PATENT DOCUMENT

Publication Number: US-8610521-B2
Application Number: US-201113283441-A
Country: US
Kind Code: B2

Title: Noise-suppressing orbital relay assembly

Abstract:
An orbiting relay assembly may be provided that has one or more switches. The switches may be provided with electrical contacts. An actuator such as an electromagnetic actuator may rotate guiding structures such as a rotating yoke about a rotational axis. The guiding structures may have portions that receive movable electrical coupling structures such as metal balls or cylinders. There may be multiple movable electrical coupling structures in a relay. The electrical coupling structures may be distributed radially outwards from the rotational axis, may be distributed circumferentially about the rotational axis, or may be distributed axially parallel to the rotational axis. The guiding structures may be configured to place the switches in one or more different operating states by moving the metal balls or other movable electrical coupling structures about the rotational axis.

Claims:
What is claimed is: 
     
       1. A relay, comprising:
 electrical contacts; 
 a base configured to support at least one of the electrical contacts; 
 a rotating actuator having a rotational axis perpendicular to the base; 
 a shaft that is rotated by the rotating actuator; 
 at least one moving electrical coupling structure; and 
 guiding structures that are rotated about the rotational axis by the shaft as the shaft is rotated about the rotational axis by the rotating actuator, wherein the guiding structures guide the at least one moving electrical coupling structure to at least one position in which the moving electrical coupling structure forms an electrical connection with at least one of the electrical contacts. 
 
     
     
       2. The relay defined in  claim 1  wherein the electrical contacts include at least one spring. 
     
     
       3. The relay defined in  claim 1  wherein the electrical contacts include at least one contact on one side of the rotational axis and at least one contact on an opposing side of the rotational axis. 
     
     
       4. The relay defined in  claim 1  further comprising an elastomeric stop structure that the guiding structures contact when the guiding structures are rotated about the rotational axis. 
     
     
       5. The relay defined in  claim 4  wherein the elastomeric stop structure comprises an elastomeric ring mounted to the base by a screw. 
     
     
       6. The relay defined in  claim 1  wherein the moving electrical coupling structure comprises a metal ball. 
     
     
       7. The relay defined in  claim 1  wherein the moving electrical coupling structure comprises one of a plurality of moving metal balls and wherein the guiding structures form a rotating yoke with portions that are configured in a circumferentially distributed pattern around the rotational axis to receive the plurality of moving metal balls in a circumferentially distributed pattern. 
     
     
       8. The relay defined in  claim 1  wherein the moving electrical coupling structure comprises one of at least first and second metal balls, wherein the guiding structures are configured to form a yoke with a first portion that receives the first ball and a second portion that receives the second ball. 
     
     
       9. The relay defined in  claim 8  wherein the electrical contacts include first, second, and third contacts on the base. 
     
     
       10. The relay defined in  claim 9  wherein the electrical contacts include first and second springs, wherein the first ball is interposed between the first spring and the base for movement between a first position in which the first ball electrically couples the first contact to the first spring and a second position in which the first ball electrically couples the second contact to the first spring, and wherein the second ball is interposed between the second spring and the base for movement between a first position in which the second ball electrically couples the third contact to the second spring and a second position in which the third contact and the second spring are not electrically coupled by the second ball. 
     
     
       11. The relay defined in  claim 10  wherein the rotating actuator is configured to simultaneously move the first and second balls. 
     
     
       12. The relay of  claim 1  wherein the guiding structures comprise at least one recess to fit a conducting ball for electrically coupling a plurality of device components to a power supply and for electrically coupling two terminals in a control circuitry. 
     
     
       13. The relay of  claim 12  further wherein the guiding structures comprise a plurality of recesses, each one of the plurality of recesses adapted to fit one of a plurality of conducting balls;
 at least one conducting ball adapted to electrically coupling the plurality of device components to the power supply; and 
 at least one conducting ball adapted to electrically coupling the two terminals in the control circuitry. 
 
     
     
       14. A relay, comprising:
 at least a first switch having at least first and second operating states; 
 at least one metal ball in the first switch; and 
 a rotating yoke that is configured to move the metal ball between a position that places the switch in the first operating state and a position that places the switch in the second operating state. 
 
     
     
       15. The relay defined in  claim 14  further comprising:
 an additional switch; and 
 at least one additional metal ball in the additional switch, wherein the rotating yoke is configured to move the additional metal ball simultaneously with the first metal ball. 
 
