Temperature responsive probe apparatus

A thermal probe assembly has a unitary outer shell or housing forming an open end adapted to receive an electrical connector unit and having an inboard end defining a probe portion; the outer shell or housing has deformable wall portions forming a bore; a pair of terminals with electrical conductor portions connected to a thermistor have a plastics material mounting member premolded thereon; the plastics material mounting member is slidably fit in the bore to position the thermistor within the bore and to axially locate the thermistor in spaced relationship to the inboard end of the outer shell or housing; portions of the plastics material mounting member interlock with cooperating portions of the bore to operatively lock the thermistor in place within the outer shell or housing.

FIELD OF THE INVENTION 
This invention relates generally to temperature sensor assemblies and more 
particularly to such sensor assemblies as are effective for producing an 
electrical signal indicative of the sensed temperature and even more 
particularly to such sensor assemblies having electrical terminals, for 
operative connection to associated electrical circuitry, wherein such 
electrical terminals are joined to a temperature responding member as, for 
example, a thermistor. 
BACKGROUND OF THE INVENTION 
The prior art has provided various specific forms of thermal probe 
assemblies wherein, for example, a probe portion encloses a thermistor for 
sensing and reacting to the temperature of a medium in heat transfer 
relationship. In such prior art sensor assemblies, there are usually two 
or more electrical terminal members, as for connection to associated 
electrical circuitry, and electrical wire leads electrically connected as 
to a thermistor, or other temperature reactive means, and, basically, 
mechanically connected to operative ends of the electrical terminal 
members. Such mechanical connection is usually made as by crimping of a 
portion of the related electrical terminals against the respective 
coacting electrical wire leads. It is not unusual, in those situations, 
that the crimping connection is attempted to be enhanced by silver 
soldering or welding thereof. Examples of such means of connection are 
disclosed in U.S. Pat. No. 4,243,968 dated Jan. 6, 1981, with the inventor 
being Douglas R. Scott and U.S. Pat. No. 5,046,857 dated Sep. 10, 1991, 
with the inventors being John R. Metzger et al. 
In prior art structures wherein, for example, a thermistor is employed as 
the temperature sensing means, thus wire leads of such thermistor are, in 
fact, the electrical wire leads which are crimped by portions of the 
respective cooperating terminals. For example, in the prior art as 
exemplified in U.S. Pat. No. 5,046,857, typically the thermistor 20 
thereof is both mechanically and electrically connected to the wire leads 
38--38 before any attempt of connection to the terminals 16 and 18. Once 
such wire leads 38--38 are connected to the thermistor 20 then such wire 
leads 38--38 are connected by their respective end portions 36--36 being 
contained in and crimped by the end portions 16c and 18c. 
Even though the diametrical size of the wire leads may somewhat vary as 
between two different sensor assemblies of the prior art, it is not 
unusual to have the diameter of such wire leads be anywhere from, and 
including, 0.41 mm. (0.016 in.) to and including 0.51 mm. (0.020 in.). 
It appears that attempts have been made in the prior art to at least reduce 
if not eliminate failures at the connections joining the generally 
cylindrical wire leads to the cooperating terminals. The prior art 
structures experience such failures, electrical and/or mechanical, 
especially when during normal use the prior art sensor assembly is exposed 
to vibrations or mechanical shock. When such a failure occurs the 
temperature sensor assembly is made non-functional and the continued 
successful operation of the apparatus employing the failed prior art 
sensor is placed at risk. 
The invention as herein disclosed is primarily directed. The solution of 
the aforestated as well as other related and attendant problems of the 
prior art. 
SUMMARY OF THE INVENTION 
According to the invention, a temperature responsive assembly comprises 
housing means, passage means formed in said housing means, an internal 
body means adapted to be positioned within said passage means, said 
internal body means when so positioned within said passage means forming a 
chamber-like portion in said passage means, first electrical conductor 
means having first and second electrical conductor portions integrally 
formed with each other and extending through said internal body means as 
to have said first electrical conductor portion adapted for electrical 
connection to associated first electrical circuit means and as to have 
said second electrical conductor portion extending into said chamber-like 
portion and electrically connected to one electrical side of electrical 
resistance means which varies the magnitude of the resistance of said 
resistance means in response to sensed temperature, and second electrical 
conductor means having third and fourth electrical conductor portions 
integrally formed with each other and extending through said internal body 
means as to have said third electrical conductor portion adapted for 
electrical connection to associated second electrical circuit means and as 
to have said fourth electrical conductor portion extending into said 
chamber-like portion and electrically connected to a second electrical 
side of said electrical resistance means. 
