Abstract: A surface mount circuit protection device includes a laminar PTC resistive element having first and second major surfaces and a thickness therebetween. A first electrode layer substantially coextensive the first surface is formed of a first metal material of a type adapted to be soldered to a printed circuit substrate. A second electrode layer formed at the second major surface includes structure forming or defining a weld plate. The metal weld plate has a thermal mass and thickness capable of withstanding resistance micro spot welding of a strap interconnect without significant resultant damage to the device. The device is preferably surface mounted to a printed circuit board assembly forming a battery protection circuit connected to a battery/cell by battery strap interconnects, wherein one of the battery strap interconnects is micro spot welded to the weld plate of the device.

Abstract: A surface mount circuit protection device includes a laminar PTC resistive element having first and second major surfaces and a thickness therebetween. A first electrode layer substantially coextensive the first surface is formed of a first metal material of a type adapted to be soldered to a printed circuit substrate. A second electrode layer formed at the second major surface includes structure forming or defining a weld plate. The metal weld plate has a thermal mass and thickness capable of withstanding resistance micro spot welding of a strap interconnect without significant resultant damage to the device. The device is preferably surface mounted to a printed circuit board assembly forming a battery protection circuit connected to a battery/cell by battery strap interconnects, wherein one of the battery strap interconnects is micro spot welded to the weld plate of the device.

Abstract: A surface mount circuit protection device includes a laminar PTC resistive element having first and second major surfaces and a thickness therebetween. A first electrode layer substantially coextensive the first surface is formed of a first metal material of a type adapted to be soldered to a printed circuit substrate. A second electrode layer formed at the second major surface includes structure forming or defining a weld plate. The metal weld plate has a thermal mass and thickness capable of withstanding resistance micro spot welding of a strap interconnect without significant resultant damage to the device. The device is preferably surface mounted to a printed circuit board assembly forming a battery protection circuit connected to a battery/cell by battery strap interconnects, wherein one of the battery strap interconnects is micro spot welded to the weld plate of the device.

Abstract: A foamable copolymer based coupling is provided for securely affixing a light emitting glass lamp in a metal base to form a lamp assembly. The copolymer is preferably selected from ethylene vinyl acetate, ethylene methyl acrylate, and combinations thereof. The foamable coupling may be placed around one end of the glass lamp or in the lamp base before the lamp and base are matingly engaged. The assembled lamp is then heated to a temperature, which causes the foamable coupling to expand and securely affix the lamp in the base.

Abstract: A foamable copolymer based coupling is provided for securely affixing a light emitting glass lamp in a metal base to form a lamp assembly. The copolymer is preferably selected from ethylene vinyl acetate, ethylene methyl acrylate, and combinations thereof. The foamable coupling may be placed around one end of the glass lamp or in the lamp base before the lamp and base are matingly engaged. The assembled lamp is then heated to a temperature, which causes the foamable coupling to expand and securely affix the lamp in the base.

Abstract: A process for manufacturing a composite polymeric circuit protection device in which a polymeric assembly is provided and is then subdivided into individual devices (2). The assembly is made by providing first and second laminates (7,8), each of which includes a laminar polymer element having at least one conductive surface, providing a pattern on at least one of the conductive surfaces on one laminate, securing the laminates in a stack (1) in a desired configuration, at least one conductive surface of at least one of the laminates forming an external conductive surface (3) of the stack, and making a plurality of electrical connections (31,51) between a conductive surface of the first laminate and a conductive surface of the second laminate. The laminar polymer elements may be PTC conductive polymer compositions, so that the individual devices made by the process exhibit PTC behavior. Additional electrical components may be attached directly to the surface of the device or assembly.

Abstract: A foamable copolymer based coupling is provided for securely affixing a light emitting glass lamp in a metal base to form a lamp assembly. The copolymer is preferably selected from ethylene vinyl acetate, ethylene methyl acrylate, and combinations thereof. The foamable coupling may be placed around one end of the glass lamp or in the lamp base before the lamp and base are matingly engaged. The assembled lamp is then heated to a temperature, which causes the foamable coupling to expand and securely affix the lamp in the base.

