Abstract:
Provided is a solenoid switch of a motor including a solenoid case, a solenoid having at least one control terminal for connection to at least one external control cable, two power terminals for connection to external power cables, two stationary serrated electrical contacts mounted within the solenoid case, where each serrated electrical contact is electrically connected to a corresponding one of the power terminals, two movable electrical contacts coupled to the solenoid and electrically connected to windings of the motor, where each movable electrical contact corresponds to one of the two serrated electrical contacts, and is movable by applied force of the solenoid. In response to a control signal received by the at least one control terminal, the solenoid is energized and moves the two movable electrical contacts to mate with the corresponding two serrated electrical contacts resulting in an electrical connection between the power cables and the motor windings.

Description:
FIELD 
       [0001]    This invention relates generally to electrical contacts for use in a solenoid switch. The invention seeks to ensure proper physical mating between the connection surfaces of the electrical contacts in icy conditions. 
       BACKGROUND 
       [0002]    Conventional electrical solenoid switches have electrical contacts that physically move in response to a control voltage. These contacts are physically separated to open the switch thereby de-energizing the load (e.g. an electric motor), and are physically connected (i.e. mated) to close the switch thereby energizing the load (e.g. an electric motor). 
         [0003]    However, these solenoid switches may be installed in cold climates where icing of the internal parts becomes problematic. Over time, moisture enters the switch housing and accumulates as ice on the mating surface of the electrical contacts. When the solenoid is controlled to apply power to the load (e.g. the motor), the contacts physically move and attempt to mate with each other. However, the ice that has accumulated on the mating surface acts as an insulator and prevents proper mating. This leads to operational malfunction of the load (e.g. the motor not turning ON). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements. 
           [0005]      FIG. 1  shows a diagram of a motor with a solenoid mounted to its side and having serrated contacts. 
           [0006]      FIG. 2  shows a mechanical drawing of the mating surface of the serrated contact. 
           [0007]      FIG. 3  shows another mechanical drawing of the mating surface of the serrated contact. 
           [0008]      FIG. 4  shows four combinations of the serrated contact mating with other types of contacts. 
           [0009]      FIG. 5  shows a cross sectional mechanical drawing of the solenoid with serrated contacts mating to blade contacts. 
           [0010]      FIG. 6  shows a cross sectional mechanical drawing of the solenoid with serrated contacts mating to other serrated contacts. 
           [0011]      FIG. 7  shows an exploded mechanical drawing of the solenoid. 
           [0012]      FIG. 8  shows another exploded mechanical drawing of the solenoid. 
           [0013]      FIG. 9  shows a mechanical drawing of the movable contacts in the solenoid. 
           [0014]      FIG. 10  shows another mechanical drawing of the movable contacts in the solenoid. 
       
    
    
     SUMMARY 
       [0015]    In one embodiment, provided is a solenoid switch for a motor. The solenoid switch comprising a solenoid case, a solenoid having at least one control terminal positioned on an outer surface of the solenoid case, for connection to at least one external control cable, two power terminals positioned on the outer surface of the solenoid case, for connection to external power cables, two stationary serrated electrical contacts mounted within the solenoid case, each stationary serrated electrical contact electrically connected to a corresponding one of the power terminals, two movable electrical contacts coupled to the solenoid and electrically connected to windings of the motor, each movable electrical contact corresponding to one of the two stationary serrated electrical contacts, and movable by applied force of the solenoid. In response to a control signal received by the at least one control terminal, the solenoid is energized and physically moves the two movable electrical contacts to mate with the corresponding two stationary serrated electrical contacts resulting in an electrical connection between the power cables and the motor windings. 
         [0016]    In one embodiment, provides is a solenoid switch. The solenoid switch comprising a solenoid case, a solenoid having at least one control terminal positioned on an outer surface of the solenoid case, for connection to at least one external control cable, two power terminals positioned on the outer surface of the solenoid case, for connection to external power cables, a stationary serrated electrical contact mounted within the solenoid case, and electrically connected to one of the power terminals, a movable non-serrated electrical contact coupled to the solenoid and electrically connected to an electrical load, the movable non-serrated electrical contact corresponding to the stationary serrated electrical contact, and movable by applied force of the solenoid. In response to a control signal received by the at least one control terminal, the solenoid is energized and physically moves the movable non-serrated electrical contact to mate with the corresponding stationary serrated electrical contact resulting in an electrical connection between the power cables and the electrical load. 
