Note: Descriptions are shown in the official language in which they were submitted.
~3~7 `
~ t~ ti~
Thi~ invention rel~te~ in general to electrical
devlces and in particular to tho~e utilized in the starting
or starting and protecting of dynamoelectric machines, a
method of making an electrical device, and a terminal. ;
BacXqround of_the Invention
In the past, various protector devices have been
employed for taking a winding circuit of a dynamoelectric
machine off the line in the event of the occurrence of a
winding circuit overload which, of course, may have a deleteriou -~ ;
affect on components of such dynamoelectric machine, ~uch as
for in~tance buring-out the winding circuit. One such pro-
tector device i9 di9cloged in U.S.P. 2,771,528 i~su~d to
; D. E. Moran on November 20, 1956. ~19O in the past, various
~tarter device~ have been employed to render a 3tart winding
generally ineffective in the winding circuit of a dynamoele~tric
machine, such as a split phase electric motor for instance,
when the dynamoelectric machine i9 energized and attains a
presel~cted speed. Some of the~e starter devices are well known ~ -
to the art, such a~ centrifugal starting 9witches and starting
relays or the like. Po9itive temperature coefficient resietors~
have al~o been employed a9 starter devices with the winding
circuit of a split pha9e motor to render the start winding
generally ineffective at a preselected motor speQd, as shown
'
'
5~7,
Eor instance in the elec-trical devices illustrated in U.S.
patent No~ 3,737,752 dated ~une 5, 1973 - Strachan and
U.S. Patent No. 3,559,016 dated January 26, 1971 - Gerteis,
respectively.
These past motor starter devices and proteetor deviees
were mounted to a dynamoelectric machine in various manners.
For instance, some were disposed on a terminal board in the
dynamoelectric machine, and others were laced or otherwise
disposed in or adjacent the windings of the dynamoelectric
machine. Still others of the past starter devices and pro-
tector devices were mounted to the housing of a dynamo-
electric machine and connected by leads to the winding
circuit thereof.
In an air conditioning or refrigeration eompressor
unit or the like, a hermetic motor is sealed therein, and
either a male or Eemale plug member or eluster is eonneeted
in cireuit relation with the winding circuit of the hermetic
motor and remotely located therefrom so as to be mounted on
a housing or jacke-t of the compressor unit. U.S. Patent
Nos. 3,921,117 dated November 18, 1975 to Blaha and
; 3,955,170 dated May 4, 1976 - Geisheeker respectively
disclosed plug-on and plug-in type motor starter devices
which may be assembled to the aforementioned male or
female plug members of a compressor unit. In U.S.
Patent 3,168,661 dated February 2, 1965 - Rini, a combination ~;
starter-protector devices is disclosed as being plugged onto
a male plug member r such as that previously mentioned. Another
eombination starter-proteetor deviee\is illustrated in
U.S. Patent No. 4,042,860 dated August 16, 1977,
and assigned to the common assignee of this application.
~ -2-
S~7,
Variations in the tolerances of the male terminal ~ ~
with respect to the size thereof and/or in the mounted ~.
spacing thereof in the aforementioned plug members are,
of course, encountered, and such tolerance variations may
also prevail in the cooperating female terminals of the
electrical device adapted to be assembled onto such plug .
members. Due to such variations, at least one of the `~
disadvantageous or undesirable features of such past :
electrical devices is believed to be that the female i
terminals thereof were sometimes rather loosely mounted ~ ~:
on the cooperating male terminals of the plug members.
Of course, it is also believed that such loose mounting
resulted in an ancillary disadvantageous or undesirable
feature wherein the female terminals of the past electrical
devices may have been displaced from their cooperating
male terminals of the plug members in response to vibrations
or the like established by or during the operation of the ~ ~
apparatus with which the plug members are associated. ~.
Still another ancillary disadvantageous or undesirable
feature effected by the aforementioned loose mounting is :~
believed to be that such looseness may result in increased
\
:; ~
,
electrical resistance between the male terminal and the
female terminal so as to cause overheating.
When the aforementioned tolerance variations do exist,
another disad~antageous or undesirable feature of the past
electrical devices is believed to be that the female ter-
minals thereof may be spread apart and/or twisted when such
female terminals are inserted into assembly engagement with
the male terminals of the plug member. A further disadvan-
tageous or undesirable feature of the past electrical devices
is believed to be that the spreading and/or twisting movement
of the female terminals in response to the assembly there-
of on the male terminals may have been transmitted to other
electrical components o:E the electr.ical device connected
with the female te.rminals thereof so as to deleteriously
affect such other electrical components and/or their con-
nections with the female terminals. For instance, in some
of the past devices, a PTCR was embraced between contact .:
plates of the female terminals, and the aforementioned
displacement movement of the female terminals upon mounting ..
,
. 20 association with the male terminals caused the contact
plates to abrase or scrub the chemically treated surfaces ~
of the PTCR with which the contact plates were engaged. : -
In this manner~ the abrasions caused by the rubbing en- .~.
: gagement of the contact plates against the chemically
treated surfaces of the PTCR caused hot spots therein
resulting in the failure of the PTCR.
~ 4 -
5~73
SummarY of the Invention
Amon~ the s~veral objects of the invention may be ~;
noted the provision of electrical deviceis t a method of making ~
an electrical device, and a terminal which overcomes the ` ~`
disadvantageous or undeisirable features discussed herein~
above, as well as others, with respect to the~prior art: the
provision of such electrical devices, method, and terminal ;~
in which limited displacement movement of the terminal in the
electrical device effected upon the assembly thereof onto
male mounting terminalis is generally isolated ~rom other
component9 of the electrical device connected with the terminal;
and the provision of such electrical devices, method, and
terminal having componentis which are sirn~listic in de~ign,
and easily manufactured and/or a9~embled. The~e a-~ well as
other objects and advantageous features of the invention will
be in part apparent and in part pointed out hereinafter.
