Breaker apparatus

This application claims benefit of provisional application Serial No. 60/350,186 Filed Nov. 2, 2001

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a breaker apparatus which fits a movable electrode with a pair of fixed electrodes and separates the movable electrode from the pair of fixed electrodes to thereby open and close a circuit.

2. Description of Related Art

In a breaker apparatus of this type, for example, there is known a breaker apparatus which is disclosed in JP-A-2000-235824. According to this breaker apparatus, a fixed-side housing, including a pair of mutually insulated fixed electrodes, is fitted with a movable-side housing including a movable electrode to thereby short-circuit a pair of fixed electrodes. By pulling a handle disposed on the movable-side housing, the movable-side housing is separated from the fixed-side housing to thereby remove the short-circuit between the pair of fixed electrodes.

However, in this breaker apparatus, when separating the movable-side housing, an operator holds the handle by hand and separates the movable-side housing at a stretch with all his or her strength. This means that, on the back surface side (on the opposite side to the fixed-side housing) of the movable-side housing, there is a relatively large operation space required in the fitting and separating direction of the two housings. Therefore, when sufficient operation space cannot be secured, for example, in a space within an engine room of an automobile, it is difficult to install the above-mentioned breaker apparatus.

SUMMARY OF THE INVENTION

To solve the above problem, the present applicants have proposed a breaker apparatus having the following structure. In this breaker apparatus, a driven pin is disposed in a fixed-side housing in a movable-side housing a drive member is disposed which is prevented from moving in the two-housing fitting direction but is allowed to move in a direction at right angles to the fitting direction. The drive member includes an inclined groove which is inclined with respect to the moving direction of the drive member. When the two housings are made to approach each other to thereby bring the driven pin into engagement with the entrance of the inclined groove and the drive member is moved from this engaged state, due to the engagement between the inclined groove and driven pin, the movable-side housing is pulled near to the fixed-side housing so that the two housings are fitted with each other. Also, when the drive member is moved from the fitted state in the opposite direction to the fitting direction, due to the engagement between the inclined groove and driven pin, the movable-side housing is separated from the fixed-side housing. In this manner, when removing the two housings from each other, by using a cam action due to the engagement between the inclined groove and driven pin, the movable-side housing can be separated from the fixed-side housing with a small operation force.

Further, in the present breaker apparatus, the fixed electrodes are disposed in an intermediate portion of a power circuit of an electric car and are used as a means to break the power circuit. In this structure,.when the movable electrode is suddenly removed from the fixed electrodes while the power circuit is electrically energized to thereby open the power circuit, there occurs an arc. In view of this, there can be expected the following structure: a relay circuit serving as switching means for opening and closing the power circuit, and a microswitch serving as a detect means which detects the movement of the drive member to thereby operate the relay circuit.

According to this structure, in a state where the two housings are fitted with each other and the fixed electrodes are fitted with the movable electrode (in a state where energization is permitted between the pair of fixed electrodes), the relay circuit executes its closing operation to thereby close the power circuit. When the movement of the drive member to separate the two housings from each other is started, just after the start of the movement of the drive member, the movement of the drive member is detected by the microswitch, and the relay circuit is allowed to execute its opening operation to thereby open the power circuit. When the movement of the drive member is moved further, the movable electrode is separated from the fixed electrodes and since the power circuit is already opened by the relay circuit, occurrence of the arc between the electrodes can be prevented.

However, between the start of the opening operation of the relay circuit and the time when the opening operation is completed and the energization of the power circuit stops, there exists a time lag (of the order of 150 msec.). Therefore, to prevent the occurrence of the arc, from the start of the opening operation of the relay circuit to the time when the fixed and movable electrodes are separated from each other, there is necessary the time that is longer than the above time lag.

Here, the moving operation of the drive member from the fitted state of the two housings (i.e., the closed state of the power circuit) to the time when the opening operation of the relay circuit is started and, after then, the fixed and movable electrodes are separated from each other is a linear-shaped one-action operation to be executed in a direction at right angles to the fitting direction of the two housings. Therefore, when the drive member is operated with great force, there is a fear that, although the opening operation of the relay circuit is not completed but the power circuit remains closed, the movable electrode can be removed from the fixed electrodes.

