Claims
- 1. A flat resistor,
- comprising the following separate generally flat components assembled into a stack in the following order:
- a first flat metal outer plate having a plurality of assembly tabs bent transversely therefrom,
- a first thin flat outer electrical insulator having alignment slots therein for receiving said tabs with an alignment fit,
- a first thin flat sheet metal electrical resistance element separate from said first insulator and having oversized slots therein for receiving said tabs with a clearance fit for obviating any engagement between said tabs and said first resistance element,
- a first thin flat inner electrical insulator separate from said first electrical resistance element and having alignment slots therein for receiving said tabs with an alignment fit,
- a metal midplate having oversize slots therein for receiving said tabs with a clearance fit,
- a second thin flat inner insulator having alignment slots therein for receiving said tabs with an alignment fit,
- a second thin flat sheet metal resistance element separate from said second inner insulator and having oversize slots therein for receiving said tabs with a clearance fit for obviating any engagement between said tabs and said second resistance element,
- a second thin flat outer insulator separate from said second electrical resistance element and having alignment slots therein for receiving said tabs with an alignment fit,
- and a second metal outer plate having alignment slots therein for receiving said tabs with an alignment fit,
- said tabs on said first outer plate being bent into secure engagement with said second outer plate for compressing and retaining the stack of said components.
- 2. A flat resistor according to claim 1,
- in which each of said resistance elements is in the form of a resistive sheet metal stamping having portions comprising first and second end terminals,
- and a plurality of resistive ribbons interconnected between said terminals and formed in one piece therewith.
- 3. A flat resistor according to claim 2,
- in which at least one of said resistance elements comprises an intermediate terminal,
- said ribbons being interconnected between said first terminal and said intermediate terminal and also between said intermediate terminal and said second terminal.
- 4. A flat resistor according to claim 1,
- in which each of said resistance elements comprises a pair of alignment tabs sheared therefrom and bent outwardly toward the adjacent outer insulator,
- said outer insulators having additional alignment slots therein for closely receiving said alignment tabs on the adjacent resistance elements to prevent any engagement between said resistance elements and said alignment tabs on said first outer plate.
- 5. A flat resistor according to claim 4,
- in which each of said outer plates comprises portions for forming recesses in said outer plates opposite said outer plates opposite said alignment tabs on said resistance elements for obviating any contact between said resistance elements and the corresponding outer plates.
- 6. A flat resistor,
- comprising the following separate generally flat components assembled into a stack in the following order:
- a first flat sheet metal supporting plate,
- a first thin flat electrical insulator,
- a flat sheet metal electrical resistance element separate from said first insulator,
- a second thin flat electrical insulator separate from said electrical resistance element,
- and a second sheet metal supporting plate,
- said resistor also comprising a plurality of assembly members extending between said first and second supporting plates for securing said plates together and for clamping said insulators and said resistance element therebetween,
- said insulators having alignment openings therein for receiving said members with an alignment fit,
- said resistance element having oversize openings therein for receiving said members with a clearance fit for obviating any contact between said resistance element and said members,
- said resistance element comprising a plurality of alignment tabs formed in one piece with said resistance element and extending transversely toward said first insulator,
- said first insulator having alignment slots therein for receiving said alignment tabs on said resistance element with an alignment fit to maintain alignment between said resistance element and said first insulator.
- 7. A flat resistor according to claim 6,
- in which said first supporting plate comprises portions for forming voids therein opposite said alignment tabs for obviating any contact between said alignment tabs and said first supporting plate.
- 8. A flat resistor according to claim 7,
- in which said voids take the form of recesses in said first supporting plate formed opposite said alignment tabs on said resistance element.
- 9. A flat resistor according to claim 8,
- in which said recesses are provided by embossments formed in said first supporting plate whereby the recesses are formed on one side of said first supporting plate and protrusions are formed on the opposite side thereof.
- 10. A flat resistor,
- comprising the following separate generally flat components assembled in a stack in the following order:
- a flat metal outer plate having a plurality of assembly members extending transversely therefrom,
- a first thin flat outer electrical insulator having alignment openings therein for receiving said assembly members with an alignment fit,
- a first thin flat sheet metal electrical resistance element separate from said first outer insulator and having oversize openings therein for receiving said assembly members with a clearance fit for obviating any engagement between said assembly members and said first resistance element,
- a first thin flat inner electrical insulator separate from said first electrical resistance element and having alignment openings therein for receiving said assembly members with an alignment fit,
- a metal midplate having oversize openings therein for receiving said assembly members with a clearance fit,
- a second thin flat inner insulator having alignment openings therein for receiving said alignment members with an alignment fit,
- a second thin flat sheet metal electrical resistance element separate from said second inner insulator and having oversize openings therein for receiving said assembly members with a clearance fit for obviating any engagement between said assembly members and said second resistance element,
- a second thin flat outer insulator separate from said second electrical resistance element and having alignment openings therein for receiving said alignment members with an alignment fit,
- and a second metal outer plate having alignment openings therein for receiving said assembly members with an alignment fit,
- said assembly members including means for compressing and retaining the stack of said components together,
- each of said resistance elements comprising a plurality of alignment tabs formed thereon and bent outwardly toward the adjacent outer insulator,
- said outer insulators having alignment slots therein for closely receiving said alignment tabs on the adjacent resistance elements to prevent any engagement between said resistance elements and said assembly members.