~ In general, an electrical de~ice in one form of
the inven~ion i3 adapted to be associated in electrical
contacting engagement with a set of terminals for connection
in circuit relation with a winding circuit of a dynamoelectric
machine. The electrical device has a casing, means for control-
ling starting of the dynamoelectric machine, and a pair o~
means for electrically contacting and supporting the starting
meansin the casing. A set of means i9 d~sposed in the casing
so a~ to be limitedly displacably movable for receiving respective
-5- --
ones of the terminal~ of the terminal ~et upon the association
in the electrical contacting engag~ment thferfewith and also
connected in electrical conductive fengagement with the
contact and supporting means. frhe receiving means of the set
the,reof include means fox at least limiting tran,--,lation of
the displacement movement from the receiving means to th~e contact
and supporting mean9 in the event of the occurrence o the
displacement movement upon thfe association of the receiving
means with hte respective ones of the terminals~ . -
Also in general and in one form of the invention,
the above descr:ibe~, electrical device may utilize controlling
means operable generally in response to current applied thereto
to increase it9 resistance generally as a function of the :~
: temperature so as to render a start winding of the winding
circuit generally ineffective therein when the dynamoelectric
machine is engaged to a preselected speed. Anothex circuit
for controlling the pafsfage of the current to the winding
circuit include9 a thermally responsive current carrying
switch means in the casing and operable from a current passing
position toward a current i.nterrupting position in response to .
--6--
.
~ ~ f~
. L~ ~ ~ ~ U ~,
a preselected thermal condi~ion occa~ioned upon winding
circuit ov2rload. Mean~ i9 provided for connecting the switch
means in circuit relation with one of the contact and ~upport~
ing means, and the controlling mean9 and switch means are
associated in heat t~ansfer relation 90 as to delay the return
of the switch means from its current interrupting position in
response to heat of the controlling means upon the application
of current thereto.
~urther in general and in one form of the invention,
a terminal has a socket with an opening therein, and a generally
elongate sectionis integral with said socket and extend~ there-
from. A distal end portion is a~sociated with the ~ection,
and another generally elongate section extends generally in
spaced relation with respect to the first named section and is
as~ociated with the distal end portion. A free end portion on
the another section is disposed ~enerally adjacent the socket,
and at least one of the first named and another section is
adapted for yielding at a location generally between the distal
end portion and the socket.
Al~o in ~eneral, a method in one form of the
.~ invention i9 provided for making an electrical device so
as to generally isolate an electrical component thereof from
limited displacement movement of terminai means supported
in the electrical device and associated\both mechanically
; 25 and electrically with the electrical component upon the
-
: ,, : '
03-AC-5018
5~
moun-ting of the terminal means to a mating terminal. This
method comprises integrally forming one of a pair of legs
of a generally U-shaped configuration with a socket portion of
the terminal msans and connecting the other of the legs in the
mechanical and electrical association with the electrical
component so that at least one of the one and other legs .
generally absorbs the limited displacement movement of the
terminal means upon the mounting thereof to the mating terminal.
Brief Description of the Drawings
FIG. 1 is a greatly enlarged plan view of a terminal
in one form of the invention;
FIG. 2 is a side elevational view of the terminal
of FIG. 1;
FIG. 3 is a left end elevational view of the
terminal of FIG. l;
FIG. 4 is a plan view of a blanked-out body of
the terminal of FIG. l;
FIGS,5 and 10 are plan views of electrical devices
in one form of the invention with a portion of the casing
thereof broken away and illustrating principles of a method
of making an electrical device in one form of the invention,
respectively;
FIGS. 6 and 11 are left side elevational views of
the electrical devices of FIGS. 5 and 10, respectively;
FIGS. 7 and 12 are sectional views taken across a
connection inlet opening o the deive of FIGS. 5 and 10,
respectively; ~ :
: - 8 -
FIG. a is a graphical repre~entation of typical
resistance and temperat~re chaxacteristics of a PTCR utilized
in the electrical devices of FIGS. 5 and 10, respectively; and
FIGS. ~ and 13 are schemat.ic circuit diagrams
illustrating the use of the electrical devices of FIGS. 5
and 10 in circuit relation with a windiny circuit of a prime
mover, respectively.
corresponding re~erence characters indicate corres-
ponding parts throughout the several views of the drawings.
The exemplifications set out herein illustrate
preferred embodiments of the invention in one form thereof/
; and ~uch exemplification9 are n~t to be construed a~ limiting ~ -
~ the ~cope of the invention in any manner. ~; ~
~ ' .
De~ailed Description of the Prefer.red Embodiments
Referring now to the drawings in detail and in
; particular to FIGS~ 1-3~ a terminal or terminal means 11 has
an integral body 13 formed o~ a generally thin material, such
~ as a strip of metal for instance, which has good electrical ,
: conductive properties or characteristics. Body 13 has mean~,
such as an electrical connector section illustrated as a `
female socket or split ~leeve portion 15 for instance, for ~ -
receiving in releasable electrical contacting engagement another
terminal adapted for as~ociatlon therewith, as di~cu~sed in
greater detail hereinafter. Means, subh as a supporting ~r
connection section illustrated a5 a generally U-~haped
:
. . ~.;
'
)7~ ~:
coniguration or a tab 17 for in0tance, is integral with
split sleeve portion or receiving mean~ 15 and adapted for
association or connection in electrical conductive relation,
such as both electrical and mechanical engagement for instance,
with an electrical component, as al30 discussed in greater
detail hereina~ter. Connection means or the U-shaped config-
uration 17 comprises a pair of spaced apart generally opposite
adjacent end portions 19, 21 with one of t~e end portions 19
being integral with split sleeve portion lS while the other
of the end portion 21 i8 spaced generally adjacent the split
~leeve portion for the connection or as~ociation with the
aforementioned electrical component. U-shaped configuration 17
also includes means, such a9 at least one re9ilient or yield-
able section, between end portions 19, 21 thereof operable
generally for yielding in the event of t:he occurrence of
disp1acement movement of split sleeve portion 15 upon th~
association thereof in the electrical contacting engagement
with the aforementioned another terminal so as to at least in
part limit the trans~ation or transmi~ ion o such displacement
movement from the ~plit sleeve portion through the ~-shaped
; configuration to the aforementioned electrical component when
it i~ a~90ciated with end portion 21. While supporting section
17 is illustrated and described as a generally U-shaped
con~iguration merely for convenience of disclosure, it is
contemplated that configurations other than such generally !~
--10--
LS~7.
U-shaped configuration9 may be utilized within the ,3cope of the
invention ~o a,, to achieve the objects and advantages thereof.
