Abstract: An extended resistance temperature sensor formed of a plurality of lengths of pre-insulated resistance temperature detector (RTD) wire. The RTD wire is either unheated, self heated, alternatingly self heated or is heated by means of strands of heater wire integrated with or placed closely adjacent to the RTD wire. The RTD wire itself, or together with the heater wire, is bonded together in one elongated embodiment. Alternatively the RTD wire, or with the heater wire, may be encased in insulated shrink tubing, thin wall metal tubing or both. Connectors are provided at each end of the elongated structure to supply electrical current for heating purposes or to connect the RTD wire to detection circuitry, or both, and the configuration of RTD wire is doubled back on itself to form a U-shaped structure with the connectors adjacent each other. Protective sheaths are provided over the connectors.

Abstract: A motor protector having a can and internal electrical contact is hermetically sealed to a disk-shaped header of conductive material having a flattened edge for orientation during fabrication with spaced conductive pins sealed in and insulated therefrom. A heater-support with holes for fabrication is bonded to one conductive pin, a bimetallic element parallel to the axes of the pins having a contact element normally contacting the can contact. A heater without right angle bends is bonded to each of the electrically conductive pins, is spaced from the movable contact and rests parallel to the axes of the conductive pins. The motor protector is fabricated by providing a fixture having two depressions, one somewhat in the shape of the movable contact with upwardly extending pins for mating with the support apertures therein and the second for receiving the header in an upright position and adjacent the first. The support is placed on the fixture with the pins extending therethrough for support orientation.

Abstract: An exothermic resistor for use in a hot wire air flow meter, having a wire (2) in the form of a coil made of a metal, a pair of lead wires (3) connected to connections (21) formed at the opposite ends of the coil, and a support member (4) which integrally supports the connection as well as the coil located between the connections. An example of the support member is in the form of a tubular cylinder closed at its both ends. The support member is formed from glass only or formed of a layer of a glass-ceramic-composite material. The hot wire air flow meter is designed to be easely mass-produced and to have improved transient response characteristics with respect to abrupt changes in the air flow rate.

Abstract: A PTC thermistor device including a PTC thermistor element of a circular configuration, and a casing made of a plastic material. The casing has a substantially parallelepipedic body portion and a projecting portion having a pair of parallel side surfaces and a planar top surface. A terminal fitting is provided in contact with the PTC element and has plug portions projecting from the casing at the opposite sides of the projecting portion. The plugs has projecting lengths which are not higher than the height of the projecting portion of the casing.

Abstract: A process for transforming a cylindrical electrical part into a component having at least one flat surface, suitable for use as a surface mounted device.

Abstract: A process of automatic sequential production of potentiometers, and potentiometers obtained thereby. The potentiometers are generally low profile rotary-type potentiometers. The potentiometers are formed with a low profile cylindrical casing into which is inserted a laminate electrical resistance element of an incomplete annular shape, the ends of which remain connected to terminals. The casing engages a slider, which is in permanent mechanical and electrical contact with the resistance element and a collector terminal. The slider is assembled on a slider-holder rotatably attached through an aperture formed axially through the body and which is operable from the external surface of the casing. The process consists of automatically assembling the potentiometers in an in-line process. The metallic components are formed on a continuous metallic band by die-cutting the band to produce such components.

Abstract: A surface mount wirewound resistor having a conventional wirewound resistor embedded in a plastic body member with terminal axial leads of the resistor being severed at the opposite ends of the body member. A U-shaped metallic terminal pad and clip is secured to the ends of the body member and is in electrical contact with the severed ends of the axial leads. The upper and lower portions of the terminal pad are in coplanar relationship with the upper and lower surfaces of the body member. An alternate surface mount wirewound resistor has metallic tabs that extend from the resistance element embedded in the plastic body member, with the tabs being bent upwardly from the ends thereof and into coplanar relationship with the upper surface of the body member.

Abstract: A thermometer probe comprising a temperature sensing element for sensing temperature of an object to be sensed, a conductor connected to the temperature sensing element for transferring the sensed temperature, an insulator for coating the conductor, and a water-resistant sheath for enclosing the temperature sensing element, the conductor, and the insulator. The opening end of the sheath is welded for enclosure of the temperature sensing element.

