Abstract: A high power current-limiting fuse comprises a cylindrical envelope which closely surrounds a metallic fusible element in the form of a wire or ribbon. The cylindrical envelope is made of high density rigid ceramic such as Alumina of formula Al.sub.2 O.sub.3, and Beryllium oxide of formula BeO. The two ends of the envelope are metalized to form two terminals respectively connected to the ends of the fusible element, whereby the current-limiting fuse is connectable to an electric circuit to be protected through the two so formed terminals. A sheath of fiberglass or ceramic can be mounted around the cylindrical envelope so as to increase the mechanical rigidity of the current-limiting fuse.

Abstract: A resettable, current-responsive, circuit interrupter device is made by blanking two wide but thin terminals and carrier stubs therefore, and embedding them up to a substantial part of their thickness in a side wall of an insulating housing so that sides of the embedded terminal portions are exposed from the housing material along the side wall inside the housing, so that terminal ends extend from the bottom of the housing to be connected in a circuit and through the top of the housing to be accessible for test purposes. An electrical contact is secured on an exposed side surface of one embedded terminal portion and a thermostatic strip element is secured to an exposed side surface of the other embedded terminal portion to extend closely along the one housing side to normally engage the contact in a very compact, closed circuit position of the device.

Abstract: A fractional amp fuse (10) with a thin film fusible element (16) connecting thick film pads (14) supported by a polished insulating substrate (12). The fuse subassembly has leads (24) attached by resistance welding and is encapsulated in a ceramic insulating material (18). The entire fuse is enclosed in a plastic-like material (20).

Abstract: A sub-miniature fuse for electrical protection includes an assembly of an outer tube and an inner tube made of insulating material. The inner tube has electrodes and a fusible metal link sputtered onto its outer surface. The assembly of inner and outer tubes is terminated electrically at its ends with axial leads, or with surface mounting pads, or with radial leads.

Abstract: An electrical fuse comprises a fusible conductor welded or bonded onto separated contact surfaces. The fusible conductor is coated with a metal, selected solely for optimum welding or bonding to contact zones of the contact surfaces. The metallic coating of the fusible conductor is then removed at the fusible portion of the coated fusible conductor by etching after the fusible conductor is welded or bonded to the contact surfaces the contact zones surrounding the point of contact protected by a resin cover resistant to the etchant. The electrical characteristic of the fuse is thus determined solely by the core wire and its properties. The resin cover in the contact zones is preserved between the fusible conductor and each contact surface for improved safety against cracks or micro-cracks and their possible adverse effects.

Abstract: The invention relates to a method for the production of a sub-miniature fuse, as well as to a sub-miniature fuse. Known casing with three chambers and a separate cover are difficult to manufacture and are prone to faults due to their complicated shape. According to the invention, an internally substantially smooth surface and externally cylindrical casing is formed, preferably from identical tube halves, whose end faces are closed either by correspondingly constructed connecting electrodes or by concomitantly shaped end walls, the electrodes always carrying the fuse wire on their inside and the connecting leads on their outside. Preference is given to the use of an intermediate member, which encloses the electrodes and the fuse wire fixed thereto. In each case production is simplified. There is also no need for shrink-on tubes for the insulation of contact caps.

Abstract: Within an electrically insulating housing there is provided a continuous hollow space open at both ends. Tubular portions of end contacts are insertably disposed at both ends of the hollow space. Flat portions of the end contacts form clamping locations for a fusible conductor and also solder legs. At the clamping locations there are clamped the ends of the fusible conductor. Each of the solder legs form an associated wave soldering region and a reflow soldering region. During fabrication of the fuse device the end contacts which then still possess a tubular-shaped configuration are inserted into the ends of the hollow space of the electrically insulating housing. There is then drawn-in the fusible conductor and predetermined portions of each of the end contacts are pressed flat for form the flat portions. In this way, the ends of the fusible conductor are clamped at the clamping locations. Thereafter, the flat portions are bent to form the solder legs.

