U.S. patent number 3,889,362 [Application Number 05/509,075] was granted by the patent office on 1975-06-17 for method of making electrical resistance element.
This patent grant is currently assigned to Robertshaw Controls Company. Invention is credited to Hugh J. Tyler.
United States Patent |
3,889,362 |
Tyler |
June 17, 1975 |
Method of making electrical resistance element
Abstract
A method of making an electrical resistance element is disclosed
comprising the steps of providing a conductor having a pair of lead
attaching ends, forming each lead attaching end with a plurality of
spaced and predetermined lead attaching parts therealong, attaching
a pair of leads respectively to one preselected lead attaching part
of each end of the conductor so that a desired electrical
resistance is provided, and completely covering the conductor and
part of the leads with an encasing structure.
Inventors: |
Tyler; Hugh J. (Santa Ana,
CA) |
Assignee: |
Robertshaw Controls Company
(Richmond, VA)
|
Family
ID: |
27021040 |
Appl.
No.: |
05/509,075 |
Filed: |
September 25, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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410539 |
Oct 29, 1973 |
3852570 |
|
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Current U.S.
Class: |
29/619; 29/612;
29/855; 29/611; 29/621 |
Current CPC
Class: |
H02K
11/25 (20160101); H05B 3/565 (20130101); H05B
3/36 (20130101); H01C 10/46 (20130101); H05B
3/56 (20130101); Y10T 29/49098 (20150115); Y10T
29/49171 (20150115); H05B 2203/003 (20130101); Y10T
29/49083 (20150115); Y10T 29/49101 (20150115); H05B
2203/017 (20130101); Y10T 29/49085 (20150115) |
Current International
Class: |
H01C
10/46 (20060101); H01C 10/00 (20060101); H05B
3/34 (20060101); H05B 3/58 (20060101); H02K
11/00 (20060101); H05B 3/54 (20060101); H05B
3/36 (20060101); H01c 001/14 (); H01c 017/00 () |
Field of
Search: |
;29/613,612,619,621,628,610,611 ;219/523,528,529,541,544,549
;338/25,26,29,212,195,214,203,295,287,309,320 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lanham; C. W.
Assistant Examiner: DiPalma; Victor A.
Attorney, Agent or Firm: Candor, Candor & Tassone
Parent Case Text
This is a division of application Ser. No. 410,539, filed Oct. 29,
1973, now U.S. Pat. No. 3,852,570.
Claims
What is claimed is:
1. A method of making an electrical element comprising the steps of
providing a conductor having a pair of lead attaching ends, forming
each lead attaching end with a plurality of spaced and
predetermined lead attaching parts therealong, attaching a pair of
leads respectively to one preselected lead attaching part of each
end of said conductor so that a desired electrical resistance is
provided through said conductor between said leads, and completely
covering said conductor and part of said leads with an encasing
structure whereby the remainder of said leads extend from said
encasing structure.
2. A method of making an electrical element as set forth in claim 1
and including the step of initially disposing said conductor
generally in one plane in said encasing structure.
3. A method of making an electrical element as set forth in claim 2
and including the step of disposing said conductor in a tortuous
pattern between the lead attaching parts that provide the shortest
electrical circuit through said conductor between said lead
attaching ends thereof.
4. A method of making an electrical element as set forth in claim 3
and including the step of forming each lead attaching end in a
tortuous pattern between adjacent lead attaching parts thereof.
5. A method of making an electrical element as set forth in claim 4
and including the step of forming the lead attaching parts of each
lead end so that the same are disposed in aligned relation with
each other.
6. A method of making an electrical element as set forth in claim 5
and including the step of forming the lead attaching parts of said
lead ends so that the same are disposed in two rows disposed
parallel and spaced from each other.
7. A method of making an electrical element as set forth in claim 6
and including the steps of disposing said leads between said rows,
and securing outwardly turned ends of said leads to the desired
lead attaching parts.
8. A method of making an electrical element as set forth in claim 1
and including the step of forming said encasing structure from a
pair of flexible tape-like strips superimposed on each other and
securing said part of said leads and said conductor
therebetween.
9. A method of making an electrical element as set forth in claim 1
wherein said element comprises a temperature sensor.
10. A method of making an electrical element as set forth in claim
1 wherein said element comprises an electrical heating element.
Description
This invention relates to an improved electrical resistance element
and to a method of making the same.
It is well known from the U.S. Pat. No. 3,537,053, to Snoberger et
al, that a flexible temperature sensor can be provided for motor
protection purposes and be formed by a conductor that is secured
between two flexible stip-like members superimposed upon each other
with a pair of leads being attached to the respective ends of the
conductor so that the conductor will provide a certain electrical
resistance between the leads at certain temperatures whereby such
flexible temperature sensor can be utilized for motor protection
purposes by being inserted in the coil means of an electrical motor
to detect the temperature changes therein by having the changes in
the electrical resistance of the encased conductor sensed by an
appropriate sensor.
