Electric motor protector sensor

Claim 2

A sensor for an electric motor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a covering member of electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to the thermistor surface portions and extending out from said cover member, and an electrically insulating, thermally conductive elastomer having a thermal conductivity of between 1.5-6.0×10 -3 (cal/°C.-cm-sec) positioned around the thermistor within the covering member for protecting the thermistor from external forces and maintaining the integrity of the electrical contact between the lead members and the thermistor while providing good heat transfer to the thermistor.

Claim 3

A sensor according to claim 1 wherein said thermistor displays a selected temperature coefficient of resistance over a selected temperature range and displays a relatively different temperature coefficient of resistance over another selected temperature range.

Claim 4

A sensor according to claim 1 wherein said covering member is capable of withstanding elevated temperatures and is heat shrinkable for encasing the thermistor ends of the lead members.

Claim 5

A sensor according to claim 3 wherein said covering has a thickness of between 0.006 and 0.020 of an inch and is made from a material selected from the group consisting of a radiation cross-lined polyvinylidine fluoride, a high temperature polyamide resin, a polyethylene tetraphthalate and tetrafluoroethylene.

Claim 6

A sensor according to claim 1 further including a sleeve member adjacent said covering member for encircling said lead members to improve the ability of the sensor to withstand lead member pullout.

Claim 7

A sensor according to claim 5 wherein said lead members extending from said cover member are twisted around each other thereby creating crevices between the wires and said sleeve member is made from an electrically insulating material with an adhesive for adhering to the lead members and flowing into said crevices when heated.

Claim 8

A sensor according to claim 1 wherein said electrically insulating, thermally conductive elastomer is heat curable.

Claim 9

A sensor according to claim 7 wherein said thermally conductive elastomer has the properties of: Hardness: 70-90 (shore A, points) Elongation: 50-75% Thermal Conductivity: 1.5-6.0×10 -3 (cal/°C.-cm-sec) Thermal Expansion: 1.5-2.6×10 -4 (in/in/°C.) Dielectric Strength: 400-600 (volts/mil).

Claim 10

A sensor for an electric motor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a covering of electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to the thermistor surface portions and extending out from said cover member, and a sleeve member of electrically insulating material adjacent but separate and spaced apart from said covering member only encircling and engaging said lead members to improve the ability of the sensor to withstand lead member pull-out.

Claim 11

A sensor for an electric motor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a covering of electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to the thermistor surface portions and extending out from said cover member, and a sleeve member of electrically insulating material adjacent but separate and spaced apart from said covering member only encircling and engaging said lead members to improve the ability of the sensor to withstand lead member pull-out.

Claim 12

A sensor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a covering of electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to the thermistor surface portions and extending out from said cover members, said lead members extending from the cover member being twisted around each other thereby creating crevices between the wires, and a sleeve member of electrically insulating material adjacent but separate from said cover member for encircling and engaging said lead members having an adhesive lining for adhering to the lead members and flowing into said crevices when heated to improve the ability of the sensor to withstand lead member pull-out.

Claim 13

A sensor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a covering of electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to the thermistor surface portions and extending out from said cover members, said lead members extending from the cover member being twisted around each other thereby creating crevices between the wires, and a sleeve member of electrically insulating material adjacent but separate from said cover member for encircling and engaging said lead members having an adhesive lining for adhering to the lead members and flowing into said crevices when heated to improve the ability of the sensor to withstand lead member pull-out.

Claim 14

A sensor according to claim 10 further including a thermally conductive elastomer positioned around said thermistor within the covering member for protecting the thermistor from external forces and maintaining the integrity of the electrical contact between the lead members and the thermistor while providing good heat transfer to the thermistor.

Claim 15

A sensor according to claim 11 wherein said thermally conductive enclosure has the properties of: Hardness: 70-90 (shore A, points) Elongation: 50-75% Thermal Conductivity: 1.5-6.0×10 -3 (cal/°C.-cm-sec) Thermal Expansion: 1.5-2.6×10 -4 (in/in/°C.) Dielectric Strength: 400-600 (volts/mil).

Claim 16

A sensor according to claim 12 wherein said sensor is heated after assembly to cure said thermally conductive elastomer and to sealingly secure said sleeve to said lead members and said covering to said elastomer and said thermistor.

Claim 17

A sensor for insertion into the motor windings of a motor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a heat shrinkable covering member of high temperature electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to said thermistor surface portions and extending out from said cover member, at least a portion of said lead members extending out from said cover member being twisted around each other thereby creating crevices between the wires, a sleeve member of heat shrinkable high temperature electrically insulating material with an adhesive lining for adhering to the lead members and flowing into said crevices when heated, and a heat curable flexible thermally conductive electrically insulative elastomer positioned around the thermistor within the covering member for protecting the thermistor from external forces and maintaining the integrity of the electrical contact between the lead members and the thermistor while providing good heat transfer to the thermistor.

Claim 18

A sensor for insertion into the motor windings of a motor comprising a thermistor with selected temperature coefficient of resistance properties, said thermistor having opposite surface portions for connection to an electrical circuit, a heat shrinkable covering member of high temperature electrically insulating material in which said thermistor is contained, a pair of elongated electrically conductive lead members secured in electrically conductive relation to said thermistor surface portions and extending out from said cover member, at least a portion of said lead members extending out from said cover member being twisted around each other thereby creating crevices between the wires, a sleeve member of heat shrinkable high temperature electrically insulating material with an adhesive lining for adhering to the lead members and flowing into said crevices when heated, and a heat curable flexible thermally conductive electrically insulative elastomer positioned around the thermistor within the covering member for protecting the thermistor from external forces and maintaining the integrity of the electrical contact between the lead members and the thermistor while providing good heat transfer to the thermistor.