One of the basic parameters in mounting power resistors is the height of the resistor body in relation to the PCB. Therefore, many companies maintain activities to pre-form the components originally purchased in axial style; clearly this activity does not add value to their business.
The solution found by suppliers was a pre-formed resistor, with leads pressed along a specific part of its length. The advantages of such a resistor, known also as 'cropped' and 'formed', are mainly the elimination of the pre-forming step in the assembly line and the fixation of the height between the resistor body and the PCB. Nevertheless, this solution does not eliminate completely the risk that the resistor comes off the PCB during handling in the assembly line. For this reason many technicians force the pressed part of the lead against the hole of the PCB, which may bend the leads or even damage the component, not to mention the possible damage to the PCB.
Taking into account the most important requirements in the assembly of power resistors, Phoenix Passive Components engineers developed the Double Kink pre-form, which offers the best performance in combination with high cost-effectiveness. Besides eliminating one step in the production line, thereby adding value to the business, its design has two basic functions: the first is to determine and fix the height of the resistor body, protecting the PCB and the solder points from the heat caused by the power dissipation; and the second function is to lock the product on the board (snap-in), eliminating the risk of loose products falling out of the board. The ends of the leads are designed to provide easy insertion through the holes of the board until the resistor locks.
The precision of the Double Kink pre-form, approved and in use by many customers, is ensured by modern equipment and by strict quality control. It is available for wirewound and film resistors, from 0,33 to 7 W, with flexibility in height and pitch.
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