Abstract: A method of making an electrically insulated terminal in an injection nozzle. After the heating element is wound in a spiral channel on the outer surface of the main body portion of the nozzle the rear end projects radially out an opening in the collar portion. The casing is stripped from the heating element to expose the resistance wire adjacent the rear end. A steel plug having a central bore therethrough is slipped over the projecting rear end and welded into place in the opening. A steel terminal body is made with a central bore and a threaded front portion to receive an external power lead. The casing of the portion of the heating element projecting from the plug and a rear portion of the terminal body are coated with insulating material. A protective cap is securely swaged over the coating on the rear portion. The assembled cap and body are slipped over the rear end of the heating element and welded to the matching front face of the plug. The exposed resistance wire is welded to the terminal body.

Abstract: A coiled resistance element is connected to an insulator block by sequentially locating and holding the coil in place; camming the coil such that two adjacent coils are forced together and the coils on either side are forced away so as to form two gaps or openings; and, inserting the arms of an insulator block into the two gaps so as to force the two adjacent coils into the cross bar portion of a T-slot formed in the connector block. Upon removing the camming forces from the coil, the two adjacent coils will be separated and located in the cross bar portion of the T-slot to thereby secure the coil and insulator together.

Abstract: There is provided a method for assembly of temperature probes. An insertion element or sensor such as a resistance temperature detector is mounted in a receiving cavity and surrounded by sufficient packing to electrically insulate the sensor. A stalk is utilized as a conduit for routing and insulating lead wires through the support casing. The stalk is notched at a point to facilitate the connection of wires threaded through the stalk to the sensor wires and to minimize the inadvertent contact of these wires with the metallic surfaces. The notch in the stalk protects the junction from contact with the metallic sides of the guide walls and protects the junction from mechanical stresses. To further protect the junction of the lead and sensor wires, the sensor is placed adjacent and parallel to the stalk prior to insertion. The stalk and the sensor are inserted simultaneously with the stalk coming to rest before the sensor travel stops, thereby minimizing the stresses to the junction.

Abstract: A process for making an encapsulated metal oxide varistor package comprises pressing the varistor powder mixture into a disc, sintering the pressed disc, followed by slow cooling to room temperature.The sintered disc is acid etched and a fritted-silver electrode applied on each side of the disc or in the alternative an aluminum coating is arc sprayed on each side of the disk followed by an arc sprayed copper coating on top of the aluminum coating. The fritted-silver electrode coating is heated to 660.degree. C. and slow cooled to room temperature. Sn-coated copper leads are soldered on the electroded disc of either electrode process and the assembly is encapsulated in resilient epoxy resin to form the encapsulated metal oxide varistor package.

Abstract: An improved method for producing an electrode assembly for use in electrochemical gas sensors. A plurality of conductors are attached to one surface of a generally circular electrode blank. These conductors are passed through respective conductor routing holes in an electrically nonconductive mounting member. After the electrode blank is attached to the mounting member, predetermined sections of the electrode blank are cut away to divide the blank into a plurality of electrically isolated regions that are connected to respective conductors. The cut-away sections may then be filled with an electrically nonconductive filling material to provide the electrode assembly with a smooth, flush surface.

Abstract: A thermistor suitable for use in a temperature range with a maximum temperature exceeding 400.degree. C. comprises bulk thermistor material with a pair of electrical leads attached to the thermistor material by respective quantities of conductive paste each having a curing temperature substantially in excess of the aforementioned maximum temperature.

Abstract: An electric heater assembly for tools having a removable heated tip includes a tubular metal base having an open end adapted to removably receive and hold the end of the tool tip. A coating of ceramic electrical insulation material is provided on a portion of the exterior of the base and a length of Nickel-Iron alloy resistance wire is wound on the ceramic coated portion. Electrical lead wires are connected in lapped relationship to the respective ends of the resistance wire. Each lead wire includes a first portion lying between several turns of resistance wire and the ceramic coating on the base and a second portion bent back and overlaying the several turns of resistance wire. The second portion is wrapped with at least one additional turn of the resistance wire. A coating of ceramic electrical insulation material is provided over the resistance wire and the terminals to seal the same from the deliterious effects of the atmosphere.

Abstract: An electrical resistor is described which is comprised of a resistor core having at least one electrically conductive end cap mounted thereon. The end cap is in electrical contact with the butt end portion of the core and electrically insulated from the side, or periphery, portion of the core member. The end cap has an outward-extending radial portion thereon, positioned contiguous to the junction between the core and the cap.The present electrical resistors are produced by forming a resistive core member of a conductor in a dielectric matrix material and an end cap, having an internal contact surface and a receiving portion. The receiving portion is larger than the outside diameter of the core. The end cap has an outward-extending radial position adjacent the receiving portion. The end cap is mounted on the core to place the butt end portion of the core in electrical contact with the internal contact surface of the end cap, but otherwise spacedly within the end cap.

