ASSEMBLY METHOD THEREFOR

The present invention relates to a switch contact subassembly having a contact member, an actuation member and a resilient element which is supported between the contact member and the actuation member in a state clamped on the actuation member and by means of which the contact member is supported so as to be resiliently movable relative to the actuation member counter to a switching direction, a stop which is arranged on the actuation member limiting movements of the contact member relative to the actuation member in a switching direction.

The invention further relates to a construction kit for a switch contact subassembly.

Finally, the invention relates to a method for assembling a switch contact subassembly, a resilient element being clamped between a contact member and an actuation member and, further, a movement of the contact member relative to the actuation member being limited counter to a switching direction of the switch contact subassembly.

The above-mentioned switch contact subassembly and the construction kit and the assembly method therefor are known from the prior art. Such switch contact subassemblies mostly perform the switching function in relays, in particular high-current relays, and are driven for this purpose by means of the actuation member. The contact member is arranged, for example, in the form of a contact carrier or a contact bridge so as to be able to be displaced and tilted with defined abutment and pretensioning on the actuation member of a plunger relay which is constructed as a drive shaft.

In the switch contact subassemblies known from the prior art, the stop is generally formed using securing discs or snap rings which are inserted into annular grooves provided on the actuation member which is constructed as a rod-like drive shaft. These annular grooves can currently be produced only by means of cutting machining, for example, by the actuation member being produced as a turned component with grooves formed therein.

A disadvantage of the known switch contact subassemblies and construction kits and assembly methods therefor is in particular that the construction of the contact member as a turned component involves very high production costs. Furthermore, overloading of the securing discs which rest in the grooves on the contact member when opening and closing the contacts may lead to breakage of the securing discs and consequently to a loss of the switching function since the discs are not constructed for great axial forces. Furthermore, the assembly of the known switch contact subassemblies is complex.

An object of the invention is consequently to provide a switch contact subassembly which is as robust as possible and which at the same time can be produced in a simple and cost- effective manner, and a construction kit and an assembly method therefor.

For the switch contact subassembly mentioned in the introduction, this object is achieved in that the stop is formed integrally on the actuation member. That is to say, the stop and actuation member are constructed as an integral component. A construction kit for a switch contact subassembly according to the invention is distinguished in that it comprises an actuation member according to the invention which is constructed so as to be able to be used in a switch contact subassembly according to the invention. The solutions according to the invention have the advantage that, for example, no cost- intensive turned components but instead cost-effective upset or shaped components can be used to form the actuation member. Furthermore, the number of components of the switch contact subassembly is reduced, which in turn reduces the production costs and simplifies the assembly.

The solutions according to the invention can be freely combined and further improved with the following additional embodiments which are each advantageous per se.

For instance, the stop can be produced in a particularly simple and cost-effective manner by being constructed at an end portion of the actuation member directed in the switching direction. The end portion may be formed, for example, as a flange or an annular collar at the end of the actuation member even after the contact carrier and the spring have been inserted by an end of the actuation member being upset or formed in another manner. The resilient element may be supported on the actuation member counter to the switching direction by means of a resilient retention element which is formed on the actuation member. Consequently, the resilient retention element, in a similar manner to the stop, can be formed integrally on the actuation member. For example, the resilient retention element may also be an annular collar or a flange which extends along an outer periphery of the actuation member and which can be formed on the actuation member, for example, by means of upsetting or other shaping methods.

The actuation member may have a shaft and a sleeve which engages round it, the shaft being provided with the stop and the sleeve being provided with the resilient retention element. Consequently, the shaft and stop and the sleeve and resilient retention element can each be constructed integrally. It is also possible for the entire shaft to be constructed as a sleeve or so as to be hollow and for the contact member, after insertion with the spring, to be clamped by means of formation of the stop and/or the resilient retention element. In any case, the stop and resilient retention element or abutment shoulders formed thereby can be formed after the contact carrier and actuation member are combined.

The contact member can be mounted on the actuation member in a particularly simple manner if an opening in the contact member surrounds an outer periphery of the sleeve.

Consequently, the contact member can be simply pushed over the sleeve and slide along it.

