Electrical device and method

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 is also disclosed.

FIELD OF THE INVENTION 
This invention relates in general to electrical devices and in particular 
to those utilized in the starting or starting and protecting of 
dynamoelectric machines and also a method of making an electrical device. 
BACKGROUND 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 
deleterious affect on components of such dynamoelectric machine, such as 
for instance burning out the winding circuit. One such protector device is 
disclosed in U.S. Pat. No. 2,771,528 issued to D. E. Moran on Nov. 20, 
1956. Also in the past, various starter devices have been employed to 
render a start winding generally ineffective in the winding circuit of a 
dynamoelectric machine, such as a split phase electric motor for instance, 
when the dynamoelectric machine is energized and attains a preselected 
speed. Some of these starter devices are well known to the art, such as 
centrifugal starting switches and starting relays or the like. Positive 
temperature coefficient resistors have also been employed as starter 
devices with the winding circuit of a split phase motor to render the 
start winding generally ineffective at a preselected motor speed, as shown 
for instance in the electrical devices illustrated in U.S. Pat. No. 
3,737,752 and U.S. Pat. No. 3,559,016, respectively. 
These past motor starter devices and protector devices 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 
protector devices were mounted to the housing of a dynamoelectric machine 
and connected by leads to the winding circuit thereof. 
In an air conditioning or refrigeration compressor unit or the like, a 
hermetic motor is sealed therein, and either a male or female plug member 
or cluster is connected in circuit relation with the winding circuit of 
the hermetic motor and remotely located therefrom so as to be mounted on a 
housing or jacket of the compressor unit. U.S. Pat. Nos. 3,921,117 and 
3,955,170 respectively disclose 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. Pat. No. 3,168,661 a combination 
starter-protector device is disclosed as being plugged onto a male plug 
member, such as that previously mentioned. Other combination 
starter-protector devices are illustrated in U.S. Pat. Application Ser. 
No. 624,381 filed Oct. 25, 1975 and U.S. Pat. Application Ser. No. 693,409 
filed June 7, 1976, both of which are assigned to the common assignee of 
this application. 
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 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 
disadvantageous or undesirable feature of the past electrical devices is 
believed to be be that the female terminals 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 
disadvantageous 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 thereof on the male terminals may 
have been transmitted to other electrical components of the electrical 
device connected with the female terminals thereof so as to deleteriously 
affect such other electrical components and/or their connections 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 
association with the male terminals is believed to have 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 engagement of the contact plates against the 
chemically treated surfaces of the PTCR is believed to have caused hot 
spots therein resulting in the failure of the PTCR. 
SUMMARY OF THE INVENTION 
Among the several objects of the invention may be noted the provision of an 
improved electrical device and a method of making an electrical device 
which overcome the disadvantageous or undesirable features discussed 
hereinabove, as well as others, with respect to the prior art; the 
provision of such improved electrical device and method in which limited 
displacement movement of at least one terminal means in the electrical 
device effected upon the assembly thereof with mating mounting terminals 
is generally isolated from at least another component of the electrical 
device connected with the terminal means; and the provision of such 
improved electrical device and method having components which are 
simplistic in design, and easily manufactured and/or assembled. These as 
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 device in one form of the invention is 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 
controlling starting of the dynamoelectric machine, and a pair of means 
for electrically contacting and supporting the starting means in the 
casing. A set of means is disposed in the casing so as to be limitedly 
displacably movable for receiving respective ones of the terminals of the 
terminal set upon the association in the electrical contacting engagement 
therewith and also connected in electrical conductive engagement with the 
contact and supporting means. The receiving means of the set thereof 
include means for at least limiting translation of the displacement 
movement from the receiving means to the contact and supporting means in 
the event of the occurrence of the displacement movement upon the 
association of the receiving means with the respective ones of the 
terminals. 
Also in general and in one form of the invention, the above described 
electrical device may utilize a controlling means operable generally in 
response to current applied thereto to increase its 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. Another circuit for controlling 
the passage of the current to the winding circuit includes a thermally 
responsive current carrying switch means in the casing and operable from a 
current passing position toward a current interrupting position in 
response to a preselected thermal condition occasioned upon winding 
circuit overload. Means is provided for connecting the switch means in 
circuit relation with one of the contact and supporting means, and the 
controlling means and switch means are associated in heat transfer 
relation so 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. 
Also in general, a method in one form of the invention is provided for 
making an electrical device so as to generally isolate an electrical 
component thereof from limited displacement movement of terminal means 
supported in the electrical device and associated both mechanically and 
electrically with the electrical component upon the mounting 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 means 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.

