US2939807A - Method of making a heating panel - Google Patents
Method of making a heating panel Download PDFInfo
- Publication number
- US2939807A US2939807A US594834A US59483456A US2939807A US 2939807 A US2939807 A US 2939807A US 594834 A US594834 A US 594834A US 59483456 A US59483456 A US 59483456A US 2939807 A US2939807 A US 2939807A
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- sheet
- coating
- metal
- heating
- coated
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
- H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
- H05B3/262—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base the insulating base being an insulated metal plate
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49082—Resistor making
- Y10T29/49083—Heater type
Definitions
- This invention relates to heating devices and particularly to an improved electrically energized radiant heating element and the method of making it.
- An object of the invention is to provide an improved radiant heating element suitable for use in space heating panels adapted to be mounted on the walls or ceilings of buildings, in portable heaters, and 'as a heating element for water heaters, ranges, etc.
- My improved element is also suitable for use in industrial applications.
- Another object is to provide an improved radiant heating element whichv is self supporting, has inherent rigidity, yet is rugged in construction and not easily subject to damage by mechanical or heat shock.
- Still another object is to provide an improved electrical heating element wherein the resistor is fused on a self supporting backing member which may be llat or curved and wherein the resistor presents a relatively large area of heating surface.
- Another object of the invention is to provide an improved electrically tenergized heating element of sheet form which includes ya metal sheet with a resistor element mounted thereon suitably insulated from the metal sheet, and which has a vitreous or porcelain enamel coating on the front surface of the sheet for diffusing the radiation thereof.
- Fig. l is a rear view of my improved heating element with a portion of the protecting coating broken away to show the resistor;
- Fig. 2 is 1an enlarged section taken on the line 2-2 of Fig. 1;
- Fig. 3 is a section, similar to Fig. 2, of a modified form of element.
- my improved heating element comprises a sheet which is preferably of metal but may be of other suitable material.
- the sheet 10 may be of any desired thickness so long as it is self supporting and substantially rigid. Generally, met-al of sufficient section to provide the desired characteristics with lightest weight is used. While the sheet 10 is shown as at and rectangular, any regular or irregular shape may be used and the sheet may be formed into a cylinder or other shape.
- the sheet 10 is coated with a layer of frit, vitreous enamel or porcelain enamel 12, and an electrical resistor 14 is applied to the refractory coating as indicated at 14.
- Terminal electrodes 16 are suitably soldered or otherwise attached to the resistor as shown.
- the other surface of the sheet 10 has a coating 18 of frit, vitreous or porcelain enamel, and preferably the rear (element carrying) side is coated with a layer 20 of corrosion retardant material such as silicone enamel, melamine resin, or the like.
- the coating 20 protects the rear surface of the panel generally and prevents corrosion of the resistor 14 which might occur from exposure to air, water or a corrosive atmosphere. Such corrosion sometimes causes 4localized high resistance which, in turn, causes localized over heating and failure of the resistor.
- a metal backing sheet 10 is first heated uniformly to approximately 1500 F. and the vitreous layers 12 and 18 are applied, preferably by spraying from a spray gun or nozzle, while the sheet lisrnaintained at the indicated temperature.
- the coated sheet is then carefully annealed and brought to room temperature slowly such that the coating or coatings do not spall and no warping of the element takes place. It is of prime importance that the vitreous coating be uniform in thickness, and if coatings are applied to both sides of the sheet, the thickness should be the sa'me for best results.
- the coated sheet is then cleaned, preferably in a vaporizing oven with a vaporized solvent, ⁇ and is reheated to a uniform temperature of 550-700 F. or somewhat higher and maintained at this temperature while the resistor 14 is applied.
- the latter may be pure aluminum or an alloy and is applied by spraying molten metal from a gun or nozzle to a thickness of .O05 inch.
- the sheet is moved at a uniform rate past the gun which is oscillated vertically or horizontally.
