Abstract: A simplified method of manufacturing an electrothermal fuse includes the steps of screening conductive epoxy onto fuse link termination pads, placing a metal alloy fuse link into the conductive epoxy on the termination pads, curing the conductive epoxy, applying deoxidant, applying encapsulant, and curing the encapsulant. The resultant fuse of the preferred embodiment comprises a substrate, termination pads, conductive epoxy interconnects, a solder type fuse link, liquid deoxidant and encapsulant.

Abstract: A position sensor is nested into a cup-shaped portion of a molded pedal. The pedal directly drives the position sensor rotor, but the sensor is fully self contained and environmentally sealed. By nesting the sensor within the pedal, assembly is simplified and alignment of components is easily ensured. Additionally, the pedal still retains sufficient width to be designed to have adequate strength. The pedal structure may then be assembled easily and with few pieces, while still ensuring the proper functioning and internal alignment of the sensor.

Abstract: Method for storing foam covers and for installing foam covers on clothes hangers, and apparatus to perform the method. A supply of foam covers are loaded on an insert spindle. The insert spindle is suspendable, and is formed to receive therein the hook of a clothes hanger. The insert spindle may further define a spreader to assist in spreading the slot of a foam cover over the hook of the clothes hanger. After suspending the insert spindle having at least one foam cover installed thereon, the operator inserts the hook of a clothes hanger into a hanger pocket formed at a lower end of the insert spindle. To install the cover onto the hanger the operator, by grasping the foam cover at either end thereof with the thumb and forefinger of each hand, and pulling the cover with a downward and outward motion, will cause the foam cover to slide down the insert spindle over the hook and onto the clothes hanger.

Abstract: A press-fit or compliant section or deformable pin electrical connector. The connector is designed to be inserted into several plated through holes in printed circuit boards. Specifically, the pin connector can electrically and mechanically connect two or more printed circuit boards (PCBs). Uniquely, it is possible to have a single pin that is both electrically and mechanically connected to two PCBs and have the pin extending through a plated through hole of a third PCB without establishing any electrical or mechanical contact with the third PCB. Additionally, the pin has at least two compliant sections for press fitting into a plated through-hole in a PCB or the like. Each compliant section has a different size diameter. Specifically, the top compliant section is the smallest, the bottom compliant section is the largest in diameter, and the remaining compliant sections will gradually increase in size as they are located from the tip to the base of the pin.

Abstract: A rotary position sensor connected to the butterfly valve of an internal combustion engine, the sensor having a dual magnet structure interconnected by a pole piece having a generally C-shaped cross section forming a varying dimension air gap. The magnets, the pole piece and the air gap define a closed magnetic circuit. A Hall effect sensor is fixedly mounted in the air gap and is exposed to a well defined but varying magnetic field. Through the use of specific magnetic materials and sloping, curved surfaces, a precise yet tolerance friendly magnetic circuit is produced so that the sensor produces signals as a function of the angular positions of the magnets.

Abstract: A surge resistor has a thick film resistance element containing alloyed nickel-chromium mixed with alloyed copper-nickel and less than twenty percent by weight glass. The surge resistor overcomes the limitations of the prior art by offering the unexpected advantage of improved power surge handling capacity. A thick film composition used to form the surge resistor, which also includes screening agent, is fired at temperatures generally below 1,000.degree. C., yielding a highly stable and well adhered electrical resistor. In addition to improved surge capability, the composition offers lower cost and less migration than the precious metal alternatives that the composition replaces. Additional inventive surge resistors include copper-manganese and nickel-chromium in combination with less than twenty percent by weight glass.

Abstract: A position sensor has a shaped dual magnet structure carried upon a pole piece having a generally "c" shaped cross-section. The magnet and pole piece define a generally circular linear field which is concentric about the axis of rotation of the complete rotor. A Hall effect device is inserted into the open portion or gap between the two magnets and is exposed to a well defined field. Through the use of selected geometries and particular magnet materials, a precise, compact and yet tolerant magnetic circuit is produced.

Abstract: Solder active braze compositions are disclosed which enable the formation of circuit traces having improved leach resistance during soldering operations so that it is not necessary to apply protective coatings onto the circuit traces. Additionally, the solder active braze compositions disclosed herein can be readily soldered to so that it is not necessary to separately apply a coating onto the circuit trace so that electrical connections can be made to the traces by soldering. Also disclosed are electronic assemblies comprising circuit traces formed from the particular solder active braze compositions, and methods of forming such electronic assemblies.

Abstract: A voltage follower is incorporated within a molded electrical connector interface of a position sensor in a way that does not detract from the dimensions or the performance of the finished sensor. The incorporation of the voltage follower into the housing of the variable resistor provides several advantages over the prior art, including: an immunity to sag; substantially reduced sensitivity to noisy contactors; and short lead length and low output impedance, both of which result in reduced interference from external source.

Abstract: Base metal resistors based on a new approach to alloy formation of nickel and chromium metals are presented that are rugged and offer excellent stability. Fine particle size nickel and chromium powders together with fluxing agents are blended together in a preselected ratio with a glass fret and screening agent. The composition is subsequently printed and fired in a nitrogen furnace at approximately 900.degree. C. to 930.degree. C. These resistors are compatible with other prior art base metal conductors, resistors and dielectrics.

