Thermal cutoff

Abstract: A thermal cutoff (A) including a dielectric bushing (34) having opposite ends (42,44) and a hole (40) therethrough. A wire lead (B) received through the hole (40) has an enlarged contact (52) thereon adjacent one bushing end (42),and an enlarged deforma­ tion (54,56) thereon adjacent the other bushing end (44). The contact (52) and deformation (54,56) prevent rela­ tive longitudinal movement between the bushing (34) and lead (B).

Description: Background of the Invention This application relates to the art of thermal protectors and, more particularly, to thermal protectors for interrupting an electrical circuit in the event a predetermined temperature is reached or exceeded. The invention is particularly applicable to thermal cutoffs, and will be described with specific reference thereto. However, it will be appreciated that the invention has broader aspects, and can be used with thermal protectors of other types. In each of US-A-4,246,561, WO-A-83 03 706 and US-A-4,411,061 there is disclosed a thermal protector or cutoff as recited in the precharacterizing portion of independent claim 1. Each of these prior art thermal protectors or cutoffs includes a dielectric bushing received in an open end of a housing. A hole through the bushing receives a wire lead having an enlarged contact on one end inside the housing. The lead has a tail portion extending outwardly from the bushing outside of the housing. A sealing compound surrounds the tail portion of the lead adjacent the bushing, and also covers the outside end of the bushing. Under some conditions, the bond between the sealing compound and tail portion of the lead can become loose, and result in movement of the lead through the bushing further into the housing. This may result in undesirable and dangerous reclosing of open contacts in a thermal cutoff whose design temperature has been reached or exceeded. To prevent relative longitudinal movement between the bushing and the lead the prior art thermal protectors or cutoffs referred to have an enlargement formed by a deformation on the tail portion of the lead adjacent the outer end of the bushing. The enlarged contact and enlargement formed by deformation substantially prevent relative longitudinal movement between the bushing and lead. Thus, the bushing and lead are mechanically locked to one another against relative longitudinal movement. Summary of the Invention In accordance with the invention there is provided a thermal cutoff having a housing with an open end, a dielectric bushing received in said open end of the housing, said bushing having opposite ends and a hole therethrough, an electrical lead having a portion received in said hole of said bushing and having a first enlargement thereon within said housing adjacent one of said opposite ends of said bushing, said first enlargement defining an electrical contact, and a second enlargement formed by deformation of said lead adjacent the other of said opposite ends of said bushing, both said first enlargement and said second enlargement being larger than said hole through said bushing for stopping relative axial movement between said bushing and said electrical lead, said electrical lead having a tail portion at said other end of said bushing for connection of said thermal cutoff to other circuit components, characterized in that said portion of said electrical lead received in said hole of said bushing is a main lead portion having a larger diameter than said tail portion of said electrical lead, and that said main lead portion is closely received in said bushing and extends outwardly beyond said other end of said bushing to allow formation of said second enlargement on said main lead portion. The larger diameter portion of the lead extending through the bushing hole allows economical forming of a larger fixed contact for better heat dissipation, and better redistribution of lead material. The enlarged diameter lead portion also enables economical formation of the second enlargement made by deformation of the lead without seriously weakening the lead. Further, the reduced wire diameter beyond the second enlargement provides a flexible lead for connection in an electrical circuit. The improved bushing and lead assembly of the present application is preferably used in a thermal cutoff of the type having a thermal pellet that melts when the design temperature of the cutoff is reached or exceeded. Melting of the pellet causes opening of normally closed contacts to interrupt a circuit in which the cutoff is connected. Brief Description of the Drawing The drawing shows a thermal cutoff having the improved lead and bushing assembly of the present invention incorporated therein. Description of a Preferred Embodiment Referring now to the drawing, wherein the showings are for purposes of illustrating a preferred embodiment of the invention only, and not for purposes of limiting same, a thermal protector in the form of a thermal cutoff A includes an elongated cup-like cylindrical metal housing 12. A wire lead 14 is suitably attached to one end 16 of housing 12 in a known manner. A thermal pellet 18 of an organic chemical is positioned within housing 12 against end 16. Thermal pellet 18 is solid at normal operating temperatures, and melts when the design temperature of the thermal cutoff is reached or exceeded. The thermal pellet can be made from many different organic chemicals having different melting temperatures, examples of which include caffeine and animal protein. A compressed coil spring 20 is positioned within housing 12 between metal discs 22, 24. Disc 24 engages a metal star contact 30 having a plurality of circumferentially-spaced outwardly inclined resilient fingers resiliently engaging the interior of housing 12 in sliding conductive relationship therewith. A second coil spring 32 acts between star contact 30 and a dielectric bushing 34 of ceramic or the like. Housing 12 has an open end portion with a cylindrical recess 36 of a diameter larger than the remainder of housing 12. Bushing 34 is closely received in recess 36, and terminal end portion 38 of housing 12 is deformed inwardly over bushing 34 for locking same within recess 36. A central cylindrical hole 40 extends through bushing 34 between opposite ends 42, 44 thereof. An elongated wire lead B extends through bushing hole 40. Main lead portion 50 that extends through bushing hole 40 has an enlarged diameter, and is closely received through bushing hole 40. An enlargement 52 on one end portion of wire lead B defines a fixed electrical contact, and has transverse dimensions substantially larger than the diameter of bushing hole 40. The enlarged diameter portion 50 of wire lead B extends outwardly beyond bushing end 44 a sufficient amount to allow formation of an enlargement thereon. In the arrangement shown, the enlargement is in the form of opposite outwardly extending wings 54, 56 located closely adjacent bushing end 44. Wings 54, 56 are formed by flattening wire lead B so that the transverse dimension of lead B across wings 54, 56 is substantially greater than the diameter of bushing hole 40. Preferably, the entire diameter of wire lead B is not deformed so that the central portion thereof between wings 54, 56 remains of the full diameter to provide adequate strength. A reduced diameter lead tail portion 60 extends outwardly beyond wings 54, 56 to provide a flexible lead for connection in an electrical circuit. The enlargement defined by wings 54, 56 may be spaced slightly from bushing end 44 to prevent damage to the bushing when forming the deformation. This may result in limited relative longitudinal movement between bushing 34 and lead B. However, relative longitudinal movement between the two is substantially blocked. A suitable sealing compound 62, such as epoxy or the like, is positioned in surrounding relationship to wire lead B around wings 54, 56. Sealing compound 62 also completely covers bushing end 44 and housing terminal end portion 38. The sealing compound bonds to all of the surfaces it engages. The enlargement defined by opposite wings 54, 56 also provides an enhanced mechanical interlock between sealing compound 62 and wire lead B. Thermal cutoff A has spring 20 with a greater biasing force than spring 32 so that star contact 30 and fixed contact 52 are normally closed. When the design temperature is reached or exceeded, thermal pellet 18 melts and allows spring 20 to expand so that its biasing force becomes substantially less than the biasing force of spring 32. Star contact 30 then moves to the left in the drawing away from fixed contact 52 to open the circuit. In the event the bond between sealing compound 62 and wire lead B becomes broken, wire lead B cannot move from right to left in the drawing to re-establish contact between fixed contact 52 and star contact 30 because the enlargement defined by wings 54, 56 prevents such movement.

