Abstract: To form a sturdy, environmentally essentially unaffected and high-temperature resistance electrical connection between a connection wire (4) and a conductive track (2) on the substrate (1), a portion of the wire (4) is embedded in a unitary bonding element (3). The bonding element comprises about 70% of metal particles and 30% of glass particles to form a bonding spot. The bonding spot is made by applying a paste of glass and platinum powder, with the glass powder having a grain size several times larger than the platinum powder on the conductive track (2), pressing the end portion of the connection wire (4) into the spot so that the wire will be completely surrounded, and then firing the bonding spot. If the conductive track (2) is applied by film technology, firing of the conductive track (2) and of the bonding spot (3) can be carried out in a single operating step.

Abstract: An electrical component, particularly a varistor, having high strength given stressing due to temperature change and due to surge currents is composed of a ceramic body whose end faces contain solderable metallic coatings as electrodes to which power supply elements are soldered, the latter being composed of a closed strip which leaves open and inwardly-disposed area and an outwardly-disposed area on the coating and which is dimensioned such that the condition Fa:FI=Ua:Ui=1.05 through 1.35 is met, where Fa is the surface of the coating located outside of the power supply element, Fi is the surface of the coating lying inside the power supply element, Ua is the outer circumference of the power supply element and Ui is the inner circumference of the power supply element. Each power supply element contains a lead clip which is spaced from the metallic surface by bends to such a degree that the clip is not soldered to the metallic coating.

Abstract: An electroceramic heater including a pair of metallized electrodes disposed upon the sides of an electroceramic body and a pair of lead wires gap is welded to said heater. A specially sized copper pad is disposed between the lead wires and the electrodes.

Abstract: An electrical resistor having a negative temperature coefficient for incremental resistance values has a resistance wafer with solderable coatings on opposite sides thereof and current lead elements soldered to the coatings, with the soldered ends of the lead elements being each coiled to form an annular eye, the soldering covering only the region of the eye and leaving the remainder of the coatings outside of the eye free of solder.

Abstract: In a chip resistor made of thin film having its connecting electrodes for connecting the resistor to a substrate, the connecting electrodes are coated with electrical conducting paint then soldering is performed so as to ensure soldering of the connecting electrodes to the substrate.

Abstract: A discharge terminal is provided integral with a resistor network unit to provide a discharge path for high voltage static electricity so that the high voltage spike does not alter the present values of resistance within the newtwork unit.The discharge terminal is located near a lead terminal to define a discharge gap between the lead terminal and the discharge terminal such that a static spike will not reach resistive elements in the resistor network.

Abstract: An improved electric resistance heater assembly for soldering tools, glue guns, hair dryers, heat pencils, paint removers, etc., includes, as the core of the assembly, an open-ended tube of a ceramic material having good electrical insulation properties with good thermal conductivity, low heat capacity and a high softening temperature. A conduit extends lengthwise through the wall of the tube from end to end thereof and first and second spring-tempered split metallic compression bands of smaller diameter than the tube are placed at each end of the tube and retained thereon by compressive stress. A plurality of turns of resistance wire are wound about the outer periphery of the tube between the bands with each end of the wire welded to a respective one of the bands. An first electric lead is welded to the first band. A second electric lead is welded to the second band and extends lengthwise through the conduit and exits the conduit near the first band.

Abstract: A precision resistor of the type formed by defining a resistive path in a thin foil of resistance material attached to a substrate. Metallic interface layers are deposited on terminal pads between which the resistive path extends, so that when solder-coated copper leads are spot-welded to the terminal pads, the junction between the copper leads and the terminal pads is both a spot-weld and a solder connection.

Abstract: A method of soldering electrical lead strands (of a width at least 0.3 inch) to a printed electrical path is disclosed. The path is planted on an alumina ceramic substrate and a solder pad is attached to a portion of the path. A flat surface portion of each lead strand is forced into full interengagement with a pad, a CO.sub.2 defocused laser beam is directed onto the soldering assembly with the beam controlled to have a beam power of at least 100 watts, a beam spot diameter no less than the width of the lead strand and no greater than the width of the pad, and a beam on-time effective to exert a controlled thermal radius on the soldering assembly to reflow only a preselected portion of the pad and effect a solder joint between the pad and strand portion, the joint having a strength of at least 400 grams. The parameters of the beam power, beam spot diameter, and beam on-time are optimally correlated by the following equation: ##EQU1## where: C is the critical thermal radius, a is the Gaussian radius at 1/e.