- the metallic coating 14 m-ay be sprayed through a mask to provide the grid-like path desired, but I prefer to lapply a uniform coating of metal on the porcelain then etch the grid pattern. Accordingly, a silk screen I pattern is placed on the hardened metal coating and a coating of silicone Varnish or resin is squeezed over the entire surface of the sheet. The element is then placed in an etching bath, such as a 2% nitric acid solution, for a time sufficient to etch the metal completely away in the places not covered by the enamel.
- an etching bath such as a 2% nitric acid solution
- the element is removed from the etching bath and dried whereupon it is complete, the silicone still adhering to the resistor pattern forming an anti-corrosive layer.
- a border 11 of bare metal is preferably left around the margin of the sheet 10 on both sides. This uncoated border protects the coatings from being chipped at their marginal edges dur-ing handling and provides space for holes 13 which can be used to fasten the element in a frame or other support.
- Fig. 3 shows a modification wherein the element above described is provided with an additional coating 22 on its rear side.
- This coating 22 may be of rock wool, foam glass, fibre glass, or other suitable heat insulating material, and improves the heat radiating qualities of the element by reducing rad-iation from the rear side which is generally against or close to the mounting surface, such ias a wall or ceiling.
- the metal base sheet 10 may be of any suitable metal or alloy such as copper, aluminum, steel, etc.
- Stainless steel has approximately the same coecient of expansion as the vitreous enamel and therefore works very well. In general, it may be ⁇ PatentedJune7,1960
Description
June 7, 1950 B. A. NEEDHAM 2,939,807
METHOD OF MAKING A HEATING PANEL Filed June 29. 1956 /7 f TQFNIK United States O.
METHOD OFMAKING A HEATING PANEL Basil A. Needham, Bayside, N .Y., assgnor to Thermway Industries, Inc., New York, N.Y., a company of Delaware Filed June 29, 1956, ser. No.s94,s34 t 4 claims. (ci. 111-212) This invention relates to heating devices and particularly to an improved electrically energized radiant heating element and the method of making it.
An object of the invention is to provide an improved radiant heating element suitable for use in space heating panels adapted to be mounted on the walls or ceilings of buildings, in portable heaters, and 'as a heating element for water heaters, ranges, etc. My improved element is also suitable for use in industrial applications.
Another object is to provide an improved radiant heating element whichv is self supporting, has inherent rigidity, yet is rugged in construction and not easily subject to damage by mechanical or heat shock.
Still another object is to provide an improved electrical heating element wherein the resistor is fused on a self supporting backing member which may be llat or curved and wherein the resistor presents a relatively large area of heating surface.
Another object of the invention is to provide an improved electrically tenergized heating element of sheet form which includes ya metal sheet with a resistor element mounted thereon suitably insulated from the metal sheet, and which has a vitreous or porcelain enamel coating on the front surface of the sheet for diffusing the radiation thereof.
Other objects and advantages of the invention will become apparent from the following specification which describes preferred embodiments of the invention.
In the drawing accompanying the specification,
Fig. l is a rear view of my improved heating element with a portion of the protecting coating broken away to show the resistor;
Fig. 2 is 1an enlarged section taken on the line 2-2 of Fig. 1; and
Fig. 3 is a section, similar to Fig. 2, of a modified form of element.
Referring to Figs. l and 2 of the drawing, it may be seen that my improved heating element comprises a sheet which is preferably of metal but may be of other suitable material. The sheet 10 may be of any desired thickness so long as it is self supporting and substantially rigid. Generally, met-al of sufficient section to provide the desired characteristics with lightest weight is used. While the sheet 10 is shown as at and rectangular, any regular or irregular shape may be used and the sheet may be formed into a cylinder or other shape.
The sheet 10 is coated with a layer of frit, vitreous enamel or porcelain enamel 12, and an electrical resistor 14 is applied to the refractory coating as indicated at 14.
The coating 20 protects the rear surface of the panel generally and prevents corrosion of the resistor 14 which might occur from exposure to air, water or a corrosive atmosphere. Such corrosion sometimes causes 4localized high resistance which, in turn, causes localized over heating and failure of the resistor.
