CN111276307B - Resistor manufacturing method and resistor - Google Patents
Resistor manufacturing method and resistor Download PDFInfo
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- CN111276307B CN111276307B CN202010142224.1A CN202010142224A CN111276307B CN 111276307 B CN111276307 B CN 111276307B CN 202010142224 A CN202010142224 A CN 202010142224A CN 111276307 B CN111276307 B CN 111276307B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
- B05C1/02—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to separate articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
- B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
- B05C11/1042—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material provided with means for heating or cooling the liquid or other fluent material in the supplying means upstream of the applying apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
- B05C11/11—Vats or other containers for liquids or other fluent materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
- B05C9/06—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying two different liquids or other fluent materials, or the same liquid or other fluent material twice, to the same side of the work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
- B05C9/08—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying liquid or other fluent material and performing an auxiliary operation
- B05C9/14—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying liquid or other fluent material and performing an auxiliary operation the auxiliary operation involving heating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0209—Multistage baking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0254—After-treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C1/00—Details
- H01C1/02—Housing; Enclosing; Embedding; Filling the housing or enclosure
- H01C1/034—Housing; Enclosing; Embedding; Filling the housing or enclosure the housing or enclosure being formed as coating or mould without outer sheath
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
- H01C17/02—Apparatus or processes specially adapted for manufacturing resistors adapted for manufacturing resistors with envelope or housing
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
- H01C7/006—Thin film resistors
Abstract
The invention relates to the technical field of electronic devices, in particular to a resistor manufacturing method and a resistor, wherein packaging equipment used by the manufacturing method comprises a rack, a coating barrel, a position continuing wheel, a motor and a controller; a chain type conveyor belt is arranged on the rack; one end of the chain type conveying belt is provided with a successive position wheel, and a coating cylinder is arranged below the chain type conveying belt; a coating groove is arranged below the coating cylinder, and a limiting cylinder is arranged above the coating cylinder; at present, the gravity of a resistor body is generally utilized to act with a coating cylinder, so that the resistor body generates relative displacement in the process of coating the coating cylinder in rolling contact with the resistor body, and the quality of a coated paint film is influenced; therefore, the resistor body in the coating process is pressed between the limiting cylinder and the coating cylinder through the limiting cylinder arranged above the coating cylinder, and the quality of a paint film coated on the resistor body is improved through the heating pre-curing process and the secondary packaging coating curing after the paint film is coated.
Description
Technical Field
The invention relates to the technical field of electronic devices, in particular to a resistor manufacturing method and a resistor.
Background
The metal film resistor is one of film resistors. The method is characterized in that a high-temperature vacuum coating technology is adopted to closely attach nickel chromium or similar alloy on the surface of a porcelain rod to form a membrane, the membrane is cut and debugged to achieve the final required precise resistance value, then a proper connector is added for cutting, and epoxy resin is coated on the surface of the membrane for sealing protection to obtain the ceramic rod; because it is a lead wire type resistor, it is convenient for manual installation and maintenance, and can be used in most domestic electric appliances, communication and instruments and meters.
The outer layer protection paint film of the metal film resistor has defects, the paint protection film is easy to be permeated by moisture under the action of points, thermal stress and damp-heat environment, when the moisture is immersed into the paint film, electrolysis is caused under electrical load, particularly, the influence on the thread-shaped high-resistance film resistor is larger, a large potential gradient is formed in the gap between thread turns, and the film layer is thin and easy to be damaged by electrolysis, thereby influencing the quality and the service life of the metal film resistor.
Some resistor manufacturing methods and resistor technical solutions also appear in the prior art, for example, a chinese patent with application number 2009100684861 discloses a packaging process method of high temperature and high humidity resistant paint for metal film resistors; the method comprises the following steps that a universal chain type resistor automatic coating type packaging line is used, a metal film resistor is packaged for the first time and then enters a first heating tank at 140 ℃ for precuring for 2min, then enters a second heating tank at 170 ℃ or 190 ℃ for curing for 2min, then is packaged for the second time, and is cured for 2min at 170 ℃ or 190 ℃, and after the two times of packaging and corresponding curing and drying are completed, the resistor enters the next production procedure; the metal film resistor produced by the technical scheme has better high temperature resistance and high humidity resistance; this solution does not solve the quality problems caused by the unevenness of the paint film applied during the resistor encapsulation.
In view of the above, in order to overcome the above technical problems, the present inventors have designed and developed a resistor manufacturing method and a resistor, which uses a special paint film coating method to solve the above technical problems.
