Variable resistance control with multiple paddle contactor and method of making the same

Claim 2

In a variable resistance control, the combination of a resistance element having first and second ends and a first contactor surface therebetween, a first terminal electrically connected to the resistance element proximal to one of the ends, a collector element having a second contactor surface and being in spaced relationship to the resistance element, a second terminal electrically connected to the collector element, a contactor electrically engaging the first and second contactor surfaces, means for moving the contactor along a predetermined path to engage the first contactor surface at selective distances from the first terminal, the contactor comprising a piece of sheet metal having a planar portion including an upper surface, and a plurality of integral contactor paddles providing electrical engagement of the contactor with one of the contactor surfaces, the contactor paddles being wedge-shaped fingers defined by a first saw-tooth shaped shear line disposed in the planar portion and disposed substantially orthogonal to the direction of motion of the contactor along said predetermined path, each of the paddles having a wide end integral with the planar portion and substantially orthogonal to the direction of motion and a severed narrow end, each of the paddles having a first side extending from the wide end thereof to the narrow end thereof at an acute angle to the direction of motion and severed from one of the sides of an adjacent wedge-shaped finger by the shear line, each of the paddles having a severed second side extending from the wide end thereof to the narrow end thereof and a raised portion extending upwardly from the upper surface providing a portion of the electrical engagement of the plurality of contactor paddles with one of the contactor surface.

Claim 3

The resistance control of claim 1, wherein the raised portions comprise an acute-angle first bend of each of the wedge-shaped fingers proximal to respective ones of the wide ends and substantially orthogonal to the direction of motion, and a second bend of each of the wedge-shaped fingers intermediate of the wide and narrow ends and substantially orthogonal to the direction of motion.

Claim 4

The resistance control of claim 2, wherein the second bends are disposed equidistant between respective and adjacent ones of said wide ends.

Claim 5

The resistance control of claim 2, wherein the raised portions each include a contacting surface comprising a portion of the upper surface as defined by respective ones of the wedge-shaped fingers and by respective ones of the second bends, and a pair of three-dimensional curved surfaces being intermediate of respective ones of the sides and respective ones of the contacting surfaces of the contactor paddles.

Claim 6

The resistance control of claim 1, wherein the resistance control is of the rectilinear, multiturn type, the means for moving comprises a lead screw operatively engaging a driver, the driver operatively engaging said contactor, the one contactor surface comprises the first contactor surface, the contactor includes a second plurality of contactor paddles providing the electrical engagement with the second contactor surface and comprises a second plurality of wedge-shaped fingers defined by a second saw-tooth shaped shear line disposed in the planar portion and in line with the first saw-tooth shaped shear line, each having a wide end integral with the planar portion and substantially orthogonal to the direction of motion, each having a severed narrow end, each having a severed first side extending from the wide end thereof at an acute angle to the direction of motion, each having a severed second side extending from the wide end thereof to the narrow end thereof, and each having a raised portion extending upwardly from the upper surface and providing a portion of the electrical engagement of the second plurality of contactor paddles with the second contactor surface, the raised portions of all of the contactor paddles comprising an acute-angle upward bend of each of said wedge-shaped fingers proximal to respective ones of the wide ends and substantially orthogonal to the direction of motion, and a downward bend of each of the wedge-shaped fingers equidistant between respective and adjacent ones of the wide ends and substantially orthogonal to the direction of motion, each of the raised portions of both of the pluralities of wedge-shaped fingers including a contacting surface comprising a portion of the upper surface as defined by respective ones of the wedge-shaped fingers and by respective ones of the second bends.

Claim 7

In a variable resistance control of the type that includes a resistance element having first and second ends and a first contactor surface therebetween, a first terminal being electrically connected to the resistance element proximal to one of the ends, a collector element having a second contactor surface and being in spaced relationship to the resistance element, a second terminal being electrically connected to the collector element, a contactor electrically engaging the first and second contactor surfaces, and means for moving the contactor along a predetermined path to engage the first contactor surface at selective distances from the first terminal, the improvement comprising the contactor comprising a piece of sheet metal having a planar portion operatively engaging the means and having a plurality of integral contactor paddles providing electrical engagement of the contactor with one of the contactor surfaces, the contactor paddles comprising a plurality of wedge-shaped fingers defined by a saw-tooth shaped shear line disposed in the planar portion and disposed substantially orthogonal to the direction of motion of the contactor along the predetermined path, each of the paddles having a raised portion extending from a surface of the planar portion and providing a portion of the electrical engagement of the plurality of contactor paddles with the one of the contactor surfaces.