Abstract: An electrical circuit device having a ceramic substrate including a thick or thin film circuit on at least one surface thereof and an intersecting edge surface which may support termination leads anchored thereto and further retained by solder deposited upon an edge termination coating. The termination coating underlying the solder extends over the edge defined by the intersecting surfaces. The component resides in form of the substrate to include an indented area in the form of a notch or a groove which intersects both adjoining surfaces to provide a means of receiving edge termination material, so as to insure a continuous and non-interrupted deposit of the material to complete the electrical circuit between the leads and the respective circuit components of the circuit defined on the said one substrate surface.

Abstract: A precision resistor for use in electrical circuits arranged on printed circuit boards is produced from a band of thermally conductive alloy. The band is selectively surface treated with a conductive coating to improve solderability in the region of the resistor where it is connected to conductors of the circuit board.

Abstract: Electrical devices comprise a conductive polymer element and, in electrical contact therewith, a flame-sprayed layer of a metal or other highly conductive material. Electrical leads can readily be attached to the flame-sprayed layer. Particularly valuable devices are those in which at least part of the conductive polymer element is a PTC or NTC conductive polymer. The flame-sprayed layer can be formed directly by flame-spraying a suitable material onto the device, or by flame-spraying the material onto a carrier and then laminating the layer, on the carrier, to the device.

Abstract: Substantially flat thin foil electrical components, e.g. thin foil resistors, are disclosed wherein a thin metallic foil is bonded to an insulating substrate and a circuit path is formed on the foil by photographic artwork-etching or other techniques. Terminal lands of the circuit are electroplated on the foil connecting leads having paddles or flattened portions formed with a hole or slot therein are soldered to the lands such that the solder extends into the hole or slot. The value of the resistor is finally adjusted by use of a laser beam, at least one bead of rubber is applied on at least a portion of the edges of the substrates, and the resistor is encapsulated.

Abstract: A thin film foil resistor is disclosed wherein a thin metallic foil is bonded to an insulating substrate and a circuit path is formed on the foil by photographic artwork-etching techniques. After the circuit is formed, the structure is subjected to another etching process to reduce the thickness of the foil circuit thereby adjusting the value of the resistor. Terminal lands of the circuit are electroplated and the connecting leads are soldered to the lands. The value of the resistor is finally adjusted by use of a laser beam, and the resistor is encapuslated.

Abstract: A precision resistor has a thin resistive foil cemented to a much thicker rigid substrate. The foil has formed therein a pattern defining the resistive path between terminal pads. Copper leads can be spot-welded directly to these pads without damage to the junction. To that end, apertures are provided through the terminal pads, through which cement softened by the spot-welding heat can locally expand and gas evolved under pressure can escape, all without adversely affecting the junction and without substantial lifting of the terminal pads from the substrate.

Abstract: A copper sleeve is employed to join a molybdenum disilicide heating rod with a conductor by a brazing process including fluxing the interior of the sleeve, positioning the sleeve partially over one end of the heating rod and heating the junction of the sleeve and rod in a nonoxidizing flame while applying a brazing alloy to the interior of the sleeve. The conductor is then crimped to the opposite end of the sleeve for providing an electrical and mechanical connection of the conductor to the heating rod.

Abstract: An electric resistance heating element is formed by a molybdenum disilicide wire loop formed by separate lengths of the wire having ends positioned together and butt welded to the end of a molybdenum disilicide connecting wire of larger diameter than that of the lengths. The lengths diverge from each other so they are electrically separated. Electrical connections with the free ends of the separate lengths of wire can provide for electrically powering the loop.

Abstract: An electric resistance heating element of the hairpin type is provided by a molybdenum disilicide resistance wire loop transversely connected to molybdenum disilicide terminals. The resistance wire is sandwiched between the ends of two pieces of terminal wire and the ends of these pieces are butt welded together on the resistance wire, to form each terminal.

Abstract: A method for welding an electrical lead wire to a terminal pin with the use of a laser beam. The method is particularly designed for use in welding an electrical lead wire of an exhaust gas sensor to a terminal pin having an opening through which the electrical lead wire extends to the exterior of the pin. The lead wire may be made of nichrome material and the terminal pin from leaded steel. The laser beam is positioned vertically above the extended portion of the lead wire and its focal point is above the end of the lead wire. No separate filler metal is required since the lead wire material is itself available as a filler material.