Furthermore. it is also contemplated that electrical connector
sections other than the female ~ocXet or split sleeve portion
15 illustrated merely for purposes of di9clo~ure may be employed
with terminal 11 within the scope o~ the invention in order
to meet the objects and advantages thereof.
~ore particularly and referring also to FIG. 4,
body 13 of female terminal may be blanked punched or otherwise
formed from a thin metallic material or sheet, and in its blanked-
out form, the hody ha,3 a pair of oppogite ends or end edges
23, 23a. A fir~vt pair o oppo9ite ,3ide edfges 25, 25a are
provided on body 13 intersecting with end edge 23, and a
second pair of oppo,eite 9ide edge9 ~7, 27a are also provided
on the body intersecting with end edge 23a. A pair of
; shoulders, such as generally perpendicular edges 29, 29a are
provided on body 13 30 as t~ intFrconnect or interfiect with
3ide edge9 25, 25a and 27, 27a. Slot mean,a, which comprise a
pair of intersecting or integrally formed elots or slot
portions ~1, 33 are dispo,~ed through supporting section 17
of body 13, Slot portion 31 extends generally from at least
adjacent ~houlders 29, 29a toward end edge 23a being disposed
between ,3ide edges 27, 27a, and 810t portion 33 is disposed
generally ad~acent shouldv~r 29 extendin`g from ~lot portion 31
so as to intersect with s~de edge 27. In this manner, it may
--11~` .
be seen that the interposition of 510t portion 31 between t~ida '
edges 27, 27a define~ a pair of spaced apart leg9 or generally
elongate sections 35, 37 disposed generally in laterally
spaced relation on supporting section 17, and the intersection
of slot portion 33 with side edge 27 defines free end or
end portion 21 on leg 37 so as to be spaced generally adjacent
shoulder 29, i.e. split sleeve portion 15.
A distal end or bight portion 39 is integrally
provided on supporting section 17 between generally end edge
23a of body 13 and the rightward end of slot portion 31 so as
to be predeterminate].y spaced from split sleeve portion ~5 :
~as best seen in FIG. 4). Leg 35 includes end portion 19
which, a~ previously mentioned is integral with split sleeve
portion 15, and end portion 19 is generally opposite with
respect to another end or end portion 41 of the leg which i8
integrally formed with distal end 39 Oe supporting section 17.
Leg ~7 is also pro~ided with another end or end portion 43
which i~ di3posed generally in opposite relation with re~pect
to ~ree end 21 of the leg, and end portion 43 is also integrally
formed with distal end 37 of eupporting section 17. The
-. ~ '
-12- '
LS~
aforementioned yielding mean~ or section of ~upporting section
17 i9 located in at lea~t one of legs 35, 37 between opposite
end pairs 19, 41 and 21, 43, respectively, as dl~cussed in
detail hereinafter.
5ubsequent to the above de~cribed blanking of terminal
11, split sleeve portion lS may be formed by rolling, bending
or other such ~haping methods generally into the configuration
illustrated in FIG. 3. In this manner, side edyes 25, 25a of
body 13 are displaced and positioned generally in opposed or
facing relation with each other 90 as to provide an opening 45
that extends through 9plit sleeve portion 15 generally between
end edge 23 and shoulder pair 29, 29a thereof. Of course,
opposed side edges 2S, 25a de~ine~ the ~plit extending the
length of split sleeve portion 15 and intersects with opening
45 thereof 80 that the ~plit sleeve portion may resile or be
displacably movable, i.e~ to expand or ~pring open, in order
to accommodate a male terminal which may be inserted into the
opening into electrical contacting and/or mounting engagement
with terminal 11, as discu~sed hereinafter. While electrical
connector section 15and op~ning 45 thereof are provided with the
part-icular shape~ or configurations illustrated in FIGS. 1-3
merely for convenience of disclosure, it i9 contemplated ~;
that other electrical connector ~ections may be employed
having various other configurations an~ that other openings
~~ 25 may be utilized assuming a varletyof other ~hape~ within the
~' ~
-13-
~:~0~51~7,
9cope of th~ ~nvention 90 a~ to attain the objects and advan-
tages thereof. Leg pair 35, 37 may al~o be ~tamped, bent or
otherwise deformed 90 as to extend from split sleeve portion lS
in the shape illu trated generally in ~IG. 2: however, while
S legs 35, 37 are provided with such particularly illustrated
shapes and are described hereinabove as being disposed gener-
ally in laterally spaced relation with respect to each other,
it is contemplated that legs having shapes other than those
illustrated and being arranged in other ~paced relations may
also be utilized within the scope of the invention so as to
meet the ob~ects and advantages thereof. For instance,
at lea~t a part of one of legs 35, 37 may be skewed or bent with
respect to at lea~t a part of the other of the legs 90 a~ to
extend generally in dif~erent planes. Furthermore, legs 35,
lS 37 may be shaped before, after or generally simultaneously
with the shaping of ~plit sleeve portion 15, as described
above. of course, it is al80 contemplated that one of legs 35,
37, or at least a pàrt thereof, may be provided with a cros~
~ection or width, i.e. between slot 31 and side edges 27,
27a of body 13, which is less than that of the other of the
leg9 so a9 to predetermine the location of the aforementioned
yieldable means or portion of the legs adapted to resile or
- ~eild in order to effectively absorb or accommodate limited
displacement movement o~ the ~plit sleeve portion upon the
association thereof with a male mounting terminal, as discussed
.
-14
~.~0~5~7.
hereinafter.
Referring now to the drawing~ in ~eneral and
recapitulating, at l~ast in part, with respect to the foregoing,
an electrical device 61 in one form of the invention is adapted
to be a~ociated in electrical contacting engagement with at
least one terminal means, such as a male mounting terminal
63a of a set 63 thereof, for a winding circuit 65 of a
dynamoelectric machine ~FIG. 8). Electrical device 61 has a
casing 67, and an electrical component or contacting and
supporting means, such as a contact plate 69, is supported or
dispo9ed generally in a preselected position in the casing
(FIGS. 5 and 7). Mean9, 9uch as split 91eeve portion 15 of
.