Claim 8

In a variable resistance control of the type that includes a resistance element having first and second ends and a first contactor surface therebetween, a first terminal being electrically connected to the resistance element proximal to one of the ends, a collector element having a second contactor surface and being in spaced relationship to the resistance element, a second terminal being electrically connected to the collector element, a contactor electrically engaging the first and second contactor surfaces, and means for moving the contactor along a predetermined path to engage the first contactor surface at selective distances from the first terminal, the improvement comprising the contactor comprising a piece of sheet metal having a planar portion operatively engaging the means and having a plurality of integral contactor paddles providing electrical engagement of the contactor with one of the contactor surfaces, the contactor paddles comprising a plurality of wedge-shaped fingers defined by a saw-tooth shaped shear line disposed in the planar portion and disposed substantially orthogonal to the direction of motion of the contactor along the predetermined path, each of the paddles having a raised portion extending from a surface of the planar portion and providing a portion of the electrical engagement of the plurality of contactor paddles with the one of the contactor surfaces.

Claim 9

The resistance control of claim 6, wherein the contactor includes a second plurality of contactor paddles providing the electrical engagement of the contactor with the other of the contactor surfaces.

Claim 10

An electrical contactor for a variable resistance control comprising a piece of sheet metal having a planar portion including upper and lower surfaces, a first saw-tooth shaped shear line in the planar portion defining a plurality of adjacent and oppositely disposed wedge-shaped fingers, each of the fingers including both a narrow end and a pair of sides severed from the planar portion and from adjacent ones of the fingers by the shear line, each of the fingers including a wide end integral with the planar portion and proximal to a narrow end of an adjacent one of the wedge-shaped fingers, the wedge-shaped fingers having an acute-angle upward bend proximal to the wide end thereof and a downward bend intermediate of the wide and narrow ends thereof, both bends being substantially orthogonal to a line bisecting the pair of sides thereof whereby the bends are effective to move each of the narrow ends distal from adjacent ones of the wide ends thereby effectively providing clearance between adjacent sides of the wedge-shaped fingers that are defined by the shear line and thereby providing clearance space for individual flexing of the wedge-shaped fingers toward and away from the upper surface.

Claim 11

An electrical contactor for a variable resistance control comprising a piece of sheet metal having a planar portion including upper and lower surfaces, a first saw-tooth shaped shear line in the planar portion defining a plurality of adjacent and oppositely disposed wedge-shaped fingers, each of the fingers including both a narrow end and a pair of sides severed from the planar portion and from adjacent ones of the fingers by the shear line, each of the fingers including a wide end integral with the planar portion and proximal to a narrow end of an adjacent one of the wedge-shaped fingers, the wedge-shaped fingers having an acute-angle upward bend proximal to the wide end thereof and a downward bend intermediate of the wide and narrow ends thereof, both bends being substantially orthogonal to a line bisecting the pair of sides thereof whereby the bends are effective to move each of the narrow ends distal from adjacent ones of the wide ends thereby effectively providing clearance between adjacent sides of the wedge-shaped fingers that are defined by the shear line and thereby providing clearance space for individual flexing of the wedge-shaped fingers toward and away from the upper surface.

Claim 12

The electrical contactor as claimed in claim 8, wherein the downward bends are disposed substantially equidistant between respective and adjacent ones of the wide ends.

Claim 13

The electrical contactor as claimed in claim 8, wherein each of the wedge-shaped fingers includes a contacting surface comprising a portion of the upper surface as defined by respective ones of the downward bends, and a pair of three-dimensional curved surfaces being intermediate of respective ones of each of the contacting surfaces and respective ones of the sides.

Claim 14

The electrical contactor as claimed in claim 8, wherein the downward bends are disposed substantially equidistant between respective and adjacent ones of the wide ends, each of the wedge-shaped fingers includes a contacting surface comprising a portion of the upper surface as defined by respective ones of the downward bends, a pair of three-dimensional curved surfaces being intermediate of respective ones of each of the contacting surfaces and respective ones of the sides, the electrical contactor includes a second saw-tooth shaped shear line being disposed in the planar portion, being in line with the first saw-tooth shaped shear line, and defining a second plurality of wedge-shaped fingers including integral wide ends and severed narrow ends, an acute-angle upward bend in each of the second plurality of wedge-shaped fingers proximal to the wide ends thereof, and a downward bend in each of the second plurality of wedge-shaped fingers being disposed equidistant between respective and adjacent ones of the wide ends.

Claim 17

The method as claimed in claim 12, wherein the forming step comprises three-dimensional contouring of a portion of each of the raised portions, upwardly distal from the planar portion, thereby providing smooth and burr-free contacting surfaces.

Claim 18

The method as claimed in claim 12, wherein the forming step comprises: a. bending each of the wedge-shaped fingers upwardly proximal to the wide end thereof, and b. bending each of the wedge-shaped fingers downwardly intermediate of the wide and narrow ends thereof, to form a plurality of contactor paddles each having the raised portion.

Claim 19

The method as claimed in claim 14, wherein the forming step comprises forming of the raised portion beyond the midpoint of each of the fingers but equidistant between respective and adjacent ones of the ends.