Corresponding reference characters indicate corresponding parts throughout 
the several views of the drawings. 
The exemplifications set out herein illustrate preferred embodiments of the 
invention in one form thereof, and such exemplifications are not to be 
construed as limiting the scope of the invention in any manner. 
DETAILED DESCRIPTION OF THE PREFERRED 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 of a 
generally thin material, such as a strip of metal for instance, which has 
good electrical conductive properties or characteristics. Body 13 has 
means, such as an electrical connector section illustrated as a female 
socket or split sleeve portion 15 for instance, for receiving in 
releasable electrical contacting engagement another terminal adapted for 
association therewith, as discussed in greater detail hereinafter. Means, 
such as a supporting or connection section illustrated as a generally 
U-shaped configuration or a tab 17 for instance, is integral with split 
sleeve portion or receiving means 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 also 
discussed in greater detail hereinafter. Connection means or the U-shaped 
configuration 17 comprises a pair of spaced apart generally opposite 
adjacent end portions 19, 21 with one of the end portions 19 being 
integral with split sleeve portion 15 while the other of the end portion 
21 is spaced generally adjacent the split sleeve portion for the 
connection or association with the aforementioned electrical component. 
U-shaped configuration 17 also includes means, such as at least one 
resilient or yieldable section, between end portions 19, 21 thereof 
operable generally for yielding in the event of the occurrence of 
displacement movement of split sleeve portion 15 upon the association 
thereof in the electrical contacting engagement with the aforementioned 
another terminal so as to at least in part limit the translation or 
transmission of such displacement movement from the split sleeve portion 
through the U-shaped configuration to the aforementioned electrical 
component when it is associated with end portion 21. While supporting 
section 17 is illustrated and described as a generally U-shaped 
configuration merely for convenience of disclosure, it is contemplated 
that configurations other than such generally U-shaped configurations may 
be utilized within the scope of the invention so as to achieve the objects 
and advantages thereof. Furthermore, it is also contemplated that 
electrical connector sections other than the female socket or split sleeve 
portion 15 illustrated merely for purposes of disclosure may be employed 
with terminal 11 within the scope of the invention in order to meet the 
objects and advantages thereof. 
More particularly and referring also to FIG. 4, body 13 of female terminal 
11 may be blanked punched or otherwise formed from a thin metallic 
material or sheet, and in its blanked-out form, the body has a pair of 
opposite ends or end edges 23, 23a. A first pair of opposite side edges 
25, 25a are provided on body 13 intersecting with end edge 23, and a 
second pair of opposite side edges 27, 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 so as to interconnect 
or intersect with side edges 25, 25a and 27, 27a, respectively. Slot 
means, which comprise a pair of intersecting or integrally formed slots or 
slot portions 31, 33 are disposed through supporting section 17 of body 
13. Slot portion 31 extends generally from at least adjacent shoulders 29, 
29a toward end edge 23a being disposed between side edges 27, 27a, and 
slot portion 33 is disposed generally adjacent shoulder 29 extending from 
slot portion 31 so as to intersect with side edge 27. In this manner, it 
may be seen that the interposition of slot portion 31 between side edges 
27, 27a defines a pair of spaced apart legs 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 predeterminately spaced from split sleeve 
portion 15 (as best seen in FIG. 4). Leg 35 includes end portion 19 which, 
as 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 is integrally formed with distal end 39 of 
supporting section 17. Leg 37 is also provided with another end or end 
portion 43 which is disposed generally in opposite relation with respect 
to free end 21 of the leg, and end portion 43 is also integrally formed 
with distal end 39 of supporting section 17. The aforementioned yielding 
means or section of supporting section 17 is located in at least one of 
legs 35, 37 between opposite end pairs 19, 41 and 21, 43, respectively, as 
discussed in detail hereinafter. 