~erminal 11, for receivin~ the at least one terminal means or
male mounting terminal 63a in the electrical contaGting engage-
ment therewith i~ disposed in ca~ing 67 ~o as to be limitedlydisplacably movable upon the association with the male mount-
ing terminal ~FI~S. 1-3, 5 and 7). Mean9, such as supporting -;
section 17 of terminal 11, extends from ~plit sleeve portion or
receiving means 15 for connection in electrical conductive
20 relation or association, i.e. in both electrical contacting
- :,
--15--
s~
engagement and mechanical engagement, wlth contact plate 69
90 as to disposa the con~act plate in its pxei~elected
position in casing 67~ Connection means or ~upporting section
17 includes means, such a9 at lea9t one of legs 35, 37, ~or
accommodating the limited dii3placement movement of ~plit sleeve
portion 15 so as to at least generally isolatei contact plate
69 from the ~imited displacement movement upon the association
of the split sleeve portion with male mounting terminal 63a.
More particularly and with i~pecific reference to FIGS. ; ~;~
5-7, it may be noted that only terminal 11 and plate 69 are
described herein in detail, but the letter "a" will be employed
herea~ter to designate corresponding co~ponent parts of another
terminal lla and another contact plate 69a which, for purposes
of disclosure, have generally the same constructions a~ termin-
al 11 and contact plate 69, respectively7 however, it is con-
templated that such terminals and contact plate~ may be of
dis~imilar constructions within the scope o~ the lnvention so
as to meet the objects and advantageous features thereof.
Caising 67 is provided with a pair of ~eparable
casing member3 71, 73 which are retained against displacement
from each other by suitable fa~tening means, such as a plurality
of rivets 75 or the liXe. Casing members 71, 73 comprise a ?
plurality o~ wall msan~ including a sidewall 77 integrally
formed or interconnected between a pair of opposed spaced apart
walls, such as an end or top wall 79 and an end or baise wall 81,
..
--16~
.; ~ pt~ ;? ~ ; r , .~ ;
s~
and such wall mean~ plurality de ~ne~ a chamber 83 within
casing 67~ At lQa~t one g~o~ve or recess means B5 is provided
in sidewall 75 communicating with chamber 83, and supporting
sec~ion~ 17, 17a of te~minala ll, lla are di~posed in or extend ~ :
into the recess mean-q. A pair of generally parallel, 6paced
apart openings or terminal containing apertures 87, 87a
extend through sidewall 77 of casing 67 having interior ends
intersecting with rece~s means 83 and exterior ends opening . .
exteriorly of the ca~ing, re9pectively, and electrical connector
sections 15, 15a of terminals ll, lla are respectively
di~posed for limited di~placement movement within the openings,
as discussed in detail hereinafter. A pair of maans, ~uch as
; shoulder~ or ~tops 89, 91 and 89a, 91a or the like, are integ- -
rally provided on casing 67 generally adjacent the interior and
exterior ends of openings 87, 87a so a9 to abut with ~hould-
ers 29, 29a and oppo~ite end 23 of ellectrical connector
sections 15, 15a on terminal~ ll, lla for containing or
trapplng the electrical connector 8ection~ within the opening. ;:
~` Contact plates 69, 69a are illustrated for puspo~es
of disclo~ure as having a generally flat triangular shapeJ but
it i9 contemplated that contact plates having various other
~hape~ or configurations may be employed within the ~cope of
the invention ~o as to mest the objectfi and advan~ageous
features thereof. Contact pla~es 69, 69a are located or
supported on opposed end wall~ 79, 81 of casin~ 67 within
:
-17-
- I~ ~. ~ 3 ~ "~
LS~
chamber 83, and it is contemplated that reQilient means
(not shown~ may be provided betw~en at lea~t one of the opposed
end wall~ and the contact plate for urging it gen~rally toward
the other of the contact plates. A plurality of means, such ::
as abutment or ~ide edge portion indicated at 93, 93a, are
provided on contact plates 69, 69a for respective positioning
or locating engagement with sidewall 75 of casing 67, and
extension means, such as bent fingers 95, 95a, are integrally
provided on contact plate~ 69, 69a extending thererom for the
aforementioned connection in both the mechanical and electrical
engagement with free end portions 21, 21a of legs 37, 37a on
terminal~ 11, lla, re~pectively, by suitable mean6, ~uch a~ ;
soldering for instance (not shown). A plurality of indentat~ons
or dimples 97, 97a may be provided in contact plates 69, 69a
so as to insure good electrical contacting and mechanical
: supporting or positioning engagement with a pair of opposite .
sides 99, 99a of means, such as a generally cy1indrically . -
shaped P~CR 101, operable generally for controlling starting
of a dynamoelectric machine when connected in circuit relation
therewith, as discussed in deta~l hereinafter. PTCR 101 i9
-18- ..
l507~
operable generally in xeapon~e to current fl~w therethrough to
vary or increa3e it~ re~istance generally a~ a function of it~
temperature, a~ illustrat~d in FIG. 8, ~o a~ to generate heat
when energized, and of course, oppo~ite Aides 99, 99a of PTCR
101 are coated or otherwise covered or layered with a chemical
compo~ition (not shown) so as to insure the generally even or
con~tant flow or di~tribution of current throuyh the P~CR
from one o the opposite sides to the other thereof. In this
manner, PTCR 101, i~ embraced, i.e., supported or positioned in
both the electrical contacting and positioning or ~upporting
engagement, between contact plates 69, 69a within chamber
83 of ca~ing 67. While PTCR 101 is 9hown having a generally
cylindric qhape, it i9 contemplated that a PTC~ having
a ~hape other than cylindric may ~e employed within the
9aope o~ the invention so a~ to meet the object~ th~reof~
A plug~on or quick disconnect type terminal or
terminal meana 103 is attached by suitable means, ~uch as a
rivet 105 for instance, to opposite end wall 81 of casing
67 ~o aa to be disposed exteriorly thereof. To complete the
description of electric~l device ~1, a lead receiving opening
or aperture 107 i8 provided through ~idewall 77 of casing ~7
80 at~ to ihters~ct wlth reces~ meana 85, and an electrical lead
109 extends through opening 107 having an interior end elect-
` rically connected with ~upporting secti\on 17a o terminal lla
: ' .
.
. .