Application of the vvitreous coating and the resistor presents some difiiculty because the element in use is subjected to rapid heating and cooling and it has been found that unless the various coatings are applied under careilly controlled conditions, chipping and spalling may result. Furthermore, unless the vitreous coatings are applied correctly warping of the element results and this is highly objectionable. Heating elements made in accordance with the method outlined herein have proven completely satisfactory.
A metal backing sheet 10 is first heated uniformly to approximately 1500 F. and the vitreous layers 12 and 18 are applied, preferably by spraying from a spray gun or nozzle, while the sheet lisrnaintained at the indicated temperature. The coated sheet is then carefully annealed and brought to room temperature slowly such that the coating or coatings do not spall and no warping of the element takes place. It is of prime importance that the vitreous coating be uniform in thickness, and if coatings are applied to both sides of the sheet, the thickness should be the sa'me for best results.
I have found that steel coated with porcelain to a uniform thickness of one-sixteenth of an inch on each surface is ideal for the heating element herein described.
The coated sheet is then cleaned, preferably in a vaporizing oven with a vaporized solvent, `and is reheated to a uniform temperature of 550-700 F. or somewhat higher and maintained at this temperature while the resistor 14 is applied. The latter may be pure aluminum or an alloy and is applied by spraying molten metal from a gun or nozzle to a thickness of .O05 inch. During application of the metal coating, the sheet is moved at a uniform rate past the gun which is oscillated vertically or horizontally.
The metallic coating 14 m-ay be sprayed through a mask to provide the grid-like path desired, but I prefer to lapply a uniform coating of metal on the porcelain then etch the grid pattern. Accordingly, a silk screen I pattern is placed on the hardened metal coating and a coating of silicone Varnish or resin is squeezed over the entire surface of the sheet. The element is then placed in an etching bath, such as a 2% nitric acid solution, for a time sufficient to etch the metal completely away in the places not covered by the enamel.
Next, the element is removed from the etching bath and dried whereupon it is complete, the silicone still adhering to the resistor pattern forming an anti-corrosive layer.
As illustrated in Fig. l, a border 11 of bare metal is preferably left around the margin of the sheet 10 on both sides. This uncoated border protects the coatings from being chipped at their marginal edges dur-ing handling and provides space for holes 13 which can be used to fasten the element in a frame or other support.
Fig. 3 shows a modification wherein the element above described is provided with an additional coating 22 on its rear side. This coating 22 may be of rock wool, foam glass, fibre glass, or other suitable heat insulating material, and improves the heat radiating qualities of the element by reducing rad-iation from the rear side which is generally against or close to the mounting surface, such ias a wall or ceiling.
In either form of the invention, the metal base sheet 10 may be of any suitable metal or alloy such as copper, aluminum, steel, etc. Stainless steel has approximately the same coecient of expansion as the vitreous enamel and therefore works very well. In general, it may be `PatentedJune7,1960
stated that the coeicients of expansion of the metal base y and the refractory coatings used should be approximately ment is heated and cooled. This requirement is, ofi
course, not so critical if it is intended to operatethe element at'fairly low temperature. For space'heating, electrically energized panels of the sheet-element type are :operated at temperatures of approximately 150" to 375 F. In industrial use, much higher temperatures are utilized.
' I claim:
1. The method of making an electrical radiant heater.
comprising, heating a metal sheet to approximately 15 00v F. and While maintaining the sheet at such temperature? applying lan insulating, hard, vitreous coating to bothv surfaces of said sheet, annealing said coated sheet, re-
heating said coated sheet to a temperature of approxi-A 4 surfaces of said sheet, annealing said coated sheet, reheating said coated sheet to a temperature of approximately 550 F. and While maintaining the coated sheet at such temperature spraying one of the coated surfaces with molten metal, then etching said metal to provide a grid-like pattern.
