CLIAMS:1. A circuit breaker comprising:
at least one fixed contact; and
at least one moving contact configured to make and break contact with the at least one fixed contact, wherein the at least one fixed contact and the at least one moving contact are configured with complementary shapes such that both the at least one moving contact and the at least one fixed contact are manufactured from a single electrically conducting blank.

2. The circuit breaker of claim 1, wherein the electrically conducting blank is at least one strip of electrically conducting material.

3. The circuit breaker of claim 1, wherein the electrically conducting blank is a rectangular sheet of an electrically conducting material.

4. The circuit breaker of claim 1, wherein said electrically conducting blank is made of at least one electrically conducting material or its alloy or a combination thereof, said electrically conducting material being at least one of copper, mild steel, brass and aluminium.

5. A method of manufacturing a set of contacts of a circuit breaking device, the set comprising at least one fixed contact and at least one movable contact,
said method comprising:
providing an electrically conducting blank;
defining at least one contoured profile corresponding to the at least one fixed contact and the at least one movable contact on said electrically conducting blank in a complementary manner;
extracting at least one profile corresponding to the at least one fixed contact and the at least one movable contact; and
processing the extracted at least one profile to form the set of at least one fixed contact and the at least one movable contact to give them their final shape.

6. The method of claim 5, wherein said electrically conducting blank is at least one rectangular strip of electrically conducting material.

7. The method of claim 5, wherein the step of extracting comprises performing at least one shearing operation along the at least one profile.

8. The method of claim 7, wherein said shearing operation comprises at least one variant of blanking, piercing, punching and trimming operations.

9. The method of claim 5, wherein the step of processing comprises one or more combinations of bending, punching, rolling, forming, stamping and welding.

10. The method of claim 5, wherein the steps of defining and extracting are performed by a common set of tools for the at least one fixed contact and the at least one movable contact.
,TagSPECI:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of low voltage power equipment. In particular, it relates to method of manufacturing electrical contacts of a circuit breaking device with minimum scrap generation.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art
[0003] Low voltage circuit breaking devices such as circuit breakers, isolators, contactors and the like are reusable protection devices. These mechanical switching devices are capable of making, carrying and breaking currents under normal circuit conditions. They are also capable of making and carrying current for a specified time, and breaking currents under specified abnormal circuit conditions such as short circuit / overcurrent conditions. A circuit breaking device such as a circuit breaker includes a set of electrical contacts viz., a fixed contact and a movable contact. The fixed contact maintains its position while the movable contact moves to make (close) or break (open) the circuit. An operating mechanism is provided to control the make and break of the circuit which may be manual or automated as per requirement.
[0004] Conventional design of the contacts and their corresponding methods of manufacturing involve manufacture of the fixed contact and the movable contact by separate processes/ tools and make use of separate strips / sheets of electrically conducting material. Alternatively, conducting material such as copper in molten or semi molten form is extruded to produce the fixed and movable contacts. Conventional methods for producing the fixed and movable contacts further involve longer processing time and scrap generated is large.
[0005] There is therefore a need for a configuration of contact points that facilitates their manufacturing overcoming at least some of the aforementioned drawbacks of the prior art.
[0006] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0007] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0008] 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.
[0009] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0010] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

OBJECTS OF THE INVENTION
[0011] An object of the present disclosure is to mitigate short comings of conventional electrical contacts of a circuit breaking device and their corresponding methods of manufacturing.
[0012] Another object of the present disclosure is to provide electrical contacts of a circuit breaking device that simplify their method for manufacturing.
[0013] Another object of the present disclosure is to provide a cost effective method for manufacturing electrical contacts of a circuit breaking device.
[0014] Another object of the present disclosure is to provide a method for manufacturing electrical contacts of a circuit breaking device that reduces processing time.
[0015] Another object of the present disclosure is to provide a method for manufacturing electrical contacts of a circuit breaking device that makes use of common tools for producing fixed contacts and movable contacts.
[0016] Another object of the present disclosure is to provide a method for manufacturing electrical contacts of a circuit breaking device that generates minimum scrap.
[0017] Another object of the present disclosure is to provide electrical contacts for a circuit breaking device that provide optimized current path between fixed contact and movable contact.
[0018] Another object of the present disclosure is to provide a method for manufacturing electrical contacts of a circuit breaking device that can be applied for mass production.