- 19~
15~
and an exterior end electrically ~onnected with terminal
mean~ 103. 0 cour~ ad 109 define~, at l~as~ in part,
circuit means in which terminal mean~ 11 and contact plate 69
are placed in series circuit xelàtion acro~ PTCQ 101 with
both contact plate 69a and terminal lla and terminal means
103.
` A~ illustrated in an exemplary schematic diagram of
a circuit ~11 in FIG. 9, a prime mover, ~uch as an electxic
motor 113, i~ provided with a winding circuit comprising a
main or run winding 115 and an auxiliary or start winding 117
connected in circuit relation therein. An assembly or set of
: mounting or mal~ terminals or terminal means 119, 121, 123
are fi~edly mounted in a plug or the like 124 adap~ed ~or
mounting as~embly or association to a ~;tructural component
(not shown) in which motor 113 may be housed; however, it is
contemplated that terminal plug 124 may be remotely mounted
~ with respect to the motor to anoth~r structural component, such
: as a jacket or housing of a device driven by the motor such
: a~ a compressor or the like for instance (not shown). Further, . ~ ~-
male terminal~ 119, 121, 123 may be predeterminately ~paced
apart and sized within tolerance limit~ 80 as to meet certain
industry - wide standard3 or other specifications. Male
terminals 121, 123 are respectively connected in circult
relation with Ftart winding 117 and runjwinding 115 of motor
113, and male terminal 119 i8 connected in circuit relation
,
--20--
~3.
Sa~7.
.,~ .
wi~h both th~ ~tart and run winding~. Fem~le terminals 11,
lla of electrical device 61 are dispo~ed tO relea~ably receive
male terminal~ 121, 123 of the terminal set in electrical con- -
ductive relation when the electrical device is associated or
as emb~ed with motor 113, and a pair o~ leads 125, 127 are
respectively connected between line te.rminals L1, L2 and
male terminal 119 and terminal mean~ 103 o~ electrical device
61. To complete the de~cription ~f circuit 111, a` motor
energizing ~witch 129 may be interposed in lead 125.
As previously mentioned, variations in the tolerances
of male terminal9 119, 121, 123 with respect to the ~ize
thereof and/or the spaced relation therebetween in plug member
124 are, o~ coursa, encountered, and auch tolerance variations
may also occu.r in electriaal connection sections 15, 15a
of terminal3 11, lla in electrical dev:Lce 61, as previou~ly
mentioned. Due to the aforementioned tolerance variations,
electrical connector ~ections 15, 15a of terminals 11, lla
may twist and/or be both laterally and l~ngitudinally moved or
otherwise displaced wlthin their respective openings 87, 87a
of casing 67 when the electrical connector ~ections are
-21- .
~lQ15~7~
ral~a~ably or grippingly engaged in elect~cal conductive
relation on male terminal~ 121, 123 ~o as to mount electrical
device 61 in circuit xelatlon on mounting plug 124. Upon the
a~8embly of el~ctrical device 61 to mounting plug 124, as
above de~Ycribed, the tran~mis~ion or tranYlation of the
displacemsnt movement of electrical connector ~ections 15,
15a through ~upporting sections 17,. 17a o~ terminals Ll, lla
to contact plate~ 69, 69a i~ at lea~t predeterminately limited
or accommodated by the yielding or xesiling of at least one of
legs 35, 37 and leg~ 35a, 37a of th~ supporting sections,
respectively, In thi~ manner, the above described means of
supporting ~ec~ions 17, 17a for accommodating the displacement
movement of electrical connector section~ 15, 15a at leaat
predeterminately limit~ or obviates the transmission of such
displacement movement to contact plate~ 69, 69a so as to
maintain them generally in their as~embled positions within
chamber 33 of ca~ing 57 which results in the preservation of ~ ;
the chemically coated opposite slde~ 99, g9a of PTCR 101 from
deleteriQus ~cr-~bing or abra~ive action thereon of dimple~
97, 97a in the contact plates ~o as to prevent the establiah-
ment of "hot ~pots" on the PTCR and maintain the de~irable
electrical charact~ristic~ or integrity ~h~reof.
In the operation of electrical device 61 when
assembled in circuit relation onto plug\2~ and with $hc compon-
e~t part~ o~ the electrical device disposed as 3hown in the
.
' ~:
: .
-22~
..1 i
drawlng~ and as de~cribed above, an operat~r may energize
motor 113 acro~s line termir.al~ 2 by closing switch 129,
~IG. 9. In thi~ manner, power ls supplied ~rom line terminal
Ll, through the clo~ed switch 129, lead 125 and male terminai
119 to both main winding llS and qtart winding 115 of motor
113. From start winding 117, current flow~ through male term-
inal 121, female terminal 11 of electrical device 61, contact
plate 6~, PTCR 101, contact plate 69a, female terminal lla,
and therefrom through lead 109, terminal means lQ3 and lead
127 to line terminal ~2. At the ~ame time, current also
passe~ in parallel circuit relation from main winding ll5
through male terminal 123 to female terminal lla o electrical
device and therefrom through lead 109, te~minal means 103 and
lead 127 to line terminal L2.
As previou~ly mentioned and as lllu~trated in FIG. 8,
P~CR 101 i~ operable generally in re~pons~ to current flow
: therethrough to increase its resistance generally as a unction
o its temperature; therefore, assuming the temperature of
P~CR 101 to be rather low at the starting or ~tart-up period
of mo~or 113 when qwitch 129 is closed, the PTCR will initially
- p3S8 current at a value sufficiently great enough to effect
a desired ~tartlng torque of the motor during the start-up
period thereof. As the temperature of P~CR lQl increa3es in
respon~e to th~ current flow therethro\ugh, its rasistance to
such current flow al~o increa~e~q to a ~alue which, in general,
-23
a50~
renders start winding 117 ineffective in th~ motor winding cir-
cuit so a~ to electrically di~a~ssciate the ~tart winding
from ~in windin~ 115. ~he point in time during the motor
start-up period at which start winding 117 i~ rendered inef-
fective, as previously mentioned, may be predetermined so as
to generally coincide with the desired running speed of motor
113. That is to say, ~tart winding 117 may be generally
di~abled or rendered ineffective in the winding circuit of
~ motor 113 generally about the time the motor attains its run-
ning speed. ~f course, P~CR 101 will not act to obviate
current flow through start winding 117 during the running -
~peed period of motor 113, but the PTCR will throttle or
restrict the pa3sage of such current flow to such a minimal or
~mall value that the start winding is ineffective in the
winding circuit of the motor. Of course, when the operator
opens 9witch 12~, circuit 111 is interrupted across line
terminals Ll, ~2 and motor 113 is deenergized.
