CN112824344A - 圆柱型碳陶瓷固定电阻器及其制造方法 - Google Patents

圆柱型碳陶瓷固定电阻器及其制造方法 Download PDF

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CN112824344A
CN112824344A CN202010765341.3A CN202010765341A CN112824344A CN 112824344 A CN112824344 A CN 112824344A CN 202010765341 A CN202010765341 A CN 202010765341A CN 112824344 A CN112824344 A CN 112824344A
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fixed resistor
carbon ceramic
cylindrical carbon
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曾炀
杨博
郑天翔
唐凤
刘争
张鑫凯
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BEIJING 718 YOUSHENG ELECTRONICS CO LTD
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Abstract

本发明名称为圆柱型碳陶瓷固定电阻器及其制造方法，属于电力电子的技术领域。该圆柱型碳陶瓷固定电阻器具有无电感、耐高压的性能，能耐大电流、高能量冲击，圆柱型碳陶瓷固定电阻器的独特性能，能同时满足耐高压、耐大电流、耐冲击、高能吸收的要求。适用于电力传输、电力牵引、高压脉冲电路等。

Description

圆柱型碳陶瓷固定电阻器及其制造方法
技术领域
本发明属于电力电子的技术领域，该圆柱型碳陶瓷固定电阻器适用于电力传输、电力牵引、高压脉冲电路等。
技术背景
在社会发展和科技进步的大环境下，许多电子、电力系统要求电阻器在高压、高能、大电流或高频的工作条件下具有良好的稳定性和可靠性。这些设备都是技术先进、功耗大、价格昂贵的，所以对电阻器的要求极其严苛。比如电力行业中常用的高压断路器设备、新能源交通行业的电源控制设备、通信领域的广播发射器、数字广播和电视信号传输等有着高频脉冲的数字设备、医疗科学领域的X光机、激光设备以及军事航母上的飞机弹射装置等等。常见的片式膜固定电阻器、线绕固定电阻器、玻璃釉膜固定电阻器以及圆柱型金属膜固定电阻器等已经无法满足上述电子设备或者系统的要求。
发明内容
本发明目的是针对上述不足之处，提供一种圆柱型碳陶瓷固定电阻器及其制造方法，圆柱型碳陶瓷固定电阻器具有无电感、耐高压的性能，能耐大电流、高能量冲击，圆柱型碳陶瓷固定电阻器的独特性能，能同时满足耐高压、耐大电流、耐冲击、高能吸收的要求。
圆柱型碳陶瓷固定电阻器及其制造方法采取以下技术方案实现：
圆柱型碳陶瓷固定电阻器是采用氧化铝、二氧化硅、蒙脱石、长石、石墨为主料，经过球磨，加入粘结剂造粒，干压成型，烧结，端面喷涂金属电极制成；其中原材料重量百分比配比为：
Figure BSA0000215676980000011
所述粘结剂为硅酸钠、聚醋酸乙烯醇、聚乙烯醇、甲基纤维素中的一种及其混合物。
圆柱型碳陶瓷固定电阻器的制造方法如下：
将原材料氧化铝、二氧化硅、蒙脱石、长石、石墨、粘结剂按重量百分比称量好倒入球磨罐中，倒入与原材料重量相等的酒精，然后放进球磨机内球磨16～48小时，球磨完成后放入恒温水浴锅中烘干；烘干完成后加入用粘结剂配制成的粘结剂水溶液进行造粒，造粒完成后的粉料过60目筛，在过筛料中加入3％～8％的水，混合均匀后陈腐10～15分钟，装入目标尺寸的圆柱型压制成型模具中，然后使用液压成型机设定合适压力压成生坯；将压力成型的生坯在1200℃～1500℃的保护气氛中烧成圆柱型碳陶瓷固定电阻器坯料；冷却到常温后取出，进行端面电极金属化工序，然后在端电极上焊接铜质引线或者引脚，其余部位包封绝缘粉料，即制成圆柱型碳陶瓷固定电阻器。圆柱型碳陶瓷固定电阻器的尺寸大小可以根据设计要求选择。
所述氧化铝可采用市售氧化铝粉，粒度为200目～400目；二氧化硅可采用市售二氧化硅粉，粒度为200目～400目；蒙脱石可采用市售蒙脱石粉，粒度为200目～300目；长石可采用市售长石粉，粒度为200目～300目；石墨可采用市售石墨，粒径为300目～2000目。
圆柱型碳陶瓷固定电阻器的原材料中，氧化铝、二氧化硅、蒙脱石、长石材料构成多孔陶瓷材料，作为基体有着很好的抗热震性，石墨作为导电材料，物理化学性稳定，所以由此原材料形成的圆柱型碳陶瓷固定电阻器具有体电阻固定的无电感，使用温度高，可以耐受大冲击电流和脉冲能量，也能吸收高能量，并且在高压下工作。
本发明圆柱型碳陶瓷固定电阻器及其制造方法优点：
1、高可靠性，不存在膜类、线绕类电阻的失效现象；
2、大热容、耐高压、无感，能耐大电流冲击和吸收高能量；
3、无机材料构成化学惰性、热稳定；
4、外形尺寸可以根据用户需求定制；
5、采用陶瓷干压工艺制造，设备和工艺过程简单，便于工业化生产。
附图说明
图1为圆柱型碳陶瓷固定电阻器制造方法的工艺流程。
图2为圆柱型碳陶瓷固定电阻器外形图。
具体实施方式
为了更清楚地表述本发明，下面结合附图对本发明作进一步地描述。
第一实施例
参阅图1，本发明是一种圆柱型碳陶瓷固定电阻器及其制造方法。
配方：
Figure BSA0000215676980000021
将上述原材料氧化铝、二氧化硅、蒙脱石、长石、石墨、粘结剂称量好倒入球磨罐中，倒入与原材料重量相等的酒精，然后放进球磨机内球磨16小时，球磨完成后放入恒温水浴锅中烘干；烘干完成后加入用聚乙烯醇配制成的聚乙烯醇水溶液进行造粒，造粒完成后的粉料过60目筛，在过筛料中加入8％的水，混合均匀后陈腐10～15分钟，装入目标直径为22mm的圆柱型压制成型模具中，然后使用液压成型机设定12t压力压成生坯；将压制成型的生坯在1000℃～1500℃的保护气氛中烧成圆柱型碳陶瓷固定电阻器坯料；冷却到常温后取出，进行端面电极金属化工序，然后在端电极上焊接铜质引脚，其余部位包封绝缘粉料，即制成圆柱型碳陶瓷固定电阻器。
第二实施例
参阅图1，本发明是一种圆柱型碳陶瓷固定电阻器及其制造方法
配方：
Figure BSA0000215676980000031
将上述原材料氧化铝、二氧化硅、蒙脱石、长石、石墨、粘结剂称量好倒入球磨罐中，倒入与原材料重量相等的酒精，球磨完成后放入恒温水浴锅中烘干；烘干完成后加入用聚乙烯醇配制成的聚乙烯醇水溶液进行造粒，造粒完成后的粉料过60目筛，在过筛料中加入7％的水，混合均匀后陈腐10～15分钟，装入目标直径为26mm的圆柱型压制成型模具中，然后使用液压成型机设定16t压力压成生坯；将压制成型的生坯在1000℃～1500℃的保护气氛中烧成圆柱型碳陶瓷固定电阻器坯料；冷却到常温后取出，进行端面电极金属化工序，然后在端电极上焊接铜质引脚，其余部位包封绝缘粉料，即制成圆柱型碳陶瓷固定电阻器。
第三实施例
参阅图1，本发明是一种圆柱型碳陶瓷固定电阻器及其制造方法
配方：
Figure BSA0000215676980000032
将上述原材料氧化铝、二氧化硅、蒙脱石、长石、石墨、粘结剂称量好倒入球磨罐中，倒入与原材料重量相等的酒精，球磨完成后放入恒温水浴锅中烘干；烘干完成后加入用聚乙烯醇配制成的聚乙烯醇水溶液进行造粒，造粒完成后的粉料过60目筛，在过筛料中加入6％的水，混合均匀后陈腐10～15分钟，装入目标直径为11.3mm的圆柱型压制成型模具中，然后使用液压成型机设定6t压力压成生坯；将压制成型的生坯在1000℃～1500℃的保护气氛中烧成圆柱型碳陶瓷固定电阻器坯料；冷却到常温后取出，进行端面电极金属化工序，然后在端电极上焊接铜质引脚，其余部位包封绝缘粉料，即制成圆柱型碳陶瓷固定电阻器。
以上公开的仅为本发明的几个具体实施例，但本发明的保护范围并不局限于此，任何熟悉本领域的技术人员在本发明揭露的范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围内。因此，本发明的保护范围应该以权利要求的保护范围为准。