Various objects, advantages and aspects of the invention will become 
apparent when reference is made to the following detailed description 
considered in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring now in greater detail to the drawings, FIG. 1 illustrates in 
elevation a temperature sensor and control assembly 10 operatively 
connected as to an interconnecting electrical plug 12 of an associated 
electrical circuit. Referring to both FIGS. 1 and 2 the sensor assembly 10 
is preferably comprised of a unitary outer housing 14 which, also 
preferably, is molded of plastics material. 
Preferably, the outer housing 14 is comprised of plastics material and more 
particularly a 20% calcium carbonate filled polypropylene. Such is 
obtainable as from DSM Engineering Plastics of 2267 West Mill Road, 
Evansville, Ind., U.S.A. In the trade, DSM Engineering Plastics sells such 
material under the trade name or trademark Fiberfil. It should be made 
clear that the invention disclosed, described and claimed can be practiced 
employing other material; the identification of the material, Fiberfil, is 
merely to identify at least one material employable in the practice of the 
invention. 
Referring to all of FIGS. 1, 2 and 3, the housing 14 is depicted as 
comprising a relatively elongated body portion 16 having an enlarged 
base-like portion 18 with generally transitional portions 20 and 22. The 
body base portion 18 may be provided with suitable clearance passages 24 
and 26 for respectively receiving screws 28 and 30 for securing the 
assembly 10 to related structure 32 forming, for example, a portion of an 
automotive vehicle. 
The upper (as shown in FIGS. 1, 2 and 3) end of elongated body 16 is 
preferably formed as to provide a relatively transversely enlarged body 
portion 34 which, as depicted, may comprise generally parallel rib-like 
members or portions 36, 38 and 40 situated so that a coacting plug 
assembly 12 will be operatively received only if slots or clearances 
therein are of locations matched to the ribs 36, 38 and 40. Also, in the 
preferred embodiment, means are provided whereby a deflectable tab-like 
lever, carried by said plug assembly 12, is slidably received between 
opposed wall portions 42 and 44 and engageable with latch-like cross 
member 46 fixedly joined to the walls 42 and 44. 
In the preferred embodiment, stiffening or reinforcing members or portions 
48 and 50 are formed to add strength as to the lower half (as shown in 
FIGS. 1, 2 and 3) of the elongated body 16. 
As depicted in FIGS. 2 and 3, a plug or inner body 52 is carried generally 
within housing or outer body 14. 
FIGS. 4 and 5 may be considered as respectively corresponding to FIGS. 2 
and 3 without the inner body 52. 
As depicted in FIGS. 4 and 5, the housing 14 is formed with a generally 
longitudinally extending passage 54 having an end opening 56 and an 
opposite end 58 closed as by a wall portion 60. In considering both FIGS. 
4 and 5, it can be seen that in the preferred embodiment the passage 54 
may be considered as being comprised of a plurality of passage sections or 
portions. 
For example, starting at the upper end (as shown in FIGS. 4 and 5) of the 
housing 14, it can be seen that the passage means 54 comprises a first 
transversely relatively large passage portion 62 forming a shoulder 64 and 
having generally axially extending passage wall portions 66, 68, 70 and 
72. 
The passage portion 62 opens to and communicates with a next passage 
portion 74 of a transverse cross-section smaller than that of passage 
portion 62. In the preferred embodiment, the passage portion 74 is 
comprised of generally axially extending passage wall portions 76, 78, 80 
and 82. As can be seen, opposite wall portions 78 and 82 are shown 
extending downwardly to where such wall portions 78 and 82 respectively 
join translational surfaces 84 and 86 which, downwardly, are inclined 
toward each other. Somewhat in comparison, other opposite passage wall 
portions 92 and 94 extend downwardly generally parallel to each other and 
respectively join second translational surfaces 96 and 98 which, 
downwardly, are inclined toward each other as generally depicted in FIG. 
5. 
As possibly best visually presented in FIG. 4, additional opposed wall 
portions 104 and 106 extend, generally parallel to each other, and 
respectively downwardly from the lower ends or edges of inclined surfaces 
84 and 86. Wall portions 104 and 106 extend downwardly as to respectively 
join into, at the upper ends or edges thereof, inclined or transitional 
surfaces 100 and 102. The upper ends or edges of inclined or transitional 
surfaces 96, 102, 98 and 100, preferably are generally coplanar with 
respect to each other, as are the lower ends or edges of the same 
surfaces. 