Disclosure of Invention
In order to make up for the defects of the prior art, the resistor manufacturing method and the resistor provided by the invention have the advantages that the limiting cylinder is arranged above the coating cylinder, the relative height position of the limiting cylinder and the coating cylinder is controlled, so that the resistor body in the coating process is pressed between the limiting cylinder and the coating cylinder, the coating is coated on the surface of the resistor body with uniform force, and the quality of a paint film coated on the resistor body is improved through a heating pre-curing process and secondary packaging coating curing after the paint film is coated.
The invention relates to a resistor manufacturing method, which comprises the following steps:
s1: taking the surface of a ceramic material as an insulating substrate, firstly depositing a metal bottom layer on the insulating substrate as a substrate of a metal film, depositing a resistance alloy by adopting a magnetron sputtering rolling type, and then placing a resistance blank forming a film layer into a high-temperature furnace at the temperature of 500-; the resistor film layer prepared by the sputtering method is subjected to heat treatment, so that the effects of annealing, condensation, diffusion and oxidation are achieved, the internal stress of the film layer is eliminated, the thickness of the film layer is uniform, and the adhesive force and the mechanical strength of the film layer are improved;
s2: after the heat treatment of the resistor in the S1 is finished, installing lead caps and welding pins at two ends of the resistor, notching the resistor film layer and aging the resistor film layer by selecting the resistance value of the manufactured resistor, and then carrying out secondary sorting on the resistance value to prepare the resistor body with the required resistance value; the installed lead cap is convenient for welding pins, and meanwhile, the influence of vibration of the pins at two ends of the resistor on the packaging and sealing effect of the resistor body is avoided;
s3: selecting the resistor prepared in S2, painting and sealing the resistor body part of the resistor through packaging equipment, pre-curing at 140 ℃ to enable the paint to reach a gel state, performing secondary packaging, performing secondary curing at 170-180 ℃, drying and marking the packaged paint film, and obtaining a finished product of the resistor after inspection;
the packaging equipment in the S3 comprises a rack, a paint cylinder, a position continuing wheel, a motor and a controller; a chain type conveyor belt is arranged on the rack; the pins at two ends of the resistor are guided and limited by the concave parts connected with the chains on the chain type conveyor belt, the resistor is conveyed to the position of a paint film to be coated by the chain type conveyor belt, one end of the chain type conveyor belt is provided with a continuous position wheel, and a coating material cylinder is arranged below the chain type conveyor belt; the continuous position wheel is positioned between two chains of the chain type conveyor belt and is rotatably arranged on the rack; a coating groove is arranged below the coating material cylinder, the lower part of the coating material cylinder enters the coating material in the coating groove, a limiting cylinder is arranged above the coating material cylinder, a compression resistor is matched between the coating material cylinder and the limiting cylinder to package the coating material, and two ends of a cylinder shaft of the coating material cylinder are rotatably arranged on supporting rods on the side wall of the coating groove; two ends of the limiting cylinder are provided with brackets, and a cylinder shaft of the limiting cylinder is rotatably arranged on the brackets; the two ends of the support rod and the support are arranged on the rack through a screw pair, and the relative heights of the coating cylinder and the limiting cylinder are controlled by adjusting the lifting of the support rod and the support on the rack; the frame and the bracket are provided with motors; the motor respectively drives the coating cylinder, the successive position wheel, the limiting cylinder, the conveying belt and the screw rod pair to move; the controller controls the operation of the motor; when in use, the controller is started, the chain conveyor belt moves the resistor to be coated and packaged to the paint film coating area, the pins extending out of the two ends of the resistor enable the resistor to be uniformly distributed in the concave parts of the chain conveyor belt, when the length of the chain conveyor belt is longer, the stability of the horizontal plane of the chain conveyor belt is difficult to ensure, the middle part of the chain slightly sags, so that the relative position of each resistor body on the horizontal plane is different, which in turn affects the quality of the paint film coating of the resistor body, the successive position wheels are arranged between the chain type conveyor belts to connect the chain type conveyor belts of one section, so that the position interference of the longer chain type conveyor belt to the resistor processing engineering is avoided, the heights of the coating cylinder and the limiting cylinder are adjusted by driving the screw pair through the motor so as to be suitable for coating paint films of resistor bodies of different types, and after coating is finished, the resistor is conveyed to a hot curing area through a conveyor belt and is subjected to a secondary packaging and curing process; at present, paint films are coated on the resistor bodies by adopting the paint cylinders which are independently arranged below the conveyor belt, and the gravity of the resistor bodies is used for acting with the paint cylinders, so that the resistor bodies can generate relative displacement in the process of rolling contact coating of the paint cylinders and the resistor bodies, and further the quality of the coated paint films is influenced; therefore, the limiting cylinder arranged above the paint cylinder is utilized, the lead screw pair on the rack is adjusted to rotate through the motor, the relative height position of the limiting cylinder and the paint cylinder is further controlled, the resistor body in the coating process is pressed between the limiting cylinder and the paint cylinder, the paint is coated on the surface of the resistor body with uniform force, and the quality of a paint film coated on the resistor body is improved through a heating pre-curing process and secondary packaging coating curing after the paint film is coated.