Claims: A thermal cutoff (A) having a housing (12) with an open end (36), a dielectric bushing (34) received in said open end (36) of the housing (12), said bushing (34) having opposite ends (42, 44) and a hole (40) therethrough, an electrical lead (B) having a portion received in said hole (40) of said bushing (34) and having a first enlargement (52) thereon within said housing (12) adjacent one (42) of said opposite ends (42, 44) of said bushing (34), said first enlargement (52) defining an electrical contact, and a second enlargement (54, 56) formed by deformation of said lead (B) adjacent the other (44) of said opposite ends (42, 44) of said bushing (34), both said first enlargement (52) and said second enlargement (54, 56) being larger than said hole (40) through said bushing (34) for stopping relative axial movement between said bushing (34) and said electrical lead (B), said electrical lead (B) having a tail portion (60) at said other end (44) of said bushing (34) for connection of said thermal cutoff (A) to other circuit components, characterized in that said portion of said electrical lead (B) received in said hole (40) of said bushing (34) is a main lead portion (50) having a larger diameter than said tail portion (60) of said electrical lead (B), and that said main lead portion (50) is closely received in said bushing (34) and extends outwardly beyond said other end (44) of said bushing (34) to allow formation of said second enlargement (54, 56) on said main lead portion (50). A thermal cutoff (A) according to claim 1, characterized in that said second enlargement comprises a flattened portion of said main lead portion (50) providing outwardly extending opposite wings (54, 56). A thermal cutoff (A) according to claim 1, characterized in that said lead tail portion (60) of said electrical lead (B) begins beyond said second enlargement (54, 56).

Inventors: CENKY MARK ANTHONY, CENKY, MARK ANTHONY
Applicants: EMERSON ELECTRIC CO, EMERSON ELECTRIC CO.
Application year: 1988
Main classification: H01H37
IPC codes: H01H37