Metalurgical material with fabrication pads

Abstract

A fabrication pad for metallurgical material that is electron beam or laser welded to at least one end of the metallurgical material. The fabrication pad is formed of a monometallic material or other suitably chosen and can be welded to a bi-metal strip to provide a fabrication contact area when the bi-metal strip is utilized in an industrial application. The fabrication pad eliminates the need for plating as an aid to fabrication and eliminates damage to the metallurgical material caused by fabrication activities directly on the metallurgical material. The assembly improves calibration and provides a consistent mechanical output. When used in an electrical circuit breaker, the assembly provides a consistent thermal active length and consistent thermal activities.

1 . A metallurgical material comprising: 
 a metallurgically active strip; and    a fabrication pad edge welded to at least one end of said metallurgical active strip so that fabrication techniques are not performed on the metallurgical strip.    
     
     
         2 . The metallurgical material of  claim 1  wherein said metallurgically active strip is a composite material having at least two layers of dissimilar metal bonded together.  
     
     
         3 . The metallurgical material of  claim 2  wherein said fabrication pad is a monometallic material.  
     
     
         4 . The metallurgical material of  claim 3  wherein said composite material has a material thickness substantially equal to a corresponding material thickness of said fabrication pad.  
     
     
         5 . The metallurgical material of  claim 2  wherein said composite material is thermally active to provide a predetermined deflection upon the application of heat thereto, said fabrication pad being non-thermally active.  
     
     
         6 . The metallurgical material of  claim 5  wherein said metallurgically active strip has a fabrication pad welded to opposing ends thereof.  
     
     
         7 . The metallurgical material of  claim 6  wherein one of said fabrication pads is a contact member operable to make an electrical contact with an associated source of electrical current.  
     
     
         8 . The metallurgical material of  claim 7  wherein said composite material is a bi-metal having two layers of dissimilar metal bonded together.  
     
     
         9 . The metallurgical material of  claim 7  wherein said composite material is a clad material having at least three layers of dissimilar metal bonded together.  
     
     
         10 . In a circuit breaker having first and second terminals interconnected by a thermostat strip operable to disconnect said first and second terminals upon encountering predetermined parameters, the improvement comprising: 
 said thermostat strip is formed from a bi-metal material having at least two layers of dissimilar metal bonded together, said thermostat strip having a pair of opposing ends defining end edges, said bi-metal material having at least one fabrication pad welded to one end of said thermostat for connection of one of said terminals.    
     
     
         11 . The circuit breaker of  claim 10  wherein said fabrication pad is electron beam welded at the edge defined by the corresponding end of said bi-metal material.  
     
     
         12 . The circuit breaker of  claim 11  wherein said bi-metal material has a fabrication pad edge welded to each of said ends.  
     
     
         13 . The circuit breaker of  claim 11  wherein said bi-metal material has a contact member welded to an opposing end relative to said fabrication pad to provide an electrical contact with one of said terminals.  
     
     
         14 . The circuit breaker of  claim 11  wherein said fabrication pads have a thickness substantially equal to a corresponding thickness of said bi-metal material.  
     
     
         15 . The circuit breaker of  claim 11  wherein one of said fabrication pads has an electrically conductive member affixed thereto.  
     
     
         16 . A method of utilizing a metallurgical material comprising the steps of: 
 edge welding a fabrication pad to one end of said metallurgical material, said fabrication pad being formed from a monolithic metal conducive to facilitating fabrication activities; and    conducting said fabrication activities on said fabrication pad without disturbing said metallurgical material.    
     
     
         17 . The method of  claim 16  wherein said step of edge welding a fabrication pad is conducted on each opposing end of said metallurgical material to provide a pair of opposing fabrication pads.  
     
     
         18 . The method of  claim 16  further comprising the step of: 
 forming said metallurgical material from a bi-metal strip having at least two layers of dissimilar metal bonded together.    
     
     
         19 . The method of  claim 18  wherein said step of edge welding said fabrication pads provides a fabrication pad on one end of said bi-metal strip on which fabrication activities can be conducted and a contact member on an opposing end of said bi-metal strip to provide an electrical contact with an associated source of electrical current, said fabrication pad and said contact member being welded by electron beam welding.  
     
     
         20 . The method of  claim 19  wherein said step of conducting fabrication activities includes the steps of: 
 attaching a terminal to said fabrication pad; and    installing said metallurgical material into a circuit breaker.