Abstract: The disclosed fuse has a tube of insulation, terminals at the ends of the tube, a link connecting the terminals, and a granular filler. At least one end cap is made of sheet metal which has one or more integrally extending tabs and a respective hole for each tab, each tab and its hole having the same size and shape. Granular fill is introduced via said hole(s) while the tab(s) are raised to provide wide openings. The end cap is sealed by driving the tab(s) into the hole(s). After the fuse contains granular filler but before driving the tab(s) into the hole(s), the fuse may be impregnated with a fluid, first adjusting the tab(s) to be narrowly open to retain the granular filler while admitting the impregnant.

Abstract: An automobile fuse (10) for use in extreme temperature conditions such as the engine compartment of an automobile. Fuse (10) is a blade-type fuse with loads (42, 44) on fusible element (40) providing time delay characteristics to match the insulation damage curves of small diameter automobile cable harnesses. The lower portions of terminals (20) and (30) have been selectively plated with silver. The outer housing (50) has been laser etched.

Abstract: A wire length having a very small diameter is terminated to a contact member by forming a groove in the contact member, disposing the wire length entirely within and along the groove, and striking the surface of the contact on both sides of the groove deforming the sides of the groove downwardly and inwardly into the groove firmly against the wire therein. The contact members can be made in lead frames on a carrier strip and have grooves formed therein, the wire can be placed in the grooves and terminated to the contact members in an automated assembly to make, for example, fuse components where wire segments bridge gaps between associated contact sections of pairs of the contact members, and the lead frames can have housings molded thereto while on the carrier strip.

Abstract: A thermal fuse is formed by a conductive path formed in a ceramic body, the path being of a fusible alloy. A ceramic substrate and a ceramic cover, both in green form, are fused together with defined channels. The channels can be defined by a material which is burnt out, preferably when the ceramic members are fused together. The channels can be defined in other ways. The channels are filled with a fusible alloy leaving an air layer, end contacts being provided. Several channels can be formed in one assembly. The assembly can then be cut into separate fuses, each with one channel.

Abstract: A method of attaching a lead to a metal end cap of an otherwise complete miniature-type safety fuse having a fuse element secured to the interior of said end caps by connecting means, is characterized in that the attaching is effected by a soldering operation which comprises holding one end of said lead against said end cap, wherein the region where attachment is to take place there is a given amount of solder, and supplying to said region a metered amount of energy in the form of one or more energy pulses producing over a given period enough total energy to melt said quantity of solder, but of insufficient total energy to penetrate through said end cap and adversely affect the bonding of said fuse element thereto.

Abstract: An end cap connection provides a strong mechanical bond as well as a fluid resistant seal between an electrically insulative tubular member and a conductive end piece or cap. The cap is provided with a generally U-shaped channel, and a quantity of synthetic resin adhesive disposed in the channel contacts an end portion of the tubular member as well as walls of the end cap. In one embodiment of the invention, the tubular member has a generally 90.degree. edge for engagement with outer end cap walls defining the channel, such that as the tubular member is shifted toward the bottom of the channel, curved bottom walls defining the latter maintain the tube at a position spaced from the channel bottom to enable the sealing material to fully contact the inserted end of the tubular member.

Abstract: The present invention relates generally to a three chamber ferrule type fuse comprising a tube of dielectric material having a tube wall and a bore, providing a unitary sub-assembly comprising a plunger and plunger guide, and two short circuit elements, a coil spring and a ring, having the tube wall staked forming a support for the ring inserting the sub-assembly into said bore of the tube so that one end thereof rests on said ring, having the coil spring under compression, and staking the sub-assembly in place. The construction facilitates assembly by automatic machinery.

Abstract: A method for assembling terminal cup-shaped end caps over the ends of cartridge-type electrical subminiature fuses during the assembly thereof has for its novel feature the provision of a centered axially extending handling wire attached to the outer face of each end cap prior to the assembly process. By configuring the lengths of the handling wires substantially longer than the dimensions of the cap itself, the use of an alignment fixture employing the wires for handling and alignment purposes allows for precise orientation of the end caps during the press-on assembly process over the ends of the fuse body. After assembly the wires are removed from their respective end caps. A shearing station suitable for mass production lead removal has upwardly extending sheraing blades with the fuses passed sequentially past the blades with their leads extending slightly over the top of the blade cutting edges.

