CN104966598A - Current-limiting resistor and film forming method and manufacturing method thereof - Google Patents
Current-limiting resistor and film forming method and manufacturing method thereof Download PDFInfo
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- CN104966598A CN104966598A CN201510364133.1A CN201510364133A CN104966598A CN 104966598 A CN104966598 A CN 104966598A CN 201510364133 A CN201510364133 A CN 201510364133A CN 104966598 A CN104966598 A CN 104966598A
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Abstract
The invention discloses a current-limiting resistor and a film forming method and a manufacturing method thereof, and relates to the manufacturing technology of resistors, in particular to an initiating explosive device current-limiting resistor capable of withstanding a 200-time rated power load and a manufacturing technology of the initiating explosive device current-limiting resistor. The manufacturing technology is characterized by comprising the steps that firstly, a resistance film layer is sputtered on a ceramic bar through a magnetron sputtering method, and oxygen and argon are injected in the sputtering process; secondly, the ceramic bar sputtered with the resistance film layer is put in an environment with the temperature of 350 DEG C-450 DEG C to carry out heat treatment; thirdly, resistance regulation is carried out on the resistance film layer in the mode of carving a straight groove or not curving the groove, wherein the operation of curving the straight groove refers to the operation of carving the straight groove on the resistance film layer in the radial direction of the ceramic bar and the like.
Description
Technical field
The present invention relates to resistance manufacture craft, especially a kind of priming system current-limiting resistor of special purpose and manufacture craft thereof.
Background technology
Traditional cylindrical axial lead line metal-oxide film resistor primary structure comprises: cylindrical shaped alumina ceramic matrix, resistive layer, cap, lead-out wire and flame resistant protective layer.Resistor is an electric energy-transition element of heat energy, and it consumes electric energy and itself temperature is raised.The heat that resistor produces, a part increases temperature itself, another part with radiation, convection current, conduction three kinds of modes by disperses heat.When the heat that resistor leaves towards periphery equals the heat produced, the temperature of resistor surface just reaches balance.
And the rated power of resistor is decided by the overall dimension size of resistor own, the overall dimension of resistor is larger, and rated power is larger; Otherwise the overall dimension of resistor is less, and rated power is less.Usually, rated power is that the resistor of 1W needs to adopt the porcelain rod of Φ 3mm × 11mm as matrix.
The conventional resistor of homogeneous structure adopts the technique of traditional threading groove to carry out resistance trimming in the market, threading groove can amplify the resistance of resistor at double on the cylinder, but the conducting film of resistor narrows, the voltage being merely able to apply rated power on a resistor could long-term stable operation.Usually, when voltage exceedes 5 ~ 10 times of rated voltage, because the current density flowing through resistor conductive film layer unit are increases, resistor surface temperature sharply raises and causes resistive layer to burn inefficacy.Therefore, on market, the conventional resistor of homogeneous structure does not possess the instantaneous overload power bearing 200 times, does not lose efficacy in 200 milliseconds; And 200 milliseconds to 5 second time internal resistor fuse this characteristic.
Summary of the invention
Technical problem to be solved by this invention is: for above-mentioned Problems existing, the resistor providing a kind of new resistance manufacture craft and have this explained hereafter to manufacture.
The present invention provide firstly a kind of film build method of current-limiting resistor, comprising:
Step 1: adopt magnetically controlled sputter method to sputter resistive layer on porcelain rod, and pass into oxygen and argon gas in sputter procedure; Step 2: it is heat-treat in the environment of 350 DEG C ~ 450 DEG C that the porcelain rod of sputtering upper resistance film layer is positioned over temperature; Step 3: adopt the mode of carving straight trough or not cutting to carry out resistance trimming to resistive layer; Straight trough referred to along porcelain rod is radial on resistive layer, carved a straight trough described quarter.
