CA1101507A - Electrical junction box and method of making the same - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
An electrical device has a casing, a solid state component, and a pair of means in the casing for electrical contacting and positioning engagement with the solid state component. A pair of terminal means are disposed in the casing for connection in circuit with the engagement means, respectively, and at least one of the terminal means is adapted for limited displacement movement in the casing upon the mounting association of the terminal means with a pair of mating terminals. The at least one terminal means includes means associated both mechanically and electrically with one of the engagement means and adapted for isolating the one engagement means from the limited displacement movement of the at least one terminal means upon the mounting association of the terminal means with the mating terminals.
A method of making an electrical device, and a terminal are also disclosed.

Description

~3~7 `

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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 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 .

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. 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 -: ,, : ' 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 :
. . ~.;

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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 !~

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 ~' ~

~:~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 .

~.~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 - :, 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, ..
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.; ~ pt~ ;? ~ ; r , .~ ;

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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 :

- 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 , ~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, 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 .~: :' ' .
: , -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 ~` ' . ' . ~

~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 .
' , .

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~ !

~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 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.

\' ,~' ~.

-37~

Claims (27)

The embodiments of the invention in which an exclu-sive property or privilege is claimed are defined as follows:

1. An electrical device adapted to be associated in electrical mounting engagement with a pair of stationary male mounting terminals for connection in circuit relation with a winding circuit of a dynamoelectric machine, the electrical device comprising a casing; a plurality of wall means on said casing defining a chamber therein and including a pair of opposed end walls, and a sidewall interposed between said end walls; a PTCR; a pair of contact plates disposed in electrical and supporting engagement across said PTCR and mounted in said chamber between said end walls; means on said contact plates for positioning engagement with said sidewall, respectively;
first and second apertures in said casing and extending through said sidewall so as to communicate with said chamber; said chamber including recess means in said sidewall and intersecting with at least one of said first and second apertures; first and second female terminals of a generally thin metal having good electrical conductive characteristics and respectively including first and second electrical connectpr sectopms generally confined in said first and second apertures and adapted for the association in the electrical mounting engagement with the male mounting terminal pair, and first and second supporting sections integral with said first and second electrical connector sections for connection in electrical conductive engagement with said contact plates; a first end portion of said first supporting section disposed in said chamber and connected in the electrical conductive engagement with one of said contact plates; said second electrical connector section including a split sleeve portion in said second aperture and disposed for limited displacement movement therein, an opening in said split sleeve portion generally aligned with said second aperture and in which one of the male mounting terminals may be received upon the association in the electrical mounting engagement of the first and second electrical connector sections with the male mounting terminal pair; said second supporting section being disposed generally in said recess means and including a distal end portion spaced from said split sleeve portion, a first leg integrally formed between said split sleeve portion and said distal end portion, a second leg integrally formed with said distal end portion and extending generally in laterally spaced relation with said first leg, a second end portion on said second leg spaced generally adjacent said split sleeve portion and connected in the electrical conductive and mechanical engagement with the other of said contact plates, and at least one of said first leg and said second leg including a section operable generally to yield in the event of the occurrence of the displacement movement of the split sleeve portion in said second aperture upon the association of said first and second electrical connector sections in the electrical mounting engagement with the male mounting terminal pair so as to at least in part limit the translation of the displacement movement of said split sleeve portion through the second supporting section to said other contact plate.

2. An electrical device adapted to be associated in electrical contacting engagement with at least one terminal means, the electrical device comprising a casing; an electrical component in said casing; means for receiving the at least one terminal means in the electrical contacting engagement therewith and arranged in said casing so as to be limitedly displacably movable; means extending from said receiving means for connection in both electrical contacting engagement and mechanical engagement with said electrical component so as to at least in part support said electrical component in said casing, and said connection means including means for accommodating the limited displacement movement of said receiving means so as to at least generally isolate said electrical component from the limited displacement movement in the event of the occurrence thereof when said receiving means is associated in the electrical contacting engagement with the at least one terminal means.

3. An electrical device as set forth in claim 2 wherein said connection means comprises a generally U-shaped configuration integral with said receiving means and having a free end portion disposed in both the electrical contacting engagement and the mechanical engagement with said electrical component.