Abstract: In a method of manufacturing a spiral electrode assembly, a first electrode member of one polarity is covered with a separator, and the separator is extended forward beyond the leading end of the first electrode member to form an extension consisting of the separator only. This separator extension is inserted into a slot formed in a spool and is wound around the spool. After the separator extension has been wound by the length more than the length of the circumference of the spool, a second electrode member of opposite polarity is inserted in such a relation that the leading end of the first electrode member is located rear relative to that of the second electrode member. The spool is rotated to wind the two electrode members separated by the separator therearound, and the spool is then withdrawn to provide the spiral electrode assembly.

Abstract: The neutral excitation and differential current transformers of a ground fault circuit breaker are arranged for automated assembly onto the signal processor circuit board to complete the signal processor module prior to insertion within the ground fault circuit breaker housing. Electrical interconnection between the transformers is made by a unitary conducting strap having means therein for receiving the circuit neutral conductor. The completely assembled signal processor module is connected with the circuit breaker components by means of a single wire.

Abstract: An electrical component has a plurality of paired contacts with spaced inner contact sections bridged by a fuse element. The paired contacts have outer contact sections enabling mounting to a circuit panel to complete circuit paths thereon. The component is used as a fuse component to protect the circuit panel by preventing overload of a circuit path by the respective fuse element. When the circuit paths have different design in-service currents and different levels of excessive electrical currents, the corresponding fuse elements can have correspondingly different in-service current-carrying capabilities and different melting points, in the same component. The component can be surface mountable and can have DIP configuration.

Abstract: An electrical component has a plurality of paired contacts with spaced inner contact sections bridged by a fuse element. The paired contacts have outer contact sections enabling mounting to a circuit panel to complete circuit paths thereon. The component can be used as a shunt for programming the circuit panel by programming the component prior to in-service use of the panel, by the method of deliberately opening the respective fuse element between one or more selected pairs of contacts by an electrical programming current thereon, leaving other fuse elements intact for in-service path connection of their respective circuit paths. The component can be surface mountable and can have DIP configuration.

Abstract: A method of making an improved metal silicide fuse of controlled thickness for an integrated circuit structure is disclosed. The metal silicide fuse is formed by first forming a layer of known thickness of a metal capable of reacting with silicon to form a metal silicide. A layer of amorphous silicon is then formed over the metal and patterned to form the desired fuse dimensions prior to formation of the silicide. The structure is then sintered to form the metal silicide. Excess silicon remaining over the metal silicide fuse layer is then removed as is unreacted metal from areas where no silicon was present to react with the metal to form the silicide. Control of the thickness of the metal layer which subsequently reacts to form the silicide controls the thickness of the subsequently formed silicide layer to thereby form a fuse of reproducible thickness.

Abstract: A blade fuse includes parallel blades (12 and 14) secured in a body (16). A fusible link (42) welded to the blades is located in a cavity (20) of the body that is covered by a window (61). The blade fuses are assembled by blanking the fusible element from a ribbon (90) and translating it into a fuse subassembly (64). Tabs (50 and 52) secure the fusible element in the subassembly (64) until it is spot welded to blades 12 and 14. The window (61) is then blanked and translated to cover cavity (20) and secured by ultrasonic welding. A connector strip (76) is then blanked from between blades (12 and 14) to provide the blade fuse.

Abstract: An end cap assembly for a fluid resistant electrical device includes a solderable insulating tube end cap and an insert having a solderable cylindrical body portion positioned within a tubular opening of the end cap. The body portion of the insert has a circumscribing groove containing a quantity of solder. During assembly, the walls of the end cap defining the tubular opening are magneformed inwardly to tightly engage the body portion and thus provide limited frictional resistance to movement of the insert relative to the end cap. Next, the end cap and insert are heated until the solder melts. The end cap assembly provides a strong, torque resistant connection between the insert and the end cap while also maintaining a highly effective seal to preclude fluid leakage when the device is immersed.