Subsequent to the above described blanking of terminal 11, split sleeve 
portion 15 may be formed by rolling, bending or other such shaping methods 
generally into the configuration illustrated in FIG. 3. In this manner, 
side edges 25, 25a of body 13 are displaced and positioned generally in 
opposed or facing relation with each other so as to provide an opening 45 
that extends through split sleeve portion 15 generally between end edge 23 
and shoulder pair 29, 29a thereof. Of course, opposed side edges 25, 25a 
defines the split extending the length of split sleeve portion 15 and 
intersects with opening 45 thereof so that the split sleeve portion may 
resile or be displacably movable, i.e. to expand or spring 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 
discussed hereinafter. While electrical connector section 15 and opening 
45 thereof are provided with the particular shapes or configurations 
illustrated in FIGS. 1-3 merely for convenience of disclosure, it is 
contemplated that other electrical connector sections may be employed 
having various other configurations and that other openings may be 
utilized assuming a variety of other shapes within the scope of the 
invention so as to attain the objects and advantages thereof. Leg pair 35, 
37 may also be stamped, bent or otherwise deformed so as to extend from 
split sleeve portion 15 in the shape illustrated generally in FIG. 2; 
however, while legs 35, 37 are provided with such particularly illustrated 
shapes and are described hereinabove as being disposed generally 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 spaced relations may also be utilized within the scope of the 
invention so as to meet the objects and advantages thereof. For instance, 
at least a part of one of legs 35, 37 may be skewed or bent with respect 
to at least a part of the other of the legs so as to extend generally in 
different planes. Furthermore, legs 35, 37 may be shaped before, after or 
generally simultaneously with the shaping of split sleeve portion 15, as 
described above. Of course, it is also contemplated that one of legs 35, 
37, or at least a part thereof, may be provided with a crosssection 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 legs so as to predetermine the location 
of the aforementioned yieldable means or portion of the legs adapted to 
resile or yield in order to effectively absorb or accommodate limited 
displacement movement of the split sleeve portion upon the association 
thereof with a male mounting terminal, as discussed hereinafter. 
Referring now to the drawings in general and recapitulating, at least in 
part, with respect to the foregoing, an electrical device 61 in one form 
of the invention is adapted to be associated in electrical contacting 
engagement with at least one terminal means, such as a male mounting 
terminal of a set thereof, for a winding circuit of a dynamoelectric 
machine, as described in detail hereinafter (FIG. 9). 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 disposed generally in a 
preselected position in the casing (FIGS. 5 and 7). Means, such as split 
sleeve portion 15 of terminal 11, for receiving the at least one terminal 
means or male mounting terminal 63a in the electrical contacting 
engagement therewith is disposed in casing 67 so as to be limitedly 
displacably movable upon the association with the male mounting terminal 
(FIGS. 1-3, 5 and 7). Means, such as supporting section 17 of terminal 11, 
extends from split sleeve portion or receiving means 15 for connection in 
electrical conductive relation or association, i.e. in both electrical 
contacting engagement and mechanical engagement, with contact plate 69 so 
as to dispose the contact plate in its preselected position in casing 67. 
Connection means or supporting section 17 includes means, such as at least 
one of legs 35, 37, for accommodating the limited displacement movement of 
split sleeve portion 15 so as to at least generally isolate contact plate 
69 from the limited displacement movement upon the association of the 
split sleeve portion with male mounting terminal 63a. 
More particularly and with specific 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 hereafter to designate corresponding component 
parts of another terminal 11a and another contact plate 69a which, for 
purposes of disclosure, have generally the same constructions as terminal 
11 and contact plate 69, respectively; however, it is contemplated that 
such terminals and contact plates may be of dissimilar constructions 
within the scope of the invention so as to meet the objects and 
advantageous features thereof. 
Casing 67 is provided with a pair of separable casing members 71, 73 which 
are retained against displacement from each other by suitable fastening 
means, such as a plurality of rivets 75 or the like. Casing members 71, 73 
comprise a plurality of wall means 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 base wall 81, and such wall 
means plurality defines a chamber 83 within casing 67. At least one groove 
or recess means 85 is provided in sidewall 77 communicating with chamber 
83, and supporting sections 17, 17a of terminals 11, 11a are disposed in 
or extend into the recess means. A pair of generally parallel, spaced 
apart openings or terminal containing apertures 87, 87a extend through 
sidewall 77 of casing 67 having interior ends intersecting with recess 
means 83 and exterior ends opening exteriorly of the casing, respectively, 
and electrical connector sections 15, 15a of terminals 11, 11a are 
respectively disposed for limited displacement movement within the 
openings, as discussed in detail hereinafter. A pair of means, such as 
shoulders or stops 89, 91 and 89a, 91a or the like, are integrally 
provided on casing 67 generally adjacent the interior and exterior ends of 
openings 87, 87a so as to abut with shoulders 29, 29a and opposite end 23 
of electrical connector sections 15, 15a on terminals 11, 11a for 
containing or trapping the electrical connector sections within the 
opening. 