As possibly best seen in FIGS. 4 and 5, oppositely situated recesses or 
voids 110 and 112 are respectively formed into the wall portions 104 and 
106. In the preferred form, and as viewed in for example FIG. 4, each of 
the recesses 110 and 112 is of a generally V-like configuration with 
recess 110 being comprised of an upper inclined surface 114 operatively 
meeting a lower inclined surface 116. Similarly, recess or groove 112 is 
comprised of an upper inclined surface 118 operatively meeting a lower 
inclined surface 120. 
A relatively short passage 122 extends downwardly from the lower ends of 
surfaces 96, 100, 98 and 102 (also see FIG. 14). In the preferred 
embodiment, the passage 122, when viewed as in, for example, FIGS. 13, 14 
or 15 is of a generally oblong configuration having an end surface 124 
which is tapered as to be conical-like. 
Passage means 54 is shown as further comprising passage or chamber means 
126 which, as depicted, preferably has an axially extending cylindrical 
wall 128 which has an upper end 130 opening, as through surface 124, into 
passage 122. 
As shown in FIGS. 2 and 3, the preferred embodiment of the assembly 10 
comprises an inner body or plug 52 also preferably comprised of plastics 
material. 
FIGS. 6 and 7 illustrate, in elevation and in relatively larger scale, the 
plug or mounting member 52 along with first and second electrical 
conductor members 132 and 134. The mounting member or inner body 52 along 
with conductor members 132 and 134 may be considered a subassembly 136 in 
that such is made prior to the insertion thereof into the passage means 54 
of the housing or body means 14. 
Referring now in greater detail to FIGS. 6, 7, 8 and 9, the inner body or 
mounting member 52 is shown as comprising a relatively enlarged main body 
portion 138 which may be formed as to have relatively short side wall 
surfaces or portions 140 and 142 and relatively long side wall surfaces or 
portions 144 and 146. 
In the preferred embodiment surfaces or sides 144 and 146 are respectively 
provided with tabs or detent-like portions 148 and 150. As possibly best 
seen in FIGS. 6 and 8 tab-like means or portion 148 is preferably 
comprised of an inclined upper surface 152 and a lower inclined surface 
154 which, collectively, define a wedge-like portion. Similarly, the 
tab-like means or portion 150 is preferably comprised of an inclined upper 
surface 156 and a lower inclined surface 158 which, also collectively, 
define a wedge-like portion. Portions 148 and 150 may be considered as 
comprising interlocking means which cooperatively function with related 
interlocking means comprised as of recesses or voids 110 and 112 (FIGS. 3, 
4 and 5). 
The lower (as viewed in any of FIGS. 6, 7, 8 or 9) end of the generally 
main body portion 138 is formed as to provide a generally inwardly 
inclined surface means comprised of two relatively short surface portions 
160 and 162 which are functionally connected to two relatively longer 
surface portions 164 and 166 forming a generally continuous inclined 
surface 168 as possibly best shown in FIG. 11. 
Continuing downwardly from the main body portion 138, an extension-like 
body portion 170 is preferably formed integrally with the main body 
portion 138. As seen in FIGS. 6, 7, 8 and 9, the extended body portion 170 
is preferably comprised of a first extending body portion 172 which, in 
turn, carries a somewhat relatively enlarged flange-like portion 174. 
Also, formed integrally therewith a generally cylindrical body 176 extends 
further downwardly and, in turn, integrally carries a circular flange 
portion 178. 
FIGS. 16-21 illustrate the preferred operations, as performed upon metal 
stock 180, in the formation of conductor 134. 
As generally depicted in FIG. 16, the metal stock 180 is struck as by a die 
to, in effect, form a blank configuration 182 of what subsequently becomes 
the totally formed conductor member 134, as depicted, for example, in 
FIGS. 8 and 9. 
In FIG. 16, the blank 182 is shown as comprising a relatively large upper 
(as shown in FIG. 16) portion 184 integrally formed with a somewhat 
necked-down body portion 186 in turn integrally formed with a generally 
eccentrically positioned body portion 188. Such body portion 188 is, in 
turn, integrally formed with a generally eccentrically positioned body 
portion 190. Preferably, the free end of body portion 190 is generally 
circularly enlarged as at 192. 
As generally depicted, body portions or sections 184, 186, 188 and 190 
extend generally in parallel relationship. 