Abstract: A mechanical and electrical connection for a piezoelectric member of polyic material such as polyvinylidene fluoride, and method for forming such a connection. To form the connection, the piezoelectric member is first masked to prevent a preselected portion of its surface from being coated during subsequent coating operations. An electrically conductive member such as a lead wire or a solderable terminal is then attached to the nonmasked area of the piezoelectric member with adhesive such as epoxy. The masked piezoelectric member, the electrically conductive member, and (incidentally) the mask are then coated with a conductive coating such as sputtered gold to electrically connect the conductive member to the piezoelectric member. The mask can now be removed from the piezoelectric member if desired, although it can be left in place as a convenient vise.

Abstract: This invention relates to a continuous method for making electrical heating mats suitable for installation on room floors, walls and ceilings, which method includes the steps of cutting transverse cuts in a longitudinal composite metal/plastic foil material (2) and stretching the foil in a controlled way in order to provide a meander pattern of electrical resistance strip material, the method also including steps of making unit length mats with predetermined ohmic resistance and steps of providing terminations.

Abstract: A method for the heating of a fluid stream flowing in the pores of a body of specially prepared porous reticulated vitreous carbon which does not crack or substantially change in electrical resistance with time when heated to elevated temperature in air is described. The body is composed of electrically conductive rigid, interconnected and multidirectional continuous strands of vitreous carbon forming a rigid porous, three dimensional skeletal structure. The body as an electrical resistance element has current conductive paths between at least two regions; is shaped to provide particular cross-sections along the conductive paths; and has electrical connector means attached at the regions of the body so that current can be distributed through the body. The electrical resistance element is particularly useful as a heating element for air flowing through the pores in electrically powered room space heaters, hair dryers, hand dryers and the like and can also function as a self-cooling resistor.

Abstract: A method of assembling an electrical device including current relay means having housing means with at least one female terminal disposed therein and at least one switch means terminal extending exteriorly of the housing means. In this method, a solid state device is disposed at least adjacent the housing means, and the solid state device is connected in circuit relation between the at least one female terminal and the at least one switch means terminal.

Abstract: A method of constructing a self-regulating electric heater particularly useful for heating compressor lubricant and the like is disclosed in which a cylindrical body of electrically insulative ceramic is formed with an axially extending generally parallelepiped shaped slot in communication with an end of the body. A positive temperature coefficient of resistivity (PTC) resistor, configured slightly smaller and complementary with the slot, is disposed therein. Axially extending grooves are formed in two opposed parallel walls of the body which, with two other cooperating walls, define the slot. The grooves are located on opposite sides of an axial plane perpendicular to the opposed walls. A platform is formed in each groove to serve as a stop surface to limit the insertion of spring biased terminals which are inserted in the grooves to provide electrical connection with the PTC resistor.

Abstract: A heater assembly for a container such as a cooking vessel includes a heating coil in a tubular heater casing, with a connecting pin member connected to the heating coil and projecting through an insulating sleeve mounted to the end of the casing. A plug connecting pin is mounted to the part of the pin member projecting from the insulating sleeve. The end of the casing is butted directly against the insulating sleeve, and a casting material is cast around parts of the plug pin, the casing and the insulating sleeve to form an assembly thereof.

Abstract: A method of assembling an electrical device. In this method, a contact plate for a PTCR is disposed exteriorly of a casing therefor, and extensions on the contact plate are deformed into releasable securing engagement with the casing exteriorly thereof.

Abstract: A pair of pointed terminals are heated and forced through opposed side walls of an open-ended box constructed of thermoplastic material. A rolled film capacitor blank having heat fusible end electrodes is moved into the box to deflect the terminals so that the terminals are forced into firm engagement with the end electrodes. The heated terminals are effective to soften or melt the engaged portions of the electrodes to bond the terminals to the capacitor blank.

Abstract: A heater band formed of an extruded metal channel member and a heater plate assembly received within a slot extending along the length of the channel. The heater plate assembly and the extrusion are compressed together to provide a heater band having a dense cross section resulting in improved heat transfer characteristics. The heater band in accordance with the present invention has a longer life and higher heating capabilities than heater bands known to the prior art.