     
     
       16. The relay defined in  claim 15  further comprising an electromagnetic actuator configured to rotate the rotating yoke about a rotational axis, wherein the rotating yoke is configured to move the additional metal ball to adjust operation of the additional switch. 
     
     
       17. A relay, comprising:
 an electromagnetic actuator; 
 a guiding structure that is rotated by the electromagnetic actuator; and 
 first and second balls that are moved by the guiding structure. 
 
     
     
       18. The relay defined in  claim 17 , further comprising:
 a support structure; 
 at least first and second electrical contacts on the support structure; and 
 at least a third electrical contact, wherein the guiding structure is configured to move the first ball from a position in which the first ball electrically couples the first electrical contact to the third electrical contact and a position in which the first ball electrically couples the second electrical contact to the third electrical contact. 
 
     
     
       19. The relay defined in  claim 18 , further comprising:
 at least a fourth electrical contact on the support structure and at least a fifth electrical contact, wherein the guiding structure is configured to move the second ball between a position in which the second ball electrically couples the fourth electrical contact to the fifth electrical contact and a position in which the fourth electrical contact and fifth electrical contact are not electrically coupled. 
 
     
     
       20. The relay defined in  claim 19  wherein the guiding structure is rotated about a rotational axis, wherein the guiding structure comprises a yoke having first and second recesses on opposing sides of the rotational axis, and wherein the first ball is received within the first recess and the second ball is received within the second recess.