Referring to both FIGS. 16 and 17, the relatively enlarged upper body 
portion 184 terminates as at end portions 192 and 194. In the preferred 
embodiment the upper body portion 184 undergoes further forming so that 
such forming of longitudinal portions 196 and 198 takes place generally, 
respectively, on or about the phantom lines 200 and 202. The very upper 
end of upper body portion 184 is preferably provided with cut-out notches 
204 and 206. When the longitudinal portions 196 and 198 are formed-over 
such notches 204 and 206 are effective for defining the tapered end of the 
terminal end of the electrical conductor 134. Once the portions 196 and 
198 are formed-over as depicted in FIG. 18, such then, in cooperation with 
body portion 220, comprise a terminal end 135 of the continuous conductor 
134. 
In the preferred embodiment, edges 208 and 210 of body portion 186 are 
generally respectively aligned with bend or phantom lines 200 and 202. The 
body portion 186 and possibly most of the body portion 188 may be 
considered as comprising a generally medial portion of the electrical 
conductor member 134. An edge 212 of body portion 190 is shown as meeting 
a generally transverse edge 214. A relieved or cut-out portion 216 is 
formed as in body portion 188 to effectively enable the subsequent bending 
or forming of the body portion 190 relative to body portion 188 and 
generally about phantom bend line 218. 
Subsequently to the cutting of blank 182, longitudinal portions 196 and 198 
of body portion 184 are bent (upwardly from the plane of the drawing) 
generally about depicted respective bend lines 200 and 202 and, then, 
continuing with such bending about the bend lines, back downwardly toward 
the plane of the drawing as to be against the medial portion 220 and have 
respective longitudinal edges 222 and 224 juxtaposed to each other as best 
seen in FIG. 18. 
Also, the body portion 188 is bent as at indicator line 226 to have a bent 
portion 228 be at a generally 45.degree. angle with respect to body 
portion 188. Further, a bending operation is performed as at indicator 
line 230 in order to have EL juncture-like portion 232 and body 190 be at 
a generally 45.degree. angle with respect to bent portion 228 and 
generally parallel to body portion 188. 
Generally, the difference shown between FIGS. 19 and 20 resides in body 
portion 190 having been bent as about indicator line 218 (see FIGS. 16 and 
18) and making such body portion 190 be generally normal to juncture-like 
portion 232 and body portion 188. 
The arm, body portion or leg 190 is preferably further formed as to have a 
first bend, as at 236, and a second bend, as at 238 (FIG. 21), thereby 
defining a generally angled medial body portion 240 and respective end 
portions 242 and 246 which are generally parallel to each other. 
The other electrical conductor 132, as generally depicted in FIGS. 3, 8 and 
9 may be considered a mirror image of the electrical conductor 134. 
Portions of the continuous electrical conductor 132 which are like those 
of continuous electrical conductor 134, as also depicted and described in 
FIGS. 16-21, are identified with like reference numbers provided with a 
suffix "a". Only so many of such suffix "a" numbers are used as is 
believed necessary to disclose the continuous electrical conductor 132. 
After the medial body portions or extensions 240 and 240a as well as ends 
246 and 246a are formed, as depicted generally in FIG. 8, a thermistor 260 
is placed between the generally inner surfaces 248 and 248a and fixedly 
secured thereto as by, for example, soldering as to establish electrical 
conductivity through the thermistor 260 with portions 192 and 192a, of 
respective conductors 134 and 132, effectively serving as electrical 
terminals. 
In the preferred embodiment, each of the continuous conductors 134 and 132 
is comprised of CA260 Half Hard Brass which, further, is preferably 0.3175 
mm..+-.0.0127 mm. thick (0.0125.+-.0.0005 inches thick) and tin plated to 
a plate thickness of from 0.00254 mm. to 0.00762 mm. (0.0001 to 0.0003 
inches). Such material, the thickness thereof and plating, if any, is by 
way of example and not of limitation. 
The continuous conductors 132 and 134, being thusly formed, are then held 
in generally parallel spaced relationship to each other so as to be 
generally coplanar and having respective positions as depicted in FIGS. 2 
and 3 and FIGS. 8 and 9. At that time, as by a suitable molding apparatus, 
plastics material is formed onto and about portions of conductors 132 and 
134 to form the inner body 52 (FIGS. 2, 3, 6, 7, 8, 9, 10, 11 and 12). 