Abstract: A composition comprising negatively doped hot pressed particulate silicon carbide, the process for making the composition, an electrical hot surface fuel ignitor manufactured from the composition, a silicon brazed electrical connection for the ignitor and an ignitor circuit containing a dropping resistance.

Abstract: 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.

Abstract: This disclosure depicts structure and method for terminating an electrical resistor for a television CRT which could be used for arc suppression, voltage division or the like. The structure is disclosed in a preferred form as comprising a cylindrical rod of predetermined length, diameter and resistance. On at least one end of the rod, an electrically conductive coil spring is constricted in firm electrical and mechanical connection with said rod. At least a number of the turns of the spring are mechanically joined to prevent the spring from being torsionally stressed open so as to release the rod. Also disclosed is a method of making an electrical-mechanical termination.

Abstract: In the present device, a base member is included which has channels formed therein to hold lead wires. In the preferred embodiment a metal foil resistor member, having termination land sections, is secured to the base member to form a fourth side for each channel, thereby securely locating the lead wires in the channels and the lead wires are firmly connected to the termination land sections of the foil resistor. Accordingly with respect to the foil resistor assembly: there is good physical strength to withstand external forces; the resistor reliability is enhanced; the fabrication is simplified; and the resistance range capability is increased.

Abstract: A component and method for applying end caps thereto is provided. A wire extends within a body defining a body sidewall and oppositely facing body ends with opposite end portions of the wire extending outwardly beyond the body ends and bent over so that they lie adjacent to each end of the body. Two end caps are provided, each having a cylindrical first portion and a cylindrical second portion with a diameter less than the first portion and joined to the first portion by an annular shoulder. The cylindrical second portion has an end wall so that the second portion defines a chamber. A solder and flux mixture is deposited in the chambers of the end caps which are then each applied to an end portion of the body with the cylindrical first portion compressively embracing the sidewall of the body adjacent one end thereof. The shoulder of the end cap bears against the body end to maintain the end wall of the cap at a predetermined distance from the body end and thereby prevent severance of the wire end portion.

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.

Abstract: A polished ceramic substrate is provided with an insulation layer of silicon monoxide (SiO), over which a nickel metal thin-film is laid down in a spiral or serpentine pattern, taking up a desirably small area, but at the same time giving a high electrical resistance. Finally, a cover or protective layer of silicon monoxide is then deposited over the resistor, serving to protect it from the possibility of outside contamination.

Abstract: An electrical component, comprising an insulating substrate having conductive material applied to one side thereof and including terminal pad portions for attaching electrically connecting leads thereto, in which said leads are provided with relatively thick rigid portions adapted to extend externally of the component to provide means for making electrical connections thereto and have relatively thinner, less rigid portions mechanically bonded to the other side of said substrate and have end portions dressed around the edge of said substrate to said one side thereof and electrically connected to said terminal pad portions by brazing, welding or soldering. In a preferred form, said leads may be bonded to said substrate by epoxy or other suitable cement and the end portions thereof may be made even thinner than the remainder of said thinner portions to facilitate dressing them around the edge of said substrate into contact with said terminal pad portions.

Abstract: A positive temperature coefficient (PTC) resistance heater assembly is used in combination with an angle of attack vane to provide automatic means for maintaining the temperature of the vane at a level which will de-ice the vane. The heater assembly is embedded in a recess in the vane and is made up of a plurality of individual PTC resistors connected electrically and mechanically in parallel by flexible electrically conductive perforated strips which permit the individual resistors to move relative to each the other under thermal stress and which also permit the encapsulation of the resistors in a suitable thermally conductive, electrically oinsulative material that is sufficiently resilient to permit the individual resistors to expand and contract relative to the vane during use.

Abstract: A method of manufacturing a passive hermetically sealed electronic component having a coupling element of soft alloy material between the component element and the leads for providing strain relief. The component element is composed of a passive element having coated ends composed of a refractory metallic material for providing reliable electrical and mechanical connection to the coupling element.

Abstract: An ignition aid for internal combustion engines includes a sintered refractory ceramic composite heating element having a high resistance central portion interposed between a low resistance terminal end portions. The heating element is positioned in a hollow electrically conductive body adapted to be removably inserted in an aperture in an engine. The heating element is disposed between and has its terminal end portions in electrical non-point contact with a bridge portion at one end of the hollow body and an electrode rod extending into the hollow body in sealed relation therewith. In one embodiment, the electrode rod comprises a pair of relatively movable parts, one of which is resiliently biased into engagement with the heating element by a resilient PTC resistance element electrically connecting the parts. In another embodiment, the heating element terminal portions are diffusion bonded to the electrode rod and bridge portion, respectively.