       DETAILED DESCRIPTION 
       [0017]    In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings. 
         [0018]    Solenoid switches are popular devices for performing remote switching of power to large electrical loads. These solenoid switches generally include both stationary and moveable electrical contacts made of a conductive metal such as copper. The moveable electrical contacts are attached to a moveable core that is surrounded by a solenoid coil. When a small electrical current is applied to the solenoid coil, the moveable core reacts to the magnetic field produced by the solenoid coil and applies a force to the moveable electrical contact thereby forcing the moveable electrical contact to come in physical contact with the stationary electrical contact. This creates an electrical circuit between the load (e.g. the motor) and the power source. 
         [0019]    Due to the capabilities of solenoid switches, they have been implemented in various applications including power switching applications for electric motors. An example of a solenoid switching application for an electric motor is shown in  FIG. 1  where a solenoid switch is mounted to the side of an electric motor. The motor includes motor body  100 , motor shaft  102  and motor power terminals MT 1  and MT 2 . The solenoid switch includes a solenoid housing  104  (e.g., made of metal, plastic or the like) which houses various internal components of the solenoid switch. These internal components include stationary contacts SC 1 , SC 2  and moveable contacts MC 1  and MC 2 . In addition, (although not shown), the solenoid housing  104  also houses various other components such as the solenoid coil, return springs, etc., which are described in detail with respect to the later figures. 
         [0020]    In  FIG. 1 , power source  106  is electrically connected to stationary contact SC 2 , and stationary contact SC 1  is connected to motor power terminal MT 1  which is connected to the motor coils (not shown). Motor power terminal MT 2 , which is also connected to the motor coils (not shown) is connected to ground  112 . This configuration allows motor controller  108 , which is connected to the solenoid coils within solenoid housing  104  (not shown), to control MC 1  and MC 2  open or close simultaneously, thereby connecting/disconnecting the power source  106  to/from the motor terminal MT 1 . 
         [0021]    For example, when no power is applied to the solenoid coils by motor controller  108 , then both switches MC 1  and MC 2  are opened and the motor is turned OFF. In one example, when motor controller  108  applies a voltage to the solenoid coils, then MC 1  and MC 2  both move to mate with SC 1  and SC 2  respectively. This effectively applies an electrical current from power source  106  to the motor coils (not shown) via MT 1 , thereby forcing the motor to spin. 
         [0022]    As described in the background, when a solenoid switch is installed in cold weather climates, moisture can build up inside the solenoid housing  104  (and in particular on the mating surfaces of the electrical contacts SC 1 , SC 2 , MC 1  and MC 2 ). This moisture can then turn into ice which provides an insulating barrier between the electrical contacts. 
         [0023]    If ice forms on the surfaces of the electrical contacts, proper electrical connection may not be made between the contacts during operation. For example, motor controller  108  may apply a voltage to solenoid coil to force movable contacts MC 1  and MC 2  to mate with stationary contacts SC 1  and SC 2 . However, since there is ice on these contacts, a layer of ice may prevent the metal contacts (e.g., the copper contacts) from actually touching one another. This may result in a malfunction of the motor (i.e., the motor not turning ON). 
         [0024]    In order to address this problem, at least both the stationary contacts or both the moveable contacts are fitted with a serrated surface. This serrated surface is shown in  FIG. 2  as serrated disk  200 . Serrated disk  200 , for example, may be the mating surface of the stationary contact SC 1  and stationary contact SC 2  shown in  FIG. 1 . 
         [0025]    This serrated disk may include multiple small serrations of a specific three dimensional shape and size that create pressure points during mating. For example, the serrations shown in  FIG. 2  are roughly pyramid in shape having a base length and width shown as  202  and  204 . The distance between each of the serrations is shown as  208  while the overall depth  210  of contact face  206  is shown. Also shown in  FIG. 2  is height  214  of the pyramid serrations with respect to the electrical contact  212 . 
