Allen-Bradley Company, LLC

Richard E Voss

Oscar L Denes

Ivan L Brandt

Theodor Von Alten

An electrical resistor element and method of manufacturing the same. The element may comprise a fixed resistor or may be the resistive and collector component of a variable resistor. In either case, the element comprises, at least as a portion thereof, a substrate comprising an insulating substrate injection molded from ceramic-glass frit material and organic binder and lubricating material. A layer of resistive material and a layer of conducting termination material are each deposited on the unfired substrate. The organic materials in the substrate and its termination and resistive layers are substantially 'burned out' prior to simultaneously co-firing the substrate and the deposited resistive and termination layers. In the case of fixed resistors, the element may be molded as a half-shell arranged to receive leads extending from opposite ends of the half-shell molding and attached by soldering or other means to the termination areas. A substantially identical cover member molded and fired from the same material as the substrate is adhesively attached to the substrate to complete the resistor.

Electrical resistor element and method of manufacturing the same

A method of manufacturing a resistor element for fixed or variable resistors. The element comprises an insulating substrate injection molded from ceramic-glass frit material and organic binder and lubricating material and layers of resistive material and conducting termination material deposited on the unfired substrate. The organic materials in the substrate and its termination and resistive layers are substantially 'burned out' prior to simultaneously co-firing the substrate and the deposited resistive and termination layers. The fixed resistor element may be molded as a half-shell arranged to receive leads extending from opposite ends thereof and attached by soldering to the termination areas. A substantially identical cover member molded and fired from the same material as the substrate is adhesively attached to the substrate to complete the resistor. The invention further contemplates the provision of attaching respective leads by means of forming a solder ball of low melting solder on one end of a solder coated lead and fastening this end by means of a hydrogen torch to the portion of the fixed resistor subassembly containing the termination material.

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New Berlin, WI, United States of America

Richard E Voss