JP2018125489A - Resistor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent coming-off of winding resistor.SOLUTION: The resistor includes: a columnar resistive element; first and second cap terminals provided at both ends of the resistive element; and first and second rings which are provided on an outer peripheral side of each of the first and second cap terminals and exposes a part of an end face and a side face of each of the first and second cap terminals.SELECTED DRAWING: Figure 1

Description

  The present invention relates to resistors, and more particularly to wire wound resistors.

  As a resistor, for example, a winding resistor using an insulator is known in applications where high heat resistance is required. The winding resistor is manufactured by, for example, a method in which a resistance wire is wound after cap terminals are attached to both ends of an insulator that has been processed into a predetermined size in advance. The end of the winding resistance wire (contact with the cap terminal) is fixed to the side surface of the cap terminal by welding or soldering.

  However, the resistance wire fixed to the side surface of the cap terminal may come off. In addition, since the protrusion is formed on the cap terminal, the next process may be affected or surface mounting may be difficult.

  Then, the structure like the following patent documents 1 and patent documents 2 is examined.

  In Patent Document 1, a resistance wire is spirally wound over the entire length of the outer periphery of a cylindrical resistor element body. Both ends are in contact with the end face of the resistor element and are fitted over and fixed by cap terminals.

  In Patent Document 2, terminals are attached to both ends of a base around which a resistance wire is wound, and the periphery of the base is covered with a heat-resistant insulating material. The ends of the terminals are bent so as to be horizontal with the wiring board and the bottom of the cover.

Japanese Utility Model Publication No. 49-006443 Japanese Patent Laid-Open No. 06-124801

  The structure of Patent Document 1 needs to add a complicated process of fixing the resistance wire to the end face of the insulator. Therefore, there is a problem that the manufacturing process becomes complicated.

  The surface mounting with the structure of Patent Document 2 requires processing accuracy of a terminal or the like for making the terminal and the bottom surface of the covering body flush with each other. In addition, there are problems such as an increase in component size.

  An object of the present invention is to prevent disconnection of a resistance wire (winding) of a resistor. Another object of the present invention is to enable surface mounting without changing the component size of the resistor.

  According to one aspect of the present invention, a columnar resistive element, first and second cap terminals provided at both ends of the resistive element, and provided on each outer peripheral side of the first and second cap terminals. And a first ring and a second ring exposing partial regions of the end faces and side faces of the first and second cap terminals, respectively.

  The resistance element is a winding resistance element in which a resistance wire is wound around a cylindrical insulator, and first and second ends that terminate the resistance wire are exposed from the first and second rings. It is preferable that each of the first and second cap terminals to be connected to the outer surface. It is preferable that the first and second rings do not cover the connection portions of the resistance wires on the outer surfaces of the first and second cap terminals.

  The first and second rings are formed shallower than the length of the first and second cap terminals in the length direction of the resistance element.

  It is preferable that the first and second rings include stoppers that are in contact with respective end surfaces of the first and second cap terminals or a peripheral edge thereof.

  First and second lead wires can be connected to end faces of the first and second cap terminals.

  According to the present invention, it is possible to prevent disconnection of the resistance wire of the resistor. Further, according to the present invention, surface mounting is possible without changing the component size of the resistor.

FIG. 1 is a side view showing a first configuration example of the winding resistor according to the first embodiment of the present invention. It is the figure which showed together the coil | winding of the back side. Moreover, it is the figure which also showed the front view of the side end. FIG. 2 is a side view showing a second configuration example of the winding resistor according to the first embodiment of the present invention. It is the figure which showed together the coil | winding of the back side. Moreover, it is the figure which also showed the front view of the side end. 3A is a side sectional view near the side end of FIG. 1, and FIG. 3B is a side sectional view near the side end of FIG. FIG.3 (c) is sectional drawing which follows the IIIa-IIIb line | wire of Fig.3 (a) and FIG.3 (b). FIG. 4 is an exploded perspective view of the winding resistor. It is a flowchart figure which shows an example of the manufacturing process of the winding resistor by this Embodiment. It is a figure which shows the detail of the process of FIG. 5, and is a figure corresponding to FIG.3 (b). FIG. 7A is a perspective view of a resistor having the ring structure of the configuration example 1 described in the first embodiment, and FIG. 7B is a ring structure according to the second embodiment. It is a perspective view of the resistor which has this. None have a stopper structure. FIG. 8A is a perspective view of a resistor having a stopper structure in a ring according to a third embodiment, and FIG. 8A is a schematic view in which a through hole of the ring exposes only a part of an end surface of a cap terminal. It is a figure which has a circular shape. FIG. 8B is a diagram in which the through hole of the ring has a rectangular shape that exposes only a part of the end surface of the cap terminal. FIGS. 9A and 9B are perspective views of a resistor having a stopper structure in a ring according to the fourth embodiment of the present invention.

