Control device

A control device has a housing with a chamber therein, and a pair of means is mounted to the housing within the chamber for supporting a first contact and a switch having a resilient switch blade with a second contact engaged with the first contact. The supporting means include at least one deformable section, and a pair of adjusting means are adjustably movable in the housing to affect the deformations of the at least one deformable sections of the supporting means thereby to locate the first contact in an adjusted position defining a force required to break the first and second contacts upon actuation of the switch and to bias the switch blade toward another adjusted position defining another force required to remake the first and second contacts upon the actuation of the switch.

FIELD OF THE INVENTION 
This invention relates in general to controls which may be utilized in an 
automotive type air conditioning system or the like for instance and in 
particular to a control device for the system. 
BACKGROUND OF THE INVENTION 
In the past, various different types of prior art control device, such as 
fluid pressure actuated switches for instance, were utilized in an 
automotive type air conditioning system to control the energization and 
deenergization of a clutch actuated compressor in such system in response 
to a low and high value of fluid pressure measured at a preselected point 
in such system, such as in an accumulator of such system for instance. 
In some of these prior art control devices, a snap disc or Belleville type 
snap washer or the like for instance was utilized to effect the closing 
and opening of an electrical switch associated therewith in order to 
control the energization and deenergization of the clutch actuated 
compressor. The snap disc was translated from a stable configuration to an 
unstable configuration thereof in response to the occurrence of the 
aforementioned high value of the fluid pressure measured in the system, 
and in the unstable configuration, the snap disc drove a switch closed to 
complete a circuit energizing the clutch actuated compressor. Of course, 
the snap disc returned from its unstable configuration to its stable 
configuration in response to the occurrence of the aforementioned low 
value of the fluid pressure measured in the system, and the return of the 
snap disc to its stable configuration permitted the switch to open which 
interrupted the circuit effecting the deenergization of the clutch 
actuated compressor. Typically, a snap disc will translate between its 
stable and unstable configuration in response to a force differential 
which is built-in or preselected during the formation of the snap disc, 
and in at least some of these prior art control devices, the switch 
thereof may be adjustably loaded by a spring or the like in order to 
preselect the value of the force required for the snap disc to close the 
switch in response to the occurrence of the aforementioned high value of 
the fluid pressure measured in the system. However, at least one of the 
disadvantageous or undesirable features of the prior art control devices 
discussed above is believed to be that the "built-in" force differential 
of the snap disc is constant and can not be varied or adjusted. Further, 
it is also believed that the mechanical life of a snap disc may be limited 
due to the relatively high stresses which occur during the translatory 
movement of the snap disc between its stable and unstable configurations. 
SUMMARY OF THE INVENTION 
Among the several objects of the present invention may be noted the 
provision of an improved control device which overcomes the above 
discussed disadvantageous or undesirable features, as well as others, with 
respect to the prior art; the provision of such improved control device 
utilizing a switch actuated between a pair of electrical states and having 
adjusting means for adjusting the force required to effect the actuation 
of the switch from one of the electrical states to the other thereof and 
for adjusting a force differential between such required force and another 
force required to effect the return of such switch to the one electrical 
state thereof; the provision of such improved control device utilizing a 
pair of means for supporting the switch and contact means for making with 
the switch and breaking therefrom with the supporting means each having at 
least one deformable section which are deformable so as to define the 
aforementioned required force and force differential, respectively; and 
the provision of such improved control device utilizing components which 
are simplistic in design, easily assembled and economically manufactured. 
These as well as other objects and advantageous features of the present 
invention will be in part apparent and in part pointed out hereinafter. 
In general and in one form of the invention, a control device is provided 
with a housing having a chamber therein, and contact means is adapted for 
adjustable disposition in an adjusted position within the chamber. Means 
mounted to the housing for supporting the contact means includes means 
associated with the contact means within the chamber and adapted for 
permanent deformation and means exteriorly of the chamber adapted for 
electrical connection. Switch means adapted for adjustable disposition in 
another adjusted position in the chamber is operable generally for making 
with the contact means and breaking therefrom, and another means mounted 
to the housing within the chamber for supporting the switch means includes 
at least another means adapted for permanent deformation. Condition 
responsive means is movable in the housing upon the occurrence of a 
preselected condition for effecting the operation of the switch means. 
