Description:A HYBRID METAL TERMINAL ASSEMBLY FOR AN ELECTRICAL SWITCH

[0001] the present disclosure, in general, relates to a field of electric switches, and more particularly relates to a method and a hybrid metal terminal assembly for an electric switch.
BACKGROUND

[0002] Traditionally a switch is a device which is designed to interrupt the current flow in a circuit. In simple words, a Switch can make or break an electrical circuit. Every electrical and electronics application uses at least one switch to perform ON and OFF operation of the device.
[0003] Switches are a part of the control system and without it, control operation cannot be achieved. A switch can perform two functions, namely fully ON (by closing its contacts) or fully OFF (by opening its contacts).
[0004] When the contacts of a switch are closed, the switch creates a closed path for the current to flow and hence load consumes the power from source.
[0005] Fig. 1a and 1b illustrates a circuit diagram 100a and a circuit diagram 100b depicting contacts of a switch in an open configuration and in a close configuration, in accordance with an existing prior art. When the contacts of a switch are open, no power will be consumed by the load. An important function of a Switch is to divert the flow of electric current in a circuit. Consider the following circuit. When the switch is in position A, the lamp 1 turns ON and while it is in position B, lamp 2 turns ON.
[0006] There are numerous applications of switch, found in wide variety of fields such as homes, automobiles, industrial, military, aerospace and so on. In home and office applications, we use simple rocker switches to turn ON and OFF appliances like lights, computers, fans etc. In some applications, multi way switching is employed (like building wiring), where two or more switches are connected to control an electrical load from more than one location, like a Two-Way Switch
[0007] Brass electrical terminal is most commonly utilized in lamp & bulb holders, switchboards, electrical plugs & sockets, and electrical blocks. It is completely trustworthy in nature and is most commonly used for securing the copper wire in place while allowing smooth current flow. This terminal is ideal for use with both high & low voltage applications and assures quick fitting. It is made with the help of the latest CNC machines for eliminating chances of error in dimensions & structure. Brass Electrical Terminal features a hole in which electrical wire is inserted which is then secured by the application of screw / nut.
[0008] Fig. 2 illustrate a metal terminal assembly 200, in accordance with an existing prior-art. A switch may have two conductive pieces, that may be metallic, called contacts, connected to an external circuit, that touch to complete (make) the circuit, and separate to open (break) the circuit. The contact material is chosen for its resistance to corrosion, as most metals form insulating oxides that would prevent the switch from working. Contact materials may also be chosen on the basis of an electrical conductivity, hardness (resistance to abrasive wear), mechanical strength, low cost and low toxicity. The formation of oxide layers at contact surface, as well as surface roughness and contact pressure, determine the contact resistance, and wetting current of a mechanical switch. Sometimes the contacts are plated with noble metals, for their excellent conductivity and resistance to corrosion. The contact materials may be designed to wipe against each other to clean off any contamination. Non-metallic conductors, such as conductive plastic, are sometimes used. To prevent the formation of insulating oxides, a minimum wetting current may be specified for a given switch design.
[0009] Thus, there is a need for a solution to overcome above mentioned drawbacks.

OBJECTS OF THE DISCLOSURE
[0010] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0011] It is a general or primary object of the present subject matter to provide a hybrid metal terminal assembly for an electrical switch.
[0012] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY
[0013] This summary is provided to introduce concepts related to a hybrid metal terminal assembly for an electrical switch, the concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0014] The present disclosure provides a hybrid metal terminal assembly for an electrical switch. The hybrid metal terminal assembly includes a U-shaped terminal, and a conductive component. The U-shaped terminal includes a base surface having a through bore, a first side and a second side, and a pair of flexible arms extending vertically in an upwards direction from the first side and the second side. Each flexible arm comprises a receptacle. The conductive component includes a conductive surface with, an outer surface, and an inner surface, and a pair of L-shaped sides extending vertically at left and right side from the conductive surface. The U-shaped terminal and the conductive component are connected by a receipt of the pair of L-shaped sides inside the receptacles..
[0015] In an aspect of the present subject matter, each flexible arm from the pair of flexible arms is pushed in an away direction to receive each of the L-shaped sides in the receptacle.
