Low-resistance resistor and its manufacturing method

A resistor comprising:

• a resistor element made of metal sheet;
• an insulating sheet disposed at least on one of top face and bottom faces of said resistor element;
• and
• a terminal having a concave groove of a width equivalent to a sum of a thickness of said resistor element and a thickness of said insulating sheet, said terminal being electrically connected to said resistor element.

A resistor comprising:

• a resistor element made of metal wire;
• and
• a metal terminal having a concave groove covering both ends of said resistor element;
• said terminal being electrically connected to said resistor element.

A resistor comprising:

• a resistor made of metal sheet:
• an insulating sheet attached to at least one of top and bottom faces of said resistor element;
• and
• a metal terminal disposed at both ends of said resistor element, said terminal being electrically connected to said resistor element and having an L shape section face.

A resistor comprising:

• a resistor element made of metal sheet;
• an insulating substrate;
• and
• a metal terminal formed in a way to electrically connect top and bottom faces of said insulating substrate at both ends, said terminal on the top face of said insulating substrate being electrically connected to said resistor element.

A resistor comprising:

• a resistor element made of metal sheet;
• an insulating substrate;
• and
• four metal terminals formed in a way to electrically connect top and bottom faces of said insulating substrate, said terminal on a top face of said insulating, substrate being electrically connected to said resistor element.

A resistor comprising:

• a metal resistor element having a notch near both ends;
• and
• a metal terminal disposed at both ends of said resistor element, said terminal having a protrusion corresponding to said notch;
• wherein said resistor element and said terminal are electrically connected at least through said protrusion and said notch.

A resistor comprising:

• a metal resistor element having at least two through holes;
• and
• a metal terminal having at least one protrusion with a same shape as said through holes;
• wherein at least one protrusion of said terminal is inserted to at least one through hole of said resistor element, and at least one face of said terminal is electrically connected to said resistor element.

A method for manufacturing a resistor comprising:

• forming a resistor element made of metal sheet, said resistor element having a shape adjusted to obtain a predetermined resistance;
• forming a block of metal terminal having a concave groove;
• and
• electrically connecting said terminal and said resistor element by fitting said concave groove of said terminal to both ends of said resistor element.

A method for manufacturing a resistor comprising:

• forming a resistor element made of metal wire, said resistor element being adjusted to obtain a predetermined resistance;
• machining said resistor element into a predetermined shape;
• forming a block of metal terminal having a concave groove;
• and
• electrically connecting said terminal and said resistor element by fitting said concave groove of said terminal to both ends of said resistor element.

A method for manufacturing a resistor comprising:

• forming a terminal made of a metal foil pattern with a predetermined shape, top and bottom faces of said terminal being electrically connected to a part of top, side, and bottom faces of an insulating substrate;
• dividing said insulating substrate into a predetermined shape;
• forming a metal resistor element, said resistor element having a shape adjusted to obtain a predetermined resistance;
• electrically connecting said resistor element to the metal foil pattern on the top face of said insulating substrate.

A method for manufacturing a resistor comprising:

• forming a metal resistor element, said resistor element being adjusted to obtain a predetermined resistance;
• forming a block of metal terminal having at least one protrusion;
• creating at least two through holes at a predetermined position of said resistor element;
• inserting at least one of said protrusion into at least one of said through hole;
• bending an open side of said terminal to hold said resistor in a thickness direction;
• and
• electrically connecting said resistor element and said terminal.

A method for manufacturing a resistor comprising:

• a metal resistor element, said resistor element having a shape adjusted to obtain a predetermined resistance;
• forming one of a notch and groove at a predetermined position of said resistor element;
• forming a block of metal terminal with a predetermined shape, said terminal having at least one protrusion;
• sandwiching said resistor element with said terminal, and inserting said protrusion into one of said notch and groove;
• and
• electrically connecting said resistor element and said terminal.

A method for manufacturing a resistor comprising:

• a resistor element made of metal sheet, said resistor element having a shape adjusted to obtain a predetermined resistance, and having one of at least two through holes, notches, grooves, and cavities;
• forming a terminal made of metal strip, said terminal being one of sandwiched and folded on top, bottom, and side faces at both ends of said resistor element, and a part of metal being inserted and fixed to one of said through holes, notches, grooves, and cavities of said resistor element;
• and
• electrically connecting said resistor element and said terminal.

A resistor comprising:

• a resistor element made of metal sheet;
• a concave terminal whose entire face is coated with metal having a low melting point, said terminal being disposed at both ends of said resistor element through a groove of said terminal, and being electrically connected to said resistor element through said metal having a low melting point in said grove;
• and
• an insulating film covering entire face of said resistor element excluding said terminal.

A method for manufacturing a resistor comprising:

• a first step of forming a terminal by processing a concave metal terminal and then coating entire face of said terminal with metal having a low melting point;
• a second step of forming a resistor element made of metal sheet whose shape is adjusted to obtain a predetermined resistance;
• a third step of electrically connecting said resistor element and said terminal by cold forging said terminal after covering both ends of said resistor element with said terminal, heating, and cooling;
• a fourth step of forming an insulating protective film having a predetermined shape on entire face of said resistor element excluding said terminal.