Means is adjustably movable in the housing and engaged with the first 
named supporting means within the chamber for exerting an adjusting force 
thereon to permanently deform the first named permanent deformation means 
and effect the adjustable disposition of the contact means in the first 
named adjusted position thereof. Another means is adjustably movable in 
the housing and engaged with the another supporting means within the 
chamber for exerting another adjusting force thereon to permanently deform 
the at least another permanent deformation means and effect the adjustable 
disposition of the switch means in the another adjusted position thereof.

Corresponding reference characters indicate corresponding parts throughout 
the several views of the drawings. 
The exemplifications set out herein illustrate a preferred embodiment of 
the present invention in one form thereof, and such exemplifications are 
not to be construed as limiting in any manner the scope of the present 
invention or the disclosure thereof. 
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to the drawings in general, there is illustrated a method of 
assembling a control device 11, such as a condition responsive or fluid 
pressure responsive electrical switch for instance (FIGS. 1-4). Control 
device 11 has a housing 13, a contact or contact means 15, and a switch or 
switch means 17 having a resilient, electrically conductive switch blade 
element 19 with another contact or contact means 21 thereon (FIGS. 1 and 
3). A pair of means, such as supporting members 23, 25 for instance, for 
supporting contact 15 and switch 17 include yieldable or deformable 
sections, as indicated at 27 and 29, 29a, respectively, and means, such as 
a diaphragm or diaphragm means 31 for instance, is provided for actuating 
the switch to make and break contacts 15, 21 (FIGS. 1 and 3). In this 
method, supporting means or members 23, 25 and actuating means or 
diaphragm 31 are mounted or otherwise secured or arranged in assembly 
positions to housing 13, and contact 21 on switch blade 19 is engaged or 
otherwise positioned so as to be made with contact 15 in electrically 
conductive relation. Deformable section 27 of supporting member 23 is 
permanently deformed or otherwise yielded, and contact 15 is thereby 
located or otherwise adjustably moved to an adjusted position defining the 
magnitude of an altitude force F1 required to break contacts 15, 21 when 
switch 17 is actuated by diaphragm 31. Deformable sections 29, 29a of 
supporting member 25 are also permanently deformed or otherwise yielded, 
and switch blade 19 is thereby biased, urged or otherwise stressed into an 
adjusted position defining a constant force differential between the 
magnitude of the aforementioned altitude force F1 and that of another 
force F2 required to make or remake contacts 15, 21 when switch 17 is 
actuated by diaphragm 31 (FIGS. 1-3). 
More particularly and with specific reference to FIGS. 1-4, supporting 
member 23, is secured or otherwise assembled by suitable means, such as 
staking or welding or the like for instance, to a mounting section or end 
portion 33 of a terminal or terminal post 35 and the terminal post may be 
inserted or otherwise extended through a generally central opening 37 in a 
dielectric base 39 of housing 13. A free end portion 41 of the supporting 
member to which contact 15 is secured is disposed generally in overlaying 
relation with a threaded opening 43 in the base adapted for threadedly 
receiving an adjusting screw 45. Of course during the insertion of 
terminal post 35 into central opening 37 of base 39, as discussed above, 
the terminal post and base may be secured together against displacement by 
suitable means, such as a press fit or the like for instance; however, it 
is contemplated that the terminal post may be secured in its assembled 
position to the base against displacement by other suitable means well 
known to the art within the scope of the invention so as to meet the 
objects thereof. 
Either before, after of simultaneously with the above mentioned assembly of 
supporting member 23 and terminal post 35 and the securement of the 
terminal post with base 39, switch 17 may be assembled or otherwise 
mounted generally in cantilever fashion to a bridge section 49 of 
supporting member 25 by suitable means, such as staking or welding for 
instance. Thereafter and subsequent to the above discussed securement of 
terminal post 35 with base 39, a pair of depending flanges or flange means 
51, 51a spaced from deformable sections 29, 29a on supporting member 25 
are inserted or otherwise placed into a pair of generally opposite 
recesses or recess means 53, 53a provided therefor in base 39. With 
flanges 51, 51a of supporting member 25 so inserted into base recesses 53, 
53a, bridge section 49 of the supporting member is disposed or otherwise 
arranged generally in overlaying relation with another threaded opening 55 
in base 39 adapted for threadedly receiving another adjusting screw 57. 