         [0026]    By including serrations on the electrical contacts shown in  FIG. 2 , various benefits are realized. First, the serrations provide valleys where the condensation can pool without effecting the electrical contacts of the peaks of the serrations. For example, if ice forms within the valleys, it does not affect the overall operation, because the electrical connection is not performed in the valleys but rather on the peaks of the serrations. Second, the peaks of the serrations provide various pressure points that can actually break through any ice that has formed. For example, if the stationary contact SC 1  is serrated, whereas the moveable contact MC 1  is not serrated, the serrations can break through any ice that is formed on moveable contact MC 1 . In either case, a proper electrical connection is made between the contacts. 
         [0027]    It should be noted that serrated electrical disk  206  shown in  FIG. 2  may be joined to the surface of the terminals shown in  FIG. 1  using a brazing process. For example, terminal SC 1  may be manufactured separately from serrated disk  206 . These two items may then be joined together by brazing with a filler material that melts at a relatively high temperature. 
         [0028]    Although the serrated face may be brazed onto the electrical contact shown in  FIG. 1 , the electrical contacts may also be directly manufactured with a serrated face. A side view of an electrical contact manufactured directly with a serrated face is shown in  FIG. 3  as unified electrical contact  300 . The serrated contact  300  may include a base, a collar and a serrated face formed from the same piece of metal (e.g., copper). Various views of the serrated face of this unified contact is shown as  302 ,  304 ,  306  and  308 . 
         [0029]    For example,  302  shows an image of the serrated face from the a bottom view.  304  shows an image of the serrated face from a magnified bottom view.  306  shows an image of the serrated face from a magnified side view.  308  shows an image of the terminal from a top view. This unified electrical contact  300  can be molded directly into the solenoid housing  104  as the stationary electrical contact. 
         [0030]    In order to ensure that icing on the electrical contacts is not problematic, there are various possible combinations when utilizing the serrated electrical contacts. These various combinations are shown in  FIG. 4  where the stationary contacts that may or may not have serrations are mated with moveable contacts that may or may not have serrations. 
         [0031]    Example  1  shows a serrated stationary contact  400  mated with another serrated moveable contact  402 . Example  2  shows a serrated stationary contact  404  mated with a dome faced electrical contact  406 . The dome faced contact further provides prevention of icing since the condensation simply rolls off of the domed surface. Example  3  shows a serrated stationary electrical contact  408  mated to a basic flat faced moveable electrical contact  410 . Any ice that develops on the flat surface of moveable contact  410  is be chopped through by the serrations on stationary contact  408 . Example  4  shows a serrated stationary contact  412  mated to a curved blade  414 . The curved blade  414  essentially provides a curved surface where any moisture rolls off prior to turning into ice. Any remaining ice that does exist, is chopped through by the serrations on contact  412 . 
         [0032]    It should be noted that although the stationary contacts are shown to have serrations in all four of these examples, that the stationary contact may not have any serrations. The examples shown in  FIG. 4  may be swapped such that the moveable contact always has the serrations and the stationary contacts may have serrated and the other non-serrated type surfaces. As long as at least one of the contacts (i.e., the moveable or the stationary contact) has serrations, operation in icing conditions is improved. By implementing these various combinations of serrated contacts and non-serrated contacts in a solenoid switch, any moisture that develops within the switch does not pose a problem if and when it occurs. 
         [0033]    An example of an overall configuration of a solenoid switch that includes the serrated and/or non-serrated contacts is shown in both  FIGS. 5 and 6 . Specifically,  FIG. 5  shows an example of a solenoid switch that implements combination  4  shown in  FIG. 4 , whereas  FIG. 6  shows an example of a solenoid that implements combination  1  in  FIG. 4 . 
         [0034]    For example,  FIG. 5  shows an example of a solenoid switch which includes two stationary contacts  500  and  502  and two moveable contacts  516  and  520 . The stationary contacts  500  and  502  include serrated faces  514  and  518 , whereas the moveable electrical contacts  516  and  520  are implemented as curved blades. These curved blades  516  and  520  are physically connected to a rod  504  that is pushed up and down in the vertical direction in response to a magnetic field applied by solenoid coil  506 . It should be noted that the internal solenoid components are mounted within a solenoid housing  510  and mounted (e.g., to a motor) by bracket  512 . 
