Abstract: A switching element for a rotary or linear encoder which generates pulse signals indicative of rotary or linear position, and direction and rate of change of such position. The invention is characterized by use of a patterned and cured solder-mask material which defines insulated or nonconductive surfaces, with a pattern of conductive wiper-contacting segments therebetween. The invention enables fast and economical fabrication as compared to known encoder switching elements.

Abstract: A potentiometer and logic circuitry attached to a common substrate. In one aspect the potentiometer and logic circuitry is an integrated potentiometer mounted on an upper surface of a circuit board with circuitry on a lower surface of the circuit board. The circuitry conducts the position and movement of the potentiometer into potentiometer output signals.

Abstract: A one part, several-months-useful-shelf-life epoxy material suitable for potting and sealing electronic components, and which is compatible with the high, approximately 255° C. to 275° C. temperatures required for soldering modem lead-free solders comprises an intimate mixture of the following components: approximately 2 to 13 per cent by weight of diglycidyl ether bisphenol A resin; approximately 40 to 70% phenol formaldehyde resin and the following further components [(2-methylphenoxy)methyl]-oxirane or o-cresol glycidyl ether) 0.5-8% by weight; polypropyleneglycol-glycidyl ether resin (plasticizer) 2-10% by weight; cycloaliphatic polyamine (catalyst) 4-15% by weight; kaolin clay (filler) 2-20% by weight; magnesium alumino silicate (filler) 2-15% by weight; Sb2O3 (filler) 4-5% by weight, and hydrated Al2O3 (filler) 0-15% by weight.

Abstract: A variable resistive element for use in a sensing unit for measuring liquid level in a container, through interaction with a sliding electrical contact operating in conjunction with a float, includes a conductor pattern deposited on a substrate. A region of resistive material is also deposited on the substrate and makes electrical contact with the conductive pattern. A region of the conductor pattern functions as a contact area for the sliding electrical contact. This region is coated with a plating material, for example nickel or a nickel alloy. The use of the plating reduces the requirements for expensive metals in the conductor pattern. The variable resistive element is particularly suited for use in a fuel level sensor.

Abstract: An integrated digital electronic encoder that converts mechanical movement of a device input into a signal that can be applied to particular purposes is described. The encoder and associated signal conditioning and processing circuitry are embedded together as a single unit for simplicity of assembly into particular applications, and reliability. The integrated digital electronic encoder includes a substrate with first and second substantially opposed major surfaces, and a digital encoder formed on the first major surface of the substrate. The encoder comprises an actuation shaft, and the encoder is configured to generate electrical signals in response to movement of the actuation shaft. Electronic circuitry is attached to the second major surface of the substrate, preferably using surface mount technology. The electronic circuitry is electrically connected with the digital encoder to process the signals produced by the encoder.

Abstract: An electronic device includes a first conductive polymer layer sandwiched between a first external metal foil electrode and a first internal metal foil electrode, a second conductive polymer layer sandwiched between a second internal metal foil electrode and a second external metal foil electrode, a layer of fiber-reinforced epoxy resin bonding the first and second internal electrodes together, a first terminal providing electrical contact between the first internal electrode and the second external electrode, and a second terminal providing electrical contact between the second internal electrode and the first external electrode. In a preferred embodiment, the polymer layers exhibit PTC behavior, and the terminals are formed by a solder layer applied over a plated layer of conductive metal. Insulative layers are preferably provided on the external electrodes, and located so as to insulate the first and second terminals from each other.

Abstract: A surface mount conductive polymer device includes a layer of conductive polymer material laminated between first and second metal foil electrodes. A thermal stress relief area is formed as an etched-out area in each of the electrodes. The etched-out areas are equal in surface area, and they are symmetrically disposed on the two electrodes, so that the two electrodes are themselves symmetrical, and are subject to equal degrees of thermal stress relief. First and second opposed end terminals are formed on the opposed ends of the laminated structure to providing electrical connection to the first and second electrodes, respectively.

Abstract: A surge protector assembly may be provided with three terminals, a gas discharge tube having a first conductive end and a second conductive end opposite the first conductive end, a pair of metal oxide varistors conductively connected to the ends of the gas discharge tube, and a pair of bracket arms associated with the ends of the gas discharge tube. The bracket arms are movable between a steady-state position in which they cause the first and second terminals to be conductively separated from the third terminal and a shorting position in which they cause the first and second terminals to be conductively connected to the third terminal. The bracket arms are spaced from the ends of the gas discharge tube by a first distance when they are in their steady-state positions and by a second distance when they are in their shorting positions, with the first distance being greater than the second distance, and the bracket arms are spring-biased towards their shorting positions.

Abstract: A junction box includes an array of conductive polymer positive temperature coefficient (PTC) devices formed from a laminate of a layer of conductive polymer PTC material between first and second metal foil layers. The first foil layer is divided, by conventional masking and etching techniques, into an array of discrete positive electrodes, each of which defines a single PTC over-current protection device having a predetermined trip current. The second foil layer is maintained intact and is shared by the PTC devices in the array as a common ground electrode. Each discrete positive electrode is contacted by a conductive spring contact finger. Two or more contact fingers can be formed as parts of single contact element or otherwise connected together to connect two or more devices in parallel, thereby providing a higher trip current than is provided by a single device.

