Abstract: Provided herein is an improved bi-stable relay. In some embodiments, the bi-stable relay assembly may include a housing, and a core assembly within the housing. The core assembly may include a coil support structure, a first coil and a second coil along a central section of the coil support structure, a first magnet at a first end of the coil support structure, a second magnet at a second end of the coil support structure, and a first electromagnetic shell component and a second electromagnetic shell component each extending between the first and second magnets.

Abstract: A stud assembly is assembled by inserting a sphere into a cavity of a stud, where the cavity is cylindrical in shape, inserting a neck of a rivet into the cavity until the neck touches the sphere, and press-fitting the rivet into the cavity until the neck melds with the sphere.

Abstract: Provided herein is an improved a bi-stable actuator including a first core component coupleable to a housing, the first core component including a central bore containing a shaft and a shaft spring. The actuator may further include a second core component extending around the first core component, wherein the second core component and the first core component are axially moveable relative to one another, and a third core component extending within the second core component, wherein the third core component and the second core component are axially moveable relative to one another. The actuator may further include a positioning sphere extending through an opening of the first core component, wherein the positioning sphere abuts the second core component when the bi-stable actuator is in a first position, and wherein the positioning sphere abuts a detent of the shaft when the bi-stable actuator is in a second position.

Abstract: Provided herein are methods for an improved bi-stable relay. In some embodiments, a method may include providing a core assembly within a housing, the core assembly comprising a plunger extending through a coil support structure. The method may further include winding a first coil and a second coil about a central section of the coil support structure, providing a first magnet and a first ferromagnetic plate at a first end of the coil support structure, and providing a second magnet and a second ferromagnetic plate at a second end of the coil support structure. In some embodiments, the method may further include activating the first coil or the second coil to move the plunger between a first position and a second position, wherein in the first position a circuit formed by a set of contacts is closed, and wherein in the second position the circuit is open.

Abstract: Provided herein are coil support structures and methods of retaining a printed circuit board assembly (PCBA) of a relay. In some embodiments, a bi-stable relay assembly may include a coil support structure, having a central section extending between a first end section and a second end section, and set of biasable fasteners extending from the first end section and the second end section, wherein each of the set of biasable fasteners includes a sloped engagement surface and a retention slot. The coil support structure may further include a PCBA coupled to the first and second end sections of the coil support structure, wherein the coil support structure extends within the retention slot of each of the set of biasable fasteners.

Abstract: A fuse module including a mounting block having a through-hole extending therethrough, a fuse including an upper portion disposed on a top of the mounting block and having a through-hole, a lower portion disposed on a bottom of the mounting block and having a through-hole, and a fusible element disposed adjacent a sidewall of the mounting block and connecting the upper portion to the lower portion, the fuse module further including a housing having a main body portion encasing the mounting block and the fuse, the main body portion having apertures in top and bottom surfaces thereof aligned with the through-hole of the mounting block, and a cap portion connected to the main body portion and disposed over the fusible element, the cap portion having surface features extending from an interior surface thereof for absorbing energy upon occurrence of an overcurrent condition in the fuse.

Abstract: Provided herein are coil support structures and methods of retaining a printed circuit board assembly (PCBA) of a relay. In some embodiments, a bi-stable relay assembly may include a coil support structure, having a central section extending between a first end section and a second end section, and set of biasable fasteners extending from the first end section and the second end section, wherein each of the set of biasable fasteners includes a sloped engagement surface and a retention slot. The coil support structure may further include a PCBA coupled to the first and second end sections of the coil support structure, wherein the coil support structure extends within the retention slot of each of the set of biasable fasteners.

Abstract: Provided herein is an improved bi-stable relay. In some embodiments, the bi-stable relay assembly may include a housing, and a core assembly within the housing. The core assembly may include a coil support structure, a first coil and a second coil along a central section of the coil support structure, a first magnet at a first end of the coil support structure, a second magnet at a second end of the coil support structure, and a first electromagnetic shell component and a second electromagnetic shell component each extending between the first and second magnets.

Abstract: Provided herein are methods for an improved bi-stable relay. In some embodiments, a method may include providing a core assembly within a housing, the core assembly comprising a plunger extending through a coil support structure. The method may further include winding a first coil and a second coil about a central section of the coil support structure, providing a first magnet and a first ferromagnetic plate at a first end of the coil support structure, and providing a second magnet and a second ferromagnetic plate at a second end of the coil support structure. In some embodiments, the method may further include activating the first coil or the second coil to move the plunger between a first position and a second position, wherein in the first position a circuit formed by a set of contacts is closed, and wherein in the second position the circuit is open.

Abstract: Provided herein is an improved a bi-stable actuator including a first core component coupleable to a housing, the first core component including a central bore containing a shaft and a shaft spring. The actuator may further include a second core component extending around the first core component, wherein the second core component and the first core component are axially moveable relative to one another, and a third core component extending within the second core component, wherein the third core component and the second core component are axially moveable relative to one another. The actuator may further include a positioning sphere extending through an opening of the first core component, wherein the positioning sphere abuts the second core component when the bi-stable actuator is in a first position, and wherein the positioning sphere abuts a detent of the shaft when the bi-stable actuator is in a second position.

Abstract: A fuse module including a mounting block having a through-hole extending therethrough, a fuse including an upper portion disposed on a top of the mounting block and having a through-hole, a lower portion disposed on a bottom of the mounting block and having a through-hole, and a fusible element disposed adjacent a sidewall of the mounting block and connecting the upper portion to the lower portion, the fuse module further including a housing having a main body portion encasing the mounting block and the fuse, the main body portion having apertures in top and bottom surfaces thereof aligned with the through-hole of the mounting block, and a cap portion connected to the main body portion and disposed over the fusible element, the cap portion having surface features extending from an interior surface thereof for absorbing energy upon occurrence of an overcurrent condition in the fuse.

Abstract: An electrical contact assembly including an elongate stud having a coupling end and an opposing butt end, the butt end having a recess formed therein, the recess having a head portion and a shank portion defining a shoulder at a juncture therebetween, the head portion bounded by a collar and having a diameter that is larger than a diameter of the shank portion, and a contact pad having a head and a shank, the head having a top surface and a bottom surface with a tapered sidewall extending therebetween, the shank extending from the bottom surface of the head and having a diameter that is smaller than a diameter of the bottom surface, wherein the contact pad is disposed within the recess with the bottom surface of the head disposed on the shoulder and with the collar extending over and engaging the angled sidewall of the head.

Abstract: An electrical contact assembly including an elongate stud having a coupling end and an opposing butt end, the butt end having a recess formed therein, the recess having a head portion and a shank portion defining a shoulder at a juncture therebetween, the head portion bounded by a collar and having a diameter that is larger than a diameter of the shank portion, and a contact pad having a head and a shank, the head having a top surface and a bottom surface with a tapered sidewall extending therebetween, the shank extending from the bottom surface of the head and having a diameter that is smaller than a diameter of the bottom surface, wherein the contact pad is disposed within the recess with the bottom surface of the head disposed on the shoulder and with the collar extending over and engaging the angled sidewall of the head.