Abstract: An energy sensitive fusible device fabricated by thick film techniques in which a fuse element is sandwiched between two glazes on a substrate, for use in programming thick film networks.

Abstract: A plug-in fuse assembly comprises a housing made of insulating material and having relatively closely spaced vertical side walls bridged by vertical end walls and a metal plug-in fuse element having laterally spaced, generally parallel confronting terminals at the bottom thereof projecting downwardly from the bottom of said housing and upwardly extending current-carrying extensions of said terminals and a unique S-shaped fuse link extending between said current-carrying extensions. The current-carrying extensions have upper vertical outer margins which are inwardly offset from a given point to the tops thereof with respect to the corresponding vertical outer margins of the plug-in fuse element below the same, to provide clearance spaces for the downward passage of the vertical end walls of the housing, so that the overall width of the fuse is not significantly increased, if at all, by the housing end walls.

Abstract: An improved cartridge fuse has resilient plugs at opposite ends of the fuse housing through which extend a centered fuse filament held in tension by the defining walls of a plug passage hugging the fuse filament to maintain such tension. The fuse filament is placed in the plug passages by means of a needle which is passed through the fuse housing and the plugs therein to create a path for the fuse filament which, when the needle is pulled from the housing, leaves the fuse filament in a tensed centered condition in the fuse housing.

Abstract: A miniature thermal switch features simplified single-spring construction requiring only four components within an enclosure housing. None of the components requires subassembly, and all are designed for completely automated assembly of the finished switch. A fabrication method features self-alignment of the elements by means of closely confining barrier walls. A wiping action of the contacts during melting of a contact-restraining meltable pellet serves to insure an abrupt circuit interruption at the threshold temperature.

Abstract: A subminiature fuse comprises a fuse element (1) disposed within a glass sleeve (2) and connected at opposite ends to tail wires (3) which are formed with collars (4) fusion bonded to the wires (3). The collars are positioned within opposite ends of the sleeve (2) which are fused about the collars (4) to effect hermetic sealing. The collars may be glass beads disposed about the wires (4) or they may be of metal suitably having a coefficient of expansion matching that of the glass sleeve (2).

Abstract: A fuse manufactured in multiple by insertion of pairs of fuse pins in rows in a base block or in discrete fuse bases supported by a plate which aligns them in rows; winding fuse wires successively along the pins and securing the fuse wires to the pins with the fuse wire between adjacent pairs of pins constituting the fuse link; removing the remaining fuse wire from between pins which are to form adjacent fuses, placing a body member with a cavity over each fuse link and placing a cover thereon. Where a single base block is used, the laminated structure is cut apart into a multiplicity of fuses. Where needed, an extinguishing powder may be sifted on prior to placement of the cover to complete the structure. Where desired, the fuse body and the cover sheet may be vented with an additional cover strip over the vent which will yield to excess pressure. Fuse blocks with multiple fuses of the same or different values may be thus created.

Abstract: An improved machine is disclosed for assembling high-voltage fuses without an internal core, which fuses comprise at least one fusible element helically wound inside a tubular casing made of electrically insulating material and filled with a pulverulent arc-quenching material. The machine comprises a mobile head comprising a plurality of threaded rods symmetrically mounted about a central axis and whose threads are especially designed for receiving and helically guiding the fusible elements. The rotation of either the whole head or each of the threaded rods about their respective axis is synchronized to the translational movement of a slidable platform on which the head is mounted. In use, the fusible elements are wound in the threads of the threaded rods by rotation of the mobile head about its central axis. Subsequently, the fusible elements are unwound inside the tubular casing by combining a translation of the platform with a rotation of each of the threaded rods of the mobile head at a given ratio.

Abstract: A thermal fuse comprises a coiled spring interposed in a stretched condition between two opposed conductors in such a fashion that the spring is imparted with tension and is soldered by a fusible alloy having a specified fusing point. The coiled spring is cut at one portion so that a circuit between the two conductors is broken upon fusing of the fusible alloy due to the action of the coiled spring cut at one portion.