Abstract: A heating panel array is of a "sandwich" configuration and employs a serpentine resistive array fabricated from a metal foil and disposed between two sheets of fiber glass cloth, all of which are secured together by a binder having stable properties in the presence of heat generated when said array is energized. The binder contains colloidal silica spheres of submicron diameter. Methods for fabricating the panel are described which enable fabrication of a multiplicity of panels using selective etching and silk screening techniques. The fabrication process assures the absence of impurities in the heater panel construction and in conjunction with the binder enable the panel to operate without smoking and aromatic problems.

Abstract: An electric band heater of low expansion characteristics having an integral ceramic core with resistance wire sandwiched therein and encased within a metal housing, the core being formed from a wire wound ceramic sheet sandwiched between ceramic sheets; and a method for making such a heater which includes the steps of arranging an assembly of a wire wound organic-ceramic core strip between organic-ceramic insulator strips and placing the same within a metal housing, compressing and forming the assembly and then heating the assembly to bake out organic binder materials and sinter ceramic materials into a ceramic mass.

Abstract: In the fabrication of a resistance heater for a carton for packaging a pizza, an aluminum metallized sheet is adhered to a paperboard panel, a generally U-shaped strip of arc-sprayed zinc is applied to three edge portions of the upwardly facing electrically conductive metal layer of the metallized sheet, the interconnecting portion of the U-shaped strip and the immediately underlying metal layer are severed, and the metal layer is severed along a line extending adjacent the same interconnecting portion to the side thereof enclosed by the U-shaped strip, so that each of the severed sections of the interconnecting portion serves as a terminal for a corresponding leg portion of the U-shaped strip comprising the electrodes for the intermediate region of the metallized sheet.

Abstract: A method of manufacturing a resistor element for fixed or variable resistors. The element comprises an insulating substrate injection molded from ceramic-glass frit material and organic binder and lubricating material and layers of resistive material and conducting termination material deposited on the unfired substrate. The organic materials in the substrate and its termination and resistive layers are substantially "burned out" prior to simultaneously co-firing the substrate and the deposited resistive and termination layers.The fixed resistor element may be molded as a half-shell arranged to receive leads extending from opposite ends thereof and attached by soldering to the termination areas. A substantially identical cover member molded and fired from the same material as the substrate is adhesively attached to the substrate to complete the resistor.

Abstract: In a film resistor comprising a substrate of insulative material and a film of Cermet formed as resistance material on the substrate, a protective film of insulative material is formed on the surface of the film of Cermet to reduce the temperature coefficient of resistance of the film resistor. The protective film is formed of magnesium fluoride.

Abstract: A method of manufacturing a passive hermetically sealed electronic component having a coupling element of soft alloy material between the component element and the leads for providing strain relief. The component element is composed of a passive element having coated ends composed of a refractory metallic material for providing reliable electrical and mechanical connection to the coupling element.

Abstract: A continuous composite web from which electrical low temperature heating mats can be produced by transverse cutting at certain positions and possibly by effecting an edge insulation and attaching electrical connections. A method for the production of such webs is also disclosed. The web consists of resistance foil material between two insulating foil layers which are joined in the areas of direct contact to secure the resistance foil. The resistance foil material is in the form of parallel, continuous, longitudinal strips and transverse strips extending transversely to said longitudinal strips at desired intervals and connected thereto to form electrical connections between adjacent foil strips. The transverse strips extend substantially across the total width of the web and can be in the form of an insulation strip having flat foil conductive pieces on the insulation strip.

Abstract: A temperature measuring probe utilizing an RTD element and an improved mode of assembling the element in a reliable manner which is proof against shock and vibration. Specifically, the invention has its most important applications in connection with miniaturized RTD's.

Abstract: The resistance temperature detector (RTD) includes a substrate of refractory dielectric material having two or more holes bored through it. A plug of electrically conductive material is fixed within each hole in proximity to one end surface of the substrate, with the plug surface preferably having a concave meniscus shape and consisting of a metal alloy such as Ti-Ni. Lead wires, such as Ni wires, are located in the holes and are connected to the plugs through the other end surface. A film of temperature dependent resistance material is deposited on the one end surface of the substrate and is connected to the two plugs. The film may consist of a thin sensing film of metal such as platinum or of a semiconductor material, deposited in a selected pattern on the substrate and in direct contact with the plugs, or the sensing film may be deposited so as to connect pads of electrical conducting material which are deposited to cover at least a portion of the plugs.

