US3750081A - Wirewound variable resistance control and method of making the same - Google Patents

Wirewound variable resistance control and method of making the same Download PDF

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Publication number
US3750081A
US3750081A US00265965A US3750081DA US3750081A US 3750081 A US3750081 A US 3750081A US 00265965 A US00265965 A US 00265965A US 3750081D A US3750081D A US 3750081DA US 3750081 A US3750081 A US 3750081A
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US
United States
Prior art keywords
metal
tape
resistance wire
resistance
insulating tape
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00265965A
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English (en)
Inventor
J Miller
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CTS Corp
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CTS Corp
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Filing date
Publication date
Application filed by CTS Corp filed Critical CTS Corp
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Publication of US3750081A publication Critical patent/US3750081A/en
Anticipated expiration legal-status Critical
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C10/00—Adjustable resistors
    • H01C10/06—Adjustable resistors adjustable by short-circuiting different amounts of the resistive element
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49082—Resistor making
    • Y10T29/49087—Resistor making with envelope or housing
    • Y10T29/49096—Resistor making with envelope or housing with winding

Definitions

  • the present invention relates toelectrical controls, and, more particularly, to'a wirewound variable resistance electrical control of the type commonly referred to as a fader control and to a method of making the same.
  • Variable resistance fader controls are commonly employed for alternately changing the volume of a pair of loudspeakers. For example, in an automobile provided with front and rear loudspeakers, itis'p referable to adjust or balance the volume of both of the loudspeakers with a single control.
  • the metal foil After attaching terminals" to the 'wirewound resistance element, the metal foil is severed at two places betweenthe end terminals, and the center portion of the metal foil is removed.
  • the remaining end portions of the metal foil preferably are wetted with solder, depending on the application.
  • the cost per salable control remains high since the foil cuttingoperation invariably produces some elements having severed or damaged turns which can later break creating a field failure and, therefore, must be scrapped.
  • Still another object of the pres ent invention is to provide a method of shorting end turns of a resistance element by coating an insulating tape with a bonding material having a lower softening temperature than the insulatingtape, thermally bond-
  • the present invention is concerned with an improved wirewound resistance element for avariable resistance fader control having precisely prespaced pieces of conductive metal bonded to an electrically nonconductive tape for shorting the end turns of the resistance element.
  • a clad exterior conductive layer is deposited on the metal to protect the metal from undesirable oxidation effects.
  • the present invention is also concerned with an improved method of making the wirewound resistance element by bonding precisely spaced pieces of metal to an electrically nonconductive tape to produce a laminated ribbon.
  • a resistance wire is then wound around the laminated ribbon.
  • the laminated ribbon comprising the spaced pieces of metal and tape can also be combined with an insulating core and the resistance wire is then wound around the laminated ribbon and the core to produce a wirewound resistance element.
  • Pairs of terminals are located at the midpoints of the pieces of metal and are secured to theresistance winding thereby effecting an electrical connection between the piece of metal, the resistance wire,and the terminals.
  • the elements are then .cut to an appropriate length. "If the ele ment is mounted in a cylindrical housing, 'the'element preferably is formed to the shape of the housing to facilitate assembly. a
  • FIG. 1 is an isometric viewvof an electrical control made in accord with the present invention
  • FIG. 2 is an exploded view of the control shown in FIG. 1; v i
  • FIG. 3 shows the relationship between an insulating core, a laminated ribbon, and a resistance wire during the winding operation
  • FIG. 4 is a side view of a wound resistance strip shown in FIG. 2 with unsevered pairs of terminals secured to the strip;
  • FIG. 5 is a top plan view of the resistance element of FIG. 4 after' the terminalcutting and forming opera-.
  • FIG. 6 is a grossly enlarged fragmentary section 0 the resistance element takenalong line VI-VI of FIG. 4; and v t FIG. 7 is a diagrammatical representation of the inof the outer end walls of the control and the end wall 11a of the housing 11 forms the other outer. end wall thereof.
  • the open end 11b of the housing 11 is provided with a cutaway section 11c and an arcuate boss 12b extending radially outwardly from the insert 12 fits into the cutaway section 1 1c of the housing 11 to orient the insert 12 with the housing 11.
  • a skirt 120 depending from the end wall 12a and mounted within the housing 1 1 insulates the resistance element 20 from the metal housing 11.
  • a plurality of tabs 13 integral with the housing 1.1 are folded over the end wall 12a of V the insert 12 to secure the housing to the insert.
  • Both of the end walls 11a and 12a of the housing 11 and the insert 12 respectively are provided with apertures 14 and 15 and the rotor 30 is journaled therein.
  • the resistance element circumposes the rotor 30 and abuts against the inner wall of the depending skirt 120 of the insert 12. More particularly, the resistance element 20 comprises a core 21 of insulating material and a laminated ribbon containing pieces of metal 25a bonded to a tape 25b of insulating material (see FIG. 3) having a plurality of turns of resistance wire 22 wound thereon. When the tape 25b is of sufficient thickness, the resistance wire can be wound directlyzon the laminated ribbon without use of the core 21.
  • the pieces of metal 25a preferably are pieces of metal foil, e.g., copper, having a nickel plate on one side and of a width substantially the same as the tape. Any type of wire, e.g., Nichrome wire, having the proper resistance per unit length can be used.
  • SUitable end terminals 24a and 24b are clinched to the insulating core 21 and the resistance wire 22 thereby effecting an electrical contact with the resistance wire 22 and the metal foil 25a of the laminated ribbon 25.
  • the resistance element 20 is disposed in the insert 12 with the upper edge of the resistance element 20 abutting against the end wall 120.