Preferably, the diameter of described porcelain rod is 1.7mm, and long is 5.2mm; Or the diameter of described porcelain rod is 2.5mm, long is 8.0mm; Or the diameter of described porcelain rod is 3mm, long is 11mm; Or the diameter of described porcelain rod is 4.5mm, long is 17mm; Described porcelain rod adopts the high-temperature calcination technique of 800 DEG C ~ 1100 DEG C to make.
Further, in step 1, described sputter procedure continues 8 hours ~ 15 hours.
Further, in step 2, porcelain rod being positioned over temperature is in the environment of 350 DEG C ~ 450 DEG C 4 hours ~ 6 hours.
The present invention changes the manufacture method providing a kind of current-limiting resistor, adopts aforesaid film build method to complete the film-forming process step of resistive film.
Further, after film-forming process step, also comprise seasoned step: first carry out pulse to finished product resistance seasoned, it is seasoned then to carry out ac high-voltage; Or it is seasoned first to carry out ac high-voltage to finished product resistance, then carries out pulse seasoned.
Further, the pulse voltage adopted when described pulse is seasoned is
duration is 5 minutes; The voltage adopted when described ac high-voltage is seasoned is
duration is 5 minutes; Wherein P is the rated power of current-limiting resistor, and R is the resistance of current-limiting resistor.
Further, after described seasoned step, also comprise temperature shock screening step:
Finished product resistance is placed in-65 DEG C and 125 DEG C of temperature environments substituted, substitutes the finished product resistance of rejecting inefficacy after several times until temperature.
Present invention also offers a kind of current-limiting resistor; comprise porcelain rod; porcelain rod is coated with resistive layer; porcelain rod two ends add respectively is stamped end cap; the end cap at two ends is connected with lead-out wire; be coated with flame resistant protective layer at resistance outermost layer, described resistive layer is formed on porcelain rod by aforesaid film build method.
In sum, owing to have employed technique scheme, the invention has the beneficial effects as follows:
1. the resistive film in the present invention adopts the mode of magnetron sputtering to carry out film forming, adopts the low-resistance target of Ni and Cr contained alloy, and in sputter procedure, logical oxygen and argon gas, make film surface be oxidized, through long-time (8h ~ 15h) sputtering.Carry out 350 DEG C ~ 450 DEG C after magnetron sputtering film forming, the high-temperature heat treatment of 4 ~ 6h, film layer structure is effectively improved, eliminate the internal stress of rete, thus improve the ability of the resistance to heavy current impact of priming system current-limiting resistor rete.
2. select the porcelain rod with good heat dispersion and mechanical performance (containing AL
2o
380% ~ 90%), porcelain rod adopts the technique of high-temperature calcination (800 DEG C ~ 1100 DEG C), makes porcelain rod surface cleaning and forms recrystallization, improve the adhesive force of resistive layer and the impact capacity of resistance to big current.
3. the present invention adopts the technique of carving straight trough or not cutting, reduces the current density of priming system current-limiting resistor conductive film layer.Because priming system current-limiting resistor needs the impact of bearing big current, maximum current reaches 20A, the mode of traditional threading groove can cause electric current distribution uneven, resistive layer is burnt, and the present invention adopts the resistance trimming mode of the technique of carving straight trough or not cutting, the conduction width of rete can be increased to greatest extent, reduce the current density of resistor conductive film layer, improve the ability of resistor rete withstand large rush of current.
4, in technique, have employed the seasoned and seasoned screening of ac high-voltage of pulse, finished product 100% temperature shock is screened, and rejects the product of early failure.Guarantee that priming system current-limiting resistor is at the rated power load bearing 200 times, 200 milliseconds of change in resistance are less than ± and 5%.
Generally speaking, the present invention, under rated power is the overall dimension condition of 0.25W (Φ 1.7mm × 5.2mm), 0.5W (Φ 2.5mm × 8mm), 1W (Φ 3mm × 11mm), 2W (Φ 4.5mm × 17mm) resistor, achieves instantaneous overload power and is respectively 50W, 100W, 200W, 400W; At 200ms time internal resistance value change △ R≤± 5%; In the specific function of 0.2s ~ 5s time internal resistor fusing.
