US4727239A — Plug having encapsulated thermal sensor, for engi…

Claim 1

Independent Claim 127 words

As a new article of manufacture, a thermal sensor device attachable to and detachable from a cooperable electrical fitting, comprising in combination: (a) a line cord constituted of plastics substance, said line cord having at least one electrical conductor embedded in it, (b) a plug fitting on said line cord, formed integral therewith, (c) a thermal sensor unit having electrical lead means connected with said electrical conductor, (d) means encapsulating said sensor unit, (e) said encapsulated sensor unit being imbedded in said plug fitting, (f) a portion of said encapsulating means projecting from and being exposed at the exterior of said plug fitting, (g) said exposed portion of the encapsulating means being adapted to receive heat from said cooperable fitting when said plug fitting is attached thereto.

Claim 2

Dependent Claim 127 words

As a new article of manufacture, a thermal sensor device attachable to and detachable from a cooperable electrical fitting, comprising in combination: (a) a line cord constituted of plastics substance, said line cord having at least one electrical conductor embedded in it, (b) a plug fitting on said line cord, formed integral therewith, (c) a thermal sensor unit having electrical lead means connected with said electrical conductor, (d) means encapsulating said sensor unit, (e) said encapsulated sensor unit being imbedded in said plug fitting, (f) a portion of said encapsulating means projecting from and being exposed at the exterior of said plug fitting, (g) said exposed portion of the encapsulating means being adapted to receive heat from said cooperable fitting when said plug fitting is attached thereto.

Claim 3

Dependent Claim 130 words

A thermal sensor construction comprising, in combination: (a) an electrical fitting, (b) a line cord constituted of plastics substance, said line cord having at least one electrical conductor embedded in it, (c) a plug fitting on said line cord, formed integral therewith, said plug fitting being cooperable with said electrical fitting, (d) a thermal sensor unit having electrical lead means connected with said electrical conductor, (e) means encapsulating said sensor unit, (f) said encapsulated sensor unit being imbedded in said plug fitting, (g) a portion of said encapsulating means projecting from and being exposed at the exterior of said plug fitting, (h) said plug fitting being attached to said electrical fitting and the exposed portion of said encapsulating means contacting said electrical fitting and receiving heat from said electrical fitting.

Claim 4

Dependent Claim 130 words

A thermal sensor construction comprising, in combination: (a) an electrical fitting, (b) a line cord constituted of plastics substance, said line cord having at least one electrical conductor embedded in it, (c) a plug fitting on said line cord, formed integral therewith, said plug fitting being cooperable with said electrical fitting, (d) a thermal sensor unit having electrical lead means connected with said electrical conductor, (e) means encapsulating said sensor unit, (f) said encapsulated sensor unit being imbedded in said plug fitting, (g) a portion of said encapsulating means projecting from and being exposed at the exterior of said plug fitting, (h) said plug fitting being attached to said electrical fitting and the exposed portion of said encapsulating means contacting said electrical fitting and receiving heat from said electrical fitting.

Claim 5

Dependent Claim 27 words

A thermal sensor device as set forth in claim 1, wherein: (a) said encapsulating means includes a flat wall comprising a printed circuit board having circuit elements.

Claim 6

Dependent Claim 29 words

A thermal sensor device as set forth in claim 3, wherein: (a) a circuit element of said printed circuit board is connected with said conductor in the line cord.

Claim 7

Dependent Claim 34 words

A thermal sensor device as set forth in claim 3, wherein: (a) said line cord has an additional electrical conductor, b) said electrical conductors being connected with circuit elements on said printed circuit board.

Claim 8

Dependent Claim 34 words

A thermal sensor device as set forth in claim 1, wherein: (a) said encapsulating means includes a flat wall comprising a printed circuit board, and a shell attached to one side of said board.

Claim 9

Dependent Claim 31 words

A thermal sensor device as set forth in claim 6, and further including: (a) a resilient filler member disposed in said encapsulating means and engaged with said sensor element and shell.

Claim 10

Dependent Claim 28 words

A thermal sensor device as set forth in claim 6, wherein: (a) said shell has attachment tabs, (b) said printed circuit board having cut-out portions accommodating said tabs.

Claim 11

Dependent Claim 26 words

A thermal sensor device as set forth in claim 1, wherein: (a) said sensor line cord has a plurality of conductors connected with said sensor element.

Claim 12

Dependent Claim 19 words

A thermal sensor device as set forth in claim 9, wherein: (a) said plug is constituted as a receptac1e.

Claim 13

Dependent Claim 180 words

A plug for connection to terminals of an engine block heater of the type having electrical connector pins surrounded by a skirt carried by the heater, said skirt having a side wall, said plug comprising in combination: (a) a molded plug body constituted of resilient rubber-like material; (b) said plug body being telescopically receivable in the skirt of the heater, and having sockets adapted to mate with and receive the connector pins respectively of the heater when the plug is installed thereon, (c) said plug body having a thermal sensor unit comprising a thermally conductive casing, a portion of which is imbedded in the side of the plug body and retained thereby, and another portion of which is exposed and which protrudes above the surrounding surface of the plug body, (d) the resilience of the plug body being adapted to bias the conductive casing into firm engagement with the inner surface of the side wall of the skirt of the heater when the plug body is installed therein, thereby establishing good thermal contact between said side eall and said casing.

Claim 14

Dependent Claim 180 words

A plug for connection to terminals of an engine block heater of the type having electrical connector pins surrounded by a skirt carried by the heater, said skirt having a side wall, said plug comprising in combination: (a) a molded plug body constituted of resilient rubber-like material; (b) said plug body being telescopically receivable in the skirt of the heater, and having sockets adapted to mate with and receive the connector pins respectively of the heater when the plug is installed thereon, (c) said plug body having a thermal sensor unit comprising a thermally conductive casing, a portion of which is imbedded in the side of the plug body and retained thereby, and another portion of which is exposed and which protrudes above the surrounding surface of the plug body, (d) the resilience of the plug body being adapted to bias the conductive casing into firm engagement with the inner surface of the side wall of the skirt of the heater when the plug body is installed therein, thereby establishing good thermal contact between said side eall and said casing.