Claims (8)

1.圆柱型碳陶瓷固定电阻器，其特征在于，采用氧化铝、二氧化硅、蒙脱石、长石、石墨为主料，经过球磨、造粒、压制成型、烧结、端面电极金属化制成；其中原材料的重量百分配比为：
Figure FSA0000215676970000011
2.根据权利要求1所述的圆柱型碳陶瓷固定电阻器，其特征在于，所述的粘结剂选用为硅酸钠、聚醋酸乙烯醇、聚乙烯醇、甲基纤维素中的一种及其混合物。
3.根据权利要求1所述的圆柱型碳陶瓷固定电阻器，其特征在于，将原材料氧化铝、二氧化硅、蒙脱石、长石、石墨、粘结剂按重量百分比称量好倒入球磨罐中，倒入与原材料重量相等的酒精，然后放进球磨机内球磨16～48小时，球磨完成后放入恒温水浴锅中烘干；烘干完成后加入用粘结剂配制成的粘结剂水溶液进行造粒，造粒完成后的粉料过60目筛，在过筛料中加入3％～8％的水，混合均匀后陈腐10～15分钟，装入目标尺寸的圆柱型压制成型模具中，然后使用液压成型机设定合适压力压成生坯；将压力成型的生坯在1200℃～1500℃的保护气氛中烧成圆柱型碳陶瓷固定电阻器坯料；冷却到常温后取出，进行端面电极金属化工序，然后在端电极上焊接铜质引线或者引脚，其余部位包覆绝缘粉料，即制成圆柱型碳陶瓷固定电阻器。圆柱型碳陶瓷固定电阻器的尺寸大小可以根据设计要求选择。
4.根据权利要求3所述的圆柱型碳陶瓷固定电阻器，其特征在于，所述氧化铝可采用市售氧化铝粉，粒度为200目～400目。
5.根据权利要求3所述的圆柱型碳陶瓷固定电阻器，其特征在于，所述二氧化硅可采用市售二氧化硅粉，粒度为200目～400目。
6.根据权利要求3所述的圆柱型碳陶瓷固定电阻器，其特征在于，所述蒙脱石可采用市售蒙脱石粉，粒度为200目～400目。
7.根据权利要求3所述的圆柱型碳陶瓷固定电阻器，其特征在于，所述长可采用市售长石粉，粒度为200目～400目。
8.根据权利要求3所述的圆柱型碳陶瓷固定电阻器，其特征在于，所述石墨可采用市售石墨，粒径为30目0～2000目。
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