Abstract: An iron wire resistor connected in shunt with the current limiting contacts of a circuit breaker. The current limiting contacts are in series with the main contacts of the breaker, and are separated by extremely high fault currents before the main contacts can respond. Opening of the limiting contacts shunts the high fault current through the resistor. The resistor has a positive temperature coefficient of resistance and heats rapidly to sharply reduce the magnitude of the high fault current.To prevent the connection between the resistor and a low resistance copper conductor from being destroyed by the high fault current an intermediate resistance value terminal of copper clad stainless steel is employed between the resistor and the copper conductor.

Abstract: A varistor has a cylindrical core made of a sintered varistor material which includes a longitudinal opening between the core ends. A pair of terminating layers are applied to the core, each adhering to one of the ends of the core and being in electrical contact with a lead wire inserted into the longitudinal opening. An electrode film is applied to the outer longitudinal surface of the core with each end in communication with one of the terminating layers. The electrode film is divided between the terminating layers into a pair of electrode portions by a gap which is dimensioned to predetermine the electrical properties of the varistor.

Abstract: A thick film varistor comprises a varistor film sandwiched between a pair of electrodes, one of which is in contact with a cylindrical substrate. Alternatively, the electrodes may be positioned on the same surface of the film--either in contact with the substrate or the surface of the film opposite the substrate. The preferred method of manufacture involves applying a terminating layer to each end of the substrate, forming the varistor film and the electrodes on the substrate in the desired configuration, attaching a lead wire to each end of the substrate in electrical contact with an adjacent terminating layer, and enclosing the varistor film within a conformal coating.

Abstract: A drawer type electrode of a thermistor for sensing high temperatures, wherein a shaft and a sheath are connected to a thermistor, is constructed such that the shaft and the sheath are brought into contact with the positive and negative electrode surfaces of the thermistor through precious metal chips so that electrical connection between the precious metals, the shaft and the sheath will not be impaired in any way even if oxidation penetrates into the interior from the shaft and the sheath surface due to high temperature.

Abstract: An electrical connector comprising first, second and third legs, said legs being arranged to permit said second leg to be spacially separated by force from said first and third legs thus, permitting an electrical conductor to be placed between the second leg and the first and third legs and permitting said electrical conductor to be retained by said legs.

Abstract: A variable resistance control comprises a resilient nonconductive annular skirt sandwiched between a pair of substrates. The skirt has an arcuate section and a pair of posts interconnected by a bridge section. Each of the substrates comprises a circular portion carrying a resistance film and an extending portion provided with apertures and engaged by the posts. A driver is rotatably carried by the control and contactors are constrained to rotate with the driver wipingly engaging the resistance films. The apertures in the extending portions of the substrates are in line with the posts and the periphery of the bridge section substantially coincides with edges of the extending portions. Terminals are secured to the extending portions of the substrates and comprise a head and a tail. The head is received in an aperture and a pair of spaced fingers integral with the terminal are clinched into engagement with the head disposed between the spaced fingers.

Abstract: A hermetically sealed fixed film resistor including a coupling element of soft alloy material between the resistive element and the leads for providing strain relief. The resistive element is composed of a resistive film having coated ends composed of a refractory metallic material for providing reliable electrical and mechanical connection to the coupling element.

Abstract: The present hermetically-sealed electrical resistor component assembly is composed of a sleeve of high-density, non-porous, non-hydroscopic material into which there is slip-fitted an electrical resistor component. Said electrical resistor component is sealed within said sleeve by a deposit of solder at each end of said sleeve whereat said solder clings to said sleeve, to the end cap of said resistor, and to the lead wire extending from said end cap. In some embodiments silicon rubber is employed as a gasket disposed along the end of said cap whereat it abuts said sleeve. In another embodiment, the entire package is encapsulated in a plastic material such as silicone-epoxy.

Abstract: A sleeve of in-situ-solidified-from-melt material, such as a lead glass or the like, surrounds an end segment of a refractory resistance element extending from a junction between a metal supporting member and the end of the element. The solidified-from-melt material is formed not to adversely react with the refractory element and has a coefficient of linear expansion within the range from about 0.5 to 1.5 times the coefficient of linear expansion of the refractory material.

Abstract: The end of an elongated resistance element, such as a molybdenum disilicide rod, is joined to a metal member which provides both electrical connection and mechanical support.