SUMMARY
[0019] Aspects of the present disclosure relate to electrical contacts of low voltage circuit breaking device such as circuit breakers, isolators (interchangeably referred to as circuit breakers herein after and use of term circuit breaker shall cover all circuit breaking devices). In an embodiment, one or more fixed element and one or more moving element which are the current carrying paths in a circuit breaker and commonly known as contacts can be configured such that both – the moving contact and the fixed contact – can be manufactured from a single blank of a conducting material.
[0020] In an embodiment, the disclosed contacts can be configured in complementary shapes such that while one of the two is punched/blanked out of the blank of a conducting material, the remaining material can be further processed to make the other contact. Thus the proposed configuration can minimize scrap generation.
[0021] In an embodiment, the disclosed contacts reduce the tooling requirement as a common tool can be used to produce both the contacts. In another aspect the disclosed contacts also require less production time as both the contacts can be manufactured simultaneously and both these aspects have corresponding cost benefits.
[0022] Aspects of the present disclosure also relate to method of manufacturing electrical contacts of low voltage circuit breakers that minimizes scrap generation, reduces tooling variety and tooling cost and also reduces production time.
[0023] In an embodiment, the method of manufacturing a set of contacts that includes at least one fixed contact and at least one movable contact includes the step of providing an electrically conducting blank that can be used for producing both the fixed contact as well as the movable contact. The method can further include the step of defining at least one contoured profile corresponding to the at least one fixed contact and the at least one movable contact on the electrically conducting blank in a complementary manner. The method can further include the step of extracting at least one profile corresponding to the at least one fixed contact and the at least one movable contact from the single rectangular blank without any scrap generation. The method can include step of further processing comprising forming/bending the extracted at least one profile to form the set of at least one fixed contact and the at least one movable contact.
[0024] In an embodiment, the electrical conducting blank can be at least one strip of electrically conducting material. In accordance with another embodiment, the electrical conducting blank is a rectangular sheet of electrically conducting material. In accordance with another embodiment, the electrically conducting blank is made of at least one electrically conducting material or its alloy or a combination thereof, the electrical conducting material being at least one of copper, mild steel, brass and aluminium.
[0025] In an embodiment, the step of extracting includes performing at least one shearing operation along the at least one profile. In an embodiment, the shearing operation can include at least one variant of blanking, piercing, punching and trimming operations.
[0026] In an embodiment, the step of further processing can include one or more combinations of bending, punching, rolling, forming, stamping and welding.
[0027] In an embodiment, the steps of defining, extracting is performed by a common set of tools for the at least one fixed contact and the at least one movable contact.
[0028] 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
[0029] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0030] FIG. 1A illustrates a schematic representation of an exemplary electrically conducting blank with defined contoured profiles of a fixed contact and a movable contact in accordance with an embodiment of the present disclosure.
[0031] FIG. 1B illustrates an exploded view of an exemplary electrically conducting blank with an extracted profile of a movable contact in accordance with an embodiment of the present disclosure.
[0032] FIG. 2 illustrates an exemplary isometric view of a fixed contact after forming/bending of an extracted profile in accordance with an embodiment of the present disclosure.
[0033] FIG. 3 illustrates an exemplary isometric view of a current path in the contacts of a circuit breaking device assembled with fixed contact and movable contact manufactured in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0034] 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 spirit and scope of the present disclosure as defined by the appended claims.
[0035] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0036] 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.
[0037] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0038] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0039] Aspects of the present disclosure relate to electrical contacts of low voltage circuit breakers. In the conventional designs, the contacts are made/processed from separate strip/sheet of conducting material such as copper. Another alternative to this is an extrusion of copper in molten or semi molten form. All this methods require separate set of tools (in the form of punch die etc.) and the scrap generated is large.
[0040] In an embodiment, one or more fixed and one or more moving contacts can be configured such that both – the moving contact and the fixed contact – can be manufactured from a single blank of a conducting material. In an aspect, the disclosed configuration has complementary shapes of the two contacts that enables extraction of the moving contact from the fixed contact or vice versa. In an aspect, the disclosed contacts reduce the tooling requirement as a common tool can be used to produce both the contacts. In another aspect the disclosed contacts also require less production time as both the contacts can be manufactured simultaneously and both these aspects have corresponding cost benefits.
[0041] In an embodiment, the present disclosure provides a method of manufacturing electrical contacts of low voltage circuit breakers that minimizes scrap generation, reduces tooling variety and tooling cost and also reduces production time.
[0042] In an embodiment, the method of manufacturing a set of contacts that includes at least one fixed contact and at least one movable contact includes the step of providing an electrically conducting blank that can be used for producing both the fixed contact as well as the movable contact. The method can further include the step of defining at least one contoured profile corresponding to the at least one fixed contact and the at least one movable contact on the electrically conducting blank in a complementary manner. The method can further include the step of extracting at least one profile corresponding to the at least one fixed contact and the at least one movable contact. The method can still further include the step of further processing the extracted at least one profile to form the set of at least one fixed contact and the at least one movable contact.