Accompanying drawing explanation
Examples of the present invention will be described by way of reference to the accompanying drawings, wherein:
Fig. 1 is structural representation of the present invention.
Fig. 2 is outline drawing of the present invention.
Fig. 3 is measurement circuit figure.
Mark in figure: 1 is cylindrical shaped alumina ceramic matrix; 2 is resistive layer; 3 is end cap; 4 is lead-out wire; 5 is flame retardant paint protective layer.
Embodiment
All features disclosed in this specification, or the step in disclosed all methods or process, except mutually exclusive feature and/or step, all can combine by any way.
Arbitrary feature disclosed in this specification, unless specifically stated otherwise, all can be replaced by other equivalences or the alternative features with similar object.That is, unless specifically stated otherwise, each feature is an example in a series of equivalence or similar characteristics.
As shown in Figure 1 and Figure 2, the priming system current-limiting resistor of special purpose provided by the invention comprises cylindrical shaped alumina ceramic rod 1, resistive layer 2, zinc-plated end cap 3, zinc-plated lead-out wire 4, flame resistant protective layer 5.Resistive layer is covered on the surface of porcelain rod 1, and the two ends of porcelain rod are crimped with end cap 3 respectively, and end cap is welded with lead-out wire 4, is coated with one deck flame retardant paint as flame resistant protective layer 5 at the outermost layer of resistance.
In a preferred embodiment of the present invention, employing be have good heat dispersion and mechanical performance porcelain rod, AL wherein
2o
3composition accounts for 80% ~ 90% of porcelain rod total weight.Different instantaneous overload power resistors, adopt the porcelain rod of different overall dimension, the resistor as 50W instantaneous overload power adopts diameter to be 1.7mm, the long rod of the porcelain for 5.2mm; The resistor of 100W instantaneous overload power adopts diameter to be 2.5mm, the long rod of the porcelain for 8.0mm; The resistor of 200W instantaneous overload power adopts diameter to be 3mm, the long rod of the porcelain for 11mm; The resistor of 400W instantaneous overload power adopts diameter to be 4.5mm, the long rod of the porcelain for 17mm.
Described porcelain rod adopts the high-temperature calcination technique of temperatures as high 800 DEG C ~ 1100 DEG C to make, and the object of high-temperature calcination is make porcelain rod surface cleaning and form recrystallization, improves the adhesive force of resistive layer and the impact capacity of resistance to big current.
Improvement of the present invention is also that adopting the film-forming process of magnetron sputtering to sputter on porcelain rod forms resistive layer.Its detailed process is:
In sputter procedure, logical oxygen and argon gas, make film surface be oxidized, and whole sputter procedure maintains 8h ~ 15h sputtering in a preferred embodiment.
After magnetron sputtering film forming, it is that the hot environment of 350 DEG C ~ 450 DEG C is heat-treated that porcelain rod is placed in ambient temperature, film layer structure is effectively improved, eliminates the internal stress of rete, improves the ability of resistor rete withstand large rush of current.
In a preferred embodiment, heat treatment time continues 4h ~ 6h.
After film forming, need to resistive layer resistance trimming with the resistance making the resistance of resistor reach needs, the present embodiment adopts the technique of carving straight trough or not cutting to carry out resistance trimming.Carving straight trough to refer to carving a straight trough along porcelain rod is radial on resistive layer, regulating the width of straight trough and then reaching the object of adjusting resistance resistance.And the mode of not cutting is exactly do not carry out cutting to resistive film, directly using the last resistance of the resistive film resistance after film forming as resistor.Because priming system current-limiting resistor needs the impact of bearing big current, maximum current reaches 20A, the mode of traditional threading groove can cause electric current distribution uneven, resistive layer is burnt, the present embodiment adopts the resistance trimming mode of carving straight trough or not cutting, the conduction width of rete can be increased to greatest extent, reduce the current density of resistor conductive film layer, improve the ability of resistor rete withstand large rush of current.
After film forming, add upper end cap at cylindrical porcelain rod two ends, on end cap, spot welding lead-out wire, finally encapsulates flame retardant paint, obtains finished product resistance.