Upon the above discussed assembly of supporting member 25 with base 39, 
contact 21 which is mounted on a free end or end portion 59 of switch 
blade 19 is engaged or otherwise arranged in electrical contacting 
relation with contact 15 on supporting member 23. 
Subsequent to the assembly of supporting means 25 with base 39, as 
discussed above, diaphragm 31 may be engaged or otherwise arranged in 
abutment with a snap-action toggle 61 of switch 17 and in sealing relation 
between an end wall 63 of an electrically conductive cover 65 and base 39 
with a sidewall 67 of the cover extending generally about the base at 
least peripherally adjacent thereto so as to enclose supporting members 
23, 25 and switch 17 within a chamber 69 defined between diaphragm 31, the 
base and the sidewall of the cover. Although diaphragm 31 is disclosed as 
being seated in sealing engagement between a pair of annular spacers 71, 
73 which are, in turn, seated against base 39 and end wall 63 of cover 65, 
it is contemplated that the diaphragm may be sealably connected with the 
cover by suitable means, such as a peripheral weld bead or the like for 
instance, within the scope of the invention so as to meet at least some of 
the objects thereof. With base 39 and cover 65 associated in assembly 
relation so that sidewall 67 of the cover extends generally about a 
confronting peripheral part of the base, as discussed above, a pair of 
opposite surfaces 74, 74a on spacer 71 are arranged generally in spaced 
and/or overlaying relation with flanges 51, 51a when received in recesses 
53, 53a thereby to capture the flanges therein, and the cover sidewall is 
interconnected in electrical conductive relation with a pair of nodes or 
abutting projections 75, 75a or the like, for instance, provided on 
flanges 51, 51a of supporting member 25 captured in recesses 53, 53a of 
the base, as best seen in FIG. 4. When base 39 and cover 65 are arranged 
in assembly relation with each other, as discussed above, sidewall 63 of 
cover 65 is secured by suitable means, such as a plurality of crimps 76 or 
the like for instance, to the base against displacement therefrom. While 
crimps 76 are disclosed for interconnecting base 39 and cover 65 against 
displacement, it is contemplated that such interconnection may be 
accomplished by other suitable means known to the art within the scope of 
the invention so as to meet at least some of the objects thereof. 
Upon the above discussed interconnection of base 39 and cover 65, adjusting 
screw 45 may be adjustably or threadedly moved in threaded opening 43 of 
base 39 into driving or adjusting engagement with free end 41 of 
supporting member 23 in response to a manually applied adjusting force 
exerted by an operator using a suitable tool, such as a screw driver or 
the like for instance (not shown), on the adjusting screw. This adjusting 
force exerted on adjusting screw 45 is effective to permanently deform 
free end 41 of supporting member 23 about deformable section 27 thereof so 
as to move or otherwise displace contact 15 toward the adjusted position 
thereof defining the magnitude or preselected value of the aforementioned 
altitude or preselected force F1 to break contacts 15, 21 when switch 17 
is actuated by diaphragm 31. Either before, after or simultaneously with 
the above discussed adjustable movement of adjusting screw 45, adjusting 
screw 57 may be adjustably or threadedly moved in threaded opening 55 of 
base 39 into driving or adjusting engagement with bridge section 49 of 
supporting member 25 in response to another manually applied force exerted 
by an operator using a suitable tool, such as a screw driver or the like 
for instance (not shown), on the adjusting screw. This another adjusting 
force exerted on adjusting screw 57 is effective to permanently deform 
deformable sections 29, 29a of supporting member 25 generally about 
flanges 51, 51a captured in base recesses 53, 53a and in response to such 
permanent deformation of deformable sections 29, 29a of the supporting 
member, switch blade 19 is biased toward an adjusted position with contact 
21 thereon engaged with contact 15 in its adjusted position thereby to 
define the constant force differential between the aforementioned altitude 
or preselected force F1 and the aforementioned another or preselected 
force F2 to effect the making or remaking of contacts 15, 21 when switch 
17 is actuated by diaphragm 31, as discussed in greater detail 
hereinafter. 
