Abstract: A method for producing a rotary on-off switch in which a contactor plate is formed from sheet metal stock, integrally molded with a switch housing and thereafter blanked from the sheet metal stock. The switch housing has an integral set of circumferentially spaced abutments at regular intervals in an internal socket opening of the housing. A first switch operating member having a stem and a plurality of crowned teeth is internally mounted in the housing. A second switch operating member also has a set of crowned teeth disposed complementary to those on the first switch operating member, and also is disposed in the housing so that upon coaxial movement of the two operating members the second switch operating member will be caused to rotate abruptly after the second switch operating member has been displaced axially sufficiently to disengage the second switch operating member from the abutments in the housing.

Abstract: A method for producing a rotary on-off switch in which a contactor plate is formed from sheet metal stock, integrally molded with a switch housing and thereafter blanked from the sheet metal stock. The switch housing has an integral set of circumferentially spaced abutments at regular intervals in an internal socket opening of the housing. A first switch operating member having a stem and a plurality of crowned teeth is internally mounted in the housing. A second switch operating member also has a set of crowned teeth disposed complementary to those on the first switch operating member, and also is disposed in the housing so that upon coaxial movement of the two operating members the second switch operating member will be caused to rotate abruptly after the second switch operating member has been displaced axially sufficiently to disengage the second switch operating member from the abutments in the housing.

Abstract: A variable resistance control includes a metallic structure plate that functions as a heat sink and that provides both a collector and terminals, a body that is molded onto the structure plate, a resistance element that is deposited onto the body and onto portions of the terminals, a contactor, and a driver. In one embodiment, additional miniaturization is made possible by bending a tab portion of the structure plate between two of the terminals to form a stop lug for limiting rotational movement of the driver.

Abstract: A variable resistance slide control includes a housing having a front wall and having a side wall that is integral therewith. A dielectric base having a resistance element and a collector member mounted thereon is secured to the housing in spaced parallel relationship to the side wall. A contactor member engaging the resistance element and collector member is constrained to move with a slider that includes a handle portion projecting outwardly of the housing through an elongated slot which is defined by the front wall and the base. The slider includes a slider block portion with a guide groove therein interfitting with a longitudinal rail that is integral with the dielectric base, and the slider block portion slidably engages an inner surface of the side wall. A second rail is integral with the dielectric base and includes a guide surface that is slidably engageable with the slider block portion.

Abstract: An electrical control is provided with an insulated shaft extension. The insulated shaft extension is attached to a metal shaft rotatably supported in a bushing attached to the housing of the control. A hollow shaft portion of the insulated shaft extension is in concentric relationship with the metal shaft. Tabs are sheared from the hollow shaft portion to abut against a shoulder defined by a reduced diameter portion on the metal shaft. The metal shaft has a flat which mates with a flat formed in the hollow shaft portion to prevent relative rotation of the shafts. Deformable ribs extend along the flat in the hollow shaft portion to ensure engagement with the flat on the metal shaft.

Abstract: A control comprises two variable resistance controls connected in tandem to a concentric shaft arrangement, an inner shaft of the concentric shaft arrangement containing an energy absorber, the inner shaft and the energy absorber providing an energy absorbing means for the control. The inner shaft made of glass-filled thermo-plastic further provides sufficient resiliency to prevent permanent shaft deformation and related knob wobble upon subjection of the shaft to severe impact and the energy absorber gradually absorbing the energy of impact minimizes axial movement of the inner shaft by eliminating the additional normally required tolerance. Additionally, the percentages of the glass and plastic mixture employed in making the shaft control torsional deflection.

Abstract: A variable resistance control containing a one-piece stamped mounting bracket having an integral collector ring for positioning a rotatable gear and having a pair of integral yokes for aligning a lead screw in driving relationship with the rotatable gear. A contactor constrained to rotate with the gear wipingly engages a resistance element. Each of the yokes comprises a pair of arms arcuately clinched around the lead screw to secure the lead screw to the mounting bracket. Integral with the gear are two outwardly extending resilient fingers for engagement with a respective one of the yokes to arrest rotation of the gear. Continued rotation of the lead screw after rotation of the gear has been arrested flexes the resilient finger toward the lead screw for driving the gear out of engagement with the lead screw. An aperture is provided in the lead screw for insertion of a shaft or tool for remote actuation of the control or for actuation of another control.

Abstract: A variable resistance control comprises a resistance element supported on an electrically conductive supporting plate. A driver connected to the supporting plate is provided with a knob and with an integral stabilizing and particle excluding skirt. The ratio of the diameter of the stabilizing skirt to the diameter of the knob is relatively high. The stabilizing skirt rotatably engages the resistance element and encloses a contactor carried by the driver and prevents foreign particles from engaging the contactor. Indicator means integral with the stabilizing skirt and projecting beyond a truncated portion of the knob visually indicate the angular position of the contactor. The indicator means also engages a stop integral with the supporting plate and extending between the legs of the resistance element to arrest rotation of the contactor. Terminals provided with staggered ears are secured to the legs of the resistance element.

Abstract: A plug-in shaft is provided for insertion into a noncircular opening provided in a driver and integral hub of a variable resistance control providing a means to alter the rotational torque of the control. Integral with the hub is a dish shaped abuttment section and a driver engagement portion of the shaft supports a plurality of nubbins engaging the abuttment section of the hub upon insertion of the shaft into the noncircular opening to secure the shaft in a predetermined position within the slot. The nubbins engaging the dish shaped abuttment section provide radial pressure on the hub and restrain the axial movement of the shaft within the noncircular opening. An alignment portion of the shaft contiguous with the driver engagement portion rigidly prealigns the shaft in an upright and intact manner within the noncircular opening before the engagement portion and nubbins engage the noncircular opening.