a plurality of lever attachment points and a plurality of channels running therethrough, the L-shaped lever rotatively mounted onto a lever attachment point, the L-shaped lever having a first portion and a second portion, the first portion operatively engaged to the actuator assembly and the second portion operatively engaged to the contact arm, the contact arm disposed within the channel; and a contact bridge assembly, the contact bridge assembly comprising a contact bridge and a plurality of contact springs, the contact spring disposed within the lever housing and connected to the contact bridge, the contact bridge operatively engaged by the contact arm, the contact bridge moving between a first position wherein the contact bridge is not in contact with two contact points positioned directly opposite the contact bridge and a second position wherein the contact bridge is in contact with the contact points, the contact bridge serving as a conductive pathway between the two contact points, the contact arm pulling the contact bridge into the first position and compressing the contact spring attached thereto , in the second position the contact arm applying no pulling force allowing the contract spring to decompress driving the contact bridge into contact with the two contact points. 13. The electromagnetic relay in claim 12 wherein the lever assembly is comprised of an upper lever housing and a lower lever housing, a pair of contact arms, and a pair of L- shaped levers, the upper lever housing overlaying the lower lever housing, a first channel and a second channel extending through the upper and lower lever housing, a contact arm disposed within the first and the second channel, the L-shaped levers rotatably mounted onto a lever attachment point located atop the lower lever housing each L-shaped lever operatively engaged to a contact arm, the lower and upper lever housing each having a pair of contact bridge assemblies attached thereto, each contact arm operatively engaging a contact bridge on the upper lever housing and a contact bridge on the lower lever housing. 14. The electromagnetic relay in claim 12 wherein further comprising a housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the actuator assembly, the lever assembly and the contact bridge being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6mm separating the contact bridge and each contact point. 15. The electromagnetic relay in claim 12 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter. 16. An electromagnetic relay assembly comprising: a relay motor comprising a bobbin having an axially extending cavity therethrough and a conductive coil wound therearound, a generally U-shaped ferromagnetic frame having a plurality of core sections disposed in and extending through the axially extending cavity in the bobbin, and having a first and a second contact section extending generally perpendicularly from opposite ends of the core section and rising above the bobbin, the first contact section having a first tongue portion extending generally perpendicularly from the first contact section and above the bobbin, the second contact section having a second and portion extending generally perpendicularly from the second contact section and above the bobbin; an actuator assembly, the actuator assembly operatively coupled to the relay motor; and means for conductive contact, the means for conductive contact operatively coupled to the actuator assembly. 17. The electromagnetic relay in claim 16 wherein the actuator assembly is comprising an actuator frame operatively coupled to a first and a second ferromagnetic pole pieces, and a permanent magnet, the permanent magnet lying sandwiched in between the pole pieces, the actuator assembly positioned so the first tongue portion of the first contact section is positioned in between the first and second pole pieces, the actuator assembly in a latched position when the first and second pole pieces magnetically are coupled to opposing contact sections, the actuator assembly temporarily moving to an unlatched position when a current is sent through the excitation coil and the actuator assembly is magnetically coupled to only the first tongue portion. 18. The electromagnetic relay in claim 16 wherein the means for conductive contact is a contact bridge assembly, the contact bridge assembly comprising a contact bridge and a plurality of contact springs. 19. The electromagnetic relay in claim 16 wherein the actuator is operatively engaged to the means for conductive contact by way of a lever assembly, the lever assembly comprising a housing, an L-shaped lever and a contact arm, the housing having a plurality of lever attachment points and a plurality of channels running therethrough, the L-shaped lever rotatively mounted onto a lever attachment point, the L-shaped lever having a first portion and a second portion, the first portion operatively engaged to the actuator assembly and the second portion operatively engaged to the contact arm, the contact arm disposed within the channel and operatively coupled to the means for conductive contact. 20. The electromagnetic relay in claim 16 wherein further comprising a housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the actuator assembly, the lever assembly and the contact bridge being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6mm separating the contact bridge and each contact point. 21. The electromagnetic relay in claim 16 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter.

Inventors: GRUNER KLAUS A, GRUNER, KLAUS, A.
Applicants: GRUNER KLAUS A, KG COMPONENTS INC, GRUNER, KLAUS, A., KG COMPONENTS, INC.
Application year: 2000
Main classification: H01H51
IPC codes: H01H50, H01H51