(First embodiment)
Hereinafter, a winding resistor according to a first embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 is a side view showing a first configuration example of the winding resistor according to the present embodiment. FIG. 2 is a side view showing a second configuration example of the winding resistor according to the first embodiment of the present invention. 1 and 2, the resistance wire on the back side is shown together, and the front view of the side end is also shown. 3A is a side sectional view in the vicinity of the side end (region indicated by reference numeral X1) in FIG. 1, and FIG. 3B is a view in the vicinity of the side end in FIG. 2 (region indicated by reference sign X2). It is a sectional side view. FIG.3 (c) is sectional drawing which follows the IIIa-IIIb line | wire of Fig.3 (a) and FIG.3 (b). In FIG. 3A and FIG. 3B, only one end side is shown. FIG. 4 is an exploded perspective view of the winding resistor (corresponding to FIG. 2). However, the resistance wire is omitted in FIG.

  The winding resistors A1 and A2 according to the present embodiment are connected to the first and second lead wires 17a and 17b at both ends.

  The winding resistors A1 and A2 include an insulator (winding core) 3, a resistance wire (winding) 5, and first and second cap terminals 7a and 7b.

  The insulator (winding core) 3 is formed of, for example, a cylindrical insulator (alumina, mullite, forsterite, etc.).

  The resistance wire (winding) 5 can be selected from materials such as CuNi, NiCr, FeCr, and CuMnNi according to a desired resistance value.

  The first and second cap terminals 7a, 7b are bottomed cylindrical members having openings, and are made of copper, nickel, tin plating on the surface of iron, copper, stainless steel, copper-nickel alloy or the like. Can be used.

(First configuration example)
The winding resistor A1 according to the present embodiment shown in FIG. 1 has first and second rings 11a and 11b. The first and second rings 11a and 11b are disposed on the outer peripheral sides of the first and second cap terminals 7a and 7b, respectively, and are ring-shaped exposing part of the end surfaces and side surfaces of the cap terminals 7a and 7b. It is a member. The diameters of the inner peripheral surfaces of the first and second rings 11a and 11b are slightly larger than the outer diameters of the first and second cap terminals 7a and 7b.

  The first and second rings 11a and 11b are located on the outermost side of the winding resistor A1. The beginning and the end of the resistance wire (winding) 5 are connected to the side surfaces 7a-1 and 7b-1 that are not covered by the first and second rings 11a and 11b of the first and second cap terminals 7a and 7b. ing. The first and second rings 11a and 11b can be made of iron, copper, stainless steel, copper-nickel alloy or the like with copper, nickel, or tin plated. The cap terminal and the ring may be made of the same material or different materials.

  The first and second lead wires 17a and 17b are connected to respective end faces of the first and second cap terminals 7a and 7b. As the first and second lead wires 17a and 17b, for example, a surface of Cu, Fe, Al or the like subjected to Sn plating can be used.

A protective film for the resistance wire (winding) 5 made of, for example, SiO ₂ can be formed on the peripheral surface of the insulator (winding core) 3.

Hereinafter, the first and second rings 11a and 11b will be described in detail. The first and second rings 11a and 11b do not cover the connecting portion 15 of the resistance wire 5 on the outer surfaces (outer peripheral surfaces) of the first and second cap terminals 7a and 7b. That is, the depth L2 of the first and second rings 11a and 11b is formed shallower by L1-L2 = L3 than the depth L1 of the first and second cap terminals 7a and 7b ( (See FIG. 3 (a)). Adding a complicated process by making a difference in the length in the length direction of the winding resistor A1 between the first and second cap terminals 7a, 7b and the first and second rings 11a, 11b. without the first and second cap terminal 7a, 7b and the first and second ring 11a, a step _{t 2} between 11b is secured when mounted.

Further, exposed portions 7a-1 and 7b-1 that are not covered by the first and second rings 11a and 11b are formed in the first and second cap terminals 7a and 7b. Each end of the resistance wire 5 is connected to the exposed portions 7a-1 and 7b-1 by welding or the like to form a connection portion 15. More specifically, in the connecting portion 15, first and second ring 11a having a thickness of _t the first and second cap terminal 7a of _1, 7b thickness _{t 2,} it is exposed from 11b. The thickness t _2, for example, the diameter 2R of the resistance wire 5 (FIG. 3 (c)) and that an equal or higher thickness, the connecting portion 15 of the resistance wire 5, the first and second ring 11a It is protected by 11b and the step _{t 2.}

(Second configuration example)
The winding resistor A2 will be described. FIG. 3B shows a form in which stoppers 13a and 13b described below are provided, but the relationship between the first and second cap terminals 7a and 7b and the first and second rings 11a and 11b is common. .