Referring again to FIGSo 1~9 in general and
recapitulating at least in part with respect to the fore~
going, a method in one form of the invention is provided for
.~: :'
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: ,
-24-
-
o~ ~:
making electricaL d~vice 61 60 a3 to generally isolate con~act
plate 69 thereof from at l~ast limited dii~placement movement
of female terminal 11 supported in the device and ai~sociated
both mechanically and electrically with th~ contact plate upon
the mounting of the female terminal tO a ma t ing terminal, 9 uch
as one of male terminal~ 119, 121l 123. The method comprise~
integrally forming one of legs 35, 37 of the generally U-shaped
tab ox supporting i~ection 17 with the socket portion or
electrical connector section 15 of female terminal 11 for
receiving the mating terminal and connecting the other of legs
35, 37 in both the mechanical and electrical association
with contact plate 69 i~o that at least: one of the one and
: other legs 35, 37 genarally ab~orbs the limited displacement
movement o female terminal 11 upon the mounting or assembly
,
the.reof to the mating terminal..
Anot~er electrica~ device, such as a combination
starter-protector device 201, in one form of the invention is
.~ shown in FIGS. 10 12 having generally the i3ame component
part~ and functioning generally in the same manner as the
above described electrical device 61 with the exceptions
: di6cussed hereinafter, and it i~ believed that electrical
: device 201 may have additional objects and advantageous
feature~ of itB own a~ well as meeting at least some of the
objects and advantageou~ features set out above with respect to
~ 25 electrical device 61.
:
-25~ .:
1~0~
~ :lectrical device 201 i8 provided with a casing 203
compri ing a plurallty of caRing members, such as a lower
casing member or receptacle 205, an intermediate casing
member 2û7 and an upper ca4ing member or cover 20g, which are
5 interconnected against displacement from each other by 6uit-
able rneans, such as a plurality of rivets 211. Intermediate
casing member 207 and receptacle 2~9 are respectively provided ~ :
with generally annular overlapping or interfitting flages 213,
215 which are abutted together. Casing 203 has a plurality :~
10 of wall means defining a chamber 217 therewithin, and the wall
means plurality include a sidewall or sidewall means 219
respectively formed on casing.members 205, 207, 209 and
interconnected with a pair of generally opposite end walls
221, 223 respectively formed on casin~ menbers 205, 209.
Intermediate ca~ing member 207 and cover 209
include reces9 mean~ 85 which i~ provided in sidewall 219 :~
so as to communicate with charnber 217, and openings 87, 87a
';
are al80 provided through the sidewall ~f the intermediate cas-
ing member and cover so as to intersect with the recess means.
Electrical connection sections 15, 15a are received in openings
so as to be at least limitedly di~placably movable therein
when mounted to male terminals 121, 123, a~ previously
discus~ed hereinabove with re pect to electrical device 61.
Stops 89, 91 and 89a, 9~a are also provided on intermedial~e
casing member 207 and cover 20g for abutment with end edge 23
~` ' . ' . ~
--26--
~0~
and shoulder~ 29, 29a on electrical connector sections 15~
l5a of terminal9 11, lla so a~ to contain the el~ctrical connect-
or qections in opening8 87, 87a, re5~ectively. Supporting
sections 17, 17a of terminal~ 11, lla extend from electrical
connector sections 15, 15a thereof so a~ to be respectively
disposed or po~itioned in recess means 85.
PTCR 101 i5 di9po9ed in-the electrical contacting
and positioning engagement between dimples 97, 97a of contact
plateR 69, 69a within chamber 217, and abutment means 93,
93a of the contact plates are di9po~ed for po9itioning or
locating engage~ent with sidewall 219 of intermediate casing
member 207 and cover 209. Contact plate 69 is abutted or
supported on the i.nterior ~ree end of flange 215 on recept- -
acle 205, and reBilient mean9, such as a generally thin wavy
washer 225 or the like, is bia9ed between end wall 223 of
cover 209 and contact plate 69a. In thi~ manner, contact
plate 69a i9 urged toward the ele~trical contacting and
positioning engagement with opposite side 99a of PTCR 101 and
the other oppo~ite side 99a o the PTCR i9 urged into the
electrical contacting and positioning engagement with contact
pla.te 69 so as to maintain contact plate 69 in it~ seated
~ or supported engagement with the free end o flange 215 on
receptacle 205. Finger9 95, 95a of contact plate 69, 69a
: - are respectively connected in both th~ mechanical and elect-
rical conductlve engagement with the free end~ 21, 21a of
l~C1~L507~ !
of legs 35, 35a on supportlng ~ections 17, 17a of terminals
11, lla.
Another pair of terminals 227, 229 extend through
end wall 221 o~ receptacle 205 being integrally ca~t therein or
otherwi~e retained therein by suitable means, and the inter-
ior end portions of the terminals respectively define a pair
of contacts 231, 233 within chambe~ 217 generally adjacent
end wall 221 whilP the exterior end portion of the terminals
are adapted for receiving quick connect or disconnect fittings
(not shown) in circuit relation. Interrupting m~ans, such
as a current carrying~ thermal-responsive swltch means, indicated
generally at 235, ia provided with a flexible, generally disc-
shaped switch actuator or element 237 formed of a current
carryiny material, such as for instance a bimetal, and another
pair o movable contacts 239, 241 are mounted to the switch
actuator being di9po9ed in making engagement with contacta ~ .
231, 233 of terminals 227, 229 when the switch actuator i9 in . ~:
it9 at-re9t positions~ Switch actuator 237 is generally :`
~- centrally mounted to ox carried on an adjusting screw 243
which is adjustably s~r threadedly received in a threaded
opening 245 in end wall 221 of receptac1e 205 to adjust the ~-
bias on the switch as:tuator urging its movable contacts 239, ~;
241 into the making engagement with contacts 231, 233 of term~
inals 227, 229, respectively. While ~witch means 235 is pre~-
ented herein for purpo~es of disclosure, it is contemplated .
that other types of switch means having various con~igurations
may be utilized in the pre~ent in~ention eo. as to rnee~ the
.