Preferably, a heating layer is arranged at the bottom of the coating tank, a wrinkle layer is arranged on the inner wall of the bottom of the coating tank, and a filling pipe is arranged on the side wall of the coating tank; the filling pipe is communicated to the coating tank, and the filling pipe controls the filling of the coating through a ball float valve; when the paint coating device is used, the paint cylinder is driven by the motor to rotate and leach a proper amount of paint to coat the resistor body, the temperature of the paint film is required to be controlled to be in a proper range due to the influence of the coating performance of the paint, the temperature of the paint is kept for different use environments through the heating layer arranged at the bottom of the paint tank, the heating area of the heating layer for the paint is increased through the arranged wrinkle layer, the heat preservation effect is improved, the ball float valve arranged at the nozzle of the filling pipe controls the paint in the paint tank to be at a constant liquid level height, the stability of the amount of the paint leached by the paint cylinder is maintained, and the quality of the paint film coated on the resistor body is improved.
Preferably, the middle sections of the cylinder surfaces of the coating cylinder and the limiting cylinder are protruded, and the height positions of the bracket and the support rod are adjusted through the rotation of the screw pair, so that the two ends of the coating cylinder and the limiting cylinder correspond to the protruded parts of the lead caps on the resistor; when the paint film coating device is used, when the paint film is coated on the resistor, the resistor body is required to be positioned in the middle of the chain type conveyor belt, so that paint can be well coated on the resistor body, the operation of the lead screw pair is controlled by the controller, the height positions of the paint coating barrel and the limiting barrel are adjusted, the paint film is coated on the resistor body in a rolling contact mode, the resistor body is matched with the lead caps arranged at the two ends of the resistor body in an installing and rotating mode through the bulges arranged in the middle of the surfaces of the paint coating barrel and the limiting barrel, the resistor is always positioned in the middle of the paint coating barrel in the paint film coating process, and the quality of the paint film coated on the resistor body is improved.
Preferably, a heater is arranged inside the limiting cylinder, and the cylinder body of the limiting cylinder is made of metal materials; the heater is controlled by the controller, and the temperature of the cylinder body of the limiting cylinder is increased to be in a range of minus DEG C by heating of the heater; when the coating is used, the coating coated with the resistor body is conveyed to the heating groove through the conveyor belt to be solidified, the coating is influenced by natural cooling in the conveying process, an annealing effect is generated, the annealing of the paint film layer after primary packaging can influence the paint film adhesion effect of secondary coating, and the energy of secondary heating of the heating groove is wasted; through setting up the heater on spacing section of thick bamboo, kept the paint film heat of coating on the resistive element, reduced thermal scattering and disappearing in the transmission course for when the resistive element transmits to the heated bath, directly carry out the solidification that keeps warm, need not reheating, influence when having avoided coating the paint film to secondary encapsulation has improved the paint film adhesion effect of coating on the resistive element, has promoted the paint film quality of coating on the resistive element then.
Preferably, two ends of the bracket are provided with springs; two ends of the spring are respectively fixed on the bracket and the rack; when the coating machine is used, the coating material cylinder and the limiting cylinder coat the resistor body with the coating material through rotation, and when the resistor on the conveyor belt needs to be adjusted in position through the middle bulge of the cylinder surface of the coating material cylinder, the coating material cylinder and the limiting cylinder which are rigidly fixed on the rack through the lead screw pair can directly cause extrusion damage to the resistor; and the spring arranged on the support enables the limiting cylinder to buffer direct extrusion on the resistor when contacting the resistor at the position to be adjusted, meanwhile, the fixing effect of the limiting cylinder on the resistor in the paint film coating is kept, and the paint film quality coated on the resistor is improved.
Preferably, the successive position wheel comprises a cylinder body and gear teeth; the gear teeth are rotatably arranged on the cylinder body; the upper surface of the cylinder body is provided with densely distributed through holes, and an air heater is arranged in the cylinder body; during the use, the continuous position wheel transmits the resistor on the chain conveyor belt to the curing area and carries out drying treatment, and through the through-hole on the air heater and the barrel surface of setting in the continuous position wheel barrel, make hot-blast blow to the resistor on the continuous position wheel by the through-hole on, directly carry out drying treatment to the coating film layer that has just coated, reduced follow-up solidification drying time, promoted the efficiency of coating the paint film on the resistor body.