In the preferred embodiment, the plug or body 52 comprises "Zytel". "Zytel" 
is a trademark of DuPont de Nemours, E. I. & Co. for nylon resin available 
as molding powder, extrusion powder and soluble resin. The preferred 
composition is 33% glass filled nylon obtainable, for example, from DuPont 
Engineering Polymers having an address of: 1007 Market Street, Wilmington, 
Del., U.S.A. Again, this is by way of example and not of limitation in 
that other plastics materials are available for practicing the invention. 
It should be made clear that the invention disclosed, described and 
claimed can be practiced employing other plastics material; the 
identification of the material, Zytel, is merely to identify at least one 
material employable in the practice of the invention. 
Referring primarily to FIGS. 2, 3, 6, 7,8 and 9, the subassembly 136 (as 
shown in FIGS. 6 and 7) is introduced into passage portion 74 and moved 
generally longitudinally (downwardly as viewed in FIGS. 4 and 5) resulting 
in the detent members or portions 148 and 150 (of body 138) respectively 
slidably engaging ramps or transitional surfaces 84 and 86. As the 
subassembly 136 is continued to be moved downwardly (as viewed in FIGS. 4 
and 5), the detent or tab-like portions 148 and 150 slide onto the inner 
surfaces of wall portions 104 and 106, respectively. During such movement, 
the relative resilience of the plastics materials, enables the wall 
portions 104 and 106 to be urged somewhat outwardly (i.e., away from each 
other) by the general spreading thereof brought about by the mounting body 
52 and tab-like means 148 and 150, while such mounting body 52 and 
tab-like means 148 and 150 are somewhat compressed (i.e., the tab means 
148 and 150 being resiliently moved toward each other). Such resilient 
deformation enables the subassembly 136 to continue to be moved until 
detent or wedge portion 148 comes into registry with recess or void 110 
and wedge portion 150 comes into registry with recess or groove 112. When 
such occurs, the resilient: deflections incurred by wall portions 104 and 
106 (of outer housing 14) and the resilient deflections incurred by plug 
or body 52 and its wedges 148 and 150 are, in the main, released so that 
the locking detents 148 and 150 become respectively received in 
cooperating grooves or recesses 110 and 112, as depicted in FIG. 2. 
As shown in FIGS. 2, 3, 6, 7, 8, 9, 10 and 11, the plug or mounting member 
52 is preferably provided with a somewhat lower disposed circumscribing 
inclined surface 168 comprised as of relatively longer inclined surfaces 
164 and 166 and relatively shorter inclined surfaces 160 and 162. When 
body or carrier 52 is positioned (as by the respective engagements of 
recesses 110 and 112 with locking detents 148 and 150) inclined surfaces 
164 and 166 become at least in juxtaposition with inclined seating or 
abutment surfaces 100 and 102 of outer housing 14 and inclined surfaces 
160 and 162 become at least in juxtaposition with inclined seating or 
abutment surfaces 96 and 98 of outer housing 14. The expression "at least" 
is employed because such juxtaposed surfaces may be in abutting engagement 
with each other. 
With the subassembly 136 being thusly situated within outer housing 14, 
continuous conductors 132 and 134 have their upper portions (as viewed in 
FIGS. 3, 6, 7 and 8) situated generally within conduit, passage or chamber 
portion 74 (also see FIGS. 2, 4 and 5) while the lower portions 240, 240a, 
232, 232a, 188 and 188a along with thermistor 260 are situated generally 
within chamber means 126 (see FIGS. 3, 4, 5 and 7). 
Further, in the preferred embodiment, with the subassembly 136 being 
situated, as described, within passage means 54, the relationships of the 
various elements are such as to cause the flange portion 178, of body 52, 
to engage surface 124 (FIGS. 4, 5, 13 and 14) and because of the resilient 
resistance of the material comprising the flange portion 173 result in 
flange 178 undergoing limited resilient deformation and thereby precluding 
the passing of any undesired substance as from chambers 74 to and into 
chamber 126 and as from chamber 126 to and into chamber 74. 
In the preferred embodiment a thermal conducting material or heat transfer 
compound is applied to chamber means 126 as to rapidly convey the 
temperature at surface 128 (see FIGS. 3, 4 and 5) to the temperature 
responsive means 260. Doing such is generally well known in the art. In 
the preferred embodiment of the invention, the heat transfer compound 
employed is a silicone grease, commercially sold under the trade name of 
"Castall G-800" with such being obtainable from Castall, Inc. having a 
business address of: Weymouth Industrial Park, East Weymouth, Mass. 