' , .
--28--
5~
.
object~ and advantag~ous feature~ there~f. It m~y be noted
that switch actuator 237 i~ spaced generally adjacent contact
plate 69 within chamber 217 so as to be dispo~ed in heat
tran~fer relation with PT~R 101, as discus~ed in detail
hereinafter, and i.de3ired, at lea~t one opening (not
shown) ma~ be provided through contact plate 69 for facilit-
ating the transfer of heat from the PTCR to the switch act-
uator.
Lead receiving opening 107 is provided in intermed-
iate casing member 207 and cover 209 through sidewall 219 ~.
thereof 90 as to intersect with recess mean~ BS, and electrical
lead 109 extend~ through opening 107 having an interior end
electrically connected to supporting ~lection 17a of terminal
lla and an exterior end electrically connected with terminal
277. ~nother lead receiving opening :247 i9 al90 provided in
lntermediate ca8ing member 207 and cover 209 through sidewall
219 thereof 90 a~ to intersect with reces~ means B5, and another
electrical lead 249 extend~ through opening 247 having an
interior end electrically connected to ~upporting section
17 of terminal 11 and having a quick connect or di~connect
electrical fitting 251 on the exterior end thereof.
In FIG. 13, another circuit or ~ystem 261 is shown .:
having generally the same component~ and functioning generally
in the 5ame manner a8 the previously discribed circuit 111
~: 25 with the following exceptions. In c~r~uit 261, emale terminal~ !
-29-
~IU~5~7,
o electrical device 201 are di~posed to rel~a~ably or grip-
pingly receive ma~ terminal~ 121, 125 in plug 1~4 when the
electrical device i~ associated or aRsembled with motor 113.
Lead 125 having starter switch 129 interposed thereln i9
connected between male terminal 119 and line terminal Ll,
and lead 127 is connected hetween terminal ~27 of electrical
device 201 and line terminal L2. A capacitor 263 i5 connected
in circuit relation between terminal 229 of electrical device
201 and electrical fitting 251 of lead 249 extending from
the electrical device.
As previoucsly mentioned, variations in the tol-
erances of male terminal~ 119, 121, 123 with respect to the size
thereof and/or the spaced relation th~rebetween in plug member
124 are, of course, encountered and ~3uch tolerance variations
may al~o occur ln electrical connection sections 15, 15a
o~ terminal9 11, 17a in electrical device 201, Due to the
aforementioned tol~rance ~ariations, electrical connector
sections 15, 15a of terminals 11, lla may twist and~or be
both laterally and longitudinally moved or moved or otherwi~e
di~placed within their respective openings 87, 87a o~ intermed-
iate ca~inq member 207 and cover 209 when the electrical
connector ~ections are releasably or girppingly engaged in
electrical conductive relation on male terminals 121, 123 so
a~ to mount electrical device 201 in c\rcuit relation on
mounting plug 124. Upon the asSembly of electrical device
, . ' ' ~.
. 30-
l. . , - ';,; ~, ",,. ,tt; ~ "~ " S ~t;, . ~ 1"., ; ~S
L5~1~
201 to mounting plug 124, as above dei~cribed, the transmission
or tran~lation of the di3placem~nt movement of electrical
connector ~ections 15, 15a ~hrough.-qupporting sectiona 17,
17a of terminal3 11, lla to contact pla~es ~9, 69a i~i at least
predeterminately limited or accommodated by the yielding
or resiling of at least one of legs 35, 37 and legs 35a, 37a
of the supporting sections, re~pectively. In this manner, the
above de~cribed means of supporting sectionQ 17, 17a for accom-
modating the displacem~nt movement of electrical connector
sections 15, 15a at lea~t predeterminately limits or obviatesthe tran~mi~sion of suah di~pla~ement movement to contact
plates 69, 69a 80 aa to maintain them generally in th~ir
assembled positions within chamber 217 of aasing 203 which
results in the preservation of the chemically coated opposite
sides 99, 99a o~ P~CR 101 from deleteriou~ scrubbing or abra~
ive action thereon of dimple9 97, 97a in the contact plates so
as ~o prevent the e~tabli~hment of "hot ~pot~" on the PTCR and
maintain the desirable electrical characteristic9 or integrity
thereof,
In the operation of electrical device 201 when ~
assembled in.circuit relation onto plug 124 and with the ~ . -
component parts of the electrical device diapo~ed as shown in
FIGS. 10-13 and as de~cribed above, m4tor 113 i9 energized in
circuit 251 acro~s line terminals Ll, L2 upon closure of switch
129. In this manner, power i~ supplied from line terminal Ll
-3~- .
5~
through lead 125, closed qwitch 12~ therein, male ~erminal
119 to both main winding 115 and start winding 117 of motor
113. From main winding 115, the current flows through male
termlrlal 123, female terminal lla of electrical device 201
and lead 109 to terminal 227 thereof~ and ~rom terminal 227
through lead 127 to line terminal L2. At the same time, cur-
rent also passes in parallel circuit relation from-start
winding 117 through male terminal 121, female terminal 11
of electrical device, contact plate 69, PTCR 101, contact
1~ plate 69a to female terminal lla and thererom through lead ~:
109 and terminal 227 of the electrical device to lead 127
and line terminal ~2. It may also be noted that capacitor
263 is charged by currènt flowing through electrical device
201 from female term~inal lla thereof through lead 249 and the
capacitor to terminal 229 of the electriaal device and there-
from through switch means 237 and terminal 227 to lead 127 and
line terminal ~2. of course, capacitor 263 is operable
to shift the phase of the current through start winding 117 o-f
motor 113 to ef~c:t a de9ired starting torque ~f ~h~ motor
during the starting or start-up period thereof. of course,
as the temperature of PTCR 101 increa~es in response to current
flow therethrough, it~ resistance to such current 10w al~o
increase~ to a value which, in general, renders start winding
117 ineffective in th~ motor winding circuit, as previously
mentioned and as illu~trated in the graphical repre~entation
. ~
.~ .