Abstract: A switching element, specifically an encoder element, is fabricated by forming a conductive track on an insulative substrate, and then screen printing an insulative layer on the track in a predetermined pattern that forms a contact array that comprises a plurality of conductive contacts separated by nonconductive areas. The substrate may be a polymeric resin, and the track comprises (a) a copper base layer formed on a surface of the substrate in the configuration of the track, (b) a first metal-plated layer, preferably of nickel, on the base layer, and (c) a second metal-plated layer, preferably of gold, on the first metal-plated layer. The insulative layer is formed of a thick film dielectric material comprising a difunctional monomer (e.g., diallyl isophthalate), a glycol ether ester (e.g., ethylene glycol monobutyl ether acetate), an inorganic filler (e.g., BaSO4), and an acetate surface modifier (e.g., an ethyl acrylate/ethylhexylacrylate copolymer).

Abstract: An inductive component includes a substrate on the surface of which is a lower insulation layer having a shallow concavity or trench, a first plurality of conductive elements formed in the trench, a magnetic core formed over the first plurality of conductive elements, and a second plurality of conductive elements formed over the core. The first and second pluralities of conductive elements are connected to each other so as to form an inductive coil around the core. First and second core insulation layers are disposed between the core and the first and second pluralities of conductive elements, respectively. The component is fabricated by a method in which it is built up in the trench using thin film techniques. A first array of conductors is patterned over the lower insulation layer, and a first core insulation layer is applied over the first conductor array. A magnetic core is formed on top of the first core insulation layer, and a second core insulation layer is applied over the core.

Abstract: An electronic device has three conductive polymer layers sandwiched between two external electrodes and two internal electrodes. The electrodes are staggered to create a first set of electrodes, in contact with a first terminal, alternating with a second set of electrodes in contact with a second terminal.

Abstract: An electronic device includes two or more conductive polymer layers sandwiched between two external electrodes and one or more internal electrodes.

Abstract: Positive temperature coefficient polymer (PTC) materials of high loading with uniformly distributed electrically conductive material are manufactured by first producing an intimate mixture (pre-mix or master batch) of a crystalline polymer (e. g. high density polyethylene) with an electrically conductive filler (e. g. carbon black) in proportions that is less rich in the filler than the final PTC product. The intimate mixture, pre-mix or master batch, is utilized in a subsequent step in a molten liquid form for admixing with more filler material in quantities to produce the desired loading of the filler in the polymer matrix. The resulting the admixture is extruded, shaped and formed by conventional equipment to provide a positive temperature coefficient polymer composition that, when equipped with electrodes, is suitable for forming positive temperature coefficient circuit protecting devices.

Abstract: A conductive polymer device has three or more conductive polymer layers sandwiched between two external electrodes and two or more internal electrodes. The electrodes are staggered to create a first set of electrodes, in contact with a first terminal, alternating with a second set of electrodes in contact with a second terminal.

Abstract: A battery protection device includes an upper foil electrode laminated to the upper surface of a conductive polymer PTC layer, and a lower foil electrode laminated to the lower surface of the PTC layer. An isolated portion of the lower electrode is formed by creating an annular isolation gap in the lower electrode. A first via is formed through the upper electrode, the PTC layer, and the isolated portion of the lower electrode. The diameter of the first via is smaller than the diameter of the isolated electrode portion, so that an annular area of the isolated electrode portion is left between the opening and the isolation gap. The internal wall surface of the first via and the annular electrode area are plated with a conductive metallization layer, which forms a first contact seat that is conductively connected by the metallized surface of the first via with the upper electrode. A first contact element is fixed to the first contact seat.

Abstract: A multi-layered printed circuit board having a plurality of burried passive elements and a method for producing the circuit board wherein the passive elements can include resistors, capacitors and inductors. The method includes the steps of manufacturing individual layers of the multi-layer printed circuit board with electrical circuits thereon and subsequently screening polymer inks having resistive, dielectric or magnetic values to form the resistors, capacitors and inductors. Each layer of the circuit board is cured to dry the polymer ink and thereafter the individual layers are bonded together to form the multi-layer board.

Abstract: A passive component integrated circuit chip formed on an insulative substrate includes a first conductive metallic layer on a major surface of the substrate; a layer of dielectric material on top of the first conductive metallic layer; a second conductive metallic layer on top of the formation of dielectric material; a layer of insulative material on top of the layer of dielectric material and on and around the second conductive metallic layer, but not completely covering the second conductive metallic layer; a conductive via in contact with a portion of the second conductive metallic layer left uncovered by the layer of insulative material; a resistive layer on top of the layer of insulative material and in contact with the conductive via; a conductive contact in contact with the resistive layer; and a passivation layer on top of the resistive layer so as to provide a seal between the resistive layer and the conductive contact.

Abstract: A surge r or network comprises a substrate layer having a first thick film resistive element, a dielectric layer covering the first thick film resistive element and a second thick film resistive element applied to the dielectric layer. The dielectric layer has a pair of vias that extend therethrough so that the first resistive element is electrically connected to the second resistive element through the vias. A pair of electrical terminals are coupled to the first resistive layer at the substrate. The first resistive element comprises a first pair of unconnected adjacent tracks that each spiral respectively inward in a serpentine pattern. Each one of the tracks has an electrical pad disposed at a first end thereof for attachment to respective ones of the pair of electrical terminals. A second end of the tracks is disposed at a center of each serpentine pattern. The second resistive element comprises a second pair of adjacent tracks that each spiral respectively outward in a serpentine pattern.

Abstract: A method and apparatus to convert absolute angular or linear position to digital information utilizes a ternary coding scheme. The code is arranged along a single track. Sensors placed at essentially equal intervals distinguish three states per position. The sensor outputs are converted from ternary to binary data by combinatorial logic. The sensors may be mechanical contacts, optical detectors, magnetic detectors, or capacitive detectors. Such an encoder may be used as a potentiometer, multiposition switch replacement, shaft encoder, or length measurement device.