However, it has been found according to the teachings of this
invention that the precision or accuracy of the above described
temperature sensor depends upon the length of the wire between the
soldered connections of the leads thereto as well as the uniformity
of the conductor throughout its length and that measurement of the
actual resistance of such conductor during assembly of the sensor
is not feasible.
Accordingly, it is a feature of this invention to provide an
improved electrical resistance element of the above type or the
like wherein a desired electrical resistance of the conductor can
be readily ascertained during the making of such electrical
resistance element or the like.
In particular, one embodiment of the electrical resistance element
of this invention comprises a conductor having a pair of lead
attaching ends each having a plurality of spaced and predetermined
lead attaching parts therealong. A pair of leads are respectively
electrically attached to one preselected lead attaching part of
each end of the conductor so that the desired electrical resistance
is provided through the conductor between the attached leads
because a testing of the electrical resistance of the conductor
between various lead attaching parts thereof can be readily
determined before the leads are attached thereto. After the leads
have been attached to the preselected lead attaching parts of the
lead attaching ends of the conductor, an encasing structure
completely covers the conductor and the attaching parts of the
leads whereby the remainder of the leads can extend from the
encasing structure for control device attaching purposes or the
like, the encasing structure comprising a pair of flexible
tape-like strips superimposed on each other and securing the
conductor and the attaching parts of the leads therebetween.
Accordingly, it is an object of this invention to provide an
improved electrical resistance element having one or more of the
novel features set forth above or hereinafter shown or
described.
Another object of this invention is to provide an improved method
of making such an electrical resistance element or the like, the
method of this invention having one or more of the novel features
set forth above or hereinafter shown or described.
Other objects, uses and advantages of this invention are apparent
from a reading of this description, which proceeds with reference
to the accompanying drawings forming a part thereof and
wherein:
FIG. 1 is a perspective view illustrating one embodiment of the
improved electrical resistance element of this invention.
FIG. 2 is a schematic broken away, cross-sectional view of an
electrical motor utilizing the electrical resistance element of
FIG. 1 for motor protection purposes.
FIG. 3 is an exploded perspective view illustrating the various
parts of the electrical resistance element of FIG. 1.
FIG. 4 is a perspective view illustrating the method of making the
electrical resistance element of FIG. 1.
FIG. 5 is a top view of part of another electrical resistance
element of this invention.
While the various features of this invention are hereinafter
described and illustrated as being particularly adapted to provide
a temperature sensor for motor protection purposes or the like, it
is to be understood that the various features of this invention may
be utilized singly or in any combination thereof to provide an
electrical resistance element for other purposes as desired, such
as for making an electrical heating element or the like.
Therefore, this invention is not to be limited to only the
embodiments illustrated in the drawings, because the drawings are
merely utilized to illustrate one of the wide variety of uses of
this invention.
Referring now to FIGS. 1 and 3, the improved electrical resistance
element of this invention is generally indicated by the reference
numeral 10 and comprises a pair of flexible tape-like strips 11 and
12 formed of insulating material hereinafter set forth and being
superimposed upon each other to be heat sealed together by an
apparatus that is generally indicated by the reference numeral 14
in FIG. 4 and hereinafter described, the tape-like strip 12 having
printed, etched or otherwise disposed thereon a conductor 15 formed
in a predetermined tortuous path between two lead attaching ends
thereof that are generally indicated by the reference numerals 16
and 17 in FIG. 3.
The lead attaching ends 16 and 17 of the conductor 15 are each
provided with a plurality of flat rectangular lead attaching parts
18, 19 and 20, spaced from each other along the respective lead
attaching ends 16 and 17 so that the conductor 15 between each pair
of adjacent lead attaching parts 18 and 19 or 19 and 20 has a
length thereof also disposed in a tortuous path therebetween so
that resistance can be added or subtracted to the remainder of the
conductor 15 depending upon where leads are attached to the lead
attaching ends 16 and 17 thereof as will be apparent
hereinafter.
For example, it may be desired to make the electrical resistance
element 10 so that the same has a resistance of approximately 75
ohms between the desired lead attaching location thereof when the
element 10 is at approximately 75.degree.F.
Thus, before a pair of leads 21 and 22 are attached thereto, the
strip 10 with the conductor 15 thereon is maintained at
75.degree.F. and the resistance of the conductor 15 is
appropriately measured between the lead attaching parts 18 of the
lead attaching ends 16 and 17, the resistance of the conductor 15
is measured between the lead attaching parts 19 of the lead
attaching ends 16 and 17 and the resistance of the conductor 15 is
measured between the lead attaching parts 20 of the lead attaching
ends 16 and 17 to find out which combination of lead attaching
parts 18, 19 or 20 will provide a resistance closest to the desired
75 ohms. In fact, such testing or measuring could be between the
lead attaching parts 18 and 19 of the respective lead attaching
ends 16 and 17, etc., as desired.