Contact plates 69, 69a are illustrated for pusposes of disclosure as having 
a generally flat triangular shape, but it is contemplated that contact 
plates having various other shapes or configurations may be employed 
within the scope of the invention so as to meet the objects and 
advantageous features thereof. Contact plates 69, 69a are located or 
supported on opposed end walls 79, 81 of casing 67 within chamber 83, and 
it is contemplated that resilient means (not shown) may be provided 
between at least one of the opposed end walls and the contact plate for 
urging it generally toward the other of the contact plates. A plurality of 
means, such as abutment or side edge portion indicated at 93, 93a, are 
provided on contact plates 69, 69a for respective positioning or locating 
engagement with sidewall 77 of casing 67, and extension means, such as 
bent fingers 95, 95a, are integrally provided on contact plates 69, 69a 
extending therefrom for the aforementioned connection in both the 
mechanical and electrical engagement with free end portions 21, 21a of 
legs 37, 37a on terminals 11, 11a, respectively, by suitable means, such 
as soldering for instance (not shown). A plurality of indentations 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 cylindrically shaped PTCR 101, operable generally for 
controlling starting of a dynamoelectric machine when connected in circuit 
relation therewith, as discussed in detail hereinafter. PTCR 101 is 
operable generally in response to current flow therethrough to vary or 
increase its resistance generally as a function of its temperature, as 
illustrated in FIG. 8, so as to generate heat when energized, and of 
course, opposite sides 99, 99a of PTCR 101 are coated or otherwise covered 
or layered with a chemical composition (not shown) so as to insure the 
generally even or constant flow or distribution of current through the 
PTCR from one of the opposite sides to the other thereof. In this manner, 
PTCR 101, is embraced, i.e., supported or positioned in both the 
electrical contacting and positioning or supporting engagement, between 
contact plates 69, 69a within chamber 83 of casing 67. While PTCR 101 is 
shown having a generally cylindric shape, it is contemplated that a PTCR 
having a shape other than cylindric may be employed within the scope of 
the invention so as to meet the objects thereof. 
A plug-on or quick disconnect type terminal or terminal means 103 is 
attached by suitable means, such as a rivet 105 for instance, to opposite 
end wall 81 of casing 67 so as to be disposed exteriorly thereof. To 
complete the description of electrical device 61, a lead receiving opening 
or aperture 107 is provided through sidewall 77 of casing 67 so as to 
intersect with recess means 85, and an electrical lead 109 extends through 
opening 107 having an interior end electrically connected with supporting 
section 17a of terminal 11a and an exterior end electrically connected 
with terminal means 103. Of course, lead 109 defines, at least in part, 
circuit means in which terminal means 11 and contact plate 69 are placed 
in series circuit relation across PTCR 101 with both contact plate 69a and 
terminal 11a and terminal means 103. 
As illustrated in an exemplary schematic diagram of a circuit 111 in FIG. 
9, a prime mover, such as an electric motor 113, is 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 male terminals or terminal means 119, 121, 123 are 
fixedly mounted in a plug or the like 124 adapted for mounting assembly or 
association to a structural 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 another structural 
component, such as a jacket or housing of a device driven by the motor 
such as a compressor or the like for instance (not shown). Further, male 
terminals 119, 121, 123 may be predeterminately spaced apart and sized 
within tolerance limits so as to meet certain industry -- wide standards 
or other specifications. Male terminals 121, 123 are respectively 
connected in circuit relation with start winding 117 and run winding 115 
of motor 113, and male terminal 119 is connected in circuit relation with 
both the start and run windings. Female terminals 11, 11a of electrical 
device 61 are disposed to releasably receive male terminals 121, 123 of 
the terminal set in electrical conductive relation when the electrical 
device is associated or assembled with motor 113, and a pair of leads 125, 
127 are respectively connected between line terminals L1, L2 and male 
terminal 119 and terminal means 103 of electrical device 61. To complete 
the description of circuit 111, a motor energizing switch 129 may be 
interposed in lead 125. 
As previously mentioned, variations in the tolerances of male terminals 
119, 121, 123 with respect to the size thereof and/or the spaced relation 
therebetween in plug member 124 are, of course, encountered, and such 
tolerance variations may also occur in electrical connection sections 15, 
15a of terminals 11, 11a in electrical device 61, as previously mentioned. 