[0016] In an aspect of the present subject matter, the receptacle and the L-shaped side connect through a snap fit arrangement.
[0017] In an aspect of the present subject matter, the U-shaped terminal is made up of mild steel.
[0018] In an aspect of the present subject matter, the conductive component is made up of brass.
[0019] In an aspect of the present subject matter, a screw passes through the through bore in the base surface of the U-shaped terminal.
[0020] In an aspect of the present subject matter, the screw clamps a wire between the inner portion of the conductive surface while passing through the through bore.
[0021] In an aspect of the present subject matter, the conductive component further comprises a contact tip fixed on the upper portion of the conductive component.
[0022] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0024] Fig. 1a and 1b illustrates a circuit diagram and a circuit diagram depicting contacts of a switch in an open configuration and in a close configuration, in accordance with an existing prior art;
[0025] Fig. 2 illustrate a metal terminal assembly, in accordance with an existing prior-art;
[0026] Fig. 3 illustrates a diagram depicting a hybrid metal terminal assembly for an electric switch, in accordance with an embodiment of the present subject matter;
[0027] Fig. 4a illustrates an image depicting the U-shaped terminal, in accordance with an embodiment of the present subject matter;
[0028] Fig. 4b illustrates an image depicting a top view of the U-shaped terminal, in accordance with an embodiment of the present subject matter;
[0029] Fig. 4c illustrates an image depicting a front view of the U-shaped terminal, in accordance with an embodiment of the present subject matter; and
[0030] Fig. 4d illustrates an image depicting a side view of the U-shaped terminal, in accordance with an embodiment of the present subject matter;
[0031] Fig. 5a illustrates an image depicting the conductive component, in accordance with an embodiment of the present subject matter;
[0032] Fig. 5b illustrates an image depicting a top view of the conductive component, in accordance with an embodiment of the present subject matter; and
[0033] Fig. 5c illustrates an image depicting a side view of the conductive component, in accordance with an embodiment of the present subject matter;
[0034] Fig. 6 illustrates an image depicting a receipt of the pair of L-shaped sides in the receptacles of the U-shaped terminal, in accordance with an embodiment of the present subject matter; and
[0035] Fig. 7 illustrates an image depicting a side view of the hybrid metal terminal assembly, in accordance with an embodiment of the present subject matter.
DETAILED DESCRIPTION
[0036] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0037] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0038] Fig. 3 illustrates a diagram 300 depicting a hybrid metal terminal assembly 302 for an electric switch, in accordance with an embodiment of the present subject matter. The hybrid metal terminal assembly 302 may be made up with a combination of two different materials. The different materials may be brass and mils steel. In an embodiment, the brass may be replaced with one of copper, phosphorus and bronze for making the hybrid metal terminal assembly 302.
[0039] Continuing with the above embodiment, the hybrid metal terminal assembly 302 may include a U-shaped terminal 304, and a conductive component 306. The U-shaped terminal 304 may be made up of mild steel. In a preferred embodiment of the present subject matter, the conductive component 306 may be made up of brass. The U-shaped terminal 304 may be received in the conductive component 306 for assembling the hybrid metal terminal assembly 302.
[0040] To that understanding, the conductive component 306 may be configured to provide an electrical conductivity to the hybrid metal terminal assembly 302. The conductive component 306 may be configured to receive the U-shaped terminal 304 and tightly secure the U-shaped terminal 304 in a snap fit connection. The hybrid metal terminal assembly 302 may utilise a lesser amount of brass being used to form the conductive component 306. Further, the conductive component 306 may be secured on top of the U-shaped terminal 304.
[0041] Continuing with the above embodiment, when the U-shaped terminal 304 is in a snap fit connection with the conductive component 306, a screw may be passed through the U-shaped terminal 304. The screw may clamp a wire between an inner side of the conductive component 306 while passing through the U-shaped terminal 304. The combination of the U-shaped terminal 304 and the conductive component 306 may be utilized for performing a gripping of the screw and the wire between the hybrid metal terminal assembly 302.
[0042] Fig. 4a illustrates an image 400a depicting the U-shaped terminal 304, in accordance with an embodiment of the present subject matter. The U-shaped terminal 304 may be connected with a conductive component to assemble a hybrid metal terminal assembly for an electric switch. The hybrid metal terminal assembly may be the hybrid metal terminal assembly 302 as referred in the fig. 3.
