Potentiometer contact method

Claim 1

A method of producing a potentiometer contact device adapted for brushing movement along a potentiometer resistance element with minimal contact-resistance-variation, said method comprising the steps of: arranging a group of fine-gauge wires in a flat elongate striplike array in parallel and side-by-side relationship with the wires under tension; at a plate-applying station firmly securing to each of the wires of the array at a location therealong a thin flat plate whereby to unite the wires into a firm unitary structure thereat; at a molding station, molding about the array and plate at said location an insulation body having first and second extremities in the direction of the array while leaving extending beyond the extremities of the body respective elongate sections of the wires in side-by-side disposition; at an operating station, severing the wires of the array along a line extending transversely of the array adjacent one extremity of the body while leaving an elongate section of the wires extending outwardly from the body, and forming the wires comprised in the latter elongate section thereof into a set of elongate resilient contact fingers each having a contact point disposed in a common line transversely of the array distant from the body; wherein the array of wires is drawn forwardly in the direction of the elongate array in an intermittent step-by-step series of movements successively past the Plate-applying station and the molding station to the operating station, whereby the array of wires as it leaves the plate-applying station supports thereon successively applied plates, and as it leaves the molding station supports thereon successively applied insulation bodies, whereby upon arrival at the operating station a molded body with entrained plate and wires may be gripped and positioned as an integral unitary structure for severance of the wires and formation of contact points and contact fingers to complete production of a complete potentiometer contact device.

Claim 2

A method of producing a potentiometer contact device adapted for brushing movement along a potentiometer resistance element with minimal contact-resistance-variation, said method comprising the steps of: arranging a group of fine-gauge wires in a flat elongate striplike array in parallel and side-by-side relationship with the wires under tension; at a plate-applying station firmly securing to each of the wires of the array at a location therealong a thin flat plate whereby to unite the wires into a firm unitary structure thereat; at a molding station, molding about the array and plate at said location an insulation body having first and second extremities in the direction of the array while leaving extending beyond the extremities of the body respective elongate sections of the wires in side-by-side disposition; at an operating station, severing the wires of the array along a line extending transversely of the array adjacent one extremity of the body while leaving an elongate section of the wires extending outwardly from the body, and forming the wires comprised in the latter elongate section thereof into a set of elongate resilient contact fingers each having a contact point disposed in a common line transversely of the array distant from the body; wherein the array of wires is drawn forwardly in the direction of the elongate array in an intermittent step-by-step series of movements successively past the Plate-applying station and the molding station to the operating station, whereby the array of wires as it leaves the plate-applying station supports thereon successively applied plates, and as it leaves the molding station supports thereon successively applied insulation bodies, whereby upon arrival at the operating station a molded body with entrained plate and wires may be gripped and positioned as an integral unitary structure for severance of the wires and formation of contact points and contact fingers to complete production of a complete potentiometer contact device.

Claim 3

A method of producing a potentiometer contact device adapted for brushing movement along a potentiometer resistance element with minimal contact-resistance-variation, said method comprising the steps of: arranging a group of fine-gauge wires in a flat elongate strip-like array in parallel and side-by-side relationship with the wires under tension; at a plate-applying station firmly securing to each of the wires of the array at a location therealong a thin flat plate by providing the plate with a coating of solder and heating the plate and solder while pressing the plate toward the wires whereby to substantially embed the wires in the solder along a face of the plate so as to unite the wires into a firm unitary structure thereat; a molding station, molding about the array and plate at said location an insulation body having first and second extremities in the direction of the array while leaving extending beyond the extremities of the body respective elongate sections of the wires in side-by-side disposition; at an operating station, severing the wires of the array along a line extending transversely of the array adjacent one extremity of the body while leaving an elongate section of the wires extending outwardly from the body, and forming the wires comprised in the latter elongate section thereof into a set of elongate resilient contact fingers each having a contact point disposed in a common line transversely of the array distant from the body.

Claim 4

A method of producing a potentiometer contact device adapted for brushing movement along a potentiometer resistance element with minimal contact-resistance-variation, said method comprising the steps of: arranging a group of fine-gauge wires in a flat elongate strip-like array in parallel and side-by-side relationship with the wires under tension; at a plate-applying station firmly securing to each of the wires of the array at a location therealong a thin flat plate by providing the plate with a coating of solder and heating the plate and solder while pressing the plate toward the wires whereby to substantially embed the wires in the solder along a face of the plate so as to unite the wires into a firm unitary structure thereat; a molding station, molding about the array and plate at said location an insulation body having first and second extremities in the direction of the array while leaving extending beyond the extremities of the body respective elongate sections of the wires in side-by-side disposition; at an operating station, severing the wires of the array along a line extending transversely of the array adjacent one extremity of the body while leaving an elongate section of the wires extending outwardly from the body, and forming the wires comprised in the latter elongate section thereof into a set of elongate resilient contact fingers each having a contact point disposed in a common line transversely of the array distant from the body.