Abstract A resistor device of simple construction particularly adapted for use as a precision, low ohmic value resistor. The terminal leads are axially aligned and extend outwardly from a molded housing. The inner end of each lead is shaped into a flat surface to facilitate the welding thereto of a resistor element and to minimize twisting of the embedded end of the lead. A radially extending disc shaped portion on each lead is adjacent the flat portion and is embedded in the molded housing to prevent axial movement of the embedded end of the lead. The embedded flat and disc shaped portions serve to minimize forces from acting on the weld joints to break the welds. The resistance element is free standing wire shaped into a serpentine configuration and embedded in the molded housing.
A molded electrical resistor comprising first and second axially aligned and spaced apart electrical leads, each lead being circular in cross section throughout most of its length but having an integral substantially flat portion at one end and an integral radially extending disc shaped portion located inwardly from and adjacent the flat portion, a resistance wire having first and second ends, each end of the resistance wire being welded to a flat portion on a respective one of the leads, said resistance wire being self supporting when welded to the leads, each of said flat portions on the end of a lead having a continuous surface that is wider than the diameter of its respective lead that has a circular cross section, thereby to provide a flat surface to facilitate welding the resistance wire thereto, a plastic housing molded about and engaging the self supporting resistance wire and the ends of the leads that include the flat and radially extending portions, whereby the leads are bound in the molded housing by the flat and radial portions thereby to minimize twisting and axial forces on the welds that secure the resistance wire to said leads.
Claim 2
Dependent Claim
194 words
A molded electrical resistor comprising first and second axially aligned and spaced apart electrical leads, each lead being circular in cross section throughout most of its length but having an integral substantially flat portion at one end and an integral radially extending disc shaped portion located inwardly from and adjacent the flat portion, a resistance wire having first and second ends, each end of the resistance wire being welded to a flat portion on a respective one of the leads, said resistance wire being self supporting when welded to the leads, each of said flat portions on the end of a lead having a continuous surface that is wider than the diameter of its respective lead that has a circular cross section, thereby to provide a flat surface to facilitate welding the resistance wire thereto, a plastic housing molded about and engaging the self supporting resistance wire and the ends of the leads that include the flat and radially extending portions, whereby the leads are bound in the molded housing by the flat and radial portions thereby to minimize twisting and axial forces on the welds that secure the resistance wire to said leads.