- 11. A flat resistor according to claim 10,
- in which each of said outer plates comprises portions forming voids therein opposite said alignment tabs for obviating any contact between said resistance elements and the corresponding outer plates.
- 12. A flat resistor,
- comprising the following separate generally flat components assembled into a stack in the following general order:
- a first flat electrically conductive supporting plate,
- a first flat electrical insulator,
- a thin flat electrical resistance element separate from said first insulator,
- a second thin flat electrical insulator separate from said electrical resistance element,
- and a second electrically conductive supporting plate,
- said resistor also comprising a plurality of assembly members extending between said first and second supporting plates for securing said plates together and for clamping said insulators and said resistance element therebetween,
- said insulators having alignment openings therein for receiving said members with an alignment fit,
- said resistance element having oversize openings therein for receiving said members with a clearance fit for obviating any electrical contact between said resistance element and said members,
- said resistance element comprising a plurality of alignment elements formed in one piece with said resistance element and extending transversely toward said first insulator,
- said first insulator having alignment openings therein for receiving said alignment elements on said resistance element with an alignment fit to maintain alignment between said resistance element and said first insulator.
- 13. A flat resistor according to claim 12,
- in which said first supporting plate comprises portions for forming voids therein opposite said alignment elements for obviating any contact between said alignment elements and said first supporting plate.
- 14. A flat resistor according to claim 13,
- in which said voids take the form of recesses in said first supporting plate formed opposite said alignment elements on said resistance element.
- 15. A flat resistor according to claim 14,
- in which said recesses are provided by embossments formed in said first supporting plate such that the recesses are formed on one side of said first supporting plate and protrusions are formed on the opposite side thereof.
- 16. A thermally fused flat resistor,
- comprising the combination of the following separate generally flat components assembled into a stack in the following general order:
- a first flat electrically conductive supporting plate,
- a first thin flat electrical insulator,
- a thin flat electrical resistance element separate from said first insulator,
- a second thin flat electrical insulator separate from said electrical resistance element, and
- a second electrically conductive supporting plate,
- said resistor also comprising means extending between said first and second supporting plates for securing said plates together and for clamping said insulators and said resistance element therebetween,
- one of said plates having projecting means thereon forming a seat,
- a thermal fuse engaging said seat,
- and spring means mounted on said second plate for resiliently pressing said fuse against said seat.
- 17. A resistor according to claim 16,
- in which said spring means comprise a wire spring mounted on said second plate and resiliently pressing said fuse against said seat on said second plate.
- 18. A flat resistor, comprising the following separate generally flat components assembled into a stack in the following general order:
- a first flat metal cover plate,
- a first thin flat outer electrical insulator,
- a first thin flat electrical resistance element separate from said first outer insulator,
- a first thin flat inner electrical insulator separate from said first electrical resistance element,
- a metal midplate,
- a second thin flat inner electrical insulator,
- a second thin flat resistance element separate from said second inner insulator,
- a second thin flat outer insulator separate from said second resistance element,
- and a second metal outer plate,
- said midplate having projecting structure thereon forming a seat,
- a thermal fuse engaging said seat,
- and spring means mounted on said midplate for resiliently pressing said fuse against said seat.
- 19. A flat resistor, comprising the following generally flat components assembled into a stack in the following order:
- a first flat metal outer plate having a plurality of assembly tabs bent transversely therefrom,
- a first thin flat outer electrical insulator having alignment slots therein for receiving said tabs with an alignment fit,
- a first thin flat sheet metal electrical resistance element having oversize slots therein for receiving said tabs with a clearance fit for obviating any engagement between said tabs and said first resistance element,
- a first thin flat inner electrical insulator having alignment slots therein for receiving said tabs with an alignment fit,
- a metal midplate having oversize slots therein for receiving said tabs with a clearance fit,
- a second thin flat inner insulator having alignment slots therein for receiving said tabs with an alignment fit,
- a second thin flat sheet metal resistance element having oversize slots therein for receiving said tabs with a clearance fit for obviating any engagement between said tabs and said second resistance element,
- a second thin flat outer insulator having alignment slots therein for receiving said tabs with an alignment fit,
- and a second metal outer plate having alignment slots therein for receiving said tabs with an alignment fit,
- said tabs on said first outer plate being bent into secure engagement with said second outer plate for compressing and retaining the stack of said components,
- in which each of said resistance elements comprising a pair of alignment tabs sheared therefrom and bent outwardly toward the adjacent outer insulator,
- said outer insulators having additional alignment slots therein for closely receiving said alignment tabs on the adjacent resistance elements to prevent any engagement between said resistance elements and said alignment tabs on said first outer plate,
- each of said outer plates comprising portions for forming recesses in said outer plates opposite said alignment tabs on said resistance elements for obviating any contact between said resistance elements and the corresponding outer plates,
- each of said alignment tabs on said resistance elements including an end portion bent transversely relative thereto against the corresponding outer insulator and forming a flange for securing each resistance element and the corresponding outer insulator together to facilitate assembly of the components,
- each flange being opposite the corresponding recess in the corresponding outer plate,
- each recess affording clearance between the corresponding flange and the corresponding outer plate.