The shaft and the sleeve may be connected to each other in a positive-locking and/or non- positive-locking manner. For positive-locking connection or axial fixing of the shaft and sleeve, positive-locking elements, such as, for example, channels, may be formed on the outer periphery of the shaft and/or on the inner periphery of the sleeve. The sleeve may be connected to the shaft in a positive-locking and/or non-positive-locking manner after being positioned on the shaft, for example, by means of compression, press-fitting and/or eddy current shaping. A construction kit according to the invention can be improved, for example, by the construction kit comprising a shaft having a stop formed therein and a sleeve having a resilient retention element formed therein, the shaft being able to be displaceably received in the sleeve in a preassembly state. A method according to the invention can, for example, be improved by the stop being formed on a shaft, the shaft being inserted into a sleeve which is provided with a resilient retention element and the sleeve subsequently being fixed to the shaft. Consequently, the shaft and sleeve with the contact member arranged therebetween and the spring can be readily displaced into a desired position relative to each other until sufficient resilient pretensioning is achieved. Subsequently, the sleeve can be fixed to the shaft and consequently the switch contact subassembly can be provided. In each case, it is advantageous if the sleeve is arranged between the shaft and the contact member so that the contact member can slide along the outer periphery of the sleeve which is fitted to the shaft.

The invention is described in greater detail below by way of example, with reference to possible embodiments and the appended drawings. The feature combinations set out in these embodiments are merely for the purposes of illustration. Individual features may also be omitted in accordance with their advantages described above, if the advantage of the respective feature is not significant in specific applications. In the drawings:

Figure 1 is a schematic, perspective exploded view of a switch contact subassembly according to the invention;

Figure 2 is a schematic, perspective view of the switch contact subassembly shown in Figure 1 in a final assembly position,

Figure 3 is a schematic sectioned view of the switch contact subassembly shown in Figures 1 and 2 in a final assembly position along the longitudinal axis of the actuation member; Figure 4 is a schematic, perspective exploded view of another embodiment of a switch contact subassembly according to the invention;

Figure 5 is a schematic, perspective view of the switch contact subassembly shown in Figure 4 in a final assembly position;

Figure 6 is a schematic, perspective cross-sectional view of the switch contact subassembly shown in Figures 4 and 5 in a final assembly position along the longitudinal axis of the actuation member;

Figure 7 is a schematic, perspective exploded view of a switch contact subassembly according to the prior art;

Figure 8 is a schematic, perspective view of the switch contact subassembly shown in Figure 7 according to the prior art in a final assembly position; and Figure 9 is a schematic, perspective cross-sectional view of the switch contact subassembly shown in Figures 7 and 8 according to the prior art in a final assembly position along the longitudinal axis of the actuation member. The invention is first explained with reference to Figure 1 , which is a schematic, perspective exploded view of a first embodiment of a switch contact subassembly 1 according to the invention, and consequently in a preassembly position V, in which the switch contact subassembly 1 is provided as a construction kit 50. The switch contact subassembly 1 comprises a contact member 2, an actuation member 3 and a resilient element 4.

The contact member 2 is constructed as a contact bridge and comprises a contact carrier 20 and two contact elements 21 which are each associated with a contact arm 20a or 20b of the contact carrier 20. The contact elements 21 are constructed so as to be able to be fitted to an upper side or switching side 22 of the contact carrier 20. The switching side 22 is directed in a switching direction S of the switch contact subassembly 1. In the switching direction S, the contact elements 21 are intended to be connected to counter-contact elements (not shown) of a switch relay (not shown) by a switching force acting in the switching direction S being applied to the contact elements 21 via the actuation member 3, the spring 4 and the contact carrier 20. An opening 23 is formed centrally between the contact arms 20a, 20b and the contact carrier 20 and extends from the upper side 22 thereof as far as a lower side 24 of the contact carrier 20 that is directed counter to the switching direction S in the direction of the resilient element 4. The opening 23 is constructed so as to receive the actuation member 3.

The actuation member 3 comprises a shaft 30 which is hollow in the embodiment shown in Figure 1. An upper end portion 31 of the shaft 30 is constructed as an annular collar or flange and forms a stop 32 which is directed counter to the switching direction S. Below the stop 32, with spacing therefrom counter to the switching direction S, a resilient retention element 33 is formed on the shaft 30 in the form of an annular collar or a flange. An upper side of the resilient retention element 33 directed in the switching direction S forms an abutment 34 for the resilient element 4. A resilient receiving portion 35 of the actuation member 3 extends between the stop 32 and the abutment 34. An actuation portion 36 of the actuation member 3 is arranged below the resilient retention element 33. The end portion 31 with the stop 32 is generally formed after the contact member 2 and the resilient element 4 have been fitted over the resilient receiving portion 35.

The resilient element 4 has a resilient member 40 which is constructed as a helical spring. An upper resilient end 41 of the resilient member 40 is directed in the switching direction S towards the contact member 2. A lower resilient end 42 is directed counter to the switching direction S towards the resilient retention member 33 on the actuation member 3. Inside the resilient member 40, this forms a receiving space 43 which is constructed to receive the resilient receiving portion 33 on the actuation member 3.