Such testing of the resistance of the conductor 15 on the strip 12
can be made at a location remote from the apparatus 14 and the
resistance between the various lead attaching parts of the lead
attaching ends 16 and 17 could be appropriately marked on the
tape-like strip 12 so that subsequently a person can attach the
leads 21 and 22 thereto at whichever resistance producing
arrangement is desired.
In any event, it can be seen that the conductors 21 and 22 are
adapted to have the insulation 23 thereof removed adjacent the ends
24 and 25 thereof with the ends 24 and 25 respectively having
outwardly turned parts 26 so that the lead ends 24 and 25 can be
disposed between the spaced and parallel lead attaching ends 16 and
17 while the outwardly turned parts 26 thereof will respectively
contact the lead attaching parts 18, 19 or 20 as illustrated to be
readily soldered or otherwise suitably electrically attached
thereto, the lead attaching parts 18, 19 and 20 being substantially
large rectangularly shaped conductor sections printed, etched or
otherwise disposed on the tape-like member 12 as illustrated to
facilitate lead attachment thereto.
After the lead ends 24 and 25 have been attached to the desired
lead attaching parts 18, 19 or 20, or any desired combination of
the parts 18, 19 and 20, of the conductor 15, which in the
embodiment illustrated in the drawings are the lead attaching parts
19 of the lead attaching ends 16 and 17 in the manner illustrated
in FIG. 3, the strip 11 can be superimposed thereon and be heat
sealed thereto by the apparatus 14 whereby the conductor 15 and the
end parts 24 and 25 of the leads 21 and 22 are completely covered
or encased in the flexible strips 11 and 12 in the manner
illustrated in FIG. 1 to complete the electrical resistance element
of this invention. Thus, it can be seen that the actual resistance
of the conductor 15 between the lead attaching parts 26 of the
leads 21 and 22 has been accurately provided as the resistance
between the lead attaching parts 19 of the lead attaching ends 16
and 17 of the conductor 15 was readily predetermined in the manner
previously described so that the electrical resistance element 10
will be most accurate for its intended purpose.
For example, the completed electrical resistance element 10 is
adapted to be readily disposed between various coils 27 and 28 of
the coil means 29 of an electrical motor means 30 as illustrated in
FIG. 2 and be interconnected by the leads 21 and 22 thereof to a
control device 31 which will sense the change in the resistance of
the conductor 15 as the motor 30 heats up so that should the
temperature of the motor 30 exceed a certain limit, the sensor 31
can turn off the motor 30 to avoid an adverse situation whereby it
can be seen that the element 10 of this invention can be utilized
for motor protection purposes.
For further details of the use of the element 10 for motor
protection purposes and the various advantages thereof over other
known types of motor protection temperature sensing means, see the
aforementioned U.S. Pat. No. 3,537,053, to Snoberger et al, which
is incorporated in this application by reference.
As previously stated, the tape-like strips 11 and 12 are formed
from non-conductive material and can each comprise a polyimide
resulting from the polycondensation reaction between pyromellitic
dianhydride and an aromatic diamine sold by the E. I. DuPont de
Nemours & Company, Inc., of Wilmington, Delaware, under the
trade name of "Kapton." The heat sealing facing surfaces of the
strips 12 and 11 can be coated with a copolymer of
tetrafluoroethylene and a hexafluoropropylene sold under the
trademark of "Fep-Teflon" by E. I. duPont de Nemours & Company,
Inc., of Wilmington, Delaware.
In this manner, when the teflon coated sides of the strips 11 and
12 are brought together in the manner illustrated in FIG. 4 and
heated by heat sealing elements 32 and 33, the facing sides of the
strips 11 and 12 are completely heat sealed together in the manner
fully set forth in the aforementioned U.S. Pat. No. 3,537,053, to
Snoberger et al.
While one particular tortuous pattent of the conductor 15 of the
element 10 of this invention is provided in FIGS. 1 and 3, it is to
be understood that various other patterns of the conductor 15 can
be utilized and another such arrangement is illustrated in FIG. 5
wherein a flexible strip 34 has a conductor 35 printed, etched or
otherwise disposed thereon in a tortuous pattern and having lead
attaching ends 36 and 37 respectively provided with spaced lead
attaching parts 38, 39 and 40 therealong for subsequently having
leads attached thereto and be covered by a superimposed strip in
the same manner as the strip 12 previously described.
However, it can readily be seen in FIG. 5 that the particular
tortuous pattern of the conductor 35 between adjacent lead
attaching parts 38 and 39 or 39 and 40 of the respective lead
attaching ends 36 and 37 places a greater amount of the trim
resistors in what would be considered the sensing area of the strip
34 than might be the case with the areas disposed between the
attaching parts of the conductor 15 previously described.
Therefore, it can be seen that this invention not only provides an
improved electrical resistance element, but also this invention
provides an improved method of making such an electrical resistance
element or the like.
While the form and method of this invention now preferred have been
illustrated and described as required by the Patent Statute, it is
to be understood that other forms and methods can be utilized and
still come within the scope of the appended claims.
* * * * *