4. The method of claim 3k including the stepv of Y applying facoating of silicone varnish to said grid-like pattern.
References Cited in the ile of this patent UNITED STATES PATENTS 617,375 'Voigt Jan. 10, 1899 2,061,107 Schellenger Nov. 17, 1936 2,119,680 Long June 7, 1938 2,179,566 Stoekle Nov. 14, 1939 2,357,473 Jira Sept. 5, 1944 2,432,800 Reichold Dec. 16, 1947 2,441,960 Eisler May 25, 1948 2,486,148 Glynn et al. Oct. 25, 1949 2,502,291 Taylor Mar. 28, 1950 2,542,726l Sullivan Feb. 20, 1951 2,679,569 Hall May 25, 1954 2,695,351 Beck Nov. 23, 1954 2,739,085 McBride f.. Mar. 20, 1956 FOREIGN PATENTS 162,632 Australia Apr. 29,
Claims (1)
1. THE METHOD OF MAKING AN ELECTRICAL RADIANT HEATER COMPRISING, HEATING A METAL SHEET TO APPROXIMATELY 1500* F. AND WHILE MAINTIANING THE SHEET AT SUCH TEMPERATURE APPLYING AN INSULATING, HARD, VITREOUS COATING TO BOTH SURFACES OF SAID SHEET, ANNEALING SAID COATED SHEET, REHEATING SAID COATED SHEET TO A TEMPEATURE OF APPROXIMATELY 550*F. AND WHILE MAINTAINING THE COATED SHEET AT SUCH TEMPERATURE APPLYING A COATING OF METAL TO ONE COATED SURFACE THEREOF, THEN ETCHING SAID METAL COATING TO PROVIDE A GRID-LIKE PATTERN.
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US594834A US2939807A (en) | 1956-06-29 | 1956-06-29 | Method of making a heating panel |
Applications Claiming Priority (1)
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US594834A US2939807A (en) | 1956-06-29 | 1956-06-29 | Method of making a heating panel |
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US2939807A true US2939807A (en) | 1960-06-07 |
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US594834A Expired - Lifetime US2939807A (en) | 1956-06-29 | 1956-06-29 | Method of making a heating panel |
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Cited By (53)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3026398A (en) * | 1959-04-22 | 1962-03-20 | Gen Electric | Baseboard electric heating system and electric heating units therefor |
US3057989A (en) * | 1958-05-23 | 1962-10-09 | Thermway Ind Inc | Curtain wall |
US3067310A (en) * | 1959-12-02 | 1962-12-04 | Frank C Walz | Microfilm electric heaters |
US3071749A (en) * | 1960-05-17 | 1963-01-01 | Budd Co | Adjustable resistors and method of making the same |
US3072500A (en) * | 1959-05-06 | 1963-01-08 | Motson Services Inc | Printed circuit |
US3108170A (en) * | 1958-02-17 | 1963-10-22 | Maxwell K Murphy | Heating element |
US3109228A (en) * | 1959-08-10 | 1963-11-05 | Thermway Ind Inc | Manufacture of electric radiant heating panels |
US3126470A (en) * | 1964-03-24 | Electric water heating apparatus | ||
US3174211A (en) * | 1965-03-23 | Gaszak method of manufacturing a resistance-heating type water heater | ||
US3177338A (en) * | 1962-06-29 | 1965-04-06 | Smith Corp A O | Multi-operator resistor grid welding apparatus |
US3197335A (en) * | 1962-04-09 | 1965-07-27 | Stanley W Leszynski | Surface-mounted electrical resistance structure and method for producing same |
US3202951A (en) * | 1961-08-16 | 1965-08-24 | Krinsky Albert | Alloys and electrical transducers |
US3231718A (en) * | 1962-02-05 | 1966-01-25 | Akay Corp | Automatic electric food warmer tray |
US3243313A (en) * | 1960-04-25 | 1966-03-29 | Ling Temco Vought Inc | Heat-resistant article |
US3252831A (en) * | 1964-05-06 | 1966-05-24 | Electra Mfg Company | Electrical resistor and method of producing the same |