- 20. A flat resistor,
- comprising the following generally flat components assembled into a stack in the following order:
- a first flat sheet metal supporting plate,
- a thin flat electrical insulator,
- a flat sheet metal electrical resistance element,
- a second thin flat electrical insulator,
- and a second sheet metal supporting plate,
- said resistor also comprising a plurality of assembly members extending between said first and second supporting plates for securing said plates together and for clamping said insulators and said resistance element therebetween,
- said insulators having alignment openings therein for receiving said members with an alignment fit,
- said resistance element having oversize openings therein for receiving said members with a clearance fit for obviating any contact between said resistance element and said members,
- said resistance element comprising a plurality of alignment tabs formed in one piece with said resistance element and extending transversely toward said first insulator,
- said first insulator having alignment slots therein for receiving said alignment tabs on said resistance element with an alignment fit to maintain alignment between said resistance element and said first insulator,
- said first supporting plate comprising a portion thereof for forming voids therein opposite said alignment tabs for obviating any contact between said alignment tabs and said first supporting plate,
- said voids taking the form of recesses in said first supporting plate formed opposite said alignment tabs on said resistance element,
- said recesses being provided by embossments formed in said first supporting plate whereby the recesses are formed on one side of said first supporting plate and protrusions are formed on the opposite side thereof,
- each of said alignment tabs on said resistance element including an end portion bent transversely relative thereto against the corresponding insulator and forming a flange for securing said resistance element and the corresponding insulator together to facilitate assembly of the components,
- each flange being opposite the corresponding recess in the corresponding supporting plate,
- each recess affording clearance between each flange and the corresponding supporting plate.
- 21. A flat resistor,
- compromising the following generally flat components assembled in a stack in the following order:
- a flat metal outer plate having a plurality of assembly members extending transversely therefrom,
- a first thin flat outer electrical insulator having alignment openings therein for receiving said assembly members with an alignment fit,
- a first thin flat sheet metal electrical resistance element having oversize openings therein for receiving said assembly members with a clearance fit for obviating any engagement between said assembly members and said first resistance element,
- a first thin flat inner electrical insulator having alignment openings therein for receiving said assembly members with an alignment fit,
- a metal midplate having oversize openings therein for receiving said assembly members with a clearance fit,
- a second thin flat inner insulator having alignment openings therein for receiving said alignment members with an alignment fit,
- a second thin flat sheet metal resistance element having oversize openings therein for receiving said assembly members with a clearance fit for obviating any engagement between said assembly members and said second resistance element,
- a second thin flat outer insulation having alignment openings therein for receiving said alignment members with an alignment fit,
- and a second metal outer plate having alignment openings therein for receiving said assembly members with an alignment fit,
- said assembly members including means for compressing and retaining the stack of said components together,
- each of said resistance elements comprising a plurality of alignment tabs formed thereon and bent outwardly toward the adjacent outer insulator,
- said outer insulators having alignment slots therein for closely receiving said alignment tabs on the adjacent resistance elements to prevent any engagement between said resistance elements and said assembly members,
- each of said outer plates comprising a portion thereof forming voids therein opposite said alignment tabs for obviating any contact between said resistance elements and the corresponding outer plates,
- each of said alignment tabs on said resistance elements including and end portion bent transversely relative thereto against the corresponding outer insulator and forming a flange for securing each resistance element and the corresponding outer insulator together to facilitate the assembly of the components,
- each flange being opposite the corresponding void in the corresponding outer plate,
- each void affording clearance between the corresponding flange and the corresponding outer plate.
- 22. A flat resistor according to claim 21,
- in which said voids take the form of recesses formed in said outer plates opposite said alignment tabs on said resistance elements.
- 23. A flat resistor according to claim 22,
- in which said recesses in said outer plates are provided by embossments formed in said outer plates and having said recesses opposite said alignment tabs and protuberances projection outwardly for said outer plates,
- said recesses being effective to obviate any contact between said alignment tabs and said outer plates.