  As shown in FIG. 4, for example, on the end side (side end) of the first and second rings 11a and 11b, the diameter of the inner side surface (inner peripheral surface) of the first and second rings 11a and 11b. Portions 13a and 13b having a smaller diameter are formed. This structure is, for example, a structure in which a through hole is formed in the bottom surface of the cap terminal. As shown in FIG. 3B, the portions 13a and 13b having a diameter smaller than the diameters of the inner surfaces (inner peripheral surfaces) of the first and second rings 11a and 11b are the first and second caps. It is smaller than the diameter of the outer surface of the terminals 7a and 7b. In this structure, when the first and second rings 11a and 11b are inserted into the first and second cap terminals 7a and 7b and pushed inward, the portions 13a and 13b having a small diameter are converted into the first and second cap terminals 7a and 7b. By contacting the first and second end faces 7a-2, 7b-2 (peripheral portions 7a-3, 7b-3) of the cap terminals 7a, 7b, more than that of the first and second rings 11a, 11b. Serves as a stopper to stop the insertion. Hereinafter, this portion is referred to as first and second stoppers 13a and 13b.

  The opening diameter of the through hole 13c in the first and second stoppers 13a and 13b is at least equal to or larger than the diameter of the first and second lead wires 17a and 17b, and the outer diameter of the first and second cap terminals 7a and 7b. It is as follows. The shape, details, etc. are not particularly limited as long as they serve as stoppers (to the extent that they are caught on the periphery of the cap terminal).

  FIG. 5 is a flowchart showing an example of the manufacturing process of the winding resistor A2 according to the present embodiment. FIG. 6 is a diagram showing details of the process of FIG. 5 and corresponds to FIG. Reference is also made to FIGS. 1 to 4 as appropriate. In FIG. 6, only one end side is shown.

  First, in step S1, the first and second cap terminals 7a and 7b are attached to the insulator (core) 3 (FIGS. 6A and 6B). For example, the first and second cap terminals 7a and 7b made of metal are mounted (press-fitted) from both ends of the insulator 3 made of a columnar insulator formed in advance to a predetermined size (see AR1 in FIG. 6A). .

  Next, in step S2, the first and second rings 11a and 11b are mounted (FIGS. 6C and 6D). For example, metal first and second rings 11a and 11b are attached to the outer periphery of the end portions (side ends) of the cap terminals 7a and 7b in the AR2 direction by press fitting or the like.

  When the first and second stoppers 13a and 13b are formed on the first and second rings 11a and 11b, the first and second stoppers 13a and 13b are pushed to the positions where the first and second stoppers 13a and 13b are formed. And positioning of the 2nd rings 11a and 11b in the insertion direction can be performed. At this time, the end surfaces of the cap terminals 7a and 7b are exposed from the first and second rings 11a and 11b (see FIG. 6D). The first and second rings 11a and 11b are ring-shaped, that is, since holes are formed in the end faces, air can easily escape during the pushing process (see AR3 in FIG. 6C). Therefore, variation in dimensional accuracy depending on air accumulation is suppressed, and the performance of the winding resistor is stabilized.

  In step S3, the resistance wire 5 is wound. For example, the resistance wire 5 is wound around the outer peripheral surface of the insulator 3 at a predetermined pitch. The resistance value of the winding resistor A2 depends on the type of the wire of the resistance wire 5 to be wound. Further, the resistance value of the winding resistor A2 can be adjusted by the winding pitch of the resistance wire 5 to be wound. The start end and the end of the resistance wire 5 are welded to the side surfaces of the first and second cap terminals 7a, 7b. At this time, the start end and the end of the resistance wire 5 are welded to the exposed portions 7a-1 and 7b-1 that are not covered by the first and second rings 11a and 11b.

  In step S4, the first and second lead wires 17a and 17b are welded and connected. For example, the first and second lead wires 17a and 17b are connected to the end surfaces 7a-2 and 7b-2 of the first and second cap terminals 7a and 7b exposed from the ends of the first and second rings 11a and 11b. Weld.

  In addition, when the winding resistor is surface-mounted, it is not necessary to weld the lead wire.

  Next, a protective film (not shown) is formed. The protective film may be formed on the entire surface excluding the first and second lead wires 17a and 17b with, for example, an epoxy resin. The step of forming the protective film is optional and is formed as necessary.

  Further, for example, display is performed using a color code. For example, a color code representing a resistance value is applied to the surface after drying and baking.

  Next, inspection / inspection of the winding resistor A2 is performed. For example, an inspection such as an appearance image inspection or resistance value measurement of the winding resistor A2 is performed.

  Through the above steps, for example, a winding resistor A2 as shown in FIG. 2 and the like can be manufactured.

  In the winding resistor A1 of the first configuration example not having the stopper structure, in step S2, the first and second cap terminals 7a and 7b and the first and second rings 11a and 11b Position by adjusting the position.

  According to the present embodiment, the ring-shaped member is located on the outermost side of the winding resistor A2. By forming the first and second cap terminals 7a, 7b and the first and second rings 11a, 11b covering a part of the outer periphery thereof, a step is formed in the radial direction of the cylindrical insulator 3. And this level | step-difference part can be used as resistance wire welding. Therefore, the connection part of the resistance wire 5 is protected.

  Moreover, by making the first and second rings 11a and 11b into ring shapes having holes in the end faces, air can easily escape during press-fitting, and the performance is stabilized.

  Further, by making a difference between the depths of the cap terminal and the ring, a step and a welding margin are secured between the cap terminal and the ring when they are