[0043] The U-shaped terminal 304 may be made up of mild steel. In a preferred embodiment of the present subject matter, the U-shaped terminal 304 may include a base surface 402 having a through bore 404, a first side 406 and a second side 408 opposite to the first side 406, and a pair of flexible arms 410a, 410b. The first side 406 and the second side 408 may be vertically extending from the base surface 402. Further, each flexible arm from the pair of flexible arms 410a, 410b may be extending vertically in an upwards direction from the first side 406 and the second side 408.
[0044] To that understanding, the pair of flexible arms 410a, 410b may include a pair of receptacles 412a, 412b. Each receptacle 412a, 412b may be configured to receive an L-shaped side of the conductive component and secure the L-shaped side in a snap fit connection to attach the U-shaped terminal 304 with the conductive component for assembling the hybrid metal terminal assembly. In order to receive the pair of L-shaped sides, the pair of flexible arms 410a, 412b may be pushed in an away direction such that the pair of L-shaped sides is brought in a vicinity of the pair of flexible arms 410a, 410b, specifically in the vicinity of the receptacles 412a, 412b. Further, the pair of L-shaped sides is snap fitted in the receptacles 412a, 412b.
[0045] To that understanding, the through bore 404 may allow a passage to a screw in the base surface 402 of the U-shaped terminal 304. The screw may clamp a wire between an inner portion of a conductive surface of a conductive component while passing through the through bore 404.
[0046] Fig. 4b illustrates an image 400b depicting a top view of the U-shaped terminal 304, in accordance with an embodiment of the present subject matter. The through bore 404 may be configured to provide a passage to a screw that may secure a wire between the conductive component and the screw.
[0047] Fig. 4c illustrates an image 400c depicting a front view of the U-shaped terminal 304, in accordance with an embodiment of the present subject matter. The pair of flexible arms 410a, 410b may be pushed in an away direction to receive the L-shaped side from the pair of L-shaped sides in each flexible arm of the conductive component in the receptacles to attach the conductive component with the U-shaped terminal 304 and assemble the hybrid metal terminal assembly.
[0048] Fig. 4d illustrates an image 400d depicting a side view of the U-shaped terminal 304, in accordance with an embodiment of the present subject matter. The receptacles 412a, 412b of the pair of flexible arms 410a, 410b may be configured to receive the pair of L-shaped sides of the conductive component.
[0049] Fig. 5a illustrates an image 500a depicting the conductive component 306, in accordance with an embodiment of the present subject matter. The conductive component 306 may be made up of brass and may be configured to provide an electrical conductivity to a hybrid metal terminal assembly 302. The hybrid metal terminal assembly may be the hybrid metal terminal assembly 302 as referred in the fig. 3.
[0050] To that understanding, the conductive component 306 may include a conductive surface 502, and a pair of L-shaped sides 504a, 504b. The conductive surface 502 may include an outer surface 502a having a profiled slot 502c, and an inner surface 502b. The profiled slot 502c may be a rectangular shaped slot with a curved surface, configured to provide position and align a moving contact. The pair of L-shaped sides 504a, 504b may be extending vertically at a left and a right side from the conductive surface 502. The conductive component 306 may be attached to a U-shaped terminal for assembling the hybrid metal terminal assembly, by a receipt of the pair of L-shaped sides 504a, 504b inside receptacles of the U-shaped terminal. The U-shaped terminal may be the U-shaped terminal 304 as referred in the fig. 3. The receptacles may be present in each flexible arm of the U-shaped terminal and each flexible arm may be pushed in an away direction to receive the pair of L-shaped sides 504a, 504b in the receptacles. The receptacles and each L-shaped side from the pair of L-shaped sides 504a, 504b may be configured to connect through a snap fit arrangement with one another. Moving forward, the conductive component 306 may also include a contact tip fixed on an upper portion of the conductive component 306.
[0051] Continuing with the above embodiment, a screw that may be passing through a through bore of the U-shaped terminal may clamp a wire between the inner surface 504b of the conductive surface 504 while passing through the through bore.