Description:
BACKGROUND 
     This relates generally to relays and, more particularly, to relays for use in electronic devices. 
     Relays are sometimes used to control the application of alternating current (AC) power. A traditional relay of this type contains an AC switch that can be alternately placed in an open or closed position using a solenoid. Conventional relay designs such as those based on slapping metal contacts are, however, bulky and noisy. Conventional relays may also be difficult to scale to provide additional switching capabilities. 
     It would therefore be desirable to be able to provide improved relay configurations. 
     SUMMARY 
     An orbiting relay assembly may be provided that has one or more switches. The switches may be provided with electrical contacts. A controllable actuator such as an electromagnetic actuator may rotate guiding structures such as a rotating yoke about a rotational axis. The guiding structures may have portions that receive movable electrical coupling structures such as metal balls or cylinders. 
     The movable electrical coupling structures may be used to make electrical connections between the electrical contacts for the switches. When, for example, a movable electrical coupling structure is moved into one position, the movable electrical coupling structure may be used to place a switch into a first operating state. When the movable electrical coupling structure is moved into another position, the movable electrical coupling structure may be used to place the switch in a second operating state. The rotating yoke or other guiding structures may be configured to move multiple electrical coupling structures simultaneously, so that the states of multiple switches in the relay can be configured simultaneously. 
     In configurations in which there are multiple movable electrical coupling structures in a relay, the electrical coupling structures may be distributed radially outwards from the rotational axis, may be distributed circumferentially about the rotational axis, and/or may be distributed axially parallel to the rotational axis. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of a system of the type in which an orbiting relay may be used in accordance with an embodiment of the present invention. 
         FIG. 2  is a state diagram showing how an orbiting relay may be placed in open and closed positions in accordance with an embodiment of the present invention. 
         FIG. 3  is a top view of a portion of an orbiting relay in accordance with an embodiment of the present invention. 
         FIG. 4  is a top view of the relay shown in  FIG. 3  in a configuration in which spring contacts are present in accordance with an embodiment of the present invention. 
         FIGS. 5 ,  6 , and  7  are perspective views of the illustrative orbiting relay of  FIGS. 3 and 4  in accordance with an embodiment of the present invention. 
         FIG. 8  is a side view of a portion of an orbiting relay showing how a ball may be used to form a short circuit connection between a spring contact and a selected one of two stationary contacts mounted on a support structure in accordance with an embodiment of the present invention. 
         FIG. 9  is a side view of the portion of the orbiting relay of  FIG. 8  in a configuration in which the ball has been used to form a short circuit between the spring contact and a different selected one of the two stationary contacts in accordance with an embodiment of the present invention. 
         FIG. 10  is a side view of a portion of an orbiting relay having three possible ball positions and having three corresponding spring-based detents in accordance with an embodiment of the present invention. 
         FIG. 11  is a side view of a portion of an orbiting relay having three possible ball positions and having three corresponding detents formed from recesses in the vicinity of three electrical contact locations in accordance with an embodiment of the present invention. 
         FIG. 12  is top view of a portion of an orbiting relay having multiple circumferentially distributed balls in accordance with an embodiment of the present invention. 
         FIG. 13  is a top view of a portion of an orbiting relay having multiple radially distributed balls in accordance with an embodiment of the present invention. 
         FIG. 14  is a side view of a portion of an orbiting relay showing how the relay may have axially distributed structures in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices such as computers, displays, and other electronic equipment often contain alternating current (AC) to direct current (DC) power converter circuitry. 
     In some applications, it may be desirable to interrupt AC power flow to AC-to-DC power converter circuitry. For example, it may be desirable to use a relay to block the application of AC power to AC-to-DC power converter circuitry when the AC-to-DC power converter circuitry is not being actively used to convert AC power to DC power. Blocking the flow of AC power in this way may help reduce standby power losses. Relays may also be used to interrupt the flow of DC power and may be used in a wide variety of other circuit applications. Examples of circuit applications in which an orbiting relay is used as an AC relay are sometimes described herein as an example. This is, however, merely illustrative. Relays may be used as part of any suitable circuitry. 
     A system environment in which a relay such as an orbiting relay may be used is shown in  FIG. 1 . As shown in  FIG. 1 , equipment  10  may include a relay such as relay  12 . Equipment such as equipment  10  may be incorporated into a computer, a display, a portable electronic device, or other suitable electronic equipment. In the example shown in  FIG.1 , equipment  10  has an alternating current section (AC) in which relay  12  is used to control the flow of AC power from alternating power source  40  to device components  42  and a direct current section (DC) in which control circuitry  24  uses DC signals to monitor the state of relay  12 . Relays such as relay  12 , may be used in other types of system environments if desired. The use of relay  12  in equipment  10  of  FIG. 1  is merely illustrative. 