4. An electrical device as set forth in claim 2 wherein said connection means comprises a pair of spaced apart legs having integrally connected generally opposite adjacent ends, one of said legs being integral with said receiving means and the other of said legs having a free end portion disposed in both the electrical contacting engagement and the mechanical engagement with the electrical component, and at least one of said one and other legs including said accommodating means.

5. An electrical device as set forth in claim 2 further comprising a PTCR supported at least in part in said casing by said electrical component in electrical contacting engagement therewith.

6. An electrical device as set forth in claim 5 further comprising thermally responsive current carrying switch means disposed in said casing for heat transfer relation with said PTCR.

7. An electrical device adapted to be associated in electrical contacting engagement with a set of terminals, the electrical device comprising a casing; a PTCR; a pair of means for electrically contacting and supporting said PTCR

within said casing; and a set of means disposed in said casing so as to be limitedly displacably movable for receiving respective ones of the terminals of the terminal set in the electrical contacting engagement therewith and connected in electrical conductive engagement with said contact and supporting means, and at least one of said receiving means of said set thereof including means for at least limiting translation of the displacement movement from said at least one receiving means to one of said contacting and supporting means in the event of the occurrence of the displacement movement of said at least one receiving means when it is associated with its respective one terminal.

8. An electrical device as set forth in claim 7 further comprising switch means disposed in said casing generally adjacent said PTCR for heat transfer relation therewith.

9. An electrical device as set forth in claim 7 wherein said receiving means respectively comprise socket means accessible from exteriorly of said casing and with which the respective one terminal may be associated in the electrical contacting engagement therewith.

10. An electrical device as set forth in claim 7 wherein said translation limiting means comprises at least one yieldable section and associated with the at least one receiving means.

11. An electrical device as set forth in claim 7 wherein said at least one receiving means further includes a pair of legs, one of said legs being integral with said at least one receiving means, an end portion on the other of said legs spaced generally adjacent said at least receiving means and connected in the electrical conductive engagement with said one contact and supporting means, and said translation limiting means comprising a section in at least one of said one leg and said other leg operable generally to yield in the event of the occurrence of the displacement movement of said at least one receiving means when it is associated with its respective one terminal.

12. An electrical device adapted to be mounted in assembly relation with a set of male mounting terminals, the electrical device comprising a casing; a PTCR; a pair of means for electrical contact across said PTCR and for positioning said PTCR within said casing; a pair of female terminal means connected in electrical conductive relation with said contact and positioning means and arranged in said casing for the mounting in the assembly relation with respective ones of the male mounting terminals of the set thereof, at least a part of at least one of said female terminal means being adapted for limited displacement movement in said casing upon the mounting assembly relation of said female terminal means with its respective one male mounting terminal, and means integral with said at least part of said at least one female terminal means and mechanically connected with one of said contact and position-ing means for generally isolating said one contact and positioning means from the displacement movement of said at least part of said at least one female terminal means in the event of the occurrence of the displacement movement upon the mounting assembly relation of said female terminal means with the respective ones of the male mounting terminal.

13. An electrical device as set forth in claim 12 further comprising circuit means arranged at least in part within said casing and connected with one of said contact and positioning means.

14. An electrical device as set forth in claim 12 further comprising switch means connected in said circuit means and disposed generally adjacent said PTCR for heat transfer relation therewith.

15. An electrical device as set forth in claim 14 further comprising means disposed in said casing and extending exteriorly thereof adapted for coupling said circuit means to a power source.

16. An electrical device adapted to be associated with a set of male mounting terminals for connection in circuit relation with a winding circuit of a dynamoelectric machine, the electrical device comprising a casing; means for controlling starting of the dynamoelectric machine; a pair of means disposed in said casing for electrical contacting and supporting engagement across said starting controlling means; and a pair of female terminal means for the association with two male mounting terminals of the set thereof and respectively including means for receiving in electrical contacting engagement a respective one of the two terminals and disposed so as to be limitedly displacably movable in said casing upon the association of said female terminals with the two male mounting terminals, means integral with said receiving means for connection in electrical conductive engagement with respective ones of said contacting and supporting means, and said connection means including means operable generally for yielding in the event of the occurrence of the displacement movement upon the association of said female terminal means with the two male mounting terminals so as to at least limit the translation of the displacement movement to said respective ones of said contacting and supporting means.