The present invention aims at eliminating the drawbacks found in the above-mentioned conventional breaker apparatus. Accordingly, it is an object of the invention to provide a breaker apparatus which can prevent the movable electrode from being separated from the fixed electrodes while a main circuit remains closed.

In attaining the above object, according to a first aspect of the invention, there is provided a breaker apparatus having a pair of fixed electrodes disposed in series in a main circuit to be opened and closed by switching means. The breaker apparatus also includes a movable electrode disposed in a movable-side housing that is fitted with and separated from the pair of fixed electrodes to thereby allow or prevent energization between the pair of fixed electrodes independently of the opening and closing operation of the switching means. The breaker apparatus further comprises a guide means for guiding a fixed-side housing, with the pair of fixed electrodes disposed therein, and a movable-side housing, with the movable electrode disposed therein, in the fitting and separating direction of the movable electrode and fixed electrodes. A driven pin is disposed in the fixed-side housing and a drive member is disposed in the movable-side housing in such a manner that it is prevented from moving in the fitting and separating direction of the movable electrode and fixed electrodes and it is allowed to move in a direction at right angles to the electrode fitting and separating direction. An inclined groove formed in the drive member has a base end portion open on the side edge thereof opposed to the fixed-side housing, and inclined with respect to the moving direction of the drive member. A loose fit groove is formed in the drive member and, while the fixed-side electrodes and movable electrode are fitted with each other, extends in parallel to the moving direction of the drive member from a terminal end portion of the inclined groove where the driven pin is situated. A detect means which, when the drive member is present at an energization allowable position for positioning the driven pin in the loose fit groove, allows the switching means to execute its closing operation to thereby close the main circuit, and also which, in a process where the drive member moves from the energization allowable position to an energization preventive position for positioning the driven pin in the terminal end portion of the inclined groove, allows the switching means to execute its opening operation to thereby open the main circuit.

According to a second aspect of the invention, the drive member includes a protect portion which, while the fixed electrodes and movable electrode are fitted with each other, is situated to cover the detect means.

According to a third aspect of the invention, when the drive member moves from the energization allowable position to the energization preventive position, the detect means starts the opening operation of the switching means before the drive member reaches the energization preventive position, characterized by operation resistance increasing means which, as the drive member moves to the energization prevented position side after the switching means starts the opening operation, increases the operation resistance of the drive member.

According to the first aspect of the invention, when the drive member is moved with the driven pin engaged with the base end portion of the inclined groove, the two housings approach each other while they are guided by the guide means. When the drive member reaches the energization preventive position, not only the fitting engagement between the two housings but also the fitting engagement between the fixed and movable electrodes are completed and energization is allowed between the pair of fixed electrodes. When the drive member is moved to the energization allowable position, the switching means executes its closing operation to thereby close the main circuit, so that energization between the fixed electrodes is allowed. In a process where the drive member is moved in the opposite direction from this state, the driven pin moves within the loose fit groove during the movement of the drive member from the energization allowable position to the energization preventive position. Therefore, the opening operation of the switching means is executed while the fixed and movable electrodes remain unmovable with respect to each other in the separating direction (i.e., while maintaining their mutual fitting engagement), so that the main circuit is opened.

When the drive member is moved further, the movable electrode is separated from the fixed electrodes to thereby prevent energization between the pair of fixed electrodes. In this manner, according to the first aspect of the invention, due to provision of the loose fit groove, the opening operation of the switching means for opening the main circuit can be completed while maintaining the mutual fitting engagement between the fixed and movable electrodes.

According to the second aspect of the invention, since there is formed in the drive member the protect portion for covering the detect means, the detect means can be prevented from being operated unpreparedly due to interference by external foreign bodies. Thus, the unprepared execution of the opening operation of the switching means for opening the main circuit can be prevented.