     Relay  12  may be, for example, an orbiting (rotating) relay that is controlled by a rotating electromagnetic actuator such as rotating solenoid  32  formed from a single coil of wire producing an efficient high-torque output or other suitable electrically controllable actuator. As shown in  FIG. 1 , relay  12  may have a first set of terminals associated with switch  34  and a second set of terminals associated with switch  36 . The use of two switches in relay  12  is merely illustrative. In general, relay  12  may contain any suitable number of switch circuits. 
     Structures  38  may be used to couple switches such as switches  34  and  36  together. When solenoid  32  controls the position of structures  38 , the positions of switches  34  and  36  are therefore changed simultaneously (in this illustrative configuration). 
     In the  FIG. 1  example, the terminals associated with switch  34  include terminals A, B, and C. Control circuitry  24  may be used to monitor the state of switch  34  by applying DC signals across switch  34 . The terminals associated with switch  36  include terminals X and Y. The state of switch  36  may be used to control AC power flow from AC line source  40  to device components  42 . 
     The position of switches  34  and  36  may be controlled simultaneously using an electromagnetic actuator such as solenoid  32  to control the position of structures  38 . Solenoid  32  may be a rotating solenoid (i.e., a rotating electromagnetic actuator). Control signals may be applied to solenoid  32  using a circuit formed from paths  28  and  30 . 
     Relay  12  of  FIG. 1  may have two different states. In a first state (shown in  FIG. 1 ), switch  36  is in an open position, so that there is an open circuit between terminals X and Y. When switch  36  is open, switch  34  is in a position in which terminal A is shorted to terminal B. In a second state, switch  36  is closed and terminals X and Y are shorted together. When switch  36  is closed, switch  34  is in a position in which terminal A is shorted to terminal C instead of terminal B. 
     Control circuitry  24  may receive user input on path  26 . User input may be provided using buttons, using an on-screen computer interface, using voice control, or using any other suitable user input interface arrangement. 
     Based on input such as user input  26  and/or other suitable switching criteria, control circuitry  24  may adjust the state of switch  36  using solenoid  32 . When it is desired to place relay  12  and switches  34  and  36  in a first state (e.g., with switch  36  open), a control signal (e.g., a current) may be supplied to solenoid  32  in direction  44  (e.g., a positive current may be applied). When it is desired to place relay  12  and switches  34  and  36  in a second state (e.g., with switch  36  closed), a control signal of opposite polarity may be applied (i.e., a negative current flowing in direction  46  may be applied using paths  28  and  30 ). 
       FIG. 2  is a state diagram showing how a relay  12  may be switched between states  48  and  52 . During the operations of state  48 , relay  12  may be positioned so that terminal A in switch  34  is coupled to terminal B and so that terminals X and Y in switch  36  are disconnected. When used in equipment such as equipment  10  of  FIG. 1 , the open state of switch  36  can block AC current from flowing through device components  42  from AC source  40 . During the operations of state  52 , switch  34  is in a position in which terminal A is connected to terminal C and switch  36  is closed. With switch  36  closed, current can flow between terminals X and Y, so that AC power from AC source  40  may be used to power device components  42 . Components  42  may include integrated circuits, sensors, status indicator lights, audio circuitry, display circuitry, AC-to-DC power converter circuitry, and other circuitry. 
     User input or other input may be used in controlling transitions between states  48  and  52 . For example, control circuitry  24  may apply a positive pulse to solenoid  32  to move relay from state  48  to state  52  whenever control circuitry  24  detects that switch  34  is in a state in which terminals A and B are connected and a turn on command from a button has been received by control circuitry  24  or other suitable turn on criteria have been satisfied (see, e.g., line  50 ). Control circuitry  24  may apply a negative pulse to solenoid  32  to move relay from state  52  to state  48  whenever control circuitry  24  detects that switch  34  is in a state in which terminals A and C are connected and a turn off command from an on-screen user input command is received or other suitable turn off criteria have been satisfied (see, e.g., line  54 ). 
       FIG. 3  is a top view of illustrative relay structures that may be used to implement a relay such a relay  12  of  FIG. 1 . As shown in  FIG. 3 , relay  12  may have movable electrical coupling structures such as balls  70  and  80 . The movable electrical coupling structures may be formed from metal (e.g., copper, gold, copper coated with gold, etc.). If desired, cylinders or other rolling structures may be used to implement these moving switch structures. Arrangements in which relay  12  has balls such as balls  70  and  80  are sometimes described herein as an example. 
     Contacts such a contacts C, B, and X may be supported using a support structure such as base frame  56 . Base frame  56  may be formed from a dielectric such as plastic, glass, ceramic, or other structure having an insulating surface. Contacts such as contacts C, B, and X may be formed from a conductive material such as metal. For example, contacts C, B, and X may be formed from a metal such as copper, gold, copper or other metals plated with gold or other metals, or other conductive material. 