Abstract: A plug-in electrical fuse comprises a fusible wire (9) disposed within an insulating housing (1) and connected between the ends of two blade-like terminals (4) secured within and projecting from the housing. Fuses of this type are manufactured by forming a strip of terminal members from strip metal, each member comprising two spaced substantially-coplanar blade-like terminal portions interconnected at their leading ends (5) by an integral cross-bar portion, and each terminal member being integrally connected with each adjacent terminal member in the strip by an interconnecting bar of the metal strip. Fusible wire is secured to the terminal portions adjacent their rear ends to form a strip of terminal and wire assemblies, and this strip of assemblies is mounted in a strip of insulating housings with the fusible wires disposed within the housings and the leading ends of the terminal portions projecting therefrom.

Abstract: A method of making a spiral wound fuse body comprising a core of insulating material formed by a limp, dead yarn made of twisted together initially sizing-coated strands of fine ceramic filaments having no sizing to leave a conductive residue under fuse blowing conditions is mass produced by spiral winding fuse wire upon a continuous length of the yarn unwinding from a spool upon which the yarn was wound when the sizing was removed. The resulting self-supporting body can be wound into rolls and subsequently unwound so that individual fuse bodies can be severed from the end of the unwinding roll of fuse body-forming material.

Abstract: A porous sintered plaque is provided with a bimodal porosity that is especially well suited for use as an electrode within a molten carbonate fuel cell. The coarse porosity is sufficient for admitting gases into contact with the reaction surfaces while the fine porosity is wetted with and retains molten electrolyte on the reaction sites. The electrode structure is prepared by providing a very fine powder of such as nickel oxide and blending the powder with a suitable decomposable binder to form a solid mass. The mass is comminuted into agglomerate size particles substantially larger than the fine oxide particles and formed into a cohesive compact for subsequent sintering. Sintering is carried out at sufficient conditions to bind the agglomerates together into a porous structure having both coarse and fine porosity. Where lithiated nickel oxide cathodes are prepared, the sintering conditions can be moderate enough to retain substantial quantities of lithium within the electrode for adequate conductivity.

Abstract: In a printed circuit board, a safety means is provided to prevent the circuit elements such as semiconductor devices, resistors, and the like from suffering damage due to overcurrent flow. The safety means thus improved has a narrow gap provided within a metal foil pattern on the surface of the printed circuit board and a low-melting point metal such as solder bridges this gap to connect the metal foil.

Abstract: Apparatus for reducing the cross sectional area of a wire comprises stabilizing means arranged to receive the wire and to limit extrusion thereof in a direction transverse to its length and movable projecting means for engaging the wire while restrained by the stabilizing means so as to effect a deformation of the wire and a concomitant reduction of its cross sectional area.

Abstract: A fusible element having an ability to withstand a large number of on-off cycles is provided. The element comprises a ribbon of copper without any M-effect causing means. The element is bent in a zig-zag shape to establish a plurality of contiguous planar sections enclosing obtuse angles with each other and forming straight edges of the loci of intersection of the planes defined by the planar sections. The straight edges are non-perforated to maximize their flexure strength. Each of the planar sections is provided with at least one point of reduced cross-section remote from the straight edges. The ribbon of copper is electro-plated with sulfamate of nickel forming a dull, ductile layer of nickel.

Abstract: A fuse assembly comprises a fuse unit and housing therefor made of insulating material and having an initially fully opened side through which said plug-in fuse unit was inserted into said housing. The fuse unit has a pair of spaced, parallel, confronting terminals with portions exposed to the exterior of said housing through spaced openings in the initially fully open side of the housing. A fuse link interconnects other portions of said terminals, the fuse link being positioned to pass by an initially uncovered portion of the initially fully open side of the housing as the fuse unit is inserted into the same. The housing has a closure flap which initially has a position exposing said portion of the initially fully open side of the housing so that the fuse link can pass into the housing therethrough. The flap is folded to cover this open housing portion when the fuse link passes into the housing.

