Metal working – Method of mechanical manufacture – Electrical device making
Patent
1978-11-02
1980-06-03
Husar, Francis S.
Metal working
Method of mechanical manufacture
Electrical device making
29429, 29756, 228 47, 228180R, 228254, 264251, 264254, H01H 6902, H01H 8516
Patent
active
042054311
ABSTRACT:
A method and apparatus for making an encapsulated electrically conducting component is provided. A wire is placed across a mold cavity for forming substantially one-half of the component body. A substantially flat-surfaced second mold having a groove is placed against a first mold to hold the wire in the groove and in alignment with respect to the cavity of the first mold while fluid plastic material is injected therein to encapsulate a substantially semi-cylindrical surface portion of the wire and form one-half of the conducting component body. Next, a third mold is placed against the first mold. The third mold has a cavity defining substantially the remaining half of the component body. The fluid plastic is injected through the first mold and into the cavity in the third mold to form a completed, composite molded body. The body, with the wire projecting from each end, is taken from the mold and moved past a pair of spaced-apart anvils to bend the projecting wire portions inwardly towards the ends of the body. An end cap is aligned at each end of the body and both end caps are substantially simultaneously moved onto the body ends to force the projecting wire ends further against the respective body ends. Preferably, each end cap is treated, prior to being placed on the component body, by dropping a piece of solid solder into the end cap and then applying heat to the end cap by contacting the cap between a pair of spaced-apart electrodes and conducting electrical energy through the end cap to melt the solder. After such pre-soldered end caps have been placed on the component body ends, the end caps are preferably heated, as by contacting them with a resistance heating element, to remelt the solder to cause it to flow around the ends of the wire and provide a good electrical conducting path between the end cap and the ends of the wire.
REFERENCES:
patent: 1677178 (1928-07-01), Fay
patent: 2621369 (1952-12-01), Gantz
patent: 3247355 (1966-04-01), Olsen
patent: 3624886 (1971-12-01), Powers
patent: 3914863 (1975-10-01), Wiebe
patent: 4152798 (1979-05-01), Akaura
patent: 4157486 (1979-06-01), Fegley
patent: 4159458 (1979-06-01), Wiebe
Crosby Gene P.
Husar Francis S.
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