17. An electrical device as set forth in claim 16 wherein said connection means each comprise a bight portion spaced from said receiving means, a pair of spaced apart legs integral with said bight portion, one of said legs also being integral with said receiving means, and a end portion on the other of said legs connected in the electrical conductive engagement with said respective one contacting and supporting means.

18. An electrical device as set forth in claim 17 wherein said yielding means respectively comprise a section in at least one of said one leg and said other leg adapted to resile in the event of the occurrence of the displacement movement of the receiving means.

19. An electrical device as set forth in claim 16 wherein said receiving means respectively comprise a split sleeve portion having an opening therein into which the respective one of the two terminals may be inserted in the electrical contacting engagement upon the association of said female terminal means with the two male mounting terminals.

20. An electrical device as set forth in claim 16 wherein said female terminal means are formed from a generally thin metal having good electrical conductive characteristics, said connection means comprising a generally U-shaped configuration integral with said receiving means and having a free end disposed generally adjacent said receiving means so as to be connected in the electrical conductive engagement with said contact and supporting means, respectively.

21. An electrical device adapted to be associated in electrical contacting engagement with at least one terminal, said device comprising a casing; a plurality of wall means on said casing;
a chamber in said casing within said wall means plurality thereof;
an opening extending through one of said wall means of said wall means plurality so as to communicate with said chamber; a split sleeve contained within said opening and adapted for limited dis-placement movement therein upon the assembly of said split sleeve onto a male mounting terminal; a first extension integral with said split sleeve and extending therefrom generally into said chamber so as to be disposed at least adjacent said one wall means, a bight portion integral with said first extension, a second extension integral with said bight portion and disposed in spaced relation with said first extension, an end portion on said extension, and an electrical component in said chamber and including means for electrical conductive engagement with said end portion, and at least one of said first extension and said second extension including a yieldable section operable generally to accommodate the limited displacement movement of said split sleeve in response to the assembly thereof onto the male mounting terminal so as to generally isolate said electrical component from the limited displacement movement of said split sleeve portion.
22. An electrical device adapted to be associated in electrical mounting relation with a set of male mounting terminals for connection in circuit relation with a start winding and a run winding of a winding circuit for a dynamoelectric machine, the electrical device comprising a casing; a plurality of wall means on said casing; a chamber in said casing within said wall means plurality; a pair of apertures extending through one of said wall means of said wall means plurality so as to communicate with said chamber; said chamber including at least one recess means in said one wall means intersecting with at least one of said apertures; means in said chamber adapter for controlling energization of the start winding and operable generally in response to current applied thereto to increase its resistance generally as a function of its temperature; a pair of opposed contact plates disposed in electrical contacting engagement across said controlling means so as to support said controlling means within said chamber in predetermined spaced relation with said wall means of said wall means plurality; means on said contact plates for positioning engagement with at least said one wall means, respectively; a first female terminal means adapted for the association in the electrical mounting relation with one of the male mounting terminals of the set thereof and including means disposed within

Claim 22 continued:
one of said apertures for receiving the one male mounting terminal in the electrical mounting relation and also connected in electrical conductive relation with one of said contact plates; a second female terminal means adapted for the association in the electrical mounting engagement with another of the male mounting terminals of the set thereof and including a split sleeve portion for receiving the another male mounting terminal in the electrical mounting relation and disposed in the other of said apertures for limited displacement movement upon the association of said first and second female terminal means with the one and other male mounting terminals, respectively, a first leg integral with said split sleeve portion and extending therefrom into said at least one recess means, a distal end portion integral with said first leg and spaced from said split sleeve portion so as to be disposed at least in part in said at least one recess means, a second leg integral with said distal end portion, and an end portion on said second leg spaced generally adjacent said split sleeve portion and connected in electrical conductive relation with the other of said contact plates; another circuit adapter for controlling the passage of current to the winding circuit including thermal responsive current carrying switch means mounted in said chamber to another of said wall means of said wall means plurality and operable from a current passing position in said another circuit toward a current interrupting position, means for connecting said switch means in circuit relation with one of said one and other contact plates, and said controlling means and switch means being associated in heat transfer relation within said chamber so as to delay the return of said switch means from its current interrupting position to its current passing position in response to heat generated by said controlling means upon the application of current thereto.