US3259559A (en) * | 1962-08-22 | 1966-07-05 | Day Company | Method for electroless copper plating |
US3343329A (en) * | 1964-05-14 | 1967-09-26 | Arthur J Pohutsky | Spacer-support clip for ceiling construction |
US3349722A (en) * | 1964-11-27 | 1967-10-31 | Cleveland Technical Ct Inc | Electrical resistance rail heater |
US3370262A (en) * | 1963-05-27 | 1968-02-20 | Sprague Electric Co | Electrical resistor |
US3396055A (en) * | 1965-04-16 | 1968-08-06 | Vitreous Steel Products Compan | Radiant heating panels and resistive compositions for the same |
US3405381A (en) * | 1965-05-04 | 1968-10-08 | Vishay Intertechnology Inc | Thin film resistor |
US3505498A (en) * | 1968-07-23 | 1970-04-07 | Minnesota Mining & Mfg | Cooking utensil with integral dielectric layer and electrical heating element |
US3517436A (en) * | 1965-05-04 | 1970-06-30 | Vishay Intertechnology Inc | Precision resistor of great stability |
US3694623A (en) * | 1969-09-11 | 1972-09-26 | Matsushita Electric Ind Co Ltd | Surface heater for a toaster |
US3751633A (en) * | 1971-10-08 | 1973-08-07 | W Green | Plug-in chamber furnace |
US3767895A (en) * | 1971-12-01 | 1973-10-23 | Infra Red Circuits & Controls | Portable electric radiant space heating panel |
US3806701A (en) * | 1972-11-03 | 1974-04-23 | Rival Manufacturing Co | Electric cooking utensil having a removable vessel |
US3816704A (en) * | 1972-03-20 | 1974-06-11 | Gen Electric | Surface heating apparatus |
US3839620A (en) * | 1972-10-13 | 1974-10-01 | R Seibel | Condensation free mirror |
US3869596A (en) * | 1973-09-28 | 1975-03-04 | Safeway Products Inc | Cookware heater |
US3883719A (en) * | 1974-05-10 | 1975-05-13 | Gen Electric | Glass-ceramic cooktop with film heaters |
US3887788A (en) * | 1972-10-13 | 1975-06-03 | Seibel & Seibel Enterprises | Condensation free mirror |
US4063068A (en) * | 1976-08-12 | 1977-12-13 | Minnesota Mining And Manufacturing Company | Food heating and cooking receptacle |
US4250396A (en) * | 1979-09-04 | 1981-02-10 | Walter Leuca | Heated drafting board |
US4294009A (en) * | 1978-06-29 | 1981-10-13 | Le Material Telephonique | Method of manufacturing a hybrid integrated circuit |
WO1985003402A1 (en) * | 1984-01-20 | 1985-08-01 | Vitronics Corporation | Infrared panel emitter and method of producing the same |
US4542268A (en) * | 1980-01-28 | 1985-09-17 | Litton Systems, Inc. | Browning heater for a microwave oven |
US4677801A (en) * | 1984-09-13 | 1987-07-07 | Martin Bard | Wall, ceiling and/or floor formation and a method for producing it |
US4682009A (en) * | 1985-06-11 | 1987-07-21 | Thermotechnik G. Bauknecht Gmbh | Wall mounted combined radiactive-convective electric space heater |
EP0229351A1 (en) * | 1985-12-19 | 1987-07-22 | Buchtal Gesellschaft mit beschränkter Haftung | Flat ceramic element |
EP0280150A1 (en) * | 1987-02-17 | 1988-08-31 | Buchtal Gesellschaft mit beschränkter Haftung | Space heating element consisting of a ceramic body provided with an electrically resistant layer, especially in the form of a ceramic plate |
US4833301A (en) * | 1984-01-18 | 1989-05-23 | Vitronics Corporation | Multi-zone thermal process system utilizing nonfocused infrared panel emitters |
US4843218A (en) * | 1985-12-20 | 1989-06-27 | Bosch-Siemens Hausgerate Gmbh | Heating element for thermal heating devices, especially cooking stations |