Due to the aforementioned tolerance variations, electrical connector 
sections 15, 15a of terminals 11, 11a may twist and/or be both laterally 
and longitudinally moved or otherwise displaced within their respective 
openings 87, 87a of casing 67 when the electrical connector sections are 
releasably or grippingly engaged in electrical conductive relation on male 
terminals 121, 123 so as to mount electrical device 61 in circuit relation 
on mounting plug 124. Upon the assembly of electrical device 61 to 
mounting plug 124, as above described, the transmission or translation of 
the displacement movement of electrical connector sections 15, 15a through 
supporting sections 17, 17a of terminals 11, 11a to contact plates 69, 69a 
is 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, respectively. In this manner, the above described 
means of supporting sections 17, 17a for accommodating the displacement 
movement of electrical connector sections 15, 15a at least 
predeterminately limits or obviates the transmission of such displacement 
movement to contact plates 69, 69a so as to maintain them generally in 
their assembled positions within chamber 83 of casing 67 which results in 
the preservation of the chemically coated opposite sides 99, 99a of PTCR 
101 from deleterious scrubbing or abrasive action thereon of dimples 97, 
97a in the contact plates so as to prevent the establishment of "hot 
spots" on the PTCR and maintain the desirable electrical characteristics 
or integrity thereof. 
In the operation of electrical device 61 when assembled in circuit relation 
onto plug 124 and within the component parts of the electrical device 
disposed as shown in the drawings and as described above, an operator may 
energize motor 113 across line terminals L1, L2 by closing switch 129, 
FIG. 9. In this manner, power is supplied from line terminal L1, through 
the closed switch 129, lead 125 and male terminal 119 to both main winding 
115 and start winding 117 of motor 113. From start winding 117, current 
flows through male terminal 121, female terminal 11 of electrical device 
61, contact plate 69, PTCR 101, contact plate 69a, female terminal 11a, 
and therefrom through lead 109, terminal means 103 and lead 127 to line 
terminal L2. At the same time, current also passes in parallel circuit 
relation from main winding 115 through male terminal 123 to female 
terminal 11a of electrical device and therefrom through lead 109, terminal 
means 103 and lead 127 to line terminal L2. 
As previously mentioned and as illustrated in FIG. 8, PTCR 101 is operable 
generally in response to current flow therethrough to increase its 
resistance generally as a function of its temperature; therefore, assuming 
the temperature of PTCR 101 to be rather low at the starting or start-up 
period of motor 113 when switch 129 is closed, the PTCR will initially 
pass current at a value sufficiently great enough to effect a desired 
starting torque of the motor during the start-up period thereof. As the 
temperature of PTCR 101 increases in response to the current flow 
therethrough, its resistance to such current flow also increases to a 
value which, in general, renders start winding 117 ineffective in the 
motor winding circuit so as to electrically disassociate the start winding 
from main winding 115. The point in time during the motor start-up period 
at which start winding 117 is rendered ineffective, as previously 
mentioned, may be predetermined so as to generally coincide with the 
desired running speed of motor 113. That is to say, start winding 117 may 
be generally disabled or rendered ineffective in the winding circuit of 
motor 113 generally about the same time the motor attains its running 
speed. Of course, PTCR 101 will not act to obviate current flow through 
start winding 117 during the running speed period of motor 113, but the 
PTCR will throttle or restrict the passage of such current flow to such a 
minimal or small value that the start winding is ineffective in the 
winding circuit of the motor. Of course, when the operator opens switch 
129, circuit 111 is interrupted across line terminals L1, L2 and motor 113 
is deenergized. 
Referring again to FIGS. 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 making electrical device 61 so as to generally isolate 
contact plate 69 thereof from at least limited displacement movement of 
female terminal 11 supported in the device and associated both 
mechanically and electrically with the contact plate upon the mounting of 
the female terminal to a mating terminal, such as one of male terminals 
119, 121, 123. The method comprises integrally forming one of legs 35, 37 
of the generally U-shaped tab or supporting section 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 so 
that at least one of the one and other legs 35, 37 generally absorbs the 
limited displacement movement of female terminal 11 upon the mounting or 
assembly thereof to the mating terminal. 
Another electrical device, such as a combination starter-protector device 
201, in one form of the invention is shown in FIGS. 10-12 having generally 
the same component parts and functioning generally in the same manner as 
the above described electrical device 61 with the exceptions discussed 
hereinafter, and it is believed that electrical device 201 may have 
additional objects and advantageous features of its own as well as meeting 
at least some of the objects and advantageous features set out above with 
respect to electrical device 61. 
Electrical device 201 is provided with a casing 203 comprising a plurality 
of casing members, such as a lower casing member or receptacle 205, an 
intermediate casing member 207 and an upper casing member or cover 209, 
which are interconnected against displacement from each other by suitable 
means, such as a plurality of rivets 211. Intermediate casing member 207 
and receptacle 209 are respectively provided with generally annular 
overlapping or interfitting flages 213, 215 which are abutted together. 