Figure 2 is a schematic, perspective view of the switch contact subassembly 1 in a final assembly position E. In the final assembly position E, the lower resilient end 42 rests on the abutment 34 provided by the resilient retention element 33. The upper resilient end 41 supports the lower side 24 of the contact carrier 20 counter to the switching direction S. In the switching direction S, the upper side 22 of the contact carrier 20 abuts the stop 32 formed by the upper end portion 31.

Consequently, the contact carrier 20 is displaceably fitted on the receiving portion 35 of the actuation member 3 with the opening 23 thereof parallel with the switching direction S. The resilient element 4 is also arranged around the receiving portion 35. The contact member 2 is thus clamped between the resilient element 4 and the stop 32. The contact member 2 is resilient ly supported on the resilient retention element 33 by means of the resilient element 4.

The contact elements 21 are further secured to the upper side 22 of the contact carrier 20. A contact force which acts counter to the switching direction S on the contact elements 21 is thus resiliently transmitted via the contact carrier 20 and the resilient element 4 to the resilient retention element 33 and consequently to the actuation member 3. That is to say, a switching force which acts in the switching direction S is transmitted via the actuation portion 36 of the actuation member 3 to the resilient retention element 33, via the resilient element 4 to the contact carrier 20 and finally via the contact elements 21 to corresponding counter- contact elements (not shown).

Figure 3 is a perspective, cross-sectional view of the switch contact subassembly 1 in the final assembly position E along a longitudinal axis L of the actuation member 3 or the shaft 30 thereof. In this instance, it becomes clear that the shaft 30 is constructed in a hollow manner. The hollow construction of the shaft 30 facilitates in particular shaping or folding over of the upper end portion 31 in order to thereby form the stop 32. Furthermore, the hollow construction of the shaft 30 may facilitate formation of the resilient retention element 33 by the shaft 30 being upset in the region of the resilient retention element 33 parallel with the longitudinal axis L and an accumulation of the shaft material thereby being able to be provided and used to form the resilient retention element 33.

Figure 4 is a schematic, perspective exploded view of another embodiment of a switch contact subassembly 1 ' according to the invention, that is to say, as a construction kit 50'. In contrast to the first embodiment of a switch contact subassembly 1 according to the invention described above, in the switch contact subassembly 1 ' the resilient retention element 33 is formed on a sleeve 38 which is constructed to be pushed over a shaft 30' of an actuation member 3 ' .

The sleeve 38 has an upper sleeve portion 38a which forms the receiving portion 35 and which is arranged in the switching direction S above the resilient retention element 33. The upper sleeve portion 38a opens in an upper sleeve end 39a which is directed in a switching direction S. Below the resilient retention element 33 extends a lower sleeve portion 38b which opens counter to the switching direction S in a lower sleeve end 39b.

An actuation portion 36' of the shaft 30' is formed with a sleeve securing portion 36a in the form of channels or annular grooves which extend in an annular manner around the shaft 30' and which are spaced apart from each other parallel with the longitudinal axis L. The sleeve securing portion 36a is configured to co-operate with a shaft securing portion 36b of the sleeve 38 in order to secure the sleeve 38 to the shaft 30' parallel with the switching direction S relative to the shaft 30' in a non-displaceable manner.

Figure 5 shows the switch contact subassembly 1 ' in the final assembly position E. The sleeve 38 is connected in a positive-locking and/or non-positive-locking manner to the sleeve securing portion 36a on the actuation portion 36' of the shaft 30' via the shaft securing portion 36b thereof. An upper end portion 31 ' of the shaft 30' forms the stop 32 which supports the contact carrier 20 below which the resilient element 4 sits. The receiving portion 35' or the upper sleeve portion 39a is received in the receiving space 43 formed by the resilient member 40.

Figure 6 is a schematic, perspective cross-sectional view of the switch contact subassembly 1 ' along the longitudinal axis L in the final assembly position E. In this instance, it becomes particularly clear that the upper sleeve end 39a extends through the opening 23 in the contact carrier 20 as far as the stop 32 on the shaft 30' against which it is in abutment. The sleeve 38 surrounds the shaft 30' and is connected in the lower sleeve portion 38b in a positive- locking and/or non-positive-locking manner to the shaft 30' by the sleeve securing portion 36a co-operating with the shaft securing portion 36b.