A resistor, this resistor is suitable for the above-mentioned resistor manufacturing approach, there is metal film that is deposited on the organism of the said resistor, the outer layer of the resistor is coated with the lacquer protective film used for capsulating, the both ends of the resistor are fitted with the terminal cap; a connecting pole body is arranged in the wiring cap; the pins are fixed on the connecting pole body; the connecting pole body is in a circular truncated cone shape, and the metal film is communicated with the pins at two ends of the connecting pole body to form the whole resistor; during the use, under the resistor is in the point, thermal stress and the hot environment effect of tide, especially in the pin department at resistor both ends, the easy infiltration of moisture of lacquer protection film seal is not enough, influences the result of use of resistor then, through setting up the wiring cap at resistor both ends, the connection utmost point body that sets up in the wiring cap is connected the pin with the dipolar of resistor, has avoided the lacquer protection film direct seal not enough condition when resistor and pin junction, has guaranteed the paint film quality of coating on the resistor.
The invention has the following beneficial effects:
1. according to the invention, the limiting cylinder is arranged above the coating cylinder, the resistor body in the coating process is tightly pressed between the limiting cylinder and the coating cylinder by controlling the relative height position of the limiting cylinder and the coating cylinder, and the quality of a paint film coated on the resistor body is improved by a heating pre-curing process and secondary packaging coating curing after the paint film is coated; the heating layer and the fold layer are arranged at the bottom of the coating tank, so that the heat preservation effect on the coating is achieved, the ball float valve arranged at the pipe opening of the filling pipe controls the liquid level height in the coating tank, the stability of the amount of the coating leached by the coating cylinder is maintained, and the quality of a paint film coated on the resistor body is improved.
2. The resistor is positioned at the middle position of the coating cylinder in the process of coating a paint film by the matching of the bulges arranged at the middle parts of the surfaces of the coating cylinder and the limiting cylinder and the lead caps arranged at the two ends of the resistor body; the spring arranged on the support buffers the direct extrusion of the limiting cylinder on the resistor, simultaneously keeps the fixing effect of the resistor body, and improves the quality of a paint film coated on the resistor body.
3. According to the invention, the hot air blower arranged in the barrel of the successive wheel is used for directly drying the paint film layer which is just coated, so that the time for subsequent curing and drying is reduced; the heater arranged on the limiting cylinder keeps the heat of a paint film coated on the resistor body, improves the paint film adhesion effect coated on the resistor body, and improves the paint film quality coated on the resistor body.
Drawings
The invention is further described with reference to the following figures and embodiments.
FIG. 1 is a flow chart of a method of the present invention;
FIG. 2 is a perspective view of the packaging apparatus of the present invention;
FIG. 3 is a perspective view of a component of the packaging apparatus of the present invention;
FIG. 4 is a cross-sectional view of a component of the packaging apparatus of the present invention;
FIG. 5 is a perspective view of the neutral wheel of the present invention;
FIG. 6 is a cross-sectional view of the indexing wheel of the present invention;
FIG. 7 is a schematic diagram of the structure of the resistor of the present invention;
in the figure: the coating machine comprises a machine frame 1, a coating drum 2, a support rod 21, a successive position wheel 3, a drum body 31, gear teeth 32, a hot air blower 311, a motor 4, a conveying belt 5, a coating groove 6, a heating layer 61, a corrugated layer 62, a filling pipe 63, a limiting drum 7, a support 71, a spring 711, a heater 72, a metal film 8, a paint protective film 81, a wiring cap 82, a connecting pole body 821 and pins 83.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific embodiments.
