Temperature sensitive control sensor

Claim 1

The method of making a temperature sensitive control sensor adapted to be cast into a metal cast cooking unit, which comprises placing a pair of sheathed conductor assemblies side by side, each assembly having an outer metal sheath, a conductor having a low coefficient of resistance change with temperature change extending through and beyond the opposite ends of the sheath and insulation material between the conductor and sheath, connecting the opposed leads of a temperature sensitive resistance element between and to adjacent ends of the conductors of the assemblies, mounting a metal cover half to the assemblies at one end by securing same to the assemblies and presenting a channel for the element and the connected leads, applying ceramic insulant material in said channel about the elements and leads, and mounting a second metal cover half onto the first cover half and assemblies to completely enclose the element and its connections to the terminals of the assemblies and to rigidly hold the assemblies together and the element in proper position relative the assemblies and to protect the element and connections during casting of the sensor in molten material.

Claim 2

The method of making a temperature sensitive control sensor adapted to be cast into a metal cast cooking unit, which comprises placing a pair of sheathed conductor assemblies side by side, each assembly having an outer metal sheath, a conductor having a low coefficient of resistance change with temperature change extending through and beyond the opposite ends of the sheath and insulation material between the conductor and sheath, connecting the opposed leads of a temperature sensitive resistance element between and to adjacent ends of the conductors of the assemblies, mounting a metal cover half to the assemblies at one end by securing same to the assemblies and presenting a channel for the element and the connected leads, applying ceramic insulant material in said channel about the elements and leads, and mounting a second metal cover half onto the first cover half and assemblies to completely enclose the element and its connections to the terminals of the assemblies and to rigidly hold the assemblies together and the element in proper position relative the assemblies and to protect the element and connections during casting of the sensor in molten material.

Claim 3

The method of making a temperature sensitive control sensor for sensing temperature in a solid, liquid, or gas mass, which comprises connecting first and second spring conductors respectively to the opposite leads of a temperature sensitive resistance element and connecting terminal wires to the free ends of the spring conductor to form a sub-assembly, inserting the sub-assembly into a tubular sheath, with the ends of the terminal wires protruding from the ends of the sheath, filling the internal void space between the sub-assembly and inner sheath wall with a ceramic insulant material, And swaging the sheath except in the area of the temperature sensitive resistance element to reduce the outside sheath diameter and compact the insulant material in the area of swaging and provide a completed sensor assembly, wherein stresses between the terminals and element leads are relieved during the swaging operation by the spring conductors.

Claim 4

The method of making a temperature sensitive control sensor for sensing temperature in a solid, liquid, or gas mass, which comprises connecting first and second spring conductors respectively to the opposite leads of a temperature sensitive resistance element and connecting terminal wires to the free ends of the spring conductor to form a sub-assembly, inserting the sub-assembly into a tubular sheath, with the ends of the terminal wires protruding from the ends of the sheath, filling the internal void space between the sub-assembly and inner sheath wall with a ceramic insulant material, And swaging the sheath except in the area of the temperature sensitive resistance element to reduce the outside sheath diameter and compact the insulant material in the area of swaging and provide a completed sensor assembly, wherein stresses between the terminals and element leads are relieved during the swaging operation by the spring conductors.

Claim 6

The method of making a temperature sensitive control sensor for sensing temperature in a solid, liquid or gas mass, which comprises connecting one end of a spring conductor to one lead of a temperature sensitive resistance element and connecting a terminal wire to the other end of the resilient conductor to form a sub-assembly, inserting the sub-assembly into a tubular sheath with the end of the terminal protruding from one end of the sheath and the free lead of said element substantially aligning with the other end of the sheath, connecting the free lead to the sheath, filling the internal void space between the sub-assembly and inner sheath wall with a ceramic insulant material, and swaging the sheath except in the area of the element to reduce the outside sheath diameter and compact the insulant material in the area of swaging to form a completed sensor assembly.

Claim 7

The method of making a temperature sensitive control sensor for sensing temperature in a solid, liquid or gas mass, which comprises connecting one end of a spring conductor to one lead of a temperature sensitive resistance element and connecting a terminal wire to the other end of the resilient conductor to form a sub-assembly, inserting the sub-assembly into a tubular sheath with the end of the terminal protruding from one end of the sheath and the free lead of said element substantially aligning with the other end of the sheath, connecting the free lead to the sheath, filling the internal void space between the sub-assembly and inner sheath wall with a ceramic insulant material, and swaging the sheath except in the area of the element to reduce the outside sheath diameter and compact the insulant material in the area of swaging to form a completed sensor assembly.

Claim 9

The method of making a temperature sensitive element which comprises spatially winding a temperature sensitive resistance wire having a high coefficient of resistance change with temperature increase onto a ceramic core and connecting leads having a low coefficient of resistance change with temperature to opposite ends of said resistance wire to form a sub-assembly, and coating the sub-assembly except for the free ends of the leads with a ceramic cement which when cured is heat resisting and electrically nonconductive.

Claim 10

The method of making a temperature sensitive element which comprises spatially winding a temperature sensitive resistance wire having a high coefficient of resistance change with temperature increase onto a ceramic core and connecting leads having a low coefficient of resistance change with temperature to opposite ends of said resistance wire to form a sub-assembly, and coating the sub-assembly except for the free ends of the leads with a ceramic cement which when cured is heat resisting and electrically nonconductive.