Abstract: The rotor of a rotary position sensor mounts directly upon the rotary shaft to be sensed. The rotor prior to installation is retained in position by a pair of small protrusions extending from the rotor that cooperatively engage a pair of small indentations formed in a pair of supporting arms. During the installation process, the rotor is slipped onto the shaft and the protrusions are released from the engaged position. During operation of the position sensor, the rotor is free from direct contact with either the supporting arms or any other stationary part of the position sensor. Only the contractors engage the stationary components. This design eliminates the need for bearings and return springs prevalent in the prior art.

Abstract: A resistor network is disclosed which is suited for surface mount which does not incorporate wire terminations. The network is fabricated entirely from cermet, ceramic, and solder, yet will absorb thermal stresses normally associated with circuitry energization when properly mounted upon a substrate. This is accomplished by controlling the formation of solder bumps and simultaneously controlling the mounted distance between those bumps and a wiring substrate upon which the network is mounted. Additionally, the network may be formed to be either a SIP or DIP configuration, depending upon whether an additional groove is incorporated into the termination side of the substrate. Two alternative embodiments are also disclosed which incorporate various features of the invention.

Abstract: A glass frit for firing in reducing environments includes an unusually large amount of calcium fluoride melted therein. Also, a copper conductive composition includes the glass frit with an unusually large amount of calcium fluoride. This copper conductive composition may be a paste prepared for screen printing, in which case an appropriate screening agent known to one of ordinary skill may be incorporated, or the composition may be a fired film formed upon a suitable substrate. A high power surge resistor also incorporates the glass frit.

Abstract: Hermetically sealed chip packages are described which are capable of withstanding elevated temperatures and accompanying temperature fluctuations. The chip packages feature electrically conductive, hermetic vias which provide electrical pathways through generally dielectric ceramic substrates employed in the chip package. Methods of forming such hermetic vias are also disclosed.

Abstract: A linear permanent magnet position sensor is produced by a novel permanent magnet demagnetization process. Demagnetization field strength is controlled to demagnetize a thinner portion of the permanent magnet less than, equally, or greater than a thicker portion of the same permanent magnet. Linearity and stability are both tailored through a single demagnetization step.

Abstract: A low cost, highly sensitive tactile pointing device includes a planar substrate, an insulating spacer about a periphery of the substrate, and a planar cover. The cover in an active area carries an electrically conductive film designed to contact a conductive film carried upon an active area of the substrate. An insulating spacer and conductive dot are also located at some point within the active area to form a non-contacting rest area. Appropriate forces applied in a direction normal to the plane of the substrate or cover cause deflection, leading to contact between the cover and the substrate. The point of contact identifies intent, direction and magnitude.

Abstract: A rotor for use in a rotary position sensor includes an opening designed to receive a shaft having a flat. The rotor has a wedge within the opening designed to engage the shaft firmly but minimize insertion forces. Several troughs running parallel to the shaft and adjacent to the wedge aid in retention by adding a controlled amount of resilience to the rotor. On a shaft receiving end of the rotor there is an additional taper to help with coaxial alignment of the rotor opening and the shaft. On the shaft exiting end there is a half-moon like configuration designed to provide a force opposing surface during shaft insertion while not adversely impacting either the full insertion of the shaft or potential drag between the rotor and the sensor housing. The rotor is designed to offer unique advantage in insertion force to install the rotor on the shaft, while retention force and potential drag against the position sensor housing are minimized.

Abstract: The rotor of a rotary position sensor mounts directly upon the rotary shaft to be sensed. The rotor prior to installation is retained in position by a pair of small protrusions extending from the rotor that cooperatively engage a pair of small indentations formed in a pair of supporting arms. During the installation process, the rotor is slipped onto the shaft and the protrusions are released from the engaged position. During operation of the position sensor, the rotor is free from direct contact with either the supporting arms or any other stationary part of the position sensor. Only the contactors engage the stationary components. This design eliminates the need for bearings and return springs prevalent in the prior art.

Abstract: Base metal resistors based on a new approach to alloy formation of nickel and chromium metals are presented that are rugged and offer excellent stability. Fine particle size nickel and chromium powders together with fluxing agents are blended together in a preselected ratio with a glass frit and screening agent. The composition is subsequently printed and fired in a nitrogen furnace at approximately 900.degree. C. to 930.degree. C. These resistors are compatible with other prior art base metal conductors, resistors and dielectrics.

Abstract: A package is disclosed that incorporates recessed test vias into a circuit substrate. The test vias are preferably formed at the time of substrate manufacture with little additional cost and offer access to electrical test points after hermetic sealing of the package without competing for lead sites on an otherwise crowded package exterior. The vias are preferably recessed below the surface of the substrate and may be backfilled with insulation to prevent unintended contact. Alternatively, the vias may be incorporated into the side of a package used for mounting to a motherboard, in which case the vias will be sealed at the time of package mounting. In still another instances, the vias may be left accessible or filled with a material that is easily removed for later test and service.