As shown in fig. 1 to 7, a method for manufacturing a resistor according to the present invention includes the following steps:
s1: taking the surface of a ceramic material as an insulating substrate, firstly depositing a metal bottom layer on the insulating substrate as a substrate of a metal film, depositing a resistance alloy by adopting a magnetron sputtering rolling type, and then placing a resistance blank forming a film layer into a high-temperature furnace at the temperature of 500-; the resistor film layer prepared by the sputtering method is subjected to heat treatment, so that the effects of annealing, condensation, diffusion and oxidation are achieved, the internal stress of the film layer is eliminated, the thickness of the film layer is uniform, and the adhesive force and the mechanical strength of the film layer are improved;
s2: after the heat treatment of the resistor in the S1 is finished, installing lead caps and welding pins at two ends of the resistor, notching the resistor film layer and aging the resistor film layer by selecting the resistance value of the manufactured resistor, and then carrying out secondary sorting on the resistance value to prepare the resistor body with the required resistance value; the installed lead cap is convenient for welding pins, and meanwhile, the influence of vibration of the pins at two ends of the resistor on the packaging and sealing effect of the resistor body is avoided;
s3: selecting the resistor prepared in S2, painting and sealing the resistor body part of the resistor through packaging equipment, pre-curing at 140 ℃ to enable the paint to reach a gel state, performing secondary packaging, performing secondary curing at 170-180 ℃, drying and marking the packaged paint film, and obtaining a finished product of the resistor after inspection;
the packaging device in the S3 comprises a frame 1, a coating barrel 2, a successive position wheel 3, a motor 4 and a controller; a chain type conveyor belt 5 is arranged on the rack 1; the pins at the two ends of the resistor are guided and limited by the concave parts connected with the chain on the chain type conveyor belt 5, the resistor is conveyed to the position of a paint film coating by the chain type conveyor belt 5, one end of the chain type conveyor belt 5 is provided with a position continuing wheel 3, and a paint coating barrel 2 is arranged below the chain type conveyor belt 5; the continuous position wheel 3 is positioned between two chains of the chain type conveyor belt 5, and the continuous position wheel 3 is rotatably arranged on the rack 1; a coating groove 6 is arranged below the coating cylinder 2, the lower part of the coating cylinder 2 enters the coating in the coating groove 6, a limiting cylinder 7 is arranged above the coating cylinder 2, a compression resistor is matched between the coating cylinder 2 and the limiting cylinder 7 for coating encapsulation, and two ends of a cylinder shaft of the coating cylinder 2 are rotatably arranged on a support rod 21 on the side wall of the coating groove 6; two ends of the limiting cylinder 7 are provided with brackets 71, and a cylinder shaft of the limiting cylinder 7 is rotatably arranged on the brackets 71; the two ends of the support rod 21 and the support 71 are arranged on the rack 1 through a screw pair, and the relative heights of the coating cylinder 2 and the limiting cylinder 7 are controlled by adjusting the lifting of the support rod 21 and the support 71 on the rack 1; the frame 1 and the bracket 71 are provided with a motor 4; the motor 4 respectively drives the coating cylinder 2, the successive position wheel 3, the limiting cylinder 7, the conveying belt 5 and the screw pair to move; the controller controls the operation of the motor 4; when the device is used, the controller is started, the chain conveyor belt 5 conveys the resistors to be coated and packaged to the paint film coating area, the resistors are uniformly distributed in the concave parts of the chain conveyor belt 5 through the pins extending from the two ends of the resistors, when the length of the chain conveyor belt 5 is long, the stability of the horizontal plane of the chain conveyor belt 5 is difficult to ensure, the middle part of the chain slightly drops, the relative position of each resistor on the horizontal plane is different, the paint film coating quality of the resistors is further influenced, the position continuing wheel 3 is arranged between the chain conveyor belts 5 to connect the chain conveyor belts 5 of one section, the position interference of the longer chain conveyor belt 5 to the resistor processing engineering is avoided, the height of the coating barrel 2 and the height limiting barrel 7 is adjusted by driving the lead screw pair through the motor 4, the device is suitable for paint film coating of resistors of different types, and the resistors are conveyed to the thermosetting area through the conveyor belt 5 after coating is finished, and carrying out a secondary packaging and curing process; at present, a paint film is coated on the resistor body by a paint cylinder 2 which is independently arranged below a conveyor belt 5, and the gravity of the resistor body is acted with the paint cylinder 2, so that the resistor body can generate relative displacement in the process of coating the paint cylinder 2 in rolling contact with the resistor body, and further the quality of the coated paint film is influenced; therefore, the limiting cylinder 7 arranged above the coating cylinder 2 is utilized, the motor 4 is used for adjusting the rotation of the screw pair on the rack 1, the relative height position of the limiting cylinder 7 and the coating cylinder 2 is further controlled, the resistor body in the coating process is tightly pressed between the limiting cylinder 7 and the coating cylinder 2, the coating is coated on the surface of the resistor body with uniform force, and the quality of a paint film coated on the resistor body is improved through a heating pre-curing process and secondary packaging coating curing after the paint film is coated.