         [0035]    The configuration shown in  FIG. 5  shows that the bladed contacts  516  and  520  create an electrical connection between the stationary contacts  500  and  502 . Essentially, contacts  500  and  502  are electrically connected to one another through the load to complete the circuit and turn on the motor. Once the solenoid coil  506  is de-energized, force is no longer applied to rod assembly  504  and the force of the return spring opens the connection between the stationary contacts and the moveable contacts thereby turning off the load (e.g., turning off the motor). 
         [0036]    A close up view of the electrical contacts is also shown in  FIG. 5  where the serrated surface  518  of stationary contact  502  and the curved blade surface  520  of the moveable contact are shown in detail. The curved blade  520  in this example has a benefit in that any condensation (e.g., water) that forms on the curved blade simply rolls off the contact area where the blade contacts the serrated surface  518 . This ensures that ice does not form on the curved surface. However, even if ice does form on curved surface  520 , the serrated surface  518  breaks through any layers of ice when the moveable contact  520  is pressed up against stationary contact  502 . 
         [0037]    Another example of a solenoid switch is shown in  FIG. 6 .  FIG. 6  similarly includes a solenoid housing  610  and a mounting bracket  612 . Mounting bracket  612  shown in  FIG. 6 , however, is slightly different in that it includes holes for mounting the solenoid switch in a different orientation (e.g., perpendicular orientation to that shown in  FIG. 5 ). Similar to  FIG. 5 , the solenoid switch in  FIG. 6  also includes stationary contacts  600 ,  602  which include serrated surface  614  and  618 , respectively. In addition, the solenoid switch in  FIG. 6  also includes a moveable contact assembly  604  that includes two moveable electrical contacts  616  and  620 . However,  616  and  620  are not curved surface blades.  616  and  620  are actually serrated contacts as well. Thus, both the stationary and moveable contacts have serrated surfaces in the example shown in  FIG. 6 . 
         [0038]    During operation, the controller applies an electrical current to solenoid coil  606  which generates a magnetic field that pushes the electrode assembly  604  upwards towards the stationary contacts  600  and  602 . This forces surfaces  614 / 618  to mate with surfaces  616 / 620  and complete the circuit. When an electrical current is not applied to the solenoid coil  606 , the assembly is pushed back down away from the stationary coils by the force of the return spring and the circuit is opened. 
         [0039]    A close up view of the mating between stationary electrical contact  602  and moveable electrical contact  620  is also shown in  FIG. 6 . Specifically, the serrated surfaces  618  and  620  are aligned with one another and come in contact with one another when the moveable electrical contact assembly  604  is pushed up towards the stationary contact  602  by a magnetic force. By implementing both the stationary and moveable electrical contacts with serrated surfaces, this assures that ice does not form on the peaks of the serrations, and any ice that does form is broken away by the pressure point of each of the serration peaks. This ensures good electrical contact between the stationary and moveable electrical contacts. 
         [0040]    To support the further understanding of the solenoid examples shown in  FIGS. 5 and 6 , an exploded view is provided in  FIGS. 7 and 8 . In general, FIG. 7  shows an exploded view of the solenoid switch shown in  FIG. 5 , whereas  FIG. 8  shows an exploded view of the solenoid switch shown in  FIG. 6 . These exploded views are now be described in detail. 
         [0041]    In  FIG. 7 , for example, the internal components of the solenoid switch shown in  FIG. 5  are exploded in detail. These components include power terminals that are connected to the stationary electrical contacts with serrations  702 , solenoid coil terminals  700  for controlling power to the solenoid coil, case  704  for enclosing all the solenoid switch components, return spring  706  for opening the contacts when power is not applied to the solenoid coil, a moveable contact blade assembly  708  with two curved blade electrical contacts for making electrical connection with the stationary electrical contacts, a stationary core assembly  710  which is part of the magnetic circuit, a moveable core  712  which moves the moveable contact blade assembly  708  up and down in the vertical direction in response to a magnetic field applied by coil assembly  714 , a sleeve  716  and bottom washer  718  which are both part of the magnetic circuit of the coil assembly, a cork washer  720  which keeps the assembly compressed inside the housing, a gasket  722  which acts as a seal to prevent air and liquid from entering the housing, mounting bracket  724  which mounts the overall solenoid switch to a stationary object (e.g., a motor), and rivets  726  which are used to assemble the bracket to the case. 
