US 2003/0192877 A1 · Method and apparatus for mounting a heater thermostat and temperature sensitive fuse

Abstract

A heater having an insulating terminal mounting block, a thermostat and a terminal bushing mounted to a frame. The insulating terminal mounting block supports a plurality of removable terminal members. Each terminal member has a crimping structure at one end and a connection structure at its other end. A temperature sensitive fuse is crimped within the crimping structure of a first and a second of the terminal connection members. A unitary jumper strap connects between the connection structure of the second and a third of the terminal members. A fourth terminal member is supported by the terminal bushing. A second unitary jumper strap connects between the connection structure of the fourth terminal member and a terminal of the thermostat. One terminal of a resistive heating wire is crimped within the crimping structure of one of the terminal connection members supported by the terminal mounting block. Another terminal of the resistive heating wire is crimped within the crimping structure of the fourth terminal connection member.

Drawings

Claims29

Dependent claims

A heater apparatus comprising:

a frame having means for supporting a resistive heating wire and having a plate, said plate having a plurality of cut-outs;
a resistive heating wire, having a first and a second terminal end, supported by said means for supporting a resistive heating wire;
an insulating terminal block secured to said plate, said insulating terminal block having a top surface spaced above said plate, a first bottom surface contacting said plate, a plurality of second bottom surfaces each aligned with any of said cut-outs of said plate, and a plurality of through holes extending from said top surface to any of said second bottom surfaces;
a plurality of terminal members, each having a connection end at one end and a crimping end at an end opposite said connection end, each extending through a corresponding one of said plurality through holes in said first insulating terminal block, and each having an axial securing means for securing it such that its connection end is above the top surface of the first insulating member and its crimping end is below one of the second bottom surfaces, with the first terminal end of said resistive heating wire being crimped within the crimping end of a first of said terminal members;
a temperature-sensitive current cut-off apparatus having a first terminal, a second terminal, a temperature-sensitive current cut-off element, said first terminal crimped within the crimping end of a second of said plurality of terminal members, said second terminal crimped within the crimping end of a third of said plurality of terminal members, and arranged such that said temperature sensitive current cut-off element is a predetermined distance from said resistive heating wire;
and
a conducting jumper formed of a metal conductor with a first crimping structure at one end and a second crimping structure at an end opposite said one end, the first crimping structure being crimped to the connection end of the first of said terminal members and the second crimping structure being crimped to the connection end of the second of said terminal members.

4 more elements

A heater assembly comprising:

a mounting assembly;
a temperature-sensitive current cut-off structure;
a unitary conducting jumper;
a first, second, and third terminal structures;
a heating element;
and
an insulator support structure including a first, second, and third terminal receiving openings formed therethrough,
wherein the insulator support structure is constructed and arranged to be releasably and fixedly secured to the mounting assembly,
wherein the first terminal receiving opening of the insulator support structure is constructed and arranged to cooperate with the first terminal structure to secure the first terminal structure to the mounting assembly,
wherein the second terminal receiving opening of the insulator support structure is constructed and arranged to cooperate with the second terminal structure to secure the second terminal structure to the mounting assembly,
wherein the third terminal receiving opening of the insulator support structure is constructed and arranged to cooperate with the third terminal structure to secure the third terminal structure to the mounting assembly,
wherein the heating element is constructed and arranged to be releasably and fixedly secured to the mounting assembly, and to be coupled to the first terminal structure,
wherein the unitary conducting jumper is constructed and arranged to be secured to the first terminal structure and to the second terminal structure, and
wherein the temperature-sensitive current cut-off structure is constructed and arranged to be crimped to the second terminal structure and to the third terminal structure.