In one embodiment of the present invention, a heating layer 61 is provided at the bottom of the coating tank 6, a corrugated layer 62 is provided on the inner wall of the bottom of the coating tank 6, and a filling pipe 63 is provided on the side wall of the coating tank 6; the filling pipe 63 is communicated to the coating tank 6, and the filling pipe 63 controls the filling of the coating through a float valve; when the paint coating device is used, the paint cylinder 2 is driven by the motor 4 to rotatably leach a proper amount of paint to coat a resistor body, the temperature of a paint film during coating needs to be controlled to be within a proper range due to the influence of the coating performance of the paint, the temperature of the paint is kept for different use environments through the heating layer 61 arranged at the bottom of the paint groove 6, the heating area of the heating layer 61 for the paint is increased through the arranged wrinkle layer 62, the heat preservation effect is improved, the ball float valve arranged at the nozzle of the filling pipe 63 controls the paint in the paint groove 6 to be at a constant liquid level height, the stability of the amount of the paint leached by the paint cylinder 2 is maintained, and the quality of the paint film coated on the resistor body is improved.
As an embodiment of the invention, the middle sections of the cylinder surfaces of the coating cylinder 2 and the limiting cylinder 7 are convex, and the height positions of the bracket 71 and the support rod 21 are adjusted through the rotation of the screw pair, so that the two ends of the coating cylinder 2 and the limiting cylinder 7 correspond to the convex parts of the lead caps on the resistor; when the paint film coating device is used, when the paint film is coated on the resistor, the resistor body is required to be positioned in the middle of the chain type conveyor belt 5, so that paint can be well coated on the resistor body, the operation of the lead screw pair is controlled by the controller, the height positions of the paint cylinder 2 and the limiting cylinder 7 are adjusted to enable the paint cylinder and the resistor body to be in rolling contact coating of the paint film, the bulges arranged in the middle of the cylinder surfaces of the paint cylinder 2 and the limiting cylinder 7 are matched with the lead caps arranged at the two ends of the resistor body in an installing and rotating mode, the resistor is always positioned in the middle of the paint cylinder 2 in the paint film coating process, and the paint film quality coated on the resistor body is improved.
As an embodiment of the present invention, a heater 72 is disposed inside the limiting cylinder 7, and the cylinder 31 of the limiting cylinder 7 is made of a metal material; the heater 72 is controlled by the controller, and the heating of the heater 72 enables the temperature of the cylinder body 31 of the limiting cylinder 7 to rise to the range of 140 ℃ and 170 ℃; when the coating is used, the coating coated with the resistor body is conveyed to the heating groove through the conveyor belt 5 to be solidified, the coating is influenced by natural cooling in the conveying process, an annealing effect is generated, the annealing of the paint film layer after primary packaging can influence the paint film adhesion effect of secondary coating, and the energy of secondary heating of the heating groove is wasted; through the heater 72 arranged on the limiting cylinder 7, the heat of the paint film coated on the resistor body is kept, the heat loss in the transmission process is reduced, the resistor body is directly subjected to heat preservation and solidification when being transmitted to the heating groove, reheating is not needed, the influence on secondary packaging and paint film coating is avoided, the paint film adhesion effect coated on the resistor body is improved, and the paint film quality coated on the resistor body is improved.
As an embodiment of the present invention, the bracket 71 is provided with springs 711 at both ends; two ends of the spring 711 are respectively fixed on the bracket 71 and the frame 1; when the coating device is used, the coating barrel 2 and the limiting barrel 7 coat the coating on the resistor body through rotation, and when the position of the resistor on the conveyor belt 5 needs to be adjusted through the middle bulge of the barrel surface of the coating barrel 2, the coating barrel 2 and the limiting barrel 7 which are rigidly fixed on the rack 1 through the lead screw pair can directly cause extrusion damage to the resistor; and the spring 711 arranged on the bracket 71 ensures that when the limiting cylinder 7 contacts the resistor at the position to be adjusted, the spring 711 buffers the direct extrusion of the resistor, and simultaneously, the fixing effect of the limiting cylinder 7 on the resistor in the paint film to be coated is maintained, and the paint film quality coated on the resistor is improved.
As an embodiment of the present invention, the successive position wheel 3 includes a cylinder 31 and gear teeth 32; the gear teeth 32 are rotatably arranged on the cylinder 31; densely distributed through holes are formed in the upper surface of the cylinder 31, and an air heater 311 is arranged in the cylinder 31; during the use, continuation wheel 3 transmits the resistor on chain conveyor 5 to the curing zone and carries out drying process, through setting up air heater 311 and the barrel 31 on the surface in continuation wheel 3 barrel 31, makes hot-blast blow to the resistor on continuation wheel 3 by the through-hole, directly carries out drying process to the coating film layer that just has coated, has reduced follow-up solidification drying time, has promoted the efficiency of coating the paint film on the resistor body.