  • a washer 16 made of an appropriate insulating material is disposed in the housing 11 and abuts against the end wall 11a to provide an insulating barrier between the lower edge of the resistance element 20 and the end wall 11a of the housing 11.
  • the end terminals 24a and 24b project upwardly through slots 12d and l2e provided in the insert 12 and the end portions are formed radially outwardly beyond the slots (see FIG. 1).
  • a collector ring 26 having an opening 26a abuts against the end wall 12a of the insert 12 and a center terminal 27 extends radially outwardly from the collector ring 26 through a slot 12f provided in'the insert 12.
  • the rotor 30 molded of a suitable insulating material is provided with a cylindrical shoulder 30a engaging the inner edge of the opening 26a for positioning the collector ring coaxially with the apertures 14 and 15.
  • acontactor 31 having a pair of spaced contact fingers 32a and 32b electrically connected to each other wipingly engages the resistance element 20.
  • the contactor 31 comprises a ring portion 31a in slideable engagement with the collector ring 26, and a pair of downwardly extending cars 33 integral with the ring portion 31a and received in a pair of diametrically disposed grooves 3012 provided in the rotor constrain the contactor 31 to rotate with the rotor 30.
  • the rotor is provided with an arcuate boss 34 engageable with a stop 11d (see FIG.
  • a hollow'shaft 35, of appropriate design, fixedly secured to the rotor 30 extends outwardly of the housing.
  • precisely cut pieces of metal foil 25a are bonded to a suitable elongated insulating tape 25b, e.g., a polyester tape.
  • a suitable elongated insulating tape 25b e.g., a polyester tape.
  • the insulating tape is coated with a bonding material, e.g., a polyethylene coating, having a lower softening temperature than the tape 25b for thermally bonding the pieces of metal foil at spaced intervals to the tape.
  • the bonding material can be readily softened by applying heat to the metal foil and the tape to secure the metal foil to the tape.
  • the tape 25b with the metal foil bonded thereto is commonly referred to as a laminated ribbon 25. Any type of suitable cement can also be employed for securing the metal foil to the insulating tape.
  • a continuous metal foil can be secured to the insulating tape and precisely spaced portions of metal foil can be readily removed, e.g., by chemical etching.
  • the laminated ribbon 25 with spaced pieces of metal foil is then placed against the core of insulating mateial 21 preferably a flat strip with the tape side of the laminated ribbon 25 flush against a flat side of the core.
  • the insulating core 21 and the ribbon 25 are then fed'into a winding machine and the resistance wire 22 is wound around the insulating core 21 and the ribbon 25.
  • the ribbon 25b is of sufficient thickness such as to avoid buckling, the resistance wire 22 can be wound directly on the laminated ribbon.
  • the laminated ribbon 25 is'preferably combined with the core 21 and wound with the resistance wire 22.
  • pairs of terminals 23 are clinched to the wound resistance strip electrically connecting the resistance wire 22 and the metal foil 25a of thevribbon to the terminal pairs 23.
  • the wound resis' tance strip is then cut to short lengths by removing a section 23a from each pair of terminals 23 to produce a resistance element 20 having a pair of end terminals 24a and 24b at the ends thereof.
  • the cutting operation also divides each of the pieces of metal foil 25a of the laminated ribbon 25 into two separate parts 25c and 25d.
  • solder may be applied to i the pieces of metal foil to increase the electrical contact between the wire 22 and the metal foil 25a.
  • a variable resistance control comprising a housing, a wirewound resistance element disposed in said housing, said resistance element comprising an insulating tape, a first piece and a second piece of metal spaced from the first piece bonded to the insulating tape, a resistance wire wound around the tape with adjacent turns spaced from each other, the first piece of metal shorting a plurality of the turns of the resistance wire at one end thereof to define a first shorted portion, the second piece of metal shorting a pluralityv of the I and said first and second pieces of metal are thermally bonded to the insulating tape.
  • a variable resistance control comprising a housing, a wirewound resistance element disposed in said housing, said resistance element comprising an insulating core, an insulating tape in juxtaposition to the insulating core, a first piece and a second piece of metal foil spaced from the first piece bonded to the insulating tape, a resistance wire wound around the core and the tape with adjacent turns spaced from each other, the metal foil having a width substantially equal to the width of the tape, the first piece of metal foil shorting a-plurality of the turns of the resistance wire atone end thereof to define a first shorted portion, the second piece of metal foil shorting a plurality of the turns of the resistance wire at the other end thereof todefine a second shorted portion, said resistance wire'havinga trically connected to said first shorted portion of the turns of the resistance wire at the other end thereof to define a second shorted portion, said resistance wire having a single unshorted portion extending between the first and second shorted portions, a first end tenn
  • resistance wire a second end terminal electrically connected to said second shorted portion of the resistance wire, a contactor comprising a pair of spaced fingers wipingly engaging the resistance element between the ends thereof, and a third terminal electrically con nected with the contactor.
  • a method of shorting a portion of a wirewound re sistance element comprising the steps of bonding pieces of metal to an insulating tape to produce a laminated ribbon, winding a resistance wire around the laminated ribbon with adjacent convolutions of the resistance wire spaced from each other and in electrical contact with said pieces of metal, and securing a plurality of electrically conductive terminals to. the resistance wire.
  • step of bonding pieces of metal to an insulating tape comprises the step of coating the insulating tape with a bonding material, securing an elongated strip of metal to the insulating tape wih the bonding material, and removing spaced pieces of metal bonded to the insulating tape to produce a laminated ribbon with precisely spaced pieces of metal.
  • the insulating tape is a polyester and the bonding material is a polyethylene.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Details Of Resistors (AREA)
  • Apparatuses And Processes For Manufacturing Resistors (AREA)
  • Adjustable Resistors (AREA)
  • Laminated Bodies (AREA)
US00265965A 1972-06-26 1972-06-26 Wirewound variable resistance control and method of making the same Expired - Lifetime US3750081A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US26596572A 1972-06-26 1972-06-26

