Electrical switching apparatus, and crossbar assembly and spring cap therefor

A crossbar assembly for an electrical switching apparatus, said electrical switching apparatus comprising a housing, a number of a stationary contacts, a number of movable contacts, and a number of moving arms, each of said movable contacts being disposed on a corresponding one of said moving arms, said crossbar assembly comprising:

• a crossbar structured to pivot said number of moving arms thereby moving said movable contacts into and out of electrical communication with said stationary contacts, said crossbar having a number of molded recesses;
• a pair of contact springs disposed in each of said molded recesses;
• a spring clip enclosing said pair of contact springs within said molded recess, said spring clip being disposed between a corresponding one of said moving arms and said pair of contact springs;
• and
• a spring cap cooperating with said pair of contact springs within said molded recess, each spring cap comprising:
• a first segment disposed between said spring clip and a first contact spring of said pair of contact springs,
• a second segment disposed between said spring clip and a second contact spring of said pair of contact springs, and
• a connecting portion connecting the first segment to the second segment,
• wherein said spring cap supports said spring clip and evenly distributes bias forces of said first contact spring and said second contact spring,
• wherein said spring clip has a predetermined geometry including a plurality of bends;
• wherein the first segment and the second segment together form a contact surface having a predetermined profile;
• wherein said predetermined profile comprises a plurality of angled surfaces;
• and wherein each of said angled surfaces engages said spring clip between a corresponding pair of said bends, and
• wherein said plurality of angled surfaces includes a first ramped portion disposed at a first angle and a second ramped portion disposed at a second angle different from the first angle.

An electrical switching apparatus comprising:

• a housing;
• a number of a stationary contacts;
• a number of movable contacts;
• a number of moving arms, each of said movable contacts being disposed on a corresponding one of said moving arms;
• and
• a crossbar assembly comprising:
• a crossbar for pivoting said moving arms thereby moving said movable contacts into and out of electrical communication with said stationary contacts, said crossbar having a number of molded recesses,
• a pair of contact springs disposed in each of said molded recesses,
• a spring clip enclosing said pair of contact springs within said molded recess, said spring clip being disposed between a corresponding one of said moving arms and said pair of contact springs, and
• a spring cap cooperating with said pair of contact springs within said molded recess, each spring cap comprising:
• a first segment disposed between said spring clip and a first contact spring of said pair of contact springs,
• a second segment disposed between said spring clip and a second contact spring of said pair of contact springs, and
• a connecting portion connecting the first segment to the second segment,
• wherein said spring cap supports said spring clip and evenly distributes bias forces of said first contact spring and said second contact spring,
• wherein said spring clip has a predetermined geometry including a plurality of bends;
• wherein the first segment and the second segment together form a contact surface having a predetermined profile;
• wherein said predetermined profile comprises a plurality of angled surfaces;
• and wherein each of said angled surfaces engages said spring clip between a corresponding pair of said bends, and
• wherein said plurality of angled surfaces includes a first ramped portion disposed at a first angle and a second ramped portion disposed at a second angle different from the first angle.