[0052] Fig. 5b illustrates an image 500b depicting a top view of the conductive component 306, in accordance with an embodiment of the present subject matter. The pair of L-shaped sides 504a, 504b extending downwards from the conductive surface 502 may be received in the receptacles of the U-shaped terminal to attach the conductive component with the U-shaped terminal.
[0053] Fig. 5c illustrates an image 500c depicting a side view of the conductive component 306, in accordance with an embodiment of the present subject matter. The pair of L-shaped sides 504a, 504b extending downwards from the conductive surface 502 may be received in the receptacles of the U-shaped terminal to attach the conductive component with the U-shaped terminal.
[0054] Fig. 6 illustrates an image 600 depicting a receipt of the pair of L-shaped sides 504a, 504b in the receptacles 412a, 412b of the U-shaped terminal 304, in accordance with an embodiment of the present subject matter. For a secure receipt of the pair of L-shaped sides 504a, 504b, the pair of flexible arms 410a, 410b carrying the receptacles 412a, 412b in the U-shaped terminal 304 may be pushed in an away direction such that the conductive component 306 may be brought in a vicinity of the U-shaped terminal 304. Once the conductive component 306 is in the vicinity, the pair of L-shaped sides 504a, 504b may be snap fitted in the receptacles 412a, 412b of the U-shaped terminal 304 to assemble the hybrid metal terminal assembly 302.
[0055] Fig. 7 illustrates an image 700 depicting a side view of the hybrid metal terminal assembly 302, in accordance with an embodiment of the present subject matter. A screw passing through a through bore of the U-shaped terminal 304 may be used to clamp a wire between the screw and the conductive component 306.
[0056] The present subject matter includes a number of advantages such as, switch life increases to more than 2 lacs operations, the hybrid metal terminal assembly provides a soft operation of switches, an improved mechanism for switches, and the hybrid metal terminal assembly is cost effective, offers a reduced thread damage, a reduced component weight, suitable for high temperature, conservation of natural resources as very less amount of brass is used.
[0057] While the detailed description describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art. , Claims:1. A hybrid metal terminal assembly (302) for an electrical switch, comprising:
a U-shaped terminal (304) comprising:
a base surface (402) having a through bore (404);
a first side (406) and a second side (408) opposite to the first side (406) vertically extending from the base surface (402); and
a pair of flexible arms (410a, 410b), each flexible arm amongst the pair of flexible arms (410a, 410b) extending vertically in an upwards direction from the first side (406) and the second side (408), wherein each flexible arm comprises a receptacle (412a, 412b);
a conductive component (306) configured to provide an electrical conductivity comprising:
a conductive surface (502) with, an outer surface (502a), and an inner surface (502b); and
a pair of L-shaped sides (504a, 504b) extending vertically at left and right side from the conductive surface (502), wherein the U-shaped terminal (304) and the conductive component (306) are connected by a receipt of the pair of L-shaped sides (504a, 504b) inside the receptacles (412a, 412b) of the U shaped terminal (304).

2. The hybrid metal terminal assembly (302) as claimed in claim 1, wherein each flexible arm from the pair of flexible arms (410a, 410b) is pushed in an away direction to receive each of the L-shaped sides (504a, 504b) in the receptacle (412a, 412b).
3. The hybrid metal terminal assembly (302) as claimed in claim 1, wherein the receptacles (412a, 412b) and the pair of L-shaped sides (504a, 504b) connect through a snap fit arrangement.
4. The hybrid metal terminal assembly (302) as claimed in claim 1, wherein the U-shaped terminal (304) is made up of mild steel.
5. The hybrid metal terminal assembly (302) as claimed in claim 1, wherein the conductive component (306) is made up of brass.
6. The hybrid metal terminal assembly (302) as claimed in claim 1, further comprising a screw passing through the through bore (404) in the base surface (402) of the U-shaped terminal (304).
7. The hybrid metal terminal assembly (302) as claimed in claim 1 or 6, wherein the screw clamps a wire between the inner portion of the conductive surface (502) while passing through the through bore (404).
8. The hybrid metal terminal assembly (302) as claimed in claim 1, wherein the conductive component (306) further comprises a contact tip fixed on the upper portion of the conductive component (306).