With reference again in general to the drawings and recapitulating at least 
in part with respect to the foregoing, there is shown in one form of the 
invention control device 11 having housing 13 with chamber 69 therein 
(FIG. 1). Contact 15 is adapted for adjustable disposition in chamber 69, 
and switch or switch means 17 is operable generally in the chamber for 
making with the contact and breaking therefrom (FIG. 1). Supporting member 
25 is adapted for adjustable disposition in chamber 69 and for mounting 
switch or switch means 17 therein with respect to contact 15, and means, 
such as diaphragm 31 for instance, is movable in housing 13 and engaged 
with the switch for effecting its operation (FIGS. 1 and 3). Adjusting 
means of screw 45 is adjustably movable in housing 13 for adjusting the 
disposition of contact 15 with respect to switch 17 so as to adjustably 
establish preselected force F1 at which the switch breaks from contact 15 
in response to the movement of the switch means operation effecting means 
or diaphragm 31 (FIG. 1). Adjusting means or screw 57 is adjustably 
movable in housing 13 for adjusting the disposition of supporting member 
25 mounting switch 17 with respect to contact 15 to adjustably establish 
the differential between the preselected force F1 and preselected force F2 
at which switch 17 makes with contact 15 in response to the movement of 
diaphragm 31 (FIG. 1). 
More particularly and with specific reference to FIGS. 1-4, control device 
11 has a pair of housing members, such as base 39 and cover 65 for 
instance, and the base may be formed of any suitable dielectric material 
while the cover is formed from any suitable electrically conductive 
metallic material. Base 39 has a plurality of walls or wall means 
including a pair of opposite end walls 77, 79 interposed between a 
sidewall 81, and a pair of stepped bores or partial bores 83, 85 in the 
base intersect with the opposite end walls thereof, respectively, with the 
smaller stepped bore 83 comprising central opening 37. Opposite recesses 
53, 53a are provided in end wall 77 of base 39, and a pair of generally 
opposite slots 87, 87a are also provided in end wall 77 of base 39 so as 
to communicate generally between larger stepped bore 85 and sidewall 81 of 
the base, respectively, with spacer 71 being seated on upper end wall 77 
of the base. Threaded openings 43, 55 in base 39 extend between lower end 
wall 79 thereof and slots 87, 87a, and at least one pressure fluid passage 
or port 89 is provided through end wall 63 of cover 65 communicating with 
an expansible pressure fluid chamber 91 defined in the cover between 
diaphragm 31 and the cover end wall. 
Terminal post 35 is secured in smaller stepped bore 83 of base 39 against 
displacement therefrom, as previously mentioned, and mounting section or 
end 33 of the terminal post extends into larger stepped bore 85 of the 
base while an electrical extension section 93 of the terminal post is 
exposed exteriorly of housing 13 for association with a quick-connect 
electrical fitting or coupling of a type known to the art (not shown). 
Supporting member or terminal extension 23 has an end or end portion 95 
opposite free end 41 thereof which is secured to mounting section 33 of 
terminal post 35, and the free end of the terminal extension extends into 
slot 87 in end wall 77 of base 39 into overlaying relation with threaded 
opening 43 in the base. It may be noted that a weakening opening 96 is 
provided through terminal extension 23 between mounted end 95 and free end 
41 thereof so as to define deformable section 27 in the terminal 
extension; however, while weakening opening 96 is shown for purposes of 
disclosure, it is contemplated that other means, such as grooves, notches 
or other section reducing configurations or the like for instance, for 
defining deformable section 27 may be utilized within the scope of the 
invention so as to meet at least some of the objects thereof. When flanges 
51, 51a of supporting member 25 are positioned in recesses 53, 53a 
therefor in base 39, as previously discussed, bridge section 49 of the 
supporting member extends into slot 87a in end wall 77 of base 39 into 
overlaying relation with threaded opening 55, and a pair of arms 97, 97a 
are provided on the supporting member between the bridge section thereof 
and the flanges, respectively. It may be noted that arms 97, 97a are 
notched at 99, 99a thereby to define deformable sections 29, 29a in the 
arms at least generally adjacent flanges 51, 51a, respectively. While 
notches 99, 99a are illustrated herein for purposes of disclosure as being 
generally adjacent flanges 51, 51a for defining deformable sections 29, 
29a in supporting member 35, it is contemplated that other means, such as 
openings, grooves or other section reducing configurations may be provided 
at any location in supporting member 25 spaced from flanges 51, 51a for 
defining such deformable sections within the scope of the invention so as 
to meet at least some of the objects thereof. Furthermore, it is also 
contemplated that arms 97, 97a may be provided with various shapes other 
than that disclosed herein for purposes of illustration within the scope 
of the invention so as to meet at least some of the objects thereof. 