According to the third aspect of the invention, due to provision of the operation resistance increasing means, as the drive member moves to the energization preventive position side after the opening operation of the switching means starts, the operation resistance of the drive member can be increased. Thanks to this, as the time that is necessary from the start of the opening operation of the switching means to the separation of the movable electrode from the fixed electrodes, there can be secured sufficiently long time.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1

is a section view of a breaker apparatus according to a first embodiment of the invention, showing a state in which two housings are separated from each other;

FIG. 2

is a section view of the breaker apparatus, showing the starting state of fitting of the two housings;

FIG. 3

is a side view of a drive member, showing a state in which it is present at an energization preventive position;

FIG. 4

is a side view of the drive member, showing a state in which it is present at an energization allowable position;

FIG. 5A

is a back view of the drive member, showing a state in which it is present at an energization allowable position;

FIG. 5B

is a back view of the drive member, showing a state in which it is present at an energization preventive position;

FIG. 6

is a section view taken along the line

6

—

6

shown in

FIG. 1

; and

FIG. 7

is a perspective view of the drive member.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A description will be given below of a first embodiment of a breaker apparatus according to the invention with reference to

FIGS. 1

to

7

.

In a breaker apparatus according to the present embodiment, a pair of fixed electrodes

13

are disposed in a fixed-side housing

10

and arranged in series with a main circuit (not shown) to be opened and closed by a relay circuit (not shown) (switching means which is an element of the invention). Two movable electrodes

23

are disposed in a movable-side housing

20

and are fitted with and separated from the pair of fixed electrodes

13

, thereby permitting or preventing electric energization between the pair of fixed electrodes

13

independently of the opening and closing operations of the relay circuit.

The fixed-side housing

10

is formed in a box shape with the front side thereof corresponding to the left side in FIG.

1

and the side corresponding to the movable-side housing

20

. The fixed-side housing

10

comprises a base housing

11

, to be fixed to the body of a car, and a cover housing

12

fitted with the open surface of the housing

10

. In the base housing

11

, a pair of pin-type fixed electrodes

13

are arranged and fixed in upper and lower portions. The fixed electrodes

13

form part of the main circuit (not shown) and, in the case where the two movable electrodes

23

(to be discussed later) are fitted with the fixed electrodes

13

, the fixed electrodes

13

are short-circuited, i.e., energization is allowed between the fixed electrodes

13

. When the movable electrodes

23

are separated from the fixed electrodes

13

, the energization between the fixed electrodes

13

is prevented.

In the following description, the term “the vertical direction” is based on

FIG. 1

, whereas the term “the right and left direction” is the vertical direction of FIG.

6

.

In the cover housing

12

, there are formed insertion holes

14

into which the fixed electrodes

13

can be inserted respectively. The movable electrodes

23

can be stored in a cylindrical-shaped space between the insertion holes

14

and the outer peripheries of the fixed electrodes

13

(which will be discussed later).

The movable-side housing

20

comprises a cover

21

and two electrode mold bodies

22

. Each of the electrode mold bodies

22

includes a pair of movable electrodes

23

molded of resin. When the two housings

10

and

20

are fitted with each other, the movable electrodes

23

are respectively fitted with the pair of fixed electrodes

13

. The pair of movable electrodes

23

are connected to each other by a short-circuit piece

23

A. Therefore, when the movable electrodes

23

are fitted with the pair of fixed electrodes

13

, the movable electrodes

23

allow the fixed electrodes

13

to be short-circuited with respect to each other.

A connecting pin

24

penetrates through the electrode mold body

22

and cover

21

in the vertical direction, whereby the electrode mold body

22

can be mounted on the cover

21

in such a manner that it is prevented against removal. The inside diameter of the penetration hole of the electrode mold body

22

is set slightly larger than the outside diameter dimension of the connecting pin

24

. Thus, the electrode mold body

22

is allowed to shake in the vertical direction, as well as in the right and left directions, (in directions at right angles to the fitting and separating direction of the fixed electrode

13

and movable electrodes

23

) within the cover

21

, so that the alignment of the movable electrodes

23

and fixed electrodes

13

can be adjusted automatically when they are fitted with each other.

In the cover housing

12

of the fixed-side housing

10

, there is formed a hood portion

12

A (guide means which is an element of the invention) which is open on the upper and front sides thereof (

FIG. 1

) and has a substantially U-like shape when it is viewed from the front surface side thereof Correspondingly, in the movable-side housing

20

, there is formed a substantially U-shaped slit

25

(guide means which is an element of the invention) into which the hood portion

12

A can be fitted. When the hood portion

12

A and slit

25

are fitted with each other, they fulfil the function of a guide rail. Due to this guide function, the movable-side housing

20

is guided with respect to the fixed-side housing

10

in a direction (in a back-and-forth direction) along the fitting direction of the movable electrodes

23

and fixed electrodes

13

. Thus, the movable-side housing

20

is moved in such a manner that the play thereof in the vertical direction as well as in the right and left direction, is restricted.