     Screws such as screws  68  may be screwed into mating threads on the body of solenoid  32  (not shown in  FIG. 3 ). Solenoid  32  may have a shaft such as shaft  86 . The rotational position of shaft  86  about rotational axis  58  (i.e., the longitudinal axis of solenoid  32 ) may be controlled by applying control signals to solenoid  32  using paths such as paths  28  and  30  of  FIG. 1 . Shaft  86  may be coupled to structures such as yoke  62  for moving balls  70  and  80 . To prevent undesirable rotational slippage between yolk  62  and shaft  86 , shaft  86  and yoke body member  60  may be provided with mating engagement features. As shown in  FIG. 3 , for example, shaft  86  may be provided with one or more surfaces such as flat surface  88  and a mating opening in yoke body member  60  of yoke  62  may be provided with one or more mating flat surfaces. Engagement features of other shapes may be used if desired. 
     Yoke  62  may use recesses or other ball capture features to capture balls  70  and  80  (or other movable electrical coupling structures). Ball  70  may, for example, be captured in recess  94  in the upper portion of yoke  62 , whereas ball  80  may be captured in recess  96  in the lower portion of yoke  62  (in the orientation of  FIG. 3 ). Because recess  94  and recess  96  are formed within the same relay structure (i.e., yoke  62 ), the movement of recess  94  is coupled to the movement of recess  96  and the movement of ball  70  is coupled to the movement of ball  80 . When yoke  62  is rotated clockwise, for example, recess  94  will move ball  70  in direction  84  from position  72  on contact C to position  74  on contact B, while recess  96  moves ball  80  in direction  82  away from position  76  on contact X to position  78 . 
     Balls  70  and  80  may be used to form electrical paths for switches  34  and  36 , respectively. Because the positions of balls  70  and  80  are determined by recesses formed in a common rotating structure (yoke body  60  of yoke  62 ), the position of ball  70  and therefore the state of switch  34  is coupled to the position of ball  80  and the state of switch  36 , as described in connection with structure  38  of  FIG. 1 . 
       FIG. 3  shows the position of balls  70  and  80  when relay  12  is in its second state with contact A shorted to contact C and contacts X and Y shorted to each other. Contacts A and Y may be formed by conductive structures such as metal springs. The spring for contact A may be located above contacts B and C in the overlapping position indicated by dashed line  90 . The spring for contact Y may be located above contact X in the overlapping position indicated by dashed line  92 . 
     When relay  12  is in its second state (i.e., the state shown in  FIG. 3 ), ball  70  is coupled between contact C and contact A, so that switch  34  is in a state in which contacts A and C are shorted together. At the same time, ball  80  is coupled between contacts X and Y so that switch  36  is in a state in which contacts X and Y are shorted together (i.e., switch  36  is closed). 
     When it is desired to place relay  12  in its first state (i.e., the state shown in  FIG. 1 ), solenoid  32  may rotate shaft  86  and yoke  62  clockwise. The clockwise rotation of yoke  62  will move ball  70  in direction  84  until ball  70  leaves position  72  and comes to rest in position  74  over contact B. In position  74 , ball  70  is coupled between contact B and contact A, so switch  34  is in its first state. The clockwise rotation of yoke  62  will simultaneously move ball  80  in direction  82  away from position  76  on contact X and into position  78 . In position  78 , ball  80  does not contact any metal contacts on base  56 , so switch  36  is in its first state (i.e., switch  36  is open as shown in  FIG. 1  and contacts X and Y are not electrically coupled by ball  80 ). 
     Switch contacts A, B, C, X, and Y may be held in fixed locations using base  56  and other relay contact support structures. Because contacts A, B, C, X, and Y are maintained in fixed locations relative to base  56  as balls  70  and  80  are rotated around rotational axis  58 , a wiping motion may be produced between the surfaces of balls  70  and  80  and the corresponding surfaces of contacts A, B, C, X, and Y. This may help dislodge surface oxides and other surface materials that might impede the formation of satisfactory electrical contacts between the metal structures of relay  12 . The wiping and rolling motions that are exhibited by balls  70  and  80  may help to suppress noise relative to conventional relay designs that use slapping metal contacts. 
     The rotational configuration of relay  12  may be used to create a balanced design in which components such as balls  70  and portions of yoke  62  are located on opposing sides of rotational axis  58 . A balanced distribution of mass of this type in relay  12  may help reduce friction, may minimize noise and wear, and may otherwise improve relay performance. For example, the use of symmetrically distributed mass and evenly distributed frictional values may help enhance shock and vibration immunity, because external perturbations will not cause the relay to change positions. In arrangements of the type shown in  FIG. 3  in which components for switch  34  such as ball  70  and contacts A, B, and C are located on one side of axis  58 , whereas components for switch  36  such as ball  80  and contacts X and Y are located on an opposing side of axis  58  (180° away from the components of switch  34 ), different types of signals in relay  12  can be well isolated from one another. For example, in an environment of the type shown in  FIG. 1 , the DC signals associated with switch  34  can be well isolated from the AC signals associated with switch  36 . 
       FIG. 4  is a top view of relay  12  of  FIG. 3  in which electrical contacts (springs) A and Y are present. Springs such as springs A and Y may, if desired, be formed from a spring metal such as titanium copper, may be formed from other metals such as copper, or gold, or copper coated with gold, or may be formed from other suitable conductive material. 