5~7,
of FIG. 8. ~he point in time during the motor start-up
period at which ~tart winding 117 i9 r~ndered inePfective ~ -
may be predetermined so as to occur generally when motor
113 has attained its running ~peed.
As well-known in the art, winding circuit or
motor overload may have deleteriou3 affectæ on the compon-
ent~ of a motor, such as for instance the shorting or
buxning-out of the motor windings or winding circuit.
These overloadis or overload conditions may be effected by
a plurality of different causes or by combinations of 6uch
causes. For in~tance, some o the well-known causes of
thesQ overload condition~ are: a running overload, a
high temperature overload; an overload occasioned by a
~talled or locked rotor; and a high current overload.
Irrespective o the particular cause or combination of
causes effecting ~uch an overload condition, a deleter~
iously hi~h current i8 drawn by the motor, and such high
current is usually accompanied by or results in a high
temperature condition. Therefore, for the ~ake of si~p-
lifying the discussion of motor overloads or overload
conditions hereinafter, it is to be understood that any
--33-- .
:
~. ~ ' ' :
7. ~ ~
cau~e or causes ~or effecting auch motor ov~rload will be .
discussed only within the context of a high current draw
or condition a~compani~d by a high temperature or thermal
condition with re~pe~ct to the motor winding circuit. : ~
During the start-up and running periods of motor .
113, switch mean~i 235 is di~iposed in it~ circuit making : ~ -
or completing position in circuit 261 enqaging movable contact~
239, 241 with ~tationary contacts 231, 233. In the circuit
ma~ing position of switch means 235, bimetal switch blade
: 10 237 thereof is heatt3d in response to currant flow there-
through as well a~ the heat transmitted thereto from P~CR
101. When motor 113 i9 running or energized under normal
operating condition~, the h~at generat:ed in bimetal ~witch
blade 237 and the heat tran6erred thereto i~ predeterminately
less than that necessary for e~fecting movement of the
bimetal 6witch blade from it~ circuit making position
toward a cixcuit breaking or interrupting po~ition 90 as to
disengage or b~eak movable contacts 239, 241 from ~tationary
contacts 231, 233.
In the event of the occurrence of an overload
or high current condition, a relatively large amount of
current may be drawn in the motor winding circuit which
could deleteriously a~fect main winding 115 and start
winding 117, as previously mentioned.\ However, :~
bimetal ~witch blade 237 i9 responsive to such
:.
~34~
high curr~nt drawn ther~through to cor~e9pondingly increaise ita
generated heat thereby to e~fect ch~racteristic actuation o}
the bimetal iawitch blade to its interrupting pos1tion breaking
movable contacts 239, 241 from stationary contacts 231;, 233 to
interrupt or op~n circuit 261. In this manner, the motor w1nd-
ing circuit i8 automatically taken off the line to de energize
motor 113 in the event of the occurrence of an overload condition
or winding circuit overload whicH may exist acrosis line terminals
Ll, L2.
of course, opening of circuit 261, as discussed above,
also effects th~ de-energization of PTCR 101 and the resulant
cooling of the PTCR and switch means A235~ Even with the sup- :~
plemental heat supplied or transerred from PTCR 101 to awitch
means 235, the sw.itch means may cool suficiently in its circuit .
interrupting po~ition 50 as to.cycle ieeveral or a plurality o~
times between its circuit interrupting positlon and the circuit
completing position thereof. Such cycling of switch means 235
may ocaur throughout or aver a period of ia relatlvely short time
and is effective to repl~ce the motor winding circuit in
circuit relation across power terminals Ll, L2 for relatively
very short periods of time: however, the period o~ time the
motor winding circuit is thu~ cycled into circuit relation
across the power terminal will not deleteriously af~ect the
motor winding circuit since such time period i9 v~ry i~hort,
~5 as previou.sly mentioned. When switch means 235 i9 90 cycIed to
-35~
5~7
its circuit completing po~ition, PTCR 101 is re-energized ~; -
to again transmit heat to the switch means, and bimetal switch
blade 237 ls also again responsive to the overload condition ~o
again generate heat during the aforementioned relatively Ahort
period of time thereby to again efect the cyclical movement or
actuation of the swi~ch means to its circuit interrupting
position. Even in view of this cycling of switch means 235
or brief perioda of time subsequent to the occurrence of the -
overload condition, it ha been found that the -~upplemental
L0 heat transferrecl from PTCR 101 to the switch means is effect- -
ive to increase the "off-time" thereof, i.e., when the switch
meang i8 in it~ circuit interruptiny position, throughout the
aforementioned relatively qhort period of time. ~herefore,
the incr~ased "off-ti~e" of electrical device 201 occasioned
by the supplemental heat transferred from PTC~ 101 to switch
means 23S allows the PTCR itself to cool. When the resistanc~
and temperature of PTCR 1~1 are so reduced to a sufficiently
low value, the PTCR will again permit the passage therethrough
of cuxrent at sufficiently high enough values to again effect
energization of start winding 117 in the motor windiny circuit
so as to re~tart motor~1-13. Therefore, when switch means
235 also c0019 enough to cycle back to its circuit completing
position and remain therei current is drawn through PTCR 101 at
values great enough to effect the re-en~rgization of start
winding 117 to aid re-energized main winding 115 in the motox
-36-
31~(3~5~'7
windin~ circuit in bringing motor 113 up to it5 running
speed. When motor 113 attains its running speed, the self-
heating effect of PTCR 101 once again raises its tempera-
tur~ and re~istance to reduce current flow therethrough to a
value rendering start winding 117 ineffective in the motor
winding circuit. Thus, restarting of motor 113 as~umes that the
cause of the overload condition ha~ been alleviated or corrected,
and if not so alleviated, electrical devics 201 may again
operate or function as above described to take motor 113 off
the line across pow~r terminals Ll, L2.-
From the foregoing, it i~ now apparent that anovel terminal 11, novel electrical devices 61, 201, and a
novel method of making ~uch have been provided meeting
th~ object~ and advantages set out hereinbefore, as well as
other3, and that changes in the precise arrangement ~hapes,
connections and details of the construction set forth herein,
a~ well as the precise order of the method steps, for the
purpose of disclosure may be made by th3se having ordinary
skill in the art without departing from the spirit of the
invention or the ~cope thereof a~ set out by the claims which
follow.
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