In the preferred arrangement, the heat transfer compound is introduced into 
chamber means 126 before portions 240 and 240a become inserted into 
chamber 126. For example, referring to FIG. 4, chamber 126 may initially 
be filled with the heat transfer compound 270 to a level as at 272. When 
the subassembly 136 is placed into passage 54 and opertively connected to 
the housing 14, the heat transfer compound 270 becomes partially displaced 
causing the level of such heat transfer compound 270 to rise as to, for 
example, a level 274. For believed improved clarity, such heat transfer 
compound 270 is not depicted in any other drawing Figures. It should be 
clear that the invention can be practiced with or without the use of a 
heat transfer compound and, if a heat transfer compound is employed, the 
actual compound which may be used is not limited to the use of said 
"Castell G-800" which has been disclosed by way of example and not of 
limitation. In those situations wherein a heat transfer substance 270 is 
employed, the flange 178, pressed as against surface 124, is effective to 
preclude the flowing of the heat transfer substance 270 out of chamber 126 
and into, for example, chamber 122. 
OPERATION OF INVENTION 
With the temperature responsive probe assembly 10 assembled as hereinbefore 
disclosed and described, the assembly 10 may be operatively connected to 
related electrical coupling means 12 and associated electrical circuitry. 
For example, referring to FIG. 3, the coupling means 12 may be comprised of 
a suitable coupling body 13 receivable as by passage portions 62 and 54 
(also see FIGS. 4 and 5) and carrying electrically conductive contact 
means 63 and 65 which are in electrical engagement with terminal portions 
135a and 135, respectively. The contact means 63 and 65 may be considered 
as respectively comprising portions of electrical circuit means 67 and 69. 
As schematically illustrated in FIG. 3, circuit means 67 may comprise a 
source of electrical potential 276 being led to ground 278, as via 
conductor means 280, and electrically connected to conductor means 282 
leading as to contact means 63. Conductor means 282 may comprise 
electrical switch 284. As depicted, circuit means 69 comprises an 
associated electrical load 286 brought to ground 278 as by a conductor 
means 288 and operatively electrically connected to contact means 65 as by 
a conductor means 290. 
As is well known in the art, a thermistor is a solid-state semiconducting 
device whose electrical resistance varies with its sensed temperature. 
Both types of thermistors exist; i.e., the group of thermistors in which 
the electrical resistance increases as its sensed temperature becomes 
colder and the group of thermistors in which the electrical resistance 
decreases as its sensed temperature becomes colder. It may be assumed, for 
purposes of disclosure, that thermistor 260 is the type in which the 
resistance thereof increases with sensed temperature decrease. 
Generally, the overall system disclosed in FIG. 3 would comprise the source 
of electrical potential 276, conductor means 282 and switch means 284, 
electrical contact 63, terminal 135a of unitary conductor 132, thermistor 
260, leg 240 of unitary conductor 134, terminal 135, contact 65, conductor 
means 290, load 286 and, via conductor means 288, to ground 278. With the 
assumed type or characteristics of thermistor 260, as its sensed 
temperature decreases the resistance thereof increases with the result 
that, accordingly, both voltage and current through thermistor 260 are 
correspondingly decreased. 
EMBODIMENT OF FIG. 22 
FIG. 22 depicts a further embodiment of the inventive structure. For 
purposes of disclosure it may be assumed that the overall structure, of 
which a fragmentary portion is depicted, is as disclosed in FIG. 3. 
Accordingly, all elements shown in FIG. 22 which are like or similar to 
those of FIG. 3 are, except as otherwise noted, identified with like 
reference numbers. 
In the embodiment of FIG. 22, an elastomeric seal, such as an O-ring 292, 
is provided as about surface 172 of body 52 whereby the seal is 
resiliently deformably contained between surface 172 and opposed surface 
122 of outer housing 14. Such sealing means might be employed in those 
situations or conditions wherein sealing against intrusion or eliminating 
air leakage is required. 
EMBODIMENT OF FIG. 23 
In FIG. 23, all elements which are like or similar to any of the preceding 
Figures are, except as noted to the contrary, identified with like 
reference numbers. 
In the embodiment of FIG. 23, the outer body or housing 14 is shown as 
provided with a body portion 294 which, in turn, carries tool-engaging 
surface means 296 and 298. Preferably formed integrally with body portion 
284 and extending downwardly therefrom (as viewed in FIG. 23) is an 
axially extending body portion 300 externally threaded as at 302 for 
cooperative threaded engagement with an internally threaded portion 304 
formed as in a wall 306 of an associated structure 308. Annular sealing 
means and/or washer means 310 may be provided as between the enlarged body 
portion 294 and an outer surface 312 of wall 306. 