       FIGS. 5 and 6  are perspective views of relay  12  of  FIGS. 3 and 4 . In  FIG. 5 , relay  12  is being viewed from the side of relay  12  closest to contacts X and Y. In  FIG. 6 , relay  12  is being viewed from the side of relay  12  closest to contacts A, B, and C. 
     As shown in  FIG. 5 , relay  12  may be provided with soft stop structures such as elastomeric rings  100  on screws  68 . Rings  100  may be formed from a flexible polymer or other substance that is able to help absorb impact from portions of yoke  62  such as portion  102  of yoke  62  as yoke  62  is rotated about rotational axis  58 . The presence of soft stop structures in relay  12  such as elastomeric rings  100  or other yoke cushioning structures may help reduce noise and vibration during use of relay  12 . 
       FIG. 7  is a perspective view of relay  12  showing how relay  12  may be provided with a cover structure such as cover  104 . Cover  104  may be formed from plastic or other suitable materials. Cover  104  may be used to cover shaft  86  or, as shown in the illustrative example of  FIG. 7 , shaft  86  may protrude through an opening in cover  104 . Cover  104  may be attached to base  56  using screws  68 , snaps or other engagement features, adhesive, welds, or other suitable attachment mechanisms. 
       FIGS. 8 and 9  are side views of portions of relay  12  showing how springs such as spring A (in the example of  FIGS. 8 and 9 ) or other suitable contacts may flex to accommodate movement of movable electrical coupling structures such as balls (e.g., ball  70  in the examples of  FIGS. 8 and 9 ). In the configuration of  FIG. 8 , ball (movable electrical coupling structure)  70  is located over contact B, so spring A has flexed upwards in the vicinity of contact B. In the configuration of  FIG. 9 , ball  70  has been moved to a position that is overlapping contact C. In the  FIG. 9  configuration, spring A has flexed downward towards contact B (because ball  70  is no longer present over contact B) and has flexed upwards away from contact C (because ball  70  is interposed between spring A and contact C). The flexing of springs such as electrical contact spring A of  FIGS. 8 and 9  and other electrical contacts in relay  12  may help to ensure a satisfactory contact wiping action during relay switching. The flexing of the springs helps to ensure that sufficient contact forces are maintained between ball, spring, and contact structures over a range of part tolerances, thereby ensuring satisfactory electrical performance. Flexing springs of the type shown in  FIGS. 8 and 9  may also help to bias the ball in position, creating a bistable teeter-totter that makes the relay more robust to external perturbations. 
     If desired, orbiting relays may be provided with detent structures. A side view of a contact structure with detents is shown in  FIG. 10 . In the example of  FIG. 10 , relay structures  128  have been provided with contacts such as contacts  114 ,  116 , and  118  that are mounted to base  126 . Spring contact  110  has been used to form a switch terminal for relay structures  128 . Ball  112  may be selectively coupled between spring  110  and contact  114 ,  116 , or  118 . Recesses in spring  110  such as recesses  120 ,  122 , and  124  can be used to help to form detents for relay structures  128 . For example, recess  120  may help hold ball  112  in position over contact  118 , recess  122  may help hold ball  112  in position over contact  116 , and recess  124  may help hold ball  112  in position over contact  114 . The configuration of  FIG. 10  involves the formation of three detents. Other numbers of detents may be formed in a rotating rely if desired. The example of  FIG. 10  is merely illustrative. 
       FIG. 11  shows how detents may be formed by mounting contacts  114 ,  116 , and  118  within recesses  126 ,  128 , and  130  in base  126 . 
     The functionality of an orbiting relay such as relay  12  may be scaled by adding additional contacts. Electrical contacts may be used in forming switches with multiple positions (e.g., single pole multiple throw switches) and/or may be used in forming other types of switches. Relay  12  may contain one switch, two switches, three switches, or four or more switches (as examples). 
       FIG. 12  shows how a relay switch may be formed by circumferentially distributing multiple balls around yoke  136 . As shown in  FIG. 12 , relay switch structures  134  may include relay base structure  144  (e.g., a plastic base). Yoke structure  136  or other suitable guiding structures may be mounted to a solenoid shaft so that yoke structure  136  may be rotated about rotational axis  146  (i.e., the longitudinal axis of the solenoid or other electromagnetic actuator). Circumferentially distributed recesses (recesses in a pattern that is distributed circumferentially along circumferential dimension C about axis  146 ) may be provided in yoke structure  136  to accommodate respective balls such as balls  138 ,  140 , and  142 . 
     Each of balls  138 ,  140 , and  142  may be associated with one or more contacts. For example, each ball may be used to form an electrical connection between a first contact on base  144  and an overlapping spring or an electrical connection between a second contact on base  144  and the overlapping spring (e.g., when using the ball to form a two position switch such as switch  34  of  FIG. 1 ) or may be used to form an electrical connection between a single contact on base  144  and an overlapping spring (e.g., when using the ball to form an opened/closed switch such as switch  36  of  FIG. 1 ). Relays with any suitable number of circumferentially distributed balls or other coupling members may be used if desired. The example of  FIG. 12  in which yoke  136  has been provided with three circumferentially distributed recesses to receive three corresponding balls is merely illustrative. 
