Abstract: Sets of six steering diodes and an ungated Thyristor are simultaneously formed into surge protection circuit modules by mass production techniques. An extended lead frame is provided with three spaced parallel leads for each module. The leads are connected at one end by a bridge. The sets of components are arranged along the lead frame in a fixture. By heating, each lead is soldered between a pair of steering diodes and the steering diodes on each side of the lead frame are soldered to different conductive plates. A thyristor is soldered between the plates. The partially formed modules are removed as a unit from the fixture and may be encased simultaneously. The bridge is removed to separate the modules and the leads trimmed and bent as required.

Abstract: The rectifier sub-assembly, formed by high temperature brazing, is glass encapsulated. It has axially extending leads with enlarged head portions. The sub-assembly is prepared for surface mounting by first flattening the leads outwardly from the enlarged head portions. An electrically insulating, heat conductive epoxy body is molded around the capsule, the enlarged head portions and at least a portion of each of the flattened lead sections. The leads are trimmed and if required, bent into the appropriate shape. After forming, the leads are barrel plated to obtain the best solderable surface for the most reliable electrical connection.