US5026970A (en) * | 1988-07-29 | 1991-06-25 | Emaco Ltd. | Cooking appliances |
EP0675670A2 (en) * | 1994-03-28 | 1995-10-04 | Morillo Casals, Pilar | Radiant panel with improved printed circuit |
US5502293A (en) * | 1992-05-26 | 1996-03-26 | Terumo Kabushiki Kaisha | Heater element for a tube connecting device |
US6018288A (en) * | 1997-05-09 | 2000-01-25 | Indak Manufacturing Corp. | Flat resistors for automotive blower motor speed control or other service |
US20050002659A1 (en) * | 2001-10-09 | 2005-01-06 | Stylianos Panaghe | Radiant electric heating element |
US20050167414A1 (en) * | 2004-01-30 | 2005-08-04 | Po-Chun Kuo | Cooking device with a thick film resistive element heater |
FR2912277A1 (en) * | 2007-02-01 | 2008-08-08 | Muller & Cie Sa Soc | Electrical heating apparatus, has screen with insulator whose melting temperature is greater than melting temperature of sheath, and heating element that is in contact with rear face connected to earth when sheath is melted |
US20110085783A1 (en) * | 2009-10-08 | 2011-04-14 | Mccourt Mark J | Dual chimney flat panel convection air space heater |
US20130014772A1 (en) * | 2011-07-12 | 2013-01-17 | Qiuming Liu | Electric flue-cured tobacco |
US20170284701A1 (en) * | 2016-03-31 | 2017-10-05 | Gd Midea Environment Appliances Mfg Co., Ltd. | Electric radiator |
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Cited By (59)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3126470A (en) * | 1964-03-24 | Electric water heating apparatus | ||
US3174211A (en) * | 1965-03-23 | Gaszak method of manufacturing a resistance-heating type water heater | ||
US3108170A (en) * | 1958-02-17 | 1963-10-22 | Maxwell K Murphy | Heating element |
US3057989A (en) * | 1958-05-23 | 1962-10-09 | Thermway Ind Inc | Curtain wall |
US3026398A (en) * | 1959-04-22 | 1962-03-20 | Gen Electric | Baseboard electric heating system and electric heating units therefor |
US3072500A (en) * | 1959-05-06 | 1963-01-08 | Motson Services Inc | Printed circuit |
US3109228A (en) * | 1959-08-10 | 1963-11-05 | Thermway Ind Inc | Manufacture of electric radiant heating panels |
US3067310A (en) * | 1959-12-02 | 1962-12-04 | Frank C Walz | Microfilm electric heaters |
US3243313A (en) * | 1960-04-25 | 1966-03-29 | Ling Temco Vought Inc | Heat-resistant article |
US3071749A (en) * | 1960-05-17 | 1963-01-01 | Budd Co | Adjustable resistors and method of making the same |
US3202951A (en) * | 1961-08-16 | 1965-08-24 | Krinsky Albert | Alloys and electrical transducers |
US3231718A (en) * | 1962-02-05 | 1966-01-25 | Akay Corp | Automatic electric food warmer tray |
US3197335A (en) * | 1962-04-09 | 1965-07-27 | Stanley W Leszynski | Surface-mounted electrical resistance structure and method for producing same |
US3177338A (en) * | 1962-06-29 | 1965-04-06 | Smith Corp A O | Multi-operator resistor grid welding apparatus |
US3259559A (en) * | 1962-08-22 | 1966-07-05 | Day Company | Method for electroless copper plating |
US3370262A (en) * | 1963-05-27 | 1968-02-20 | Sprague Electric Co | Electrical resistor |
US3252831A (en) * | 1964-05-06 | 1966-05-24 | Electra Mfg Company | Electrical resistor and method of producing the same |
US3343329A (en) * | 1964-05-14 | 1967-09-26 | Arthur J Pohutsky | Spacer-support clip for ceiling construction |
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