Switch blade 19 of switch 17 includes a mounting end 101 generally opposite 
free end 59 thereof, and a pair of spaced apart, generally planar legs 
103, 105 are integrally formed between the mounting and free ends. A 
tongue 107 is integrally formed on free end 59 of switch blade 19 
extending generally in a direction toward mounting end 101 thereof, and a 
pivot end 109 is provided on the tongue. Toggle or spring blade 61 has 
another pivot end 111 pivotally engaged with pivot end 109 of switch blade 
tongue 107 and another mounting end 113 generally opposite pivot end 111. 
Toggle mounting end 113 is arranged generally in overlaying relation in 
abutment with mounting end 101 of switch blade 19 on bridge section 49 of 
supporting member 25, and mounting ends 101, 113 are secured to the bridge 
section by suitable means, such as a rivet 115 or the like for instance, 
integrally formed with the bridge section. With toggle 61 so pivotally 
engaged with tongue 107 of switch blade 19 so as to comprise toggle means 
of switch 17, it may be noted that the toggle urges the switch blade in a 
direction so as to make contact 21 on switch blade free end 59 with 
contact 15 on terminal extension 23. Furthermore, it may also be noted 
that toggle 61 may be abutted with lubrication means, such as a piece of 
Teflon tape 117 or other lubricant or the like for instance if desired, 
for lubrication purposes on the underside of diaphragm 31 which, as 
previously mentioned, is movably mounted with respect to cover 65 so as to 
be arranged in driving engagement with the toggle to effect the operation 
or actuation of switch 17. While switch 17 has been described and 
illustrated herein for the purposes of disclosure, it is contemplated that 
other switches having other configurations, component parts and different 
switching actions may be utilized within the scope of the invention so as 
to meet at least some of the objects thereof. 
Operation 
In the operation of control device 11, assume that deformable sections 27 
and 29, 29a of terminal extension 23 and supporting member 25 have been 
permanently deformed, as previously discussed hereinbefore, and also 
assume that the control device is interconnected in an electrical circuit 
(not shown). Thus, with the component parts of control device 11 disposed 
as described above and as illustrated in the drawings, current may flow, 
in one direction for instance, through the control device from terminal 
post 35 through terminal extensions 23, closed contacts 15, 21 switch 
blade 19 and bridge 49, arms 97, 97a, flanges 51, 51a and nodes 75, 75a of 
supporting member 25 to cover 65. 
In the event of the occurrence of a fluid pressure at control port 89 and 
in pressure fluid chamber 91 of control device 11, the fluid pressure acts 
on the effective area of diaphragm 31 to create an actuating force acting 
to effect the displacement or driving movement of the diaphragm downwardly 
(as best seen in FIG. 1) against toggle 61 of switch 17. When the fluid 
pressure at control port 89 attains a magnitude increasing the actuating 
force to the preselected value of the aforementioned altitude force F1, 
diaphragm 31 is driven against toggle 61 of switch 17 so as to pivotally 
move tongue 107 of switch blade 19 downwardly past the plane of switch 
blade legs 103, 105 which, of course, effects the snap-action movement of 
the switch blade in a direction breaking or disengaging its contact 21 
from contact 15 of terminal extension 23 thereby to interrupt or break the 
electrical circuit through the control device. Upon the actuation of 
switch 17 to its switching state breaking its contact 21 from contact 15, 
contact 21 is abutted with spacer 71 thereby to limit the breaking 
movement of switch blade 19. 
When the fluid pressure at control port 89 is reduced the actuating so as 
to correspondingly reduce force by the aforementioned constant force 
differential to another preselected value less than the preselected value 
at which switch 17 was actuated, diaphragm 31 moves upwardly (as best seen 
in FIG. 1) in response to such reduction of the fluid pressure at the 
control post thereby to effect the toggling snap-action return movement of 
switch blade 19 to its at-rest position remaking or reengaging its contact 
21 with contact 15 on terminal extension 23. Thus, with contacts 15, 21 
again made, the electrical circuit through control device 11 is once again 
completed. 
From the foregoing, it is now apparent that a novel control device 11 has 
been presented meeting the objects and advantageous features set out 
hereinbefore, as well as others, and that modifications as to the precise 
configurations, shapes, details and connections of such control device 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.