A resistor, which is suitable for the above resistor manufacturing method, has a body on which a metal film 8 is deposited, an outer layer of the resistor is coated with a varnish protective film 81 for encapsulation, and both ends of the resistor are mounted with terminal caps 82; a connecting pole body 821 is arranged in the wiring cap 82; the pin 83 is fixed on the connecting pole body 821; the connecting pole body 821 is in a circular truncated cone shape, and the metal film 8 and the pins 83 are communicated by two ends of the connecting pole body 821 to form the whole resistor; when the resistor is used, under the action of points, thermal stress and hot tide environment, particularly at the pins 83 at two ends of the resistor, the paint protective film 81 is not sealed enough and is easy to permeate moisture, so that the using effect of the resistor is affected, the connecting pole body 821 arranged in the connecting cap 82 connects the pins 83 with two poles of the resistor through the connecting caps 82 arranged at two ends of the resistor, the condition that the sealing is not enough when the paint protective film 81 is directly sealed at the connecting part of the resistor and the pins 83 is avoided, and the paint film quality coated on the resistor is ensured.
When the device is used, the controller is started, the chain conveyor belt 5 conveys the resistors to be coated and packaged to the paint film coating area, the resistors are uniformly distributed in the concave parts of the chain conveyor belt 5 through the pins extending from the two ends of the resistors, when the length of the chain conveyor belt 5 is long, the stability of the horizontal plane of the chain conveyor belt 5 is difficult to ensure, the middle part of the chain slightly drops, the relative position of each resistor on the horizontal plane is different, the paint film coating quality of the resistors is further influenced, the position continuing wheel 3 is arranged between the chain conveyor belts 5 to connect the chain conveyor belts 5 of one section, the position interference of the longer chain conveyor belt 5 to the resistor processing engineering is avoided, the height of the coating barrel 2 and the height limiting barrel 7 is adjusted by driving the lead screw pair through the motor 4, the device is suitable for paint film coating of resistors of different types, and the resistors are conveyed to the thermosetting area through the conveyor belt 5 after coating is finished, and carrying out a secondary packaging and curing process; the limiting cylinder 7 arranged above the paint cylinder 2 is utilized, the screw pair on the rack 1 is adjusted to rotate through the motor 4, and then the relative height position of the limiting cylinder 7 and the paint cylinder 2 is controlled, so that a resistor body in the coating process is tightly pressed between the limiting cylinder 7 and the paint cylinder 2, the paint is coated on the surface of the resistor body with uniform force, and the quality of a paint film coated on the resistor body is improved through a heating pre-curing process and secondary packaging coating curing after the paint film is coated; the heating layer 61 arranged at the bottom of the coating tank 6 keeps the temperature of the coating aiming at different use environments, the arranged fold layer 62 increases the heating area of the heating layer 61 to the coating, improves the heat preservation effect, and the float valve arranged at the orifice of the filling pipe 63 controls the coating in the coating tank 6 to be at a constant liquid level height, thereby maintaining the stability of the amount of the coating leached by the coating cylinder 2; the bulges arranged in the middle of the surfaces of the coating cylinder 2 and the limiting cylinder 7 are matched with the lead caps arranged at the two ends of the resistor body, so that the resistor is always positioned in the middle of the coating cylinder 2 in the process of coating a paint film; the heater 72 arranged on the limiting cylinder 7 keeps the heat of the paint film coated on the resistor body, reduces the heat loss in the transmission process, directly carries out heat preservation and solidification when the resistor body is transmitted to the heating groove, does not need to be heated again, avoids the influence on the paint film coating in secondary packaging, and improves the paint film adhesion effect coated on the resistor body; the spring 711 is arranged on the bracket 71, so that when the limiting cylinder 7 contacts the resistor at the position to be adjusted, the direct extrusion of the resistor is buffered by the spring 711, and the fixing effect of the limiting cylinder 7 on the resistor in the coating paint film is maintained; the hot air blower 311 arranged in the cylinder 31 of the successive position wheel 3 and the through holes on the surface of the cylinder 31 blow hot air to the resistor on the successive position wheel 3 through the through holes, and directly dry the paint film layer which is just coated, so that the subsequent curing and drying time is reduced, and the paint film coating efficiency on the resistor is improved.