23. A method of making an electrical device so as to generally isolate an electrical component thereof from limited displacement movement of terminal means supported in the device and associated both mechanically and electrically with the electrical component upon the mounting of the terminal means to a mating terminal, the method comprising integrally forming one of a pair of legs of a generally U-shaped tab with a socket portion of the terminal means for receiving the mating terminal and connecting the other of the legs in both 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.

24. A method of making an electrical device having a casing, a PTCR, a pair of contact plates for electrically contacting and supporting the PTCR in the casing, and a pair of terminal means including an electrical connection section for limited displacement movement in the casing upon the assembly thereof with mating terminals, and a supporting section for mechanical and electrical connection with the contact plates and having means for generally isolating the contact plates from the transmission thereto of the displacement movement of the electrical connector sections, respectively, the method comprising the steps of:
(a) forming the electrical connector section integrally with the supporting section of the terminal means and predeterminately providing the isolating means in the supporting section;
b) engaging both mechanically and electrically the supporting sections of the terminal means with the contact plates, respectively;
(c) assembling the PTCR between the contact plates in the electrical contacting and supporting engagement therewith and positioning the PTCR, contact plates and terminal means within the casing with the electrical connector sections disposed for the limited displacement movement thereof upon the gripping engagement with the mating terminals and with the isolating means operable generally to at least limit the transmission of the limited displacement movement of the electrical connector section through the supporting section to the contact plate, respectively.

25. An electrical device adapted to be associated in electrical contacting engagement with at least one terminal means, the electrical device comprising a casing; an electrical component in said casing; means adapted for receiving the at least one terminal means in the electrical contacting engagement therewith and disposed in said casing so as to be limitedly displacably movable; means extending from said receiving means for connection in both electrical contacting engagement and mechanical engagement with said electrical component so as to support said electrical component in said casing, said connection means including a pair of spaced apart legs having integrally connected generally opposite adjacent ends, one of said legs being integral with said receiving means and the other of said legs having a free end portion disposed in both the electrical contacting engagement and the mechanical engagement with the electrical component, and at least one of said one and other legs including means for accommodating the limited displacement movement of said receiving means so as to at least generally isolate said electrical component from the limited displacement in the event of the occurrence thereof upon the association of said receiving means with the at least one terminal means.

26. An electrical device 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 comprising a casing; means adapted for controlling starting of the dynamo-electric machine; a pair of means for electrically contacting and supporting said starting controlling means within said casing; and a set of means disposed in said casing so as to be limitedly displaceably movably adapted for receiving respective ones of the terminals of the terminal set upon the association in the electrical contacting engagement therewith and connected in electrical conductive engagement with said contact and support-ing means, and at least one of said receiving means of said set thereof including a pair of legs arranged generally in a U-shaped configuration, one of said legs being integral with said at least one receiving means, an end portion on the other of said legs spaced generally adjacent said at least one receiving means and connected in the electrical conductive engagement with one of said contact and supporting means, and means in at least one of said one leg and said other leg operable generally to yield for at least limiting translation of the displacement movement from said receiving means to said one contacting and supporting means in the event of the occurrence of the displace-ment movement upon the association of said receiving means with the respective ones of the terminals.
27. An electrical device adapted to be associated with a set of male mounting terminals for connection in circuit relation with a winding circuit of a dynamoelectric machine, the electrical device comprising a casing; means adapted for controlling starting of the dynamoelectric machine; a pair of means disposed in said casing for electrical contacting and supporting engagement across said starting controlling means;
and a pair of female terminal means adapted for the association with two male mounting terminals of the set thereof and

Claim 27 continued:
respectively including means for receiving in electrical contacting engagement a respective one of the two terminals and disposed so as to be limitedly displacably movable in said casing upon the association of said female terminals with the two male mounting terminals, means integral with said receiving means for connection in electrical conductive engagement with said contacting and supporting means, and said connection means including a bight portion spaced from said receiving means, a pair of spaced apart legs integral with said bight portion, one of said legs also being integral with said receiving means, an end portion on the other of said legs connected in the electrical conductive engagement with said respective one contacting and supporting means, and means in at least one of said one leg and said other leg operable generally for yielding in the event of the occurrence of the displacement movement upon the association of said female terminal means with the two male mounting terminals so as to at least limit the translation of the displacement movement to said contacting and supporting means.