The outer body or housing 14 has a probe-like extending portion 314, 
preferably integrally formed with axially extending body portion 300, as 
to be in the fluid or gaseous medium 316 generally in structure 308. 
Openings or passages 318, 320 and 322 are formed through the wall of 
probe-like portion 314 thereby placing the thermistor 260 into operative 
contact with the medium 316. Such passageways, in turn, define remaining 
relatively narrow portions 324, 326 and 328 of the probe extension 314. In 
the preferred embodiment, the thermistor 260 is coated with epoxy 330, as 
is well known in the art to offer a degree of protection to the thermistor 
260. 
The chamber 126 which, in the embodiment of FIG. 23, is effectively vented 
via 318, 320 and 322 to the fluid 316 to be sensed, may be of any suitable 
configuration and, as depicted, may have a longitudinally extending 
generally flat surface 332. 
By way of limited review, it should now be apparent that by producing 
subassemblies 136 in substantially constant dimensional relationships and 
producing the cooperating outer housings or bodies, as 14, also with 
substantially constant dimensional relationships, it becomes possible to 
mass produce the assemblies 10 by assembling respective ones of such 
subassemblies 136 to respective ones of cooperating outer housings or 
bodies, as 14, without any worry that, for example, the thermistor 260 
might interferingly engage the inner surface of the chamber 126. 
Further, no sealing problem exists in those situations wherein a heat 
transfer substance, as at 270, is employed because in the preferred 
embodiment, the circumscribing flange 178 carried by body 52 automatically 
seals the chamber means 126 as from chamber portion 122. That is, when 
subassembly 136 is moved into its place, i.e., assembled to outer housing 
or body 14, the sealing flange or member 178 effectively sealingly engages 
surface 124 which surrounds the opening of chamber means 126. 
With regard to sealing, the preferred embodiment also provides for 
circumscribing sealing means, as at 292, to assure against intrusion of 
undesired material into or eliminating leakage from chamber means 
containing the thermistor 260. 
EMBODIMENT OF FIGS. 25-28 
In the embodiment of FIGS. 25-28, all elements which are like or similar to 
any of the elements of preceding Figures, except as noted to the contrary, 
are identified with like reference numbers. 
Referring in particular to FIG. 25, the housing 14 is depicted as 
comprising at least two separate housing sections 15 and 17 with housing 
section 15 being of a suitable plastics material while housing section 17 
may be formed from a suitable metal such as, for example, brass. As stated 
with regard to previous Figures, housing section 15 may be comprised of a 
20% calcium carbonate filled polypropylene. Such is obtainable as from DSM 
Engineering Plastics of 2267 West Mill Road, Evansville, Ind., U.S.A. In 
the trade, DSM Engineering Plastics sells such material under the trade 
name or trademark Fiberfil. It should be made clear that the invention as 
disclosed in FIGS. 25-28 can be practiced employing other material; the 
identification of the material, Fiberfil, is merely to identify at least 
one material employable in the practice of the embodiment of FIGS. 25-28. 
In the embodiment of FIGS. 25-28 the housing section 15 is shown as having 
a lower depending portion 400 which is received in a cavity or chamber 402 
formed in housing 17. In the preferred embodiment a circular or annular 
flange-like surface 404 is formed generally about chamber 402 and such 
surface 404 provides an abutment against which an annular elastomeric 
sealing member 406 is seated. As shown for example in both FIGS. 25 and 26 
housing section 15 is preferably provided with a generally circular or 
cylindrical flange portion 408 which, as depicted, may be in sealing 
engagement with annular seal 406. In the preferred embodiment, the upper 
(as shown in FIG. 25) end of housing member 17 is formed-over, as 
generally depicted at 410 as to thereby hold housing sections 15 and 17 in 
assembled relationship and to urge flange 408 against seal 406. As also 
best shown in FIG. 25, housing section 15 is provided with an aperture 412 
which effectively communicates with chamber 126. 
FIGS. 27 and 28 depict the housing 14 of FIGS. 25 and 26 provided with 
other elements as already described as in FIGS. 1-24 to thereby complete 
the entire assembly 10. 
The various elements shown in FIGS. 25, 26, 27 and 28 function in the same 
manner as do the corresponding elements in the preceding Figures. 