The fixed-side housing

10

and movable-side housing

20

can be fitted with and separated from each other by the following cam means. That is, a pair of driven pins

15

are provided on and projected from each of the upper and lower portions of the right and left outer surfaces of the hood portion

12

A of the fixed-side housing

10

. On the movable-side housing

20

, there is disposed a drive member

30

which can cooperate with the driven pins

15

in fulfilling the function of a cam.

The drive member

30

includes a right and a left movable plate

31

,

31

each having a rectangular-plate shape long in the vertical direction, a plate-shaped connecting portion

32

(a protect portion which is an element of the invention) for connecting together the upper end portions of the two movable plates

31

, and a handle portion

33

extending upwardly from the connecting portion

32

. The components of the drive member

30

can be formed by press working a sheet of steel plate.

The movable plate

31

is stored in a vertically-extending slit

26

formed in the movable-side housing

20

in communication with the slit

25

. It is movable in the interior of the slit

26

. The movable plate

31

is allowed to move with respect to the movable-side housing

20

only in the vertical direction (a direction at right angles to the fitting and separating direction of the fixed electrodes

13

and movable electrodes

23

) which is the longitudinal direction of the slit

26

. However, the relative movements of the movable plate

31

to the movable-side housing

20

in the back-and-forth direction (a direction parallel to the fitting and separating direction of the fixed electrodes

13

and movable electrodes

23

) at right angles to the vertical direction, as well as in the right and left direction, are restricted.

Also in the movable plate

31

, there are formed two mutually parallel linear-shaped inclined grooves

34

each having a base end portion

34

A which is open on the side edge

31

A of the movable plate

31

opposed to the fixed-side housing

10

. Each of the inclined grooves

34

is formed such that, as it goes upwardly, it parts away from the side edge

31

A toward the back surface side of the movable plate

31

(in

FIG. 2

, toward the left side). In other words, it extends in an inclined direction to the relatively moving direction (the vertical direction) of the drive member

30

with respect to the movable-side housing

20

. The driven pin

15

of the fixed-side housing

10

can be engaged into the inclined groove

34

. When the movable plate

31

is moved in the downward direction (

FIG. 1

) while the driven pin

15

is introduced into the base end portion

34

A of the inclined groove

34

, the movable plate

31

and thus the movable-side housing

20

is moved in such a manner that it is drawn close to the fixed-side housing

10

due to the cam action caused by the engagement between the inclined groove

34

and driven pin

15

. When the driven pin

15

reaches the terminal end portion

34

B of the inclined groove

34

, the fitting of the two housings

10

and

20

is completed, as well as the fitting of the movable electrodes

23

and fixed electrodes

13

is completed. Also, when the drive member

30

is lifted up from this position, the movable-side housing

20

is separated from the fixed-side housing

10

and also the movable electrodes

23

are separated from the fixed electrodes

13

due to the cam action caused by the engagement between the inclined groove

34

and driven pin

15

.

Further, there is formed in the movable plate

31

, a loose fit groove

35

which extends upwardly from the terminal end portion

34

B of each of the inclined grooves

34

in parallel to the moving direction of the drive member

30

. When the drive member

30

is moved further downwardly from the fit completed position, i.e., where the driven pin

15

is situated in the terminal end portion

34

B of the inclined groove

34

, the driven pin

15

is moved within the loose fit groove

35

but the cam action is not fulfilled. Therefore, the two housings

10

and

20

are not shifted with respect to each other in the fitting and separating direction. Furthermore, the electrodes

13

and

23

are not shifted with respect to each other in the fitting and separating direction.

On the outer surface of the upper end portion of the cover housing

12

of the fixed-side housing

10

, a microswitch

36

is disposed (detect means which is an element of the invention) for detecting the position of the drive member

30

to thereby allow the relay circuit to execute its operation for opening and closing the main circuit. The microswitch

36

is stored in a storage portion

17

which is formed in a cylinder-like shape. The microswitch

36

includes a probe

36

A and a movable piece

36

B which is disposed upwardly of the probe

36

A and can be elastically shifted in the vertical direction.

