Patent ID: 6925704

Claim:
A method for making a high power resistor comprising: forming a resistor blank comprising a resistance element, a first lead, and a second lead; the resistance element having first and second opposite ends, first and second opposite side edges, a first flat surface, and a second flat surface opposite from the first flat surface; the first and second leads extending from the first and second opposite ends of the resistance element; making a pre-mold body having first and second slots fitted around the first and second opposite side edges of the resistance element and having a bottom portion engaging the first flat surface of the resistance element; depositing an electrically non conductive and heat conductive adhesive on the second flat surface of the resistance element, the adhesive having the properties of maintaining the structural integrity and adhesive capabilities of the adhesive in the temperature range of −65° C. to +275° C.; placing a heat sink in contact with the adhesive with the adhesive between the heat sink and the second flat surface of the resistance element whereby the adhesive will attach the heat sink to the second flat surface of the resistance element and will conduct heat from the resistance element to the heat sink; molding a molded body completely around the pre-molded body, the resistance element, and the adhesive, and partially around the heat sink; exposing a portion of the heat sink to the atmosphere through the molded body; whereby the heat conducting relationship of the resistance element, the adhesive and the heat sink render the resistance element capable of operating as a resistor between temperatures of from −65° C. to +275° C.