Integrated contactor mounting and power distribution system and method

Patent metadata

Field	Value
Publication number	US-9728347-B2
Application number	US-201414572311-A
Country	US
Kind code	B2
Filing date	Dec 16, 2014
Priority date	Dec 16, 2014
Publication date	Aug 8, 2017
Grant date	Aug 8, 2017

Abstract

A contactor mounting system is disclosed herein. The contactor is directly mounted to the printed wire board. Pins may be coupled to an exposed end portion of the first stationary lead and the second stationary lead of the contactor. Pins may be configured to interconnect the contactor to the printed wire board.

First claim

The invention claimed is:

1. A contactor mounting system comprising:
a contactor assembly including a housing;
a first stationary lead at least partially extending externally from the housing and having a first planar contact surface and a second surface;
pins extending from the first stationary lead and being ultrasonically bonded to the first stationary lead or integrally formed with the first stationary lead at the time the first stationary lead is formed, the pins extending in a direction normal to the second surface of the first stationary lead, configured to mate with a printed wire board, and having angled edges and a generally square-shaped cross section to resist movement of the contactor assembly in at least three directions relative to the printed wire board; and
a mobile busbar positioned within the contactor assembly, having a busbar planar contact surface configured to mate with the first planar contact surface of the first stationary lead, and configured to move from a first position in which electrical and mechanical contact between the mobile busbar and the first stationary lead is restricted to a second position in which electrical and mechanical contact between the mobile busbar and the first stationary lead is made.

2. The contactor mounting system according to claim 1 , further comprising a second stationary lead at least partially extending externally from the housing.

3. The contactor mounting system according to claim 1 , wherein a quantity of the pins and a cross-sectional size of the pins is selected to accommodate a desired transfer of current, a desired transfer of heat and a desired structural load.

4. The contactor mounting system according to claim 1 , wherein the pins are configured to mate with and couple to the printed wire board via through holes of the printed wire board.

5. The contactor mounting system according to claim 4 , wherein the through holes are plated through holes.

6. The contactor mounting system according to claim 4 , wherein the printed wire board comprises layers of copper planes.

7. The contactor mounting system according to claim 4 , wherein a quantity of the through holes is greater than a quantity of the pins to facilitate various couplings between the through holes and the pins.

8. The contactor mounting system according to claim 1 , wherein the first stationary lead is coupled to the printed wired board via the pins without an intermediary structure therebetween.

9. A stationary lead assembly comprising:
a housing having an internal portion and an external portion including a first stationary lead, the first stationary lead having a first planar contact surface and a second surface;
a printed wire board having a plurality of through holes;
pins ultrasonically bonded to the first stationary lead or integrally formed with the first stationary lead at the time the first stationary lead is formed, the pins extending in a direction normal to the second surface of the first stationary lead, and a quantity of the pins being less than a quantity of the through holes to facilitate various couplings between the through holes and the pins; and
a mobile busbar positioned within the housing, having a busbar planar contact surface configured to mate with the first planar contact surface of the first stationary lead, and configured to move from a first position in which electrical communication between the mobile busbar and at least one of the pins is restricted to a second position in which electrical communication between the mobile busbar and the at least one of the pins is made.

10. The stationary lead assembly of claim 9 , wherein the external portion is coupled to a printed wired board via the pins without an intermediary structure therebetween.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Pal Debabrata
• Horowy John

Classifications

• H01H50/14

  Terminal arrangements {(for coils H01H50/443)} · CPC title

• H01H1/5805 Primary

  Connections to printed circuits (for slide switches H01H15/005; for tumbler switches H01H23/006) · CPC title

• H01H50/12

  Ventilating; Cooling; Heating (for operating electrothermal relays H01H61/013) · CPC title

• H02B1/056

  Mounting on plugboards · CPC title