Publications (1)

Publication Number Publication Date
US3750081A true US3750081A (en) 1973-07-31

Family

ID=23012619

Family Applications (1)

Application Number Title Priority Date Filing Date
US00265965A Expired - Lifetime US3750081A (en) 1972-06-26 1972-06-26 Wirewound variable resistance control and method of making the same

Country Status (6)

Country Link
US (1) US3750081A (OSRAM)
BR (1) BR7304651D0 (OSRAM)
CA (1) CA969635A (OSRAM)
FR (1) FR2191223B1 (OSRAM)
GB (1) GB1425963A (OSRAM)
IT (1) IT986583B (OSRAM)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4125761A (en) * 1974-10-08 1978-11-14 Churchill John W Bilateral heater unit
US5093648A (en) * 1989-03-31 1992-03-03 Aisin Seiki K.K. Rotational type variable resistor
EP0644560A4 (en) * 1993-03-23 1995-07-19 Tokai Rubber Ind Ltd INSULATING TAPE OR SHEET.
US20100207718A1 (en) * 2007-09-06 2010-08-19 Werner Kahr Electrical Protective Device

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2724759A (en) * 1954-03-04 1955-11-22 Vari Ohm Corp Precision wire wound resistors
US3409855A (en) * 1966-03-14 1968-11-05 Cts Corp Variable resistance control utilizing metal foil to wire turns

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2999996A (en) * 1961-01-16 1961-09-12 Ace Electronics Associates Inc Wire wound resistor terminal cap

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2724759A (en) * 1954-03-04 1955-11-22 Vari Ohm Corp Precision wire wound resistors
US3409855A (en) * 1966-03-14 1968-11-05 Cts Corp Variable resistance control utilizing metal foil to wire turns

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4125761A (en) * 1974-10-08 1978-11-14 Churchill John W Bilateral heater unit
US5093648A (en) * 1989-03-31 1992-03-03 Aisin Seiki K.K. Rotational type variable resistor
EP0644560A4 (en) * 1993-03-23 1995-07-19 Tokai Rubber Ind Ltd INSULATING TAPE OR SHEET.
US5591522A (en) * 1993-03-23 1997-01-07 Tokai Rubber Industries, Ltd. Insulating tape or sheet
US5847322A (en) * 1993-03-23 1998-12-08 Tokai Rubber Industries, Ltd. Insulating tape or sheet
US20100207718A1 (en) * 2007-09-06 2010-08-19 Werner Kahr Electrical Protective Device
US8004385B2 (en) * 2007-09-06 2011-08-23 Epcos Ag Electrical protective device

Also Published As

Publication number Publication date
FR2191223B1 (OSRAM) 1977-09-02
IT986583B (it) 1975-01-30
FR2191223A1 (OSRAM) 1974-02-01
GB1425963A (en) 1976-02-25
DE2332160B2 (de) 1977-06-23
DE2332160A1 (de) 1974-01-10
BR7304651D0 (pt) 1974-08-22
CA969635A (en) 1975-06-17

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