When the drive member

30

is at an energization allowable position, (see

FIG. 4

) i.e., where it sets the driven pin

15

at the upper end portion of the loose fit groove

35

, the connecting portion

32

presses down the movable piece

36

B to bring it into contact with the probe

36

A to thereby allow the microswitch

36

to detect that the drive member

30

is at the energization allowable position. Due to this detection, the relay circuit is allowed to execute its closing operation for closing the main circuit. When the drive member

30

moves from the energization allowable position to an energization preventive position (see

FIG. 3

) in which the driven pin

15

is situated at the terminal end portion

34

B of the inclined groove

34

, the connecting portion

32

retreats upwardly to separate the movable piece

36

B from the probe

36

A, just after the start of the movement of the drive member

30

, and the microswitch

36

detects the movement of the drive member

30

toward the energization preventive position to thereby allow the relay circuit to start its opening operation for opening the main circuit. After approximately 150 msec. from the start of the opening operation of the relay circuit, the opening operation of the relay circuit is completed so that the main circuit is opened.

Two upper and lower notches

38

and

37

are formed in the side edge of the movable plate

31

on the opposite side to the side edge

31

A thereof where the base end portion

34

A of the inclined groove

34

is open. When the drive member

30

is in the upper-most end, i.e., where the driven pin

15

is situated at the base end portion

34

A of the inclined groove

34

(FIG.

2

), the lower notch

37

is fitted with a plate spring

27

(operation resistance increasing means which is an element of the invention) of the movable-side housing

20

, so that the drive member

30

is held at the same height. When the drive member

30

is at the energization allowable position (FIG.

4

), the upper notch

38

and plate spring

27

are fitted with each other, so that the drive member

30

is held at the energization allowable position. Additionally, when the drive member

30

is at the energization allowable position, the plate spring

27

is contacted with the inclined portion

38

A (operation resistance increasing means which is an element of the invention) of the upper notch

38

and is thereby flexed elastically, not only due to the elastic recovery of the plate spring

27

but also due to the inclination of the inclined portion

38

A. Therefore, an energization force going toward the energization allowable position side is applied to the drive member

30

.

Next, a description will be given below of the operation of the present embodiment.

To bring the movable-side housing

20

into fitting engagement with the fixed-side housing

10

, the movable electrodes

23

are moved into the hood portion

12

A and are moved laterally until the driven pins

15

move into the base end portions

34

A of the inclined grooves

34

of the movable plate

31

. In this operation, because the hood portion

12

A is open on the upper side thereof, the movable electrodes

23

may be moved down straight from the position shown in FIG.

1

and thereafter, may be moved laterally. As a result, the movable electrodes

23

and fixed electrodes

13

are brought into slight fit with each other.

Next, the drive member

30

is pressed down to the energization preventive position. During this operation, due to the engagement between the driven pins

15

and inclined grooves

34

, the two housings

10

and

20

are brought into their mutual fit completed state and the two kinds of electrodes

13

and

23

are brought into their mutual fit completed state to allow energization between the fixed electrodes

13

. The main circuit is not closed yet at the time.

Next, the drive member

30

is pressed further down to the energization allowable position. This operation is detected by the microswitch

36

and the relay circuit carries out its closing operation. Thus, the main circuit is turned into its closed state not only due to the closing operation of the relay circuit but also due to the energization allowed state between the fixed electrodes

13

, (a state in which energization is allowed). In this state, owing to the engagement between the upper notch

38

and plate spring

27

, the drive member

30

is held at the energization allowed position, while the main circuit is held in the closed state.

Additionally, while the drive member

30

remains at the energization prevented position, the further pressing-down operation is not executed (FIG.

3

), since the plate spring

27

is elastically contacted with the inclined portion

38

A of the upper notch

38

. Thus, due to the elasticity and inclination of the plate spring

27

, the drive member

30

is automatically moved to the energization allowed position side.

Next, description will be given below of the operation to remove the two housings

10

and

20

from each other.