         [0042]    It should be noted that the power terminals and coil terminals  702  and  700 , respectively, are molded into the top portion of case  704 . The power terminals are essentially the stationary electrical contacts which come into electrical contact with moveable contacts on the blade assembly  708  when power is applied to coil assembly  714 . The coil terminals  700  are electrically connected to coil assembly  714  and apply electrical current to this assembly in order to generate a magnetic field to move the moveable assembly  708  up and down in a vertical direction. When the moveable contact blade assembly  708  is moved up in a vertical direction based on a magnetic field produced by coil assembly  714 , the curved blade on assembly  708  makes electrical contact with the serrated surfaces of power terminal  702  thereby completing the circuit and applying power to a load (e.g., a motor). 
         [0043]    The exploded view of the solenoid switch shown in  FIG. 8  is that of the solenoid switch shown in  FIG. 6 . The exploded view in  FIG. 8  includes many of the same elements of that of the exploded view in  FIG. 7 . However, some of the features are different. 
         [0044]    For example, the moveable contact assembly  808  is different because it includes a bridge assembly  810  having serrated contacts, and a contact spring  812  which provides force to aid the contacts when being closed. In addition, the return spring  706  is positioned in a different location between stationary core assembly  710  and moveable core  712 . Furthermore, a nut  814  is used to secure the moveable core to the moveable contact assembly. In addition, mounting bracket  816  includes mounting holes that allow the solenoid switch to be mounted in an orientation that is perpendicular to the orientation being mounted as shown in  FIG. 7 . 
         [0045]    During operation, when a voltage is applied to coil assembly  714 , a magnetic field is generated which pushes the moveable contact assembly  808  up in a vertical direction. This results in the bridge assembly with serrated contacts  810  coming into contact with power terminals  702  thereby completing the circuit and turning on the load (i.e., the motor). 
         [0046]    As mentioned with respect to  FIG. 5 , the curved blade moveable contacts are beneficial because they direct water away from the surface of the contact where the connection is made thereby minimizing icing that that forms between the electrical connections. More detailed views of this curved blade assembly are shown in  FIGS. 9 and 10 . 
         [0047]    For example, in  FIG. 9  shows a top view  900  of the curved blade which includes a center mounting hole and the flat portion position, in between two curved portions. The orientation between the flat portion A is shown in view  902  with respect to the curved portions on the side. Further views of the curved portion can be shown in views  904  and  906 , respectively. 
         [0048]      FIG. 10  shows a view of the entire curved blade assembly which not only includes the curved blade but also the rod to which the curved blade is mounted. Two side views of the curved blade assembly are shown in views  1000  and  1004 . A top view of the curved blade assembly is shown in view  1002 . A cross sectional view of the assembly is shown in view  1006 . In general, force is applied to the rod shown in view  1004  which pushes the entire assembly up in the vertical direction within the solenoid housing thereby forcing the curved blade to come in contact with the serrated portion of the stationary electrical contacts. 
         [0049]    As shown in the figures, serrated contacts provide the benefits of reducing the amount of ice that forms on the electrical contacts and also the ability to chop through any ice that does form. This ensures that a quality electrical connection occurs between the stationary and moveable electrical contacts. The solenoid switch may be implemented in various applications including electric motor applications as described above. In these electric motor applications, the solenoid housing  104  may be mounted directly to the side of the electric motor as shown in  FIG. 1 . The solenoid housing is then electrically connected to a power source, a motor controller and then also to the power terminals of the motor (not shown). This generally allows the motor controller to open and close the solenoid switches to either apply or not apply power to the power terminals of the motor. 
         [0050]    Aside from the motor applications, the solenoid can also be implemented in just about any application where an electrical relay is beneficial. These may include various power circuits in residential, commercial and industrial settings. Regardless of the application, the solenoid switch of the present invention ensures that the proper electrical connection is made between the moveable and stationary electrical contacts even when icing would otherwise be an issue. 
         [0051]    While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings. 
         [0052]    Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain. 
         [0053]    It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. 
         [0054]    The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in fewer than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.