Moveable arm for a circuit breaker and method for making the same

1. A moveable arm assembly for a circuit breaker, comprising:

a unitary structure having two blade portions being connected by a bend location, the bend location forming a gapless surface region; and

a contact connected to the unitary structure on the gapless surface region wherein the gapless surface region and a contact surface of the contact are connected to form a joint therebetween.

2. The arm assembly as recited in claim 1 , wherein the joint includes one of a solder joint and a brazed joint.

3. The arm assembly as recited in claim 1 , wherein the unitary structure includes formed sheet metal.

4. The arm assembly as recited in claim 1 , wherein the unitary structure includes at least one of steel, copper, aluminum and an alloy thereof.

5. The arm assembly as recited in claim 1 , further comprising bend portions on the two blade portions.

6. The arm assembly as recited in claim 1 , wherein the bend location includes a flat region substantially perpendicular to the gapless surface region to assist in forming a solder bead between the gapless surface region and the contact surface.

7. A circuit breaker, comprising:

a moveable contact;

a moveable arm assembly including a unitary structure having two blade portions being connected by a bend location, the bend location forming a gapless surface region at the bend location, the moveable contact being connected to the unitary structure on the gapless surface region wherein the gapless surface region and a contact surface of the contact are connected to form a joint therebetween;

a fixed contact configured to connect with the moveable contact during an operating condition and be separated in an off or tripped condition; and

a handle configured to set or reset the moveable arm assembly in accordance with one of the operating condition and the off or tripped condition.

8. The breaker as recited in claim 7 , wherein the joint includes one of a solder joint and a brazed joint.

9. The breaker as recited in claim 8 , wherein the unitary structure includes formed sheet metal.

10. The breaker as recited in claim 8 , wherein the unitary structure includes at least one of steel, copper, aluminum and an alloy thereof.

11. The breaker as recited in claim 8 , further comprising bend portions on the two blade portions.

12. The breaker as recited in claim 8 , wherein the bend location includes a flat region substantially perpendicular to the gapless surface region to assist in forming a solder bead between the gapless surface region and the contact surface.

13. A method for forming a moveable arm assembly for a circuit breaker, comprising:

forming a blank from a conductive sheet, the blank including a unitary structure having two blade portions;

bending the two blade portions at a bend location to form a gapless surface region at the bend location; and

joining a contact to the unitary structure on the gapless surface region at the bend location to form a moveable arm assembly.

14. The method as recited in claim 13 , wherein joining includes one of soldering and brazing.

15. The method as recited in claim 13 , wherein forming a blank includes at least one of punching, stamping and cutting the unitary structure from sheet metal.

16. The method as recited in claim 13 , wherein the unitary structure includes at least one of steel, copper, aluminum and an alloy thereof.

17. The method as recited in claim 13 , further comprising bending portions on the two blade portions within a plane of the blank.

18. The method as recited in claim 13 , further comprising roughening a surface of the bend location to assist in forming a solder joint with the contact.

19. The method as recited in claim 13 , further comprising installing the moveable arm assembly in a circuit breaker.

20. The method as recited in claim 13 , wherein bending the two blade portions at a bend location includes bending the blank transversely to a plane of the blank to form the bend location.