       FIG. 13  shows how a relay may be provided with additional switch functionality by radially distributing balls along radial dimension RD. As shown in  FIG. 13 , relay switch structures  148  may include relay base structure  150  (e.g., a plastic base). Yoke structure  154  may be mounted to a solenoid shaft so that yoke structure  154  may be rotated about rotational axis  152  (i.e., the longitudinal axis of the solenoid). Yoke structure  154  may be provided with a pattern of radially distributed portions such as radially distributed recesses (recesses distributed radially outward from axis  152  along radial dimension RD) to accommodate respective balls such as balls  156 ,  158 , and  160 . 
     Each of balls  156 ,  158 , and  160  may be associated with one or more contacts. For example, each ball may be used to form an electrical connection between a first contact on base  150  and an overlapping spring or may be used to form an electrical connection between a second contact on base  150  and the overlapping spring (e.g., when using the ball to form a two position switch such as switch  34  of FIG.  1 ) or may be used to selectively form an electrical connection between a single contact on base  150  and an overlapping spring (e.g., when using the ball to form an opened/closed switch such as switch  36  of  FIG. 1 ). Relays with any suitable number of radially distributed balls or other coupling members may be used if desired. The example of  FIG. 13  in which yoke  154  has been provided with three (or more) recesses to receive three (or more) corresponding balls is merely illustrative. 
       FIG. 14  shows how a relay may be provided with additional switch functionality by axially distributing relay structures in an axially distributed pattern along axial dimension AD. As shown in  FIG. 14 , relay  162  may include switches formed from axially distributed electrical contacts, axially distributed guiding structures such as yoke structures  62 A,  62 B, and  62 C, and axially distributed movable electrical coupling structures. 
     Relay structures  162  may, for example, include axially distributed relay yoke structures  62 A,  62 B, and  62 C, each of which moves a respective ball (one of balls  200 A,  200 B, and  200 C) relative to one or more electrical contacts on a respective base structure (a respective one of base structures  56 A,  56 B, and  56 C). The yokes and bases are distributed axially along axial dimension AD (i.e., along yoke rotational axis  58 , which is the longitudinal axis for an electromagnetic actuator such as solenoid  32 ). In the  FIG. 14  example, there are two yoke structures located on one end of shaft  86  (the left hand end in the orientation of  FIG. 14 ) and one yoke structure located on the other end of shaft  86  (the right hand end in the orientation of  FIG. 14 ). This is merely illustrative. There may be one or more yoke structures (and corresponding base structures) located on only one end of shaft  86  or located on both ends of shaft  86 . 
     In general, any suitable number of yoke and base structures may be controlled by solenoid  32 . If desired, multiple techniques for creating additional switch functionality may be combined in a relay. For example, a relay may use any suitable number of axially distributed switch structures, any suitable number of circumferentially distributed switch structures, and/or any suitable number of radially distributed switch structures. 
     Orbiting relays of the type described in connection with  FIGS. 1-14  may offer performance enhancements relative to alternative relay designs. For example, orbiting (rotating) relays may have scalable switching capabilities using axially distributed contacts, radially distributed contacts, and/or circumferentially distributed contacts. Switch structures can be balanced, so that equal or nearly equal amounts of mass are located on opposing sides of the rotational axis of the relay (distributed 180° circumferentially). Balanced mass distributions such as these may reduce friction and result in quieter and smoother operation. Balanced mass and friction may also improve immunity to shocks and vibrations by recuing the impact of external perturbations on rely performance. A wiping action may be produced at the electrical contacts of the relay as the balls or other moving contact coupling members slide across the surface of the relay contacts. The wiping and rolling actions of the balls may help reduce electrical contact resistances and may help suppress noise. Optional detents may be formed (e.g., as part of switch contact structures, as part of non-contact structures, etc.). Impact noise and vibrations may be minimized using soft stop structures (e.g., elastomeric rings or other yoke cushioning structures that guiding structures such as yoke structures may contact when rotated by an actuator). The use of a bistable rotating solenoid design enables reversible switching without complicated mechanisms. A rotating solenoid may also provide positional stability by the design of the windings and magnetic structures, ensuring proper switch function. A single coil of wire may be used in implementing the rotating solenoid and a small, efficient high-torque output may be produced. Orbiting relay assemblies may be used in electronic devices such as computers or other electronic equipment to block AC power delivery or to perform other switching functions. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20111027
Publication Date: 20131217
Grant Date: 20131217
Priority Date: 20111027
Inventors: DEGNER BRETT W.
KESSLER PATRICK
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H50/54", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H51/2263", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H50/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H50/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H51/2263", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H50/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H1/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H50/54", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H50/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H1/16", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 48168291