As already briefly described, the prior art has, employed and continues to 
employ wires, which have first and second ends, for electrically 
connecting an electrical device as to, for example, electrical terminals 
which, in turn, are intended for electrical connection as to externally 
situated circuit means. With regard to the disclosed embodiments, if such 
were to include the prior art instead of the inventive structures 
disclosed, in FIGS. 7, 8, 27 and 28, for example, the electrical conductor 
members 132 and 134 would not be employed but rather, at least, portions 
188 and 188a would be cut-off, i.e., terminated as to have free ends 
extending downwardly from body 52 and portions 232 and 232a along with arm 
or leg portions 190 and 190a would be eliminated. Instead, the 
hypothetical free ends of hypothetical cut portions 188 and 188a would be 
modified as in U.S. Pat. No. 5,046,857 which depicts U-shaped end portion 
16c and 18c primarily mechanically gripping ends of wires 38. As in said 
U.S. Pat. No. 5,046,857 the other ends of the wires 38 would be 
operatively connected directly to the thermistor as depicted at 20 of said 
U.S. Pat. No. 5,046,857. Wires, terminal members with crimping portions 
engaging the wires which, in turn, lead to and directly contacting a 
temperature sensor are also shown in U.S. Pat. No. 4,243,968 which, in 
such respect, is not inconsistent to said U.S. Pat. No. 5,046,857. 
Experience has shown that such prior art wire connections are rather 
significantly subject to failure especially during use. That is, among 
possible other causes of such prior art failures is the fact that wire has 
been used for providing both a mechanical and electrical connection as 
between the terminals and a temperature sensor as described and disclosed 
in said U.S. Pat. Nos. 4,243,968 and 5,046,857. 
Wire, whether comprised of a single cross-sectional solid body or of a 
bundle or plurality of bodies, is in the main of generally cylindrical 
configuration. This in itself could lead to the failures in the prior art. 
The methods of connection shown in said U.S. Pat. Nos. 4,243,968 and 
5,046,857 result: in what may be considered a line contact, or line 
contacts, as between: (a) the wire leads 28 and 29 and crimps 48--48 of 
U.S. Pat. No. 4,243,968 and (b) the wire leads 38--38 and U-shaped 
portions 16c and 18c of U.S. Pat. No. 5,046,857. Even though the soldering 
or welding of such connections does bring about the strengthening thereof, 
such connections still are not strong enough as evidenced by the 
experienced failures thereof. 
Among the benefits obtained by the invention disclosed and taught herein, 
are having the conductor means, as for example 134, be of unitary 
one-piece construction. Also, the conductor means, as for example 134 or 
132, is not formed of wire, that is, not of metal stock of cylindrical 
cross-section as wire used in the prior art. In the preferred embodiment, 
a generally medial portion 188 of the conductor means 134 has an 
integrally formed extending arm or leg-like portion 190 which, in turn, 
has its end 192 physically and electrically connected to one electrical 
side of the thermistor 260. In viewing continuous conductor 134, as in 
FIGS. 3, 8, 9, 16-21, 22 and 23, it can be seen that, for example, the 
width of the medial portion 188 is significantly greater than the 
thickness thereof. That, in turn enhances the rigidity of the medial 
portion 188 resisting the bending thereof in directions toward and/or away 
from the cooperating continuous conductor as 132. As shown in FIGS. 18, 
19, 20 and 21 the arm or leg portion 190 is integrally formed as with and 
operatively carried by the medial portion 188 as to be an extension 
thereof. Further, it can be seen, as in FIGS. 16 and 17 as well as FIGS. 
18 and 19, that the width of the leg portion 190 is significantly greater 
than the thickness thereof. Also, as seen in FIGS. 20 and 21, when the arm 
or extension 190 is bent, as about line 218, the plane of the wider 
portion of arm 190 intersects the plane of the wider portion of medial 
portion 188. Just as recited with regard to medial portion 188, so too the 
bent (FIGS. 20 and 21) extension enhances its own rigidity resisting 
bending thereof in directions toward and away from the plane of the 
drawing as viewed, for example, in FIGS. 7, 8, 21, 23, 27 and 28. As 
already indicated, in the preferred embodiment, the plane of the wider 
portion of extension 190, when bent as depicted in FIGS. 7, 8, 20, 21, 23, 
27 and 28, is generally perpendicular to the plane of the wider portion of 
the medial section 188. 
Although only a preferred embodiment and a limited number of modifications 
of the invention have been disclosed and described it is apparent that 
other embodiments and modifications of the invention are possible within 
the scope of the appended claims.