Abstract: Glassy metal alloys of compositions in the Be-Ti-Zr system suitable as temperature sensing elements for resistance thermometers are provided. The compositions consist essentially of about 20 to 45 atom percent beryllium, about 2 to 80 atom percent zirconium, 0 to about 2 atom percent of at least one metal of vanadium, chromium, manganese, iron, nickel and cobalt, and the balance essentially titanium and incidental impurities. The alloys of the invention combine a high temperature coefficient of resistance and negligible temperature-dependent magneto-resistance.

Abstract: A transducer of an "H" shaped cross section employs a depression relatively equal to the line width of a diffused piezoresistor located in said depression. The depression is sealed by means of a glass member which acts as a "stop" for the transducer for all forces in excess of a rated force which causes a maximum diaphragm deflection relatively equal to the depth of said depression as selected in accordance with said resistor line width and the overall diaphragm diameter.

Abstract: A method of assembling a temperature responsive resistance member within a pair of separable housings. This method includes the steps of: mounting the temperature responsive resistance member in both supporting engagement and electrical contacting engagement between a pair of electrical terminals; and joining the separable housings against displacement so that the temperature responsive resistance member in both the supporting engagement and the electrical contacting engagement with the terminals is disposed within the housings in predetermined spaced relation therewith with portions of the terminals extending exteriorly of the housings.

Abstract: The specification discloses a continuous composite web from which electrical low temperature heating mats can be produced by transverse cutting at certain positions and possibly by effecting an edge insulation and attaching electrical connections. A method for the production of such webs is also disclosed. The web consists of resistance foil material between two insulating foil layers which are joined in the areas of direct contact to secure the resistance foil. The resistance foil material is in the form of parallel, continuous, longitudinal strips and transverse strips extending transversely to said longitudinal strips at desired intervals and connected thereto to form electrical connections between two and two adjacent foil strips.

Abstract: A hermetically sealed fixed film resistor including a coupling element of soft alloy material between the resistive element and the leads for providing strain relief. The resistive element is composed of a resistive film having coated ends composed of a refractory metallic material for providing reliable electrical and mechanical connection to the coupling element.

Abstract: The present hermetically-sealed electrical resistor component assembly is composed of a sleeve of high-density, non-porous, non-hydroscopic material into which there is slip-fitted an electrical resistor component. Said electrical resistor component is sealed within said sleeve by a deposit of solder at each end of said sleeve whereat said solder clings to said sleeve, to the end cap of said resistor, and to the lead wire extending from said end cap. In some embodiments silicon rubber is employed as a gasket disposed along the end of said cap whereat it abuts said sleeve. In another embodiment, the entire package is encapsulated in a plastic material such as silicone-epoxy.

Abstract: A low cost pressure transducer can be manufactured and assembled with automatic or semiautomatic production line techniques. The transducer includes a pressure fitting, a diaphragm, a strain gage comprising a bridge circuit and tabs with leads for the bridge circuit, and a termination board, all contained within a case. One end of the case is swaged over a flange on the fitting in order to sealingly clamp the diaphragm between a shoulder in the case and the fitting flange. The bridge portion of the strain gage is adhesively secured to the diaphragm. A pressure distribution member is placed over the bridge so pressure may be applied to the assembly during heat-curing of the adhesive which secures the gage to the diaphragm. The termination board has four terminals and a corresponding number of conductive strips. It is positioned in the case so that each of the conductive strips is pressed into electrical contact with a corresponding lead on the tabs of the gage.

Abstract: A heater unit of bilateral construction is formed by forming a resistor assembly of a resistor helix extending between cylindrical terminals and overlapping the same, inserting the assembly in a sheath tube, filling the tube with MgO powder, placing laminated mica end plugs over the terminals and extending into the ends of the tube, bending the tube into a U-shape, pressing the legs of the U together and feeding the pressed unit through swaging dies to deform the tube over the entire length thereof to provide a heater unit of substantially circular cross section and having two legs of substantially semicircular cross section. The resistor helix in the area of the leg portions has a cross-sectional shape corresponding to the cross-sectional shape of the sheath and the terminals and mica plugs within the sheath are flattened to provide a similar cross-sectional shape thereby locking the terminals within the sheath.