11 more elements

A heater assembly comprising:

a mounting assembly;
a temperature-sensitive current cut-off structure including a first portion and a second portion;
a first terminal structure and a second terminal structure, and
a conducting structure,
wherein the first portion of the temperature-sensitive current cut-off structure is constructed and arranged to be crimped to the first terminal structure,
wherein the first terminal structure is constructed and arranged to be releasably and fixedly secured to the mounting assembly,
wherein the second portion of the temperature-sensitive current cut-off structure is constructed and arranged to be crimped to the second terminal structure,
wherein the second terminal structure is constructed and arranged to be releasably and fixedly secured to the mounting assembly, and
wherein the conducting structure is constructed and arranged to be releasably and fixedly secured to the mounting assembly, and to be coupled to the temperature-sensitive current cut-off structure.

6 more elements

A heater assembly comprising:

a mounting assembly;
a unitary conducting jumper including a first portion and a second portion;
a first terminal structure and a second terminal structure;
and
a heating element,
wherein the first portion of the unitary conducting jumper is constructed and arranged to be secured to the first terminal structure,
wherein the first terminal structure is constructed and arranged to be releasably and fixedly secured to the mounting assembly,
wherein the second portion of the unitary conducting jumper is constructed and arranged to be secured to the second terminal structure,
wherein the second terminal structure is constructed and arranged to be releasably and fixedly secured to the mounting assembly, and
wherein the heating element is constructed and arranged to be releasably and fixedly secured to the mounting assembly, and to be coupled to the unitary conducting jumper.

7 more elements

Dependencies are inferred from the claim text.

Description4,668 words

Summary1,117 words

#The present invention is directed toward an electric heating apparatus and, more particularly, to an electric heating apparatus having a resistance wire with at least one of a thermostatic electric current control and temperature sensitive fuse.

#Electric heater assemblies having a resistance wire heating element and a thermostatic electric current control device, or thermostat, for controlling the electric current through the resistance wire based on the sensed temperature proximal to the same, are known in the art. Also known in the art are electric heater assemblies having a temperature sensitive fuse, or temperature cutout (“TCO”), to disconnect the resistance wire from its current source in response to overheating.

#One well known connection and mounting structure for heater thermostats includes a housing enclosing a current control mechanism, with two conducting terminals, or flanges, that extend from the current control mechanism out through the housing. A right-angled two-pronged fork is formed at the distal end of each of the thermostat's extending flanges. A pair of threaded screw or bolt ends are supported by a corresponding pair of ceramic bushings, each mounted to the frame of the heater assembly, so that the two screws or bolt ends are aligned on the same axis.

Brief description of the drawings7 figures

#FIGS. 1A, 1B, and 1C show a side view, a front view, and a top view, respectively, of an embodiment of a heater assembly;

#FIG. 2 shows a perspective view of a frame portion of the heater assembly of FIG. 1, prior to installation of certain depicted structures;

#FIGS. 3A, 3B, 3C show a front, side and rear view, respectively, of a terminal block of the heater assembly of FIG. 1;

Detailed description3,386 words

#In view of the above-identified and other shortcomings in the prior art, an object of the present invention is a method and apparatus for mounting and electrically connecting a TCO and a thermostat into a heater assembly using minimal parts count and minimal assembly steps.

#A further object of this invention is a method and apparatus for mounting and electrically connecting a TCO and a thermostat into a heater assembly in accordance with the object identified above, and further including universal terminal members for attaching to TCO or thermostat terminals, and a unitary connecting strap for connecting same.

#A still further object of this invention is a method and apparatus for mounting and electrically connecting a TCO and a thermostat into a heater assembly in accordance with one or more of the objects previously identified, further providing a unitary connecting strap configured to also accommodate thermostat terminals, for connecting thermostat terminals and universal terminal members of varying relative heights.

Method and apparatus for mounting a heater thermostat and temperature sensitive fuse

Life of this patent

Method and apparatus for mounting a heater thermostat and temperature sensitive fuse

Life of this patent

Life of this patent

Abstract

Drawings

Drawings

Claims29

Description4,668 words

Drawings

Classification5 codes

Life of this patent

Description4,668 words