- 24. A thermally fused flat resistor,
- comprising the combination of the following generally flat components assembled into a stack in the following general order:
- a first flat electrically conductive supporting plate,
- a first thin flat electrical insulator,
- a thin flat electrical resistance element,
- a second thin flat electrical insulator, and
- a second electrically conductive supporting plate,
- said resistor also comprising means extending between said first and second supporting plates for securing said plates together and for clamping said insulators and said resistance element therebetween,
- one of said plates having projecting structure thereon forming a seat,
- a thermal fuse engaging said seat,
- and spring means mounted on said last mentioned plate for resiliently pressing said fuse against said seat,
- said seat comprising a first lug bent from said one of said plates at a slanting angle in one direction,
- and second and third lugs bent from said one of said plates at a slanting angle in the opposite direction and disposed on opposite sides of said first lug whereby said seat is generally V-shaped,
- said spring means being connected between said first lug and said second and third lugs and being flexed against said fuse for pressing said fuse against said seat.
- 25. A resistor according to claim 24,
- in which said spring means comprise a wire spring having a U-shaped portion hooked around said first lug and first and second arm portions extending from opposite ends of said U-shaped portion and resiliently flexed part way around said fuse for pressing said fuse against said seat,
- said second and third lugs having releasible locking means for releasibly retaining said arms.
- 26. A resistor according to claim 25,
- in which said first and second lugs comprise first and second oppositely slanting ramp-like end portions for slidable engagement by said first and second arms of said wire spring,
- said locking means comprising first and second catches on said oppositely slanting ramp-like end portions for receiving and releasibly locking said arms against said respective second and third lugs.
- 27. A resistor according to claim 26,
- in which said catches comprise locking notches formed in said second and third ramp-like slanting portions for receiving and retaining said arms of said spring in their resiliently flexed positions for pressing said fuse against said seat.
- 28. A flat resistor, comprising the following generally flat components assembled into a stack in the following general order:
- a first flat metal cover plate,
- a first thin flat outer electrical insulator,
- a first thin flat electrical resistance element,
- a first thin flat inner electrical insulator,
- a metal midplate,
- a second thin flat inner electrical insulator,
- a second thin flat resistance element,
- a second thin flat outer insulator,
- and a second metal outer plate,
- said midplate having projecting structure thereon forming a seat,
- a thermal fuse engaging said seat,
- and spring means mounted on said midplate for resiliently pressing said fuse against said seat,
- said spring means comprising a wire spring mounted on said midplate and resiliently pressing said fuse against said seat on said midplate.
- 29. A flat resistor, comprising the following generally flat components assembled into a stack in the following general order:
- a first flat metal cover plate,
- a first thin flat outer electrical insulator,
- a first thin flat electrical resistance element,
- a first thin flat inner electrical insulator,
- a metal midplate,
- a second thin flat inner electrical insulator,
- a second thin flat resistance element,
- a second thin flat outer insulator,
- and a second metal outer plate,
- said midplate having projecting structure thereon forming a seat,
- a thermal fuse engaging said seat,
- and spring means mounted on said midplate for resiliently pressing said fuse against said seat,
- said seat comprising a first lug bent from said midplate at a slanting angle in one direction,
- and second and third lugs bent from said midplate at a slanting angle in the opposite direction and disposed on opposite sides of said first lug whereby said seat is generally V-shaped,
- said spring means being connected between said first lug and said second and third lugs and being flexed against said fuse for pressing said fuse against said seat,
- said seat comprising a first lug bent from said midplate at a slanting angle in one direction,
- and second and third lugs bent from said midplate at a slanting angle in the opposite direction and disposed on opposite sides of said first lug whereby said seat is generally V-shaped,
- said spring means being connected between said first lug and said second and third lugs and being flexed against said fuse for pressing said fuse against said seat.
- 30. A resistor according to claim 29,
- said spring means comprising a wire spring having a U-shaped portion hooked around said first lug,
- said spring also comprising first and second arms extending from opposite ends of said U-shaped portion and resiliently flexed part way around said fuse for pressing said fuse against said seat,
- said second and third lugs having releasible locking means for releasibly retaining said arms.
- 31. A resistor according to claim 30,
- in which said first and second lugs comprise first and second oppositely slanting ramp-like end portions for slidable engagement by said first and second arms of said wire spring,
- said locking means comprising first and second catches on said oppositely slanting ramp-like end portions for receiving and releasibly locking said arms against said respective second and third lugs.
- 32. A resistor according to claim 31,
- in which said catches comprise locking notches formed in said second and third ramp-like slanting portions for receiving and retaining said arms of said spring in their resiliently flexed positions for pressing said fuse against said seat.
Parent Case Info
This Application claims the benefit og U.S. Provisional Application No. 60/047,533 filed May 23, 1997.
US Referenced Citations (6)