Abstract: Systems and methods for a battery separator system integrating a DC contactor (solenoid) plus control electronics and all required interconnects into a single sealed enclosure for the purpose of selectively connecting and disconnecting a main and auxiliary battery under predetermined conditions. Battery monitoring and control includes programmable time delays that immunize the system from reacting to transient conditions as well as monitoring for and correcting unintended states and disabling operation when voltage conditions fall outside of prescribed limits.

Abstract: Systems and methods for a battery separator system integrating a DC contactor (solenoid) plus control electronics and all required interconnects into a single sealed enclosure for the purpose of selectively connecting and disconnecting a main and auxiliary battery under predetermined conditions. Battery monitoring and control includes programmable time delays that immunize the system from reacting to transient conditions as well as monitoring for and correcting unintended states and disabling operation when voltage conditions fall outside of prescribed limits.

Abstract: A compliant middle member to be used between encapsulated stacked circuit boards contained in an enclosure. The compliant middle member absorbing expansion forces from an encapsulant experiencing thermal expansion, thereby diverting and reducing the expansion forces exerted upon the electrical components.

Abstract: An apparatus and method directed to the art of providing an electrically insulative electric solenoid for starting internal combustion engines are provided. The solenoid has a housing; a coil unit within the housing comprising a hollow can with an open end, and a bobbin, an armature, and a bridging contact assembly positioned in the can; a flux washer abutting the open end of the can; a mounting plate abutting the open end of the housing, and an electrically insulative biasing member positioned between the mounting plate and the flux washer and between the mounting plate and the bobbin.

Abstract: An apparatus and method directed to the art of providing an electrically insulative electric solenoid for starting internal combustion engines are provided. The solenoid has a housing; a coil unit within the housing comprising a hollow can with an open end, and a bobbin, an armature, and a bridging contact assembly positioned in the can; a flux washer abutting the open end of the can; a mounting plate abutting the open end of the housing, and an electrically insulative biasing member positioned between the mounting plate and the flux washer and between the mounting plate and the bobbin.

Abstract: A compliant middle member to be used between encapsulated stacked circuit boards contained in an enclosure. The compliant middle member absorbing expansion forces from an encapsulant experiencing thermal expansion, thereby diverting and reducing the expansion forces exerted upon the electrical components.

Abstract: An embodiment of an electrical contactor according to the present invention provides improved operability and manufacturability. Such electrical contactor may include a housing substantially surrounding an electrical conductor assembly and contact actuator. The conductor assembly includes a stationary contact assembly and a movable contact assembly. The contact actuator selectively mechanically interfaces to the movable contact assembly to make or break an electrical conduction. The contactor provides improved contact bounce dampening and actuator force characteristics. Methods according to the present invention include a method of manufacturing and a method of operating a solenoid actuated electrical contactor so as to minimize solenoid plunger acceleration and impact forces while making the electrical conduction and to maximize solenoid plunger acceleration and impact forces while breaking the electrical conduction.

Abstract: An embodiment of an electrical contactor according to the present invention provides improved operability and manufacturability. Such electrical contactor may include a housing substantially surrounding an electrical conductor assembly and contact actuator. The conductor assembly includes a stationary contact assembly and a movable contact assembly. The contact actuator selectively mechanically interfaces to the movable contact assembly to make or break an electrical conduction. The contactor provides improved contact bounce dampening and actuator force characteristics. Methods according to the present invention include a method of manufacturing and a method of operating a solenoid actuated electrical contactor so as to minimize solenoid plunger acceleration and impact forces while making the electrical conduction and to maximize solenoid plunger acceleration and impact forces while breaking the electrical conduction.

Abstract: Provided is a device mounted contactor and a method of reducing continuous charge distribution, especially in a vehicle. The contactor includes a housing, and a plurality of power terminals. The device may further include a conductance shield and support structure extending from the housing. Situated at least partially in the housing is a switch, which is capable of electrically coupling at least two of the plurality of power terminals. One or more electrically insulative covers may be provided. The contactor may also provide a fused accessory terminal, which is electrically coupled to one of the power terminals through a fuse. A method according to the present invention reduces continuous electrical charge distribution in an electrical circuit by mechanically attaching a first contactor power terminal to a battery terminal and electrically coupling a second contactor power terminal to a circuit, which may include a vehicle starter.

Abstract: Provided is a device mounted contactor and a method of reducing continuous charge distribution, especially in a vehicle. The contactor includes a housing, and a plurality of power terminals. The device may further include a conductance shield and support structure extending from the housing. Situated at least partially in the housing is a switch, which is capable of electrically coupling at least two of the plurality of power terminals. One or more electrically insulative covers may be provided. The contactor may also provide a fused accessory terminal, which is electrically coupled to one of the power terminals through a fuse. A method according to the present invention reduces continuous electrical charge distribution in an electrical circuit by mechanically attaching a first contactor power terminal to a battery terminal and electrically coupling a second contactor power terminal to a circuit, which may include a vehicle starter.