Abstract: A foamable copolymer based coupling is provided for securely affixing a light emitting glass lamp in a metal base to form a lamp assembly. The copolymer is preferably selected from ethylene vinyl acetate, ethylene methyl acrylate, and combinations thereof. The foamable coupling may be placed around one end of the glass lamp or in the lamp base before the lamp and base are matingly engaged. The assembled lamp is then heated to a temperature, which causes the foamable coupling to expand and securely affix the lamp in the base.

Abstract: An electrical resistive device in which an element composed of a conductive polymer is positioned in contact with the surface layer of one or more metal electrodes. The metal electrode contains a base layer which includes a first metal, an intermediate metal layer which includes a metal that is different from the first metal, and a surface layer which (i) includes a second metal, (ii) has a center line average roughness {overscore (Ra)} of at least 1.3, and (iii) has a reflection density Rd of at least 0.60. The conductive polymer composition preferably exhibits PTC behavior density requirements, which may be, for example, circuit protection devices or heaters, have improved thermal and electrical performance over devices prepared with electrodes which do not meet the center line average roughness and reflection density requirements.

Abstract: A foamable copolymer based coupling is provided for securely affixing a light emitting glass lamp in a metal base to form a lamp assembly. The copolymer is preferably selected from ethylene vinyl acetate, ethylene methyl acrylate, and combinations thereof. The foamable coupling may be placed around one end of the glass lamp or in the lamp base before the lamp and base are matingly engaged. The assembled lamp is then heated to a temperature, which causes the foamable coupling to expand and securely affix the lamp in the base.

Abstract: A sealable enclosure including a base and a cover attachable to the base, the base and cover have respective mating surfaces, wherein the base and cover form a chamber there between when the cover is attached to the base. A compliant gel sealant is disposed on the mating surface of one of the base and cover for environmentally sealing the chamber, with a visual indicator provided for determining that the chamber is sealed. In one preferred embodiment, the visual indicator comprises a non-opaque window formed in the cover, and a non-opaque tongue extending from the mating surface of the cover, the tongue aligned with the window such that a line of sight is provided through the respective window and tongue.

Abstract: A process for manufacturing a composite polymeric circuit protection device in which a polymeric assembly is provided and is then subdivided into individual devices (2). The assembly is made by providing first and second laminates (7,8), each of which includes a laminar polymer element having at least one conductive surface, providing a pattern on at least one of the conductive surfaces on one laminate, securing the laminates in a stack (1) in a desired configuration, at least one conductive surface of at least one of the laminates forming an external conductive surface (3) of the stack, and making a plurality of electrical connections (31,51) between a conductive surface of the first laminate and a conductive surface of the second laminate. The laminar polymer elements may be PTC conductive polymer compositions, so that the individual devices made by the process exhibit PTC behavior. Additional electrical components may be attached directly to the surface of the device or assembly.

Abstract: A bi-layer covering sheath has a foamable polymeric inner layer, and a non-foamable non-heat-shrinkable polymeric outer layer surrounding and in intimate contact with the inner layer; the outer layer having a melting point that is at least 60° above the melting point of the inner layer, and the thickness and mechanical strength of the outer layer being such that the sheath retains substantially constant outer dimensions at a temperature sufficient to cause foaming of the inner layer. These sheaths are tubes for covering, generally, elongated substrates such as tubes, rods, wires, and cables, especially tubes, and caps for covering an end of such substrates.