Casing 203 has a plurality of wall means defining a chamber 217 
therewithin, and the wall means plurality includes 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 casing members 205, 209. 
Intermediate casing member 207 and cover 209 include recess means 85 which 
is provided in sidewall 219 so as to communicate with chamber 217, and 
openings 87, 87a are also provided through the sidewall of the 
intermediate casing member and cover so as to intersect with the recess 
means. Electrical connection sections 15, 15a are received in openings 87, 
87a so as to be at least limitedly displacably movable therein when 
mounted to male terminals 121, 123, as previously discussed hereinabove 
with respect to electrical device 61. Stops 89, 91 and 89a and 91a are 
also provided on intermediate casing member 207 and cover 209 for abutment 
with end edge 23 and shoulders 29, 29a on electrical connector sections 
15, 15a of terminals 11, 11a so as to contain the electrical connector 
sections in openings 87, 87a, respectively. Supporting sections 17, 17a of 
terminals 11, 11a extend from electrical connector sections 15, 15a 
thereof so as to be respectively disposed or positioned in recess means 
85. 
PTCR 101 is disposed in the electrical contacting and positioning 
engagement between dimples 97, 97a of contact plates 69, 69a within 
chamber 217, and abutment means 93, 93a of the contact plates are disposed 
for positioning or locating engagement with sidewall 219 of intermediate 
casing member 207 and cover 209. Contact plate 69 is abutted or supported 
on the interior free end of flange 215 on receptacle 205, and resilient 
means, such as a generally thin wavy washer 225 or the like, is biased 
between end wall 223 of cover 209 and contact plate 69a. In this manner, 
contact plate 69a is urged toward the electrical contacting and 
positioning engagement with opposite side 99a of PTCR 101 and the other 
opposite side 99 of the PTCR is urged into the electrical contacting and 
positioning engagement with contact plate 69 so as to maintain contact 
plate 69 in its seated or supported engagement with the free end of flange 
215 on receptacle 205. Fingers 95, 95a of contact plate 69, 69a are 
respectively connected in both the mechanical and electrical conductive 
engagement with the free ends 21, 21a of of legs 35, 35a on supporting 
sections 17, 17a of terminals 11, 11a. 
Another pair of terminals 227, 229 extend through end wall 221 of 
receptacle 205 being integrally cast therein or otherwise retained therein 
by suitable means, and the interior end portions of the terminals 
respectively define a pair of contacts 231, 233 within chamber 217 
generally adjacent end wall 221 while the exterior end portion of the 
terminals are adapted for receiving quick connect or disconnect fittings 
(not shown) in circuit relation. Interrupting means, such as a current 
carrying thermal-responsive switch means, indicated generally at 235, is 
provided with a flexible, generally disc-shaped switch actuator or element 
237 formed of a current carrying material, such as for instance a bimetal, 
and another pair of movable contacts 239, 241 are mounted to the switch 
actuator being disposed in making engagement with contacts 231, 233 of 
terminals 227, 229 when the switch actuator is in its at-rest position. 
Switch actuator 237 is generally centrally mounted to or carried on an 
adjusting screw 243 which is adjustably or threadedly received in a 
threaded opening 245 in end wall 221 of receptacle 205 to adjust the bias 
on the switch actuator urging its movable contacts 239, 241 into the 
making engagement with contacts 231, 233 of terminals 227, 229, 
respectively. While switch means 235 is presented herein for purposes of 
disclosure, it is contemplated that other types of switch means having 
various configurations may be utilized in the present invention so as to 
meet the objects and advantageous features thereof. It may be noted that 
switch actuator 237 is spaced generally adjacent contact plate 69 within 
chamber 217 so as to be disposed in heat transfer relation with PTCR 101, 
as discussed in detail hereinafter, and if desired, at least one opening 
(not shown) may be provided through contact plate 69 for facilitating the 
transfer of heat from the PTCR to the switch actuator. 
Lead receiving opening 107 is provided in intermediate casing member 207 
and cover 209 through sidewall 219 thereof so as to intersect with recess 
means 85, and electrical lead 109 extends through opening 107 having an 
interior end electrically connected to supporting section 17a of terminal 
11a and an exterior end electrically connected with terminal 227. Another 
lead receiving opening 247 is also provided in intermediate casing member 
207 and cover 209 through sidewall 219 thereof so as to intersect with 
recess means 85, and another electrical lead 249 extends through opening 
247 having an interior end electrically connected to supporting section 17 
of terminal 11 and having a quick connect or disconnect electrical fitting 
251 on the exterior end thereof. 