The foregoing illustrates and describes the principles, general features, and advantages of the present invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (7)
1. A method of manufacturing a resistor, comprising the steps of:
s1: taking the surface of a ceramic material as an insulating substrate, firstly depositing a metal bottom layer on the insulating substrate as a substrate of a metal film, depositing a resistance alloy by adopting a magnetron sputtering rolling type, and then placing a resistance blank forming a film layer into a high-temperature furnace at the temperature of 500-;
s2: after the heat treatment of the resistor in the S1 is finished, installing lead caps and welding pins at two ends of the resistor, notching the resistor film layer and aging the resistor film layer by selecting the resistance value of the manufactured resistor, and then carrying out secondary sorting on the resistance value to prepare the resistor body with the required resistance value;
s3: selecting the resistor prepared in S2, painting and sealing the resistor body part of the resistor through packaging equipment, pre-curing at 140 ℃ to enable the paint to reach a gel state, performing secondary packaging, performing secondary curing at 170-180 ℃, drying and marking the packaged paint film, and obtaining a finished product of the resistor after inspection;
the packaging equipment in the S3 comprises a rack (1), a paint barrel (2), a position continuing wheel (3), a motor (4) and a controller; a chain type conveyor belt (5) is arranged on the rack (1); the pins at two ends of the resistor are guided and limited by the concave parts connected with the chains on the chain type conveyor belt (5), the resistor is conveyed to the position of a paint film to be coated by the chain type conveyor belt (5), a position continuing wheel (3) is arranged at one end of the chain type conveyor belt (5), and a coating cylinder (2) is arranged below the chain type conveyor belt (5); the continuous position wheel (3) is positioned between two chains of the chain type conveyor belt (5), and the continuous position wheel (3) is rotatably arranged on the rack (1); a coating groove (6) is arranged below the coating cylinder (2), the lower part of the coating cylinder (2) enters the coating in the coating groove (6), a limiting cylinder (7) is arranged above the coating cylinder (2), a compression resistor is matched between the coating cylinder (2) and the limiting cylinder (7) to package the coating, and two ends of a cylinder shaft of the coating cylinder (2) are rotatably arranged on a support rod (21) on the side wall of the coating groove (6); two ends of the limiting cylinder (7) are provided with brackets (71), and a cylinder shaft of the limiting cylinder (7) is rotatably arranged on the brackets (71); the two ends of the support rod (21) and the support (71) are arranged on the rack (1) through a screw rod pair, and the relative heights of the coating cylinder (2) and the limiting cylinder (7) are controlled by adjusting the lifting of the support rod (21) and the support (71) on the rack (1); the frame (1) and the bracket (71) are provided with motors (4); the motor (4) drives the packaging equipment to run; the controller controls the operation of the motor (4).
2. A resistor manufacturing method according to claim 1, wherein: a heating layer (61) is arranged at the bottom of the coating tank (6), a wrinkle layer (62) is arranged on the inner wall of the bottom of the coating tank (6), and a filling pipe (63) is arranged on the side wall of the coating tank (6); the filling pipe (63) is communicated to the coating tank (6), and the filling pipe (63) controls the filling of the coating through a float valve.
3. A resistor manufacturing method according to claim 1, wherein: the middle sections of the surfaces of the coating cylinder (2) and the limiting cylinder (7) are protruded, and the height positions of the bracket (71) and the support rod (21) are adjusted through the rotation of the screw rod pair, so that the two ends of the coating cylinder (2) and the limiting cylinder (7) correspond to the protruded parts of the lead caps on the resistor.
4. A resistor manufacturing method according to claim 3, wherein: a heater (72) is arranged in the limiting cylinder (7), and a cylinder body (31) of the limiting cylinder (7) is made of a metal material; the heater (72) is controlled by the controller, and the heating of the heater (72) enables the temperature of the cylinder body (31) of the limiting cylinder (7) to rise to the range of 140 ℃ and 170 ℃.
5. A resistor manufacturing method according to claim 3, wherein: springs (711) are arranged at two ends of the support (71); two ends of the spring (711) are respectively fixed on the bracket (71) and the frame (1).
6. A resistor manufacturing method according to claim 1, wherein: the continuous position wheel (3) comprises a cylinder body (31) and gear teeth (32); the gear teeth (32) are rotatably arranged on the cylinder body (31); the upper surface of the cylinder body (31) is provided with densely distributed through holes, and the inside of the cylinder body (31) is provided with an air heater (311).
7. A resistor adapted for use in the method of manufacturing a resistor according to any one of claims 1 to 6, wherein: a metal film (8) is deposited on the resistor body, the outer layer of the resistor is coated with a paint protective film (81) for packaging, and two ends of the resistor are provided with wiring caps (82); a connecting pole body (821) is arranged in the wiring cap (82); the pin (83) is fixed on the connecting pole body (821); the connecting pole body (821) is in a circular truncated cone shape, and the metal film (8) and the pins (83) are communicated at two ends of the connecting pole body (821) to form the whole resistor.
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