Priming system current-limiting resistor manufacture method provided by the invention, except using above-mentioned film-forming process, is also improved follow-up experienced process and temperature shock screening technology:
Wherein experienced process is specially: carry out the seasoned and seasoned mode combined of ac high-voltage of pulse to finished product resistance and screen, in a specific embodiment, first carry out pulse to finished product resistance seasoned, uses voltage to be
5 minutes duration, then ac high-voltage carries out to finished product resistance seasoned, use voltage to be
duration is 5 minutes; In other embodiments, the order of these two kinds of sophisticated manners can be exchanged.Wherein P is resistor rated power, and R is resistor resistance.
After seasoned screening; the temperature environments again finished product resistance being placed in-65 DEG C and+125 DEG C replacements carry out temperature shock screening; in the present embodiment; the finished product resistance of early failure is rejected after 5 temperature to be done substitute; to guarantee that priming system current-limiting resistor is at the rated power load bearing 200 times, 200 milliseconds of change in resistance are less than ± and 5%.
In order to confirm technique effect of the present invention, instantaneous overload test is adopted to test the instantaneous overload performance of last resistor.
Namely instantaneous overload test is apply the rated power load of 200 times on a resistor, and the time keeps 200 milliseconds to 5 seconds.
Concrete testing program is as follows:
Instrument and meter needed for test:
1. D.C. regulated power supply: WYK-10030-H type, rated voltage is 100V, and rated current is 30A.
2. initiator resistor overload tester: YX9702A type, time controling 10ms ~ 99s is adjustable.
3. sample resistance case: 0.1 Ω ~ 0.9 Ω is adjustable.
Measurement circuit figure is D.C. regulated power supply see E in Fig. 3, figure, and Ri is sample resistance case, and Rx is tested explosive current-limiting resistor.The effect of initiator resistor overload tester: control the time being added in voltage on measured resistance device, the fusing time of record tested explosive resistor instantaneous overload.
Instantaneous overload result of the test is carried out as table 1 according to above-mentioned testing program.
Table 1 instantaneous overload test data
The current-limiting resistor that visible use the inventive method manufactures is 0.25W (Φ 1.7mm × 5.2mm) at rated power, under the overall dimension condition of 0.5W (Φ 2.5mm × 8mm), 1W (Φ 3mm × 11mm), 2W (Φ 4.5mm × 17mm) resistor, achieves instantaneous overload power and be respectively 50W, 100W, 200W, 400W; At 200ms time internal resistance value change △ R≤± 5%; In the specific function of 0.2s ~ 5s time internal resistor fusing.
The present invention is not limited to aforesaid embodiment.The present invention expands to any new feature of disclosing in this manual or any combination newly, and the step of the arbitrary new method disclosed or process or any combination newly.
Claims (10)
1. a film build method for current-limiting resistor, is characterized in that, comprising:
Step 1: adopt magnetically controlled sputter method to sputter resistive layer on porcelain rod, and pass into oxygen and argon gas in sputter procedure;
Step 2: it is heat-treat in the environment of 350 DEG C ~ 450 DEG C that the porcelain rod of sputtering upper resistance film layer is positioned over temperature;
Step 3: adopt the mode of carving straight trough or not cutting to carry out resistance trimming to resistive layer; Straight trough referred to along porcelain rod is radial on resistive layer, carved a straight trough described quarter.
2. the film build method of a kind of current-limiting resistor according to claim 1, is characterized in that, the diameter of described porcelain rod is 1.7mm, and long is 5.2mm; Or the diameter of described porcelain rod is 2.5mm, long is 8.0mm; Or the diameter of described porcelain rod is 3mm, long is 11mm; Or the diameter of described porcelain rod is 4.5mm, long is 17mm; Described porcelain rod adopts the high-temperature calcination technique of 800 DEG C ~ 1100 DEG C to make.
3. the film build method of a kind of current-limiting resistor according to claim 2, is characterized in that, in step 1, described sputter procedure continues 8 hours ~ 15 hours.