Abstract: Provided is a device mounted contactor and a method of reducing continuous charge distribution, especially in a vehicle. The contactor includes a housing, and a plurality of power terminals. The device may further include a conductance shield and support structure extending from the housing. Situated at least partially in the housing is a switch, which is capable of electrically coupling at least two of the plurality of power terminals. One or more electrically insulative covers may be provided. The contactor may also provide a fused accessory terminal, which is electrically coupled to one of the power terminals through a fuse. A method according to the present invention reduces continuous electrical charge distribution in an electrical circuit by mechanically attaching a first contactor power terminal to a battery terminal and electrically coupling a second contactor power terminal to a circuit, which may include a vehicle starter.

Abstract: Provided is a device mounted contactor and a method of reducing continuous charge distribution, especially in a vehicle. The contactor includes a housing, and a plurality of power terminals. The device may further include a conductance shield and support structure extending from the housing. Situated at least partially in the housing is a switch, which is capable of electrically coupling at least two of the plurality of power terminals. One or more electrically insulative covers may be provided. The contactor may also provide a fused accessory terminal, which is electrically coupled to one of the power terminals through a fuse. A method according to the present invention reduces continuous electrical charge distribution in an electrical circuit by mechanically attaching a first contactor power terminal to a battery terminal and electrically coupling a second contactor power terminal to a circuit, which may include a vehicle starter.

Abstract: A direct current contactor having at least one low current terminal and at least two high current terminals is disclosed. The low current terminal is connected to a spring, which is nested in a chimney-shaped receptacle, where it is coupled to the contactor's coil. The chimney shaped receptacle also has a slot that receives a terminal blade that electrically connects the spring to the coil. The housing of the solenoid is designed with longitudinally extending channels that receive the receptacles, which prevents the assembly from rotating within the housing unit. Each terminal is provided with ribbed and knurled areas to restrict rotation of the terminal in the housing and the mating connection while tightening.

Abstract: A direct current contactor having at least one low current terminal and at least two high current terminals is disclosed. The low current terminal is connected to a spring, which is nested in a chimney-shaped receptacle, where it is coupled to the contactor's coil. The chimney shaped receptacle also has a slot that receives a terminal blade that electrically connects the spring to the coil. The housing of the solenoid is designed with longitudinally extending channels that receive the receptacles, which prevents the assembly from rotating within the housing unit. Each terminal is provided with ribbed and knurled areas to restrict rotation of the terminal in the housing and the mating connection while tightening.

Abstract: An integrated solenoid system including a single housing containing a solenoid, a controller and one or more electrical connections. The controller includes temperature compensating means and/or voltage compensating means thereby providing predetermined, substantially constant currents to said solenoid. The housing includes an integral two-part end cover.

Abstract: An integrated solenoid system including a single housing containing a solenoid, a controller and one or more electrical connections. The controller includes temperature compensating means and/or voltage compensating means thereby providing predetermined, substantially constant currents to said solenoid. The housing includes an integral two-part end cover.

Abstract: An electrical control module, including a control circuit, and voltage rectifier for controlling a solenoid. The control circuit is adapted for use in a transfer switch receiving power from two power sources and sending power to a single load, such as a commercial building or hospital. The control circuit and solenoid are designed to work over a broad range of voltages to quickly and efficiently transfer power from the first power source to the second. The circuit is particularly well suited for use in a closed transition transfer switch where the second source is connected before the first source is disconnected.

Abstract: An electrical control module and circuit for controlling a solenoid. The control circuit provides a constant voltage to a solenoid for a predetermined time period after which a pulse width modulated voltage is supplied. The circuit further includes components for reverse polarity protection, transient voltage protection, low gate drive voltage protection, reduced heat dissipation and improved magnetic drive under low input voltage conditions during application of the pulse width modulated voltage. The module may be used in conjunction with a single coil or a dual coil solenoid. The circuit may be utilized on a 12 volt or a 24 volt electrical system without adjustment.

Abstract: A sound dampened solenoid utilizes pneumatic dampening to quiet the sound during the plunger's movement. An O-ring is mounted around the outer diameter of the pole piece thus sealing the pole piece to the solenoid tube. A seal is placed in the pole piece opening where the plunger push rod passes through. A pair of low friction wear bands are wrapped around the plunger. Small gaps are formed where the ends of each wear band meet. A second O-ring is located under one of the wear bands to form a seal between the plunger and the tube. In a pull solenoid, when the solenoid is energized the plunger begins to accelerate toward the pole piece causing the volume of air within the tube between the plunger assembly and pole piece to shrink. The only path for air trapped within to escape is through the gaps in the wear bands. Air is forced through the gaps at a slower rate than the rate of volume change. Air pressure within the volume rises slowing the plunger acceleration and quieting its operation.