Abstract: Applicants have created an improved device and method for protecting from the elements wires which have a portion of their electrically insulative covering stripped off, such as spliced wires, and particularly stub-spliced wires. The device comprises (a) a dimensionally-recoverable tubing, (b) a layer of sealant (which preferably also acts as an adhesive) applied to at least a portion of the interior surface of the tubing, and (c) a cap or sheath into which at least a portion of the exposed wires are inserted, wherein at least a portion of the cap or sheath is positioned interior to the dimensionally-recoverable tubing. The cap or sheath includes a configured interior shape for holding the inserted wires, and is designed to permit the adhesive/sealant to flow around the inserted wires. The cap or sheath typically forms a closure at one end of the dimensionally-recoverable tubing or is positioned at or adjacent to a closure end of the tubing.

Abstract: An electrical device (1) in which an element (7) composed of a conductive polymer is positioned in contact with the surface layer of one or more metal electrodes (3,5). The metal electrode contains a base layer (9) which comprises a first metal, an intermediate metal layer (15) which comprises a metal that is different from the first metal, and a surface layer (17) which (i) comprises a second metal, (ii) has a center line average roughness R.sub.a of at least 1.3, and (iii) has a reflection density R.sub.d of at least 0.60. The conductive polymer composition preferably exhibits PTC behavior. The electrical devices, which may be, for example, circuit protection devices or heaters, have improved thermal and electrical performance over devices prepared with electrodes which do not meet the center line average roughness and reflection density requirements.

Abstract: A PTC device suitable for attachment to a terminal of a battery. The device contains a PTC component which has a shape with an outer periphery and an inner periphery which defines a first opening in the center of the PTC component. The PTC component is made from a laminar PTC resistive element which is composed of a PTC conductive polymer composition, a first laminar electrode which is attached to a first face of the resistive element, and a second laminar electrode which is attached to a second opposite face of the resistive element. Also part of the device are a first conductive lead which has a first part which is attached to the first electrode, and a second part which extends into the first opening, and a second conductive lead.

Abstract: A circuit protection device for protecting batteries is formed from a resistive element composed of a PTC conductive polymer composition and two electrodes. The device has a resistive element thickness of 0.025 to 0.20 mm; a crosslinking level equivalent to 1 to 20 Mrads; a surface area of at most 120 mm.sup.2 ; a resistance at 20.degree. C., R.sub.20, of at most 0.030 ohm; and a resistivity at 20.degree. C., .rho..sub.20, of at most 2.0 ohm-cm. Devices of the invention are sufficiently small to be easily inserted into an assembly comprising a battery, particularly a rechargeable battery, and the device. Such assemblies are used for powering portable electronic equipment such as cellular telephones.

Abstract: A conductive polymer composition containing a particulate conductive filler dispersed in a polymeric component. The polymeric component comprises a first polymer which (i) is present in an amount 25 to 75% by weight of the total polymeric component, and (ii) is polyethylene, and a second polymer which (i) is present in an amount 25 to 75% by weight of the total polymeric component, and (ii) comprises units derived from a first monomer which is ethylene and a second monomer which is an alkyl acrylate having the formula --CH.sub.2 .dbd.CHCOOC.sub.m H.sub.2m+1 --, where m is at least 4. The resulting composition is useful in preparing electrical devices, e.g. circuit protection devices, which have lower resistivities, higher PTC anomalies, and better thermal and electrical stability than devices comprising conventional conductive polymer compositions.

Abstract: A conductive polymer composition containing a particulate conductive filler dispersed in a polymeric component. The polymeric component comprises a first polymer which (i) is present in an amount 25 to 75% by weight of the total polymeric component, and (ii) is polyethylene, and a second polymer which (i) is present in an amount 25 to 75% by weight of the total polymeric component, and (ii) comprises units derived from a first monomer which is ethylene and a second monomer which is an alkyl acrylate having the formula --CH.sub.2 .dbd.CHCOOC.sub.m H.sub.2m+1, where m is at least 4. The resulting composition is useful in preparing electrical devices, e.g. circuit protection devices, which have lower resistivities, higher PTC anomalies, and better thermal and electrical stability than devices comprising conventional conductive polymer compositions.