Figure 7 is a schematic, perspective exploded view of a switch contact subassembly 100 according to the prior art in the preassembly position V. In addition to the contact member 2 and the resilient element 4, the switch subassembly 100 has an actuation member 103 according to the prior art. The actuation member 103 has an upper retention element 133a and a lower retention element 133b which are constructed as snap rings. The upper retention element 133a forms a stop 132 for the contact member 2. The lower retention element 133b forms as a resilient retention element an abutment 134 for supporting the resilient element 4. In order to fit the upper retention element 133a to a shaft 130 of the actuation member 103, it is provided with an upper retention element receiving member 136a in the form of an annular groove. In order to receive the lower retention element 133b, the shaft 130 is provided with a lower retention element receiving member 136b which is also constructed as an annular groove. Figure 8 is a schematic, perspective view of the switch contact subassembly 100 according to the prior art in the final assembly position E. The contact member 2 is supported on the upper retention element 133a by means of a washer 37a. The spring 104 is supported on the lower retention element 133b by means of a washer 37b. Figure 9 is a schematic, perspective cross-sectional view of the switch contact subassembly 100 according to the prior art along the longitudinal axis L in the final assembly position E. In this instance, it becomes clear that the upper retention element 133a rests or engages in the upper retention element receiving member 136a in order to be supported on the shaft 103 in and counter to the switching direction S. The lower retention element 133b rests on the lower retention element receiving member 136b in order to be supported on the shaft 103 in and counter to the switching direction S.

In the context of the notion of the invention, deviations from the above-described embodiments of a switch contact subassembly 1, 1 ' according to the invention are possible. The contact member 2, the actuation member 3 and the resilient element 4 may thus be configured and proportioned in accordance with respective requirements.

The contact carrier 20 may be provided with any number of contact arms 20a, 20b and contact elements 21 which are constructed in accordance with respective requirements. The contact elements 21 do not necessarily have to be arranged on the upper side 22 of the contact carrier 20. Alternatively or in addition, the lower side 24 could also act as a switching side on which the contact elements 21 can be arranged. It is advantageous but not absolutely necessary to provide an opening 23 for receiving the actuation member 3 on the contact member 2. The opening 23 forms in a simple manner a receiving member for the actuation member 3. Such a receiving member may be produced in a different manner.

The shaft 30, 30' of the actuation member 3 can be constructed in any manner in order to comply with the respective requirements. To this end, the stop 32 may be freely arranged at the upper end portion 31 , 31 ' or at another region of the shaft. The same applies to the resilient retention element 33 which may be formed on the actuation member 3 in accordance with the respective requirements. Both the stop 32 and the resilient retention element 33 may be formed before or during the assembly of the switch contact subassembly 1, 1 ', for example, by the shaft 30, 30' and/or sleeve 38 being upset along the longitudinal axis L, which may bring about an accumulation of material which may serve to form the stop 32 or the resilient retention element 33, without weakening the shaft 30, 30' or the sleeve 38 at the position of the stop 32 or the resilient retention element 33. It is thus possible for both the shaft 30, 30' and the sleeve 38 to have a cross-sectional surface-area expansion in the region of the stop or the resilient retention element 33. This cross-sectional surface-area expansion may be, for example, in the form of at least one flange or annular collar or other elements which extend along the outer periphery of the shaft 30, 30' or sleeve 38. The receiving portion 35, 35' and the actuation portion 36, 36' may each be freely formed in order to carry the resilient element 4 or to introduce a switching force into the actuation member 3. When a sleeve 38 is used, this may be configured in accordance with the respective requirements with an upper or lower sleeve portion 38a, 38b which each form an upper or a lower sleeve end 39a, 39b.

The resilient member 40 does not necessarily have to be constructed as a helical spring, but may instead also have a different form, such as, for example, the form of a leaf spring, whose upper resilient end 41 or lower resilient end 42 may be constructed for abutment on the contact member 2 or resilient retention element 33. Accordingly, the receiving space 43 may also be constructed in accordance with the respective requirements.

List of reference numerals

, 1 ' Switch contact subassembly

Contact member

, 3' Actuation member

Resilient element 0 Contact carrier

0a Contact arm

0b Contact arm

1 Contact elements

2 Upper/Switching side

3 Opening

4 Lower side 0, 30' Shaft

1, 31 ' Upper end portion

2 Stop

3 Resilient retention element

4 Abutment

5, 35' Receiving portion

6, 36' Actuation portion

7a Washer

7b Washer

8 Sleeve

8a Upper sleeve portion

8b Lower sleeve portion

9a Upper sleeve end

9b Lower sleeve end 0 Resilient member

1 Upper resilient end

2 Lower resilient end

3 Receiving space 0, 50' Construction kit 00 Switch contact subassembly (prior art)03 Actuation member

04 Spring

30 Shaft

33a Upper retention element

33b Lower retention element

36a Upper retention element receiving member 136b Lower retention element receiving member

E Final assembly position

L Longitudinal axis

S Switching direction

V Preassembly position