Terminal and method of making

A terminal has means adapted for releasably receiving another terminal, and a tab integral with the receiving means extends therefrom. The tab includes a distal end portion spaced from the receiving means, a pair of opposite side edges between the distal end portion and the receiving means, and slot means in the tab intersecting one of the side edges generally adjacent the receiving means and extending between the side edges generally toward the distal end portion.

FIELD OF THE INVENTION 
This invention relates in general to electrical connector devices and in 
particular to a terminal and a method of making such. 
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 devces 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. Patent Application Ser. 
No. 624,381 filed Oct. 25, 1975 (now U.S. Pat. No. 4,042,860 issued Aug. 
16, 1977) and U.S. Patent Application Ser. No. 693,409 filed June 7, 1976 
(now U.S. Pat. No. 4,084,202 issued Apr. 11, 1978), 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 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 terminal which overcome at least some of the disadvantageous or 
undesirable features discussed hereinabove, as well as others, with 
respect to the prior art; the provision of such improved terminal in which 
the terminal is provided with means for absorbing displacement movement of 
at least a part thereof; and the provision of such improved terminal 
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. 
Further in general and in one form of the invention, a terminal having an 
electrical connector section, and a supporting section integral with the 
electrical connector section and extending therefrom. The supporting 
section includes a distal end portion having a distal end edge thereon 
spaced from the electrical connector section and a pair of spaced apart 
generally elongate legs. One of the legs is integral between the 
electrical connector section and the distal end portion, and the other of 
the legs is integral only with the distal end portion. Slot means in the 
supporting section has an end section terminating generally adjacent the 
distal end edge. The slot means defines the leg pair on the supporting 
section and forms a free end portion on the other leg spaced generally in 
closer relation with the electrical connector section than with the 
termination generally adjacent the distal end edge of the end section of 
the slot means.

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 in one form of the invention 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 or gripping 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 distal end edge 23a being disposed between side edges 27, 27a, 
and slot portion 33 is disposed generally adjacent shoulder 29 extending 
from at least generally adjacent a leftward or opposite end, end section 
or end portion of 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 spaced apart or 
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. in closer 
relation with split sleeve portion 15 than with end edge 23a. 
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 or 
terminating opposite end, end section or end portion of slot portion 31 so 
as to be predeterminately spaced from split sleeve portion 15 (as best 
seen in FIG. 4). Thus, free end 21 of leg 37 is spaced generally in closer 
relation with split sleeve portion 15 than with the termination generally 
adjacent distal end edge 23a of the rightward end or end section of slot 
31. 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 or yieldable 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 with 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 cross-section 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 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, 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. 
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 purposes 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. 
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 one of the contact plates 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, if desired 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. 
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 shich 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 accomodated 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 extablishment 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 plut 124 and with 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 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 foregoing, a method 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, 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. 
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 flanges 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, 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, respecticely. 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 ree ends 21, 21a 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. 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 277. 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 described 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 grippingly 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 
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 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 from female terminal 11a thereof through lead 
249 and the capacitor to terminal 229 of the electrical device and 
therefore 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 circuit 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 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 resultant 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 passage 
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 a novel terminal 11 and a novel 
method of making such have been provided meting the objects and advantages 
set out hereinbefore, as well as others, and that changes in the precise 
arrangement, shapes, connections and details of the construction set forth 
herein, as well as the precise order of the method steps, for the purpose 
of disclsoure 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.