In FIG. 13, another circuit or system 261 is shown having generally the 
same components and functioning generally in the same manner as the 
previously discribed circuit 111 with the following exceptions. In circuit 
261, female terminals of electrical device 201 are disposed to releasably 
or grippingly receive male terminals 121, 123 in plug 124 when the 
electrical device is associated or assembled with motor 113. Lead 125 
having starter switch 129 interposed therein is connected between male 
terminal 119 and line terminal L1, and lead 127 is connected between 
terminal 227 of electrical device 201 and line terminal L2. A capacitor 
263 is connected in circuit relation between terminal 229 of electrical 
device 201 and electrical fitting 251 of lead 249 extending from the 
electrical device. 
As previously mentioned, variations in the tolerances of male terminals 
119, 121, 123 with respect to the size thereof and/or the spaced relation 
therebetween in plug member 124 are, of course, encountered, and such 
tolerance variations may also occur in electrical connection sections 15, 
15a of terminals 11, 11a in electrical device 201. Due to the 
aforementioned tolerance variations, electrical connector sections 15, 15a 
of terminals 11, 11a may twist and/or be both laterally and longitudinally 
moved or moved or otherwise displaced within their respective openings 87, 
87a of intermediate casing member 207 and cover 209 when the electrical 
connector sections are releasably or girppingly engaged in electrical 
conductive relation on male terminals 121, 123 so as to mount electrical 
device 201 in circuit relation on mounting plug 124. Upon the assembly of 
electrical device 201 to mounting plug 124, as above described, the 
transmission or translation of the displacement movement of electrical 
connector sections 15, 15a through supporting sections 17, 17a of 
terminals 11, 11a to contact plates 69, 69a is 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, respectively. In 
this manner, the above described means of supporting sections 17, 17a for 
accommodating the displacement movement of electrical connector sections 
15, 15a at least predeterminately limits or obviates the transmission of 
such displacement movement to contact plates 69, 69a so as to maintain 
them generally in their assembled positions within chamber 217 of casing 
203 which results in the preservation of the chemically coated opposite 
sides 99, 99a of PTCR 101 from deleterious scrubbing or abrasive action 
thereof of dimples 97, 97a in the contact plates so as to prevent the 
establishment of "hot spots" on the PTCR and maintain the desirable 
electrical characteristics 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 disposed as shown in FIGS. 10-13 and as described above, motor 113 
is energized in circuit 261 across line terminals L1, L2 upon closure of 
switch 129. In this manner, power is supplied from line terminal L1 
through lead 125, closed switch 129 therein, male terminal 119 to both 
main winding 115 and start winding 117 of motor 113. From main winding 
115, the current flows through male terminal 123, female terminal 11a of 
electrical device 201 and lead 109 to terminal 229 thereof, and from 
terminal 229 through switch actuator 237, terminal 227 and lead 127 to 
line terminal L2. At the same time, current 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 
plate 69a to female terminal 11a and therefrom through lead 109 and 
terminal 227 of the electrical device to lead 127 and line terminal L2. It 
may also be noted that capacitor 263 is charged by current flowing through 
electrical device 201 from female terminal 11a thereof through lead 249 
and the capacitor to terminal 229 of the electrical device and there-from 
through switch actuator 237 and terminal 227 to lead 127 and line terminal 
L2. Of course, capacitor 263 is operable to shift the phase of the current 
through start winding 117 of motor 113 to effect a desired starting torque 
of the motor during the starting or start-up period thereof. Further, as 
the temperature of PTCR 101 increases in response to current flow 
therethrough, its resistance to such current flow also increases to a 
value which, in general, renders start winding 117 ineffective in the 
motor winding circuit, as previously mentioned and as illustrated in the 
graphical representation of FIG. 8. The point in time during the motor 
start-up period at which start winding 117 is rendered ineffective may be 
predetermined so as to occur generally when motor 113 has attained its 
running speed. 
As well-known in the art, winding circuit or motor overload may have 
deleterious affects on the components of a motor, such as for instance the 
shorting or burning-out of the motor windings or winding circuit. These 
overloads or overload conditions may be effected by a plurality of 
different causes or by combinations of such causes. For instance, some of 
the well-known causes of these overload conditions are: a running 
overload; a high temperature overload; an overload occasioned by a stalled 
or locked rotor; and a high current overload. Irrespective of the 
particular cause or combination of causes effecting such an overload 
condition, a deleteriously high current is drawn by the motor, and such 
high current is usually accompanied by or results in a high temperature 
condition. Therefore, for the sake of simplifying the discussion of motor 
overloads or overload conditions hereinafter, it is to be understood that 
any cause or causes for effecting such motor overload will be discussed 
only within the context of a high current draw or condition accompanied by 
a high temperature or thermal condition with respect to the motor winding 
circuit. 