Claim 15

Dependent Claim 209 words

A plug for connection to terminals of an engine block heater of the type having electrical connector pins surrounded by a skirt carried by the heater, said skirt having a side wall, said plug comprising in combination: (a) a molded plug body constituted of resilient rubber-like material, (b) said plug being adapted to be telescopically received in the skirt of the heater, and having sockets adapted to mate with and receive the connector pins respectively of the heater when the plug body is installed thereon, (c) said plug body having a thermal sensor unit comprising a thermally conductive casing, a portion of which is imbedded in the side of the plug body and retained thereby, and another portion of which is exposed and which protrudes above the surrounding surface of the plug body, (d) said imbedded casing being retractable into the plug body, within limits, as a consequence of force applied to the casing when the plug is installed on said heater, said force being applied by the inner wall surface of the side wall of the skirt of the heater and being counteracted by corresponding transaxial forces applied by the connector pins of the heater on the sockets carried by the plug body when the latter is installed.

Claim 16

Dependent Claim 209 words

A plug for connection to terminals of an engine block heater of the type having electrical connector pins surrounded by a skirt carried by the heater, said skirt having a side wall, said plug comprising in combination: (a) a molded plug body constituted of resilient rubber-like material, (b) said plug being adapted to be telescopically received in the skirt of the heater, and having sockets adapted to mate with and receive the connector pins respectively of the heater when the plug body is installed thereon, (c) said plug body having a thermal sensor unit comprising a thermally conductive casing, a portion of which is imbedded in the side of the plug body and retained thereby, and another portion of which is exposed and which protrudes above the surrounding surface of the plug body, (d) said imbedded casing being retractable into the plug body, within limits, as a consequence of force applied to the casing when the plug is installed on said heater, said force being applied by the inner wall surface of the side wall of the skirt of the heater and being counteracted by corresponding transaxial forces applied by the connector pins of the heater on the sockets carried by the plug body when the latter is installed.

Claim 17

Dependent Claim 115 words

An electrical line plug for connection to a heater assembly having electrical terminals, said plug comprising in combination: (a) a molded plug body constituted of electrically insulating material, (b) receptacles on said body adapted to mate with the terminals respectively, of the heater assembly, (c) a circuit board carried in said plug body and having at least a portion thereof completely imbedded therein, (d) an electrical component mounted on said circuit board, and (e) a cover secured to said circuit board, said cover with said board completely enclosing said electrical component so as to isolate the latter from molten substance and prevent such substance from contacting the said component during molding of the plug body.

Claim 18

Dependent Claim 115 words

An electrical line plug for connection to a heater assembly having electrical terminals, said plug comprising in combination: (a) a molded plug body constituted of electrically insulating material, (b) receptacles on said body adapted to mate with the terminals respectively, of the heater assembly, (c) a circuit board carried in said plug body and having at least a portion thereof completely imbedded therein, (d) an electrical component mounted on said circuit board, and (e) a cover secured to said circuit board, said cover with said board completely enclosing said electrical component so as to isolate the latter from molten substance and prevent such substance from contacting the said component during molding of the plug body.

Claim 19

Dependent Claim 27 words

The invention as set forth in claim 13, wherein: (a) said cover is constituted as a metal stamping, having means for securing it to the circuit board.

Claim 20

Dependent Claim 45 words

The invention as set forth in claim 1, wherein: (a) said cover has a portion which protrudes from the surface of the said plug body, so as to be accessible from the exterior of the same for enabling transfer of heat to the said component.

Claim 21

Dependent Claim 143 words

An electrical line plug for connection to a heater assembly having electrical terminals, said plug comprising in combination: (a) a molded plug body constituted of electrically insulating material, (b) receptacles on said body adapted to mate with the terminals respectively, of the heater assembly, (c) an electrical component carried in said plug body, and means in said body for making electrical connections thereto, (d) an electrically conductive cover having one portion imbedded in said plug body, and having another portion projecting above the surface of said plug body, and (e) spacer means on the plug body for retaining the cover in fixed position adjacent to but electrically insulated from said electrical oomponent, so as to electrically isolate the cover from the component and thereby eliminate the possibility of shock hazzard to personnel handling the plug and coming in contact with the said cover.

Claim 22

Dependent Claim 143 words

An electrical line plug for connection to a heater assembly having electrical terminals, said plug comprising in combination: (a) a molded plug body constituted of electrically insulating material, (b) receptacles on said body adapted to mate with the terminals respectively, of the heater assembly, (c) an electrical component carried in said plug body, and means in said body for making electrical connections thereto, (d) an electrically conductive cover having one portion imbedded in said plug body, and having another portion projecting above the surface of said plug body, and (e) spacer means on the plug body for retaining the cover in fixed position adjacent to but electrically insulated from said electrical oomponent, so as to electrically isolate the cover from the component and thereby eliminate the possibility of shock hazzard to personnel handling the plug and coming in contact with the said cover.

Claim 23

Dependent Claim 26 words

the invention as set forth in claim 16, wherein: (a) said spacer means comprises a printed circuit board having electrically insulating support areas engaging said cover.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-02-22	1991-08-24	1992-02-23	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-02-22	1995-08-24	1996-02-23	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-02-22	1999-08-24	2000-02-23	$7700.00	Window Closed / Lapsed

Plug having encapsulated thermal sensor, for engine block heater

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