[0043] In an embodiment, the electrical conducting blank can be at least one strip of electrically conducting material. In accordance with another embodiment, the electrical conducting blank is a rectangular sheet of electrically conducting material. In accordance with another embodiment, the electrically conducting blank is made of at least one electrically conducting material or its alloy or a combination thereof, the electrical conducting material being at least one of copper, mild steel, brass and aluminium.
[0044] In an embodiment, the step of extracting includes performing at least one shearing operation along the at least one profile. In an embodiment, the shearing operation can include at least one variant of blanking, piercing, punching and trimming operations.
[0045] In an embodiment, the step of extracting can be followed by further processing the extracted fixed contact and movable contact to give them their final shape. The step of further processing can include one or more combinations of bending, punching, rolling, forming, stamping and welding.
[0046] In an embodiment, the steps of defining, extracting is performed by a common set of tools for the at least one fixed contact and the at least one movable contact.
[0047] FIG. 1A illustrates a schematic representation 100 of an exemplary electrically conducting blank with defined contoured profiles of fixed contact 102 and movable contact 104 in accordance with an embodiment of the present disclosure. As illustrated the fixed contact 102 and the movable contact 104 are configured such that the two can be extracted from a single blank.
[0048] In an embodiment, the method of the present disclosure includes providing a common electrically conducting blank for producing both fixed contact 102 and movable contact 104. Contoured profiles corresponding to both fixed contact 102 and movable contact 104 can be configured on the common electrically conducting blank in a complementary manner as illustrated. This minimizes scrap considerably. In accordance with an embodiment, the electrically conducting blank is a strip of electrically conducting material. In accordance with an embodiment, the electrically conducting blank can be a rectangular sheet of electrically conducting material. In accordance with an embodiment, the electrically conducting blank is made of at least one electrically conducting material or its alloy or a combination of both wherein the electrically conducting material can be at least one of copper, mild steel, brass and aluminium.
[0049] Method of the present disclosure can include a step of extracting at least one profile corresponding to fixed contact 102 and movable contact 104. Referring to FIG. 1B, an exploded view 150 of an exemplary electrically conducting blank with an extracted profile of movable contact 104 in accordance with an embodiment of the present disclosure is illustrated. The step of extracting profile of least one profile corresponding to either the fixed contact or the movable contact, of the present disclosure can be performed by at least one shearing operation along the defined contoured profile. In accordance with an embodiment, shearing operation can include at least one variant of blanking, piercing, punching and trimming operations including but not limited to lancing, perforating, notching, nibbling, shaving, cut off, and dinking.
[0050] Method of the present disclosure can include further processing of the extracted profile to bring the contacts to their final shape. FIG. 2 illustrates an exemplary isometric view 200 of the fixed contact 102 after all operations have been completed to give it the final shape in accordance with an embodiment of the present disclosure. In an embodiment, final shape can be provided by one or more combinations of bending, punching, rolling, forming, stamping and welding.
[0051] FIG. 3 illustrates an exemplary isometric view 300 of current path 106 in the contacts of a circuit breaker with fixed contact 102 and movable contact 104 configured in accordance with an embodiment of the present disclosure. In accordance with the present disclosure, optimized current path is attained since fixed contact 102 and movable contact 104 are produced from a common electrically conducting blank.
[0052] In an aspect, the present disclosure provides a method of manufacturing a set of electrical contacts including fixed contact and movable contact by steps of defining contoured profile, extracting the defined profile and further processing the extracted profile to form the set of contacts with desired shape wherein each of these steps are performed by a common set of tools, thereby reducing tool investment and process time. Defining complementary contoured profiles for the fixed contact and the movable contact on a common electrically conducting blank can results in minimal scrap generation and therefore makes the method of the present disclosure a cost effective solution and at the same time suitable for mass production.
[0053] While the foregoing 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.

ADVANTAGES OF THE INVENTION
[0054] The present disclosure mitigates short comings of conventional electrical contacts of a circuit breaking device and their corresponding methods of manufacturing.
[0055] The present disclosure provides electrical contacts for circuit breaking device that simplify their method for manufacturing.
[0056] The present disclosure provides a cost effective method for manufacturing electrical contacts of a circuit breaking device.
[0057] The present disclosure provides a method for manufacturing electrical contacts of a circuit breaking device that reduces processing time.
[0058] The present disclosure provides a method for manufacturing electrical contacts of a circuit breaking device that makes use of common tools for producing fixed contacts and movable contacts.
[0059] The present disclosure provides a method for manufacturing electrical contacts of a circuit breaking device that generates minimum scrap.
[0060] The present disclosure provides electrical contacts for a circuit breaking device that provide optimized current path between fixed contact and movable contact.
[0061] The present disclosure provides a method for manufacturing electrical contacts of a circuit breaking device that can be applied for mass production.