During the start-up and running periods of motor 113, switch means 235 is 
disposed in its circuit making or completing position in circuit 261 
engaging movable contacts 239, 241 with stationary contacts 231, 233. In 
the circuit making position of switch means 235, bimetal switch blade 237 
thereof is heated in response to current flow therethrough as well as the 
heat transmitted thereto from PTCR 101. When motor 113 is running or 
energized under normal operating conditions, the heat generated in bimetal 
switch blade 237 and the heat transferred thereto is predeterminately less 
than that necessary for effecting movement of the bimetal switch blade 
from its circuit making position toward a circuit breaking or interrupting 
position so as to disengage or break movable contacts 239, 241 from 
stationary 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 affect main winding 115 and start 
winding 117, as previously mentioned. However, bimetal switch blade 237 is 
responsive to such high current drawn therethrough to correspondingly 
increase its generated heat thereby to effect characteristic actuation of 
the bimetal switch blade to its interrupting position breaking movable 
contacts 239, 241 from stationary contacts 231, 233 to interrupt or open 
circuit 261. In this manner, the motor winding circuit is 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 
across line terminals L1, L2. 
Of course, opening of circuit 261, as discussed above, also effects the 
de-energization of PTCR 101 and the resulant cooling of the PTCR and 
switch means 235. Even with the supplemental heat supplied or transferred 
from PTCR 101 to switch means 235, the switch means may cool sufficiently 
in its circuit interrupting position so as to cycle several or a plurality 
of times between its circuit interrupting position and the circuit 
completing position thereof. Such cycling of switch means 235 may occur 
throughout or over a period of a relatively short time and is effective to 
replace the motor winding circuit in circuit relation across power 
terminals L1, L2 for relatively very short periods of time; however, the 
period of time the motor winding circuit is thus cycled into circuit 
relation across the power terminal will not deleteriously affect the motor 
winding circuit since such time period is very short, as previously 
mentioned. When switch means 235 is so cycled to its circuit completing 
position, PTCR 101 is re-energized to again transmit heat to the switch 
means, and bimetal switch blade 237 is also again responsive to the 
overload condition to again generate heat during the aforementioned 
relatively short period of time thereby to again effect the cyclical 
movement or actuation of the switch means to its circuit interrupting 
position. Even in view of this cycling of switch means 235 for brief 
periods of time subsequent to the occurrence of the overload condition, it 
has been found that the supplemental heat transferred from PTCR 101 to the 
switch means is effective to increase the "off-time" thereof, i.e., when 
the switch means is in its circuit interrupting position, throughout the 
aforementioned relatively short period of time. Therefore, the increased 
"off-time" of electrical device 201 occasioned by the supplemental heat 
transferred from PTCR 101 to switch means 235 allows the PTCR itself to 
cool. When the resistance and temperature of PTCR 101 are so reduced to a 
sufficiently low value, the PTCR will again permit the passge therethrough 
of current at sufficiently high enough values to again effect energization 
of start winding 117 in the motor winding circuit so as to restart motor 
113. Therefore, when switch means 235 also cools enough to cycle back to 
its circuit completing position and remain there, current is drawn through 
PTCR 101 at values great enough to effect the re-energization of start 
winding 117 to aid re-energized main winding 115 in the motor winding 
circuit in bringing motor 113 up to its running speed. When motor 113 
attains its running speed, the self-heating effect of PTCR 101 once again 
raises its temperature and resistance to reduce current flow therethrough 
to a value rendering start winding 117 ineffective in the motor winding 
circuit. Thus, restarting of motor 113 assumes that the cause of the 
overload condition has been alleviated or corrected, and if not so 
alleviated, electrical device 201 may again operate or function as above 
described to take motor 113 off the line across power terminals L1, L2. 
From the foregoing, it is now apparent that novel electrical devices 61, 
201 and a novel method of making such have been provided meeting the 
objects and advantages set out hereinbefore, as well as others, and that 
changes in the precise arrangements, shapes, connections and details of 
the construction set forth herein, as well as the precise order of the 
method steps, may be made by those having ordinary skill in the art 
without departing from the spirit of the invention or the scope thereof as 
set out by the claims which follow.