Abstract: A fuse element for an electrical cartridge fuse comprises a fusible wire secured to opposite end zones of an insulating strip by metallic layers sprayed onto the end zones. The insulating strip has a slot therein between the end zones to prevent the fusible, central section of the wire from contacting the strip. The fuse element is disposed in an insulating barrel and the layers are soldered to end caps of the barrel to connect the fusible wire thereto. Fuse elements of this construction are produced by disposing a fusible wire along a continuous strip of insulating material formed at equally spaced intervals with slots and spraying the metallic layers onto the strip between the slots so as to adhere the fusible wire to the strip. Thereafter, the strip is severed at the zones between the slots so as to produce individual fuse elements. This method of manufacture facilitates the production of cartridge fuses utilizing small diameter fusible wires.

Abstract: A fusible element for electric fuses capable of combining time-lag in the range of overload currents with current-limiting action for currents in the range of short-circuit currents. The fusible element comprises a relatively wide perforated center section and axially outer heat dam sections. The center section has points of reduced cross-section imparting to it a predetermined fusing i.sup.2 .multidot.t. The center section of the fusible element is folded in a direction longitudinally thereof to effect mutual heating of the portion, or portions, thereof to different sides of the fold, or folds. This allows to increase the mass of the center section and results in an increase of time-lag. Relatively narrow heat-dam-strip sections extend from the ends of said center section. The fusing i.sup.2 .multidot.

Abstract: A method and apparatus for making plug-in fuse assemblies utilizing a strip of fuse metal having longitudinally spaced blank portions from which individual plug-in fuse elements are to be formed, each blank portion having corresponding portions spaced transversely of the length of the strip from which said fuse link portions, on the one hand, and at least said terminal blade portions, on the other hand, of a plug-in fuse element is to be formed. The strip of fuse metal is advanced past punch and die assemblies which form in each blank portion of the strip a pair of parallel confronting terminal blade portions and current-carrying extensions interconnected by a fuse link portion.

Abstract: An ambient thermally actuated switch comprises a power lead extending longitudinally into and insulated from one end of a metal casing. The power lead made of a soft low resistance material like copper is bifurcated at its inner end to form outwardly inclining arms which, in a normally closed embodiment of the switch, makes contact with the inner surface of the casing. The arms are pressed against an insulating backing member so that the arms expand outwardly into a low resistance contact with the casing. The backing member forms part of a spring-urged, longitudinally extending, sandwich of elements extending between the ends of the casing and preferably comprising a pellet of meltable material, a first partially compressed spring, said backing member, arm-deforming means positioned contiguous to and adapted to collapse said arms when released to do so, and a second fully compressed spring applying a force acting on said deforming means to force it into an arm-collapsing position when the pellet melts.

Abstract: A dual element fusible device is provided utilizing a plurality of separate arc quenching fillers disposed in layers within the fuse casing and being effectively separated from one another by an electrically insulative material which is introduced into the casing in a fluid state so that regardless of the configuration of the internal workings of the fuse, it establishes a continuous and impermeable barrier between the respective layers.

Abstract: A fuse link and a method of manufacturing same are disclosed. The fuse link comprises a fusible element extending between an upper terminal and a lower terminal. The lower terminal includes a compressed segment of a multi-strand cable to which the fusible element is attached. In practicing the method of the present invention, a segment of the multi-strand cable is first radially compressed, as by cold-forming, to produce a longitudinal receiving region or pocket indentation for receiving an end of the fusible element. Thereafter, an end of the fusible element is placed into the receiving region. The region is then further compressed and collapsed to secure the fusible element therein by crimping a compressible sleeve previously placed around the fusible element and the cable-segment.

Abstract: A helical fusible element is supported by an element support member which is disposed between two terminal assemblies, which terminal assemblies are of larger diameter than the diameter of the combination of the fusible element and the element support member. A flexible container is formed around the element support member and the fusible element on the circumference of the terminal assemblies to enclose these elements except for the ends of the terminal assemblies. A hole through the enclosure is provided through which a suitable particulate arc quenching material is admitted so as to completely fill the enclosed region. The hole is then sealed. The completed subassembly is then encapsulated in a resinous compound using a split mold. The contraction of the resinous compound as it cures compresses the flexible container and the particulate arc quenching material, thereby insuring maximum density of the arc quenching material without interfering with the desirable porous nature of the arc quenching material.