4. the film build method of a kind of current-limiting resistor according to claim 2, is characterized in that, in step 2, it is in the environment of 350 DEG C ~ 450 DEG C 4 hours ~ 6 hours that porcelain rod is positioned over temperature.
5. a manufacture method for current-limiting resistor, is characterized in that, the method in employing power 1 ~ 4 described in any one completes the film-forming process step of resistive film.
6. the manufacture method of a kind of current-limiting resistor according to claim 5, is characterized in that, after film-forming process step, also comprise seasoned step: first carry out pulse to finished product resistance seasoned, and it is seasoned then to carry out ac high-voltage; Or it is seasoned first to carry out ac high-voltage to finished product resistance, then carries out pulse seasoned.
7. the manufacture method of a kind of current-limiting resistor according to claim 6, is characterized in that, the pulse voltage adopted when described pulse is seasoned is
duration is 5 minutes; The voltage adopted when described ac high-voltage is seasoned is
duration is 5 minutes; Wherein P is the rated power of current-limiting resistor, and R is the resistance of current-limiting resistor.
8. the manufacture method of a kind of current-limiting resistor according to claim 6, is characterized in that, also comprises temperature shock screening step after described seasoned step:
Finished product resistance is placed in-65 DEG C and 125 DEG C of temperature environments substituted, substitutes the finished product resistance of rejecting inefficacy after several times until temperature.
9. a current-limiting resistor; comprise porcelain rod; porcelain rod is coated with resistive layer; porcelain rod two ends add respectively is stamped end cap; the end cap at two ends is connected with lead-out wire; be coated with flame resistant protective layer at resistance outermost layer, it is characterized in that, described resistive layer is formed on porcelain rod by the film build method in claim 1 or 3 or 4 described in any one.
10. a kind of current-limiting resistor according to claim 9, is characterized in that, the diameter of described porcelain rod is 1.7mm, and long is 5.2mm; Or the diameter of described porcelain rod is 2.5mm, long is 8.0mm; Or the diameter of described porcelain rod is 3mm, long is 11mm; Or the diameter of described porcelain rod is 4.5mm, long is 17mm; Described porcelain rod adopts the high-temperature calcination technique of 800 DEG C ~ 1100 DEG C to make.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201510364133.1A CN104966598A (en) | 2015-06-26 | 2015-06-26 | Current-limiting resistor and film forming method and manufacturing method thereof |
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| CN201510364133.1A CN104966598A (en) | 2015-06-26 | 2015-06-26 | Current-limiting resistor and film forming method and manufacturing method thereof |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107086098A (en) * | 2016-11-07 | 2017-08-22 | 蚌埠市正园电子科技有限公司 | The metalfilmresistor and its processing method of a kind of not equidistant grooves |
| CN111276307A (en) * | 2020-03-04 | 2020-06-12 | 孙文 | Resistor manufacturing method and resistor |
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| CN1050684C (en) * | 1994-04-20 | 2000-03-22 | 林自新 | Resistor with conductive film vertically cut into ring slots |
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2015
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Patent Citations (4)
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| JPS5050655A (en) * | 1973-09-06 | 1975-05-07 | ||
| CN1050684A (en) * | 1990-09-18 | 1991-04-17 | 名山县协力皮鞋厂 | Health-care shoe-pad with magnetic therapy and massage functions |
| CN1050684C (en) * | 1994-04-20 | 2000-03-22 | 林自新 | Resistor with conductive film vertically cut into ring slots |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107086098A (en) * | 2016-11-07 | 2017-08-22 | 蚌埠市正园电子科技有限公司 | The metalfilmresistor and its processing method of a kind of not equidistant grooves |
| CN111276307A (en) * | 2020-03-04 | 2020-06-12 | 孙文 | Resistor manufacturing method and resistor |
| CN111276307B (en) * | 2020-03-04 | 2021-11-26 | 深圳市三合成科技有限公司 | Resistor manufacturing method and resistor |
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