By picking up the handle portion

33

, the drive member

30

situated at the energization allowed position is lifted up. When the drive member

30

is moved toward the energization prevented position, i.e., just after the start of the movement of the drive member

30

, the relay circuit begins its opening operation and, after approximately 150 msec., the opening operation of the relay circuit is completed. Accordingly, the main circuit opens to stop the energization between the fixed electrodes.

Here, the distance from the position of the drive member

30

where the relay circuit begins the opening operation to the energization preventive position is set in such a manner that, when the lifting operation of the drive member

30

is carried out at the normal speed, it takes the time longer than about 150 msec. (which is the time lag between the start of the opening operation of the relay circuit and the opening operation of the main circuit) for the drive member

30

to move between the energization allowable and preventive positions. Therefore, when the drive member

30

reaches the energization preventive position, the main circuit is opened. Also, during the time while the drive member

30

starts from the energization allowable position and reaches the energization preventive position, the two housings

10

and

20

are not shifted in the separating direction with respect to each other since the driven pins

15

only move within the loose fit groove

35

. Therefore, the electrodes

13

and

23

are also not shifted in the separating direction with respect to each other, thereby maintaining the state where the movable electrodes

23

are removed from the fixed electrodes

13

.

After the drive member

30

reaches the energization preventive position, if the drive member

30

is further lifted, the driven pins

15

are engaged with the inclined grooves

34

, thereby starting the movements of the movable electrodes

13

in the separating direction from the fixed electrodes

23

. When the driven pins

15

reach the base end portions

34

A of the inclined grooves

34

, the movable and fixed electrodes

13

and

23

are completely separated from each other. When the movable and fixed electrodes

13

and

23

are separated from each other, there is no possibility that there can occur any arc between the movable and fixed electrodes

13

and

23

because the main circuit is already opened due to the opening operation of the relay circuit.

As described above, since the loose fit groove

35

is formed, even in case where there is a time lag between the start and completion of the opening operation of the relay circuit for opening the main circuit, the opening operation of the relay circuit for opening the main circuit can be completed while maintaining the movable and fixed electrodes

13

and

23

in the mutually fitted state.

Also, when the drive member

30

moves from the energization allowable position to the energization preventive position, i.e., during the time when the opening operation of the relay circuit for opening the main circuit starts and the drive member

30

reaches the energization preventive position, the elastic flexion amount of the plate spring

27

increases due to the inclination of the inclined portion

38

A of the upper notch

38

and the operation force (operation resistance) to be applied to the drive member also increases gradually. Therefore, a sufficient amount of time may be secured for the start of the opening operation of the relay circuit to the removal of the movable electrodes

23

from the fixed electrodes

13

.

When the movable and fixed electrodes

23

and

13

are fitted with each other, the microswitch

36

is covered from above by the connecting portion

32

of the drive member

30

. This can prevent the microswitch

36

from being mistakenly operated due to interference by external foreign bodies and thus can prevent the opening operation of the relay circuit for opening the main circuit from being carried out in error.

The invention is not limited to the embodiment explained by the above description and drawings but, for example, the following embodiments also fall within the technical scope of the invention and, further, other various modifications are also possible without departing from the subject matter of the invention.

(1) In the above embodiment, there is employed a structure in which two short-circuited movable electrodes are fitted with the two pin-shaped fixed electrodes. However, this is not limitative but there can also be employed a structure in which a pair of tongue-shaped fixed electrodes are respectively disposed on the two sides of an insulated support pillar, and a U-shaped movable electrode is fitted with the two fixed electrodes to thereby short-circuit the two fixed electrodes.

(2) A fuse device may be attached to the breaker apparatus according to the above embodiment, or there may be disposed a switch which can detect that the movable-side housing is fitted with the fixed-side housing.

(3) In the above embodiment, as the detect means which detects the movement of the drive member to thereby operate the relay circuit, there is used a microswitch. However, according to the invention, alternatively, there may be used a pair of terminal metal members in the fixed-side housing and there may be disposed a short-circuit terminal in the drive member, whereby the short-circuiting of the pair of metal members and the removal of such short-circuiting may be may be carried out using the short-circuit terminal.

(4) In the above embodiment, the microswitch is disposed in the fixed-side housing. However, according to the invention, the microswitch may also be disposed in the movable-side housing.

(5) In the above embodiment, as the switching means, there is used a relay circuit. However, according to the invention, there can also be used other means such as a transistor.