Abstract: A miniature plug-in fuse assembly is provided in which a pair of conductive legs and a fuse link interconnecting them are integrally formed from fusible metal. An insulating casing wholly encloses the fuse link and a portion of the conductive legs, the casing having a hollow body with a cover which does not extend beyond the body in its longer dimension. The cover is secured to the body by a retaining arrangement employing the ends of the conductive legs, which also provides for the insertion of a test current to test the fuse link. Other ends of the legs extend through the body to provide plug-in members. The legs are fastened to the body by protruding lugs on the plug-in members and projecting stops on the portion of the legs in the casing. A method for making the fuse assembly of this invention involves a series of die stamping steps to form the legs and fuse link from a continuous strip of fusible metal and mounting the legs and fuse link in the casing.

Abstract: A process for making a oil resistant tubular fuse for submersion in a hot oil bath is taught. An epoxy resin seal is provided between one portion of a fuse ferrule and an annular groove in the fuse body. Alternatively the epoxy resin seal may be disposed between flared portions of the ferrule and an unscored portion of the tubular body. In both cases the adhesive characteristics of the epoxy are such that the seal retains its sealing capabilities in a temperature range from -40.degree. C. to +150.degree. C.

Abstract: A method and apparatus for making an encapsulated electrically conducting component is provided. A wire is placed across a mold cavity for forming substantially one-half of the component body. A substantially flat-surfaced second mold having a groove is placed against a first mold to hold the wire in the groove and in alignment with respect to the cavity of the first mold while fluid plastic material is injected therein to encapsulate a substantially semi-cylindrical surface portion of the wire and form one-half of the conducting component body. Next, a third mold is placed against the first mold. The third mold has a cavity defining substantially the remaining half of the component body. The fluid plastic is injected through the first mold and into the cavity in the third mold to form a completed, composite molded body.

Abstract: A method and apparatus for making an encapsulated, three-piece electrically conducting component, such as a fuse, are provided wherein a progressive stamping die is used to form a pair of spaced apart blades in a sheet stock of electrically conducting metal. Each blade has at one end a terminal portion connected to a carrier member formed from the strip and at the other end a pair of spaced-apart rear bearing members and a flexibly hinged front bearing tongue disposed between the rear bearing members. The rear bearing members have a cradle with a substantially concave cross section for receiving a conducting wire therein. In the die, the tongue is forced outwardly away from the rear bearing members to provide an opening between the distal end of the bearing tongue and the cradles of the rear bearing members. A continuous wire may be inserted into the blades. Then the force on the tongue is relieved to permit it to move back toward the rear bearing members to securely clamp the wire in the cradles.

Abstract: Fuses and interconnects are fabricated by applying a metallic layer on a substrate and a fusible layer on the metallic layer. Portions of the fusible layer are removed to define discrete fuse elements having a necked portion. Portions of the metallic layer are removed to define interconnects. A portion of the metallic layer coextensive with the necked portion of the fuse elements is removed by selective side etching to form tapering portions separated by a gap without etching of the interconnects. The interconnects are protected from side etching by a separate mask layer or a mask layer used to form the interconnects may be heated to flow down over the sides of the interconnects.

Abstract: A three-piece solderless plug-in electrically conducting component is provided for mounting in an electrical connector. An elongate conducting element is transversely disposed across two spaced-apart generally parallel blades and is secured at each of its ends to a spring clip near the end of each blade. In the preferred embodiment of the present invention, the component functions as a fuse wherein the elongate conducting element is a generally cylindrical fuse wire and wherein a solid unitary body of electrically insulating material encapsulates the fuse wire and spring clip of each of the blades with the external surfaces of the fuse wire and blade spring clip portions being in intimate contact with the encapsulating material. The spring clip has a pair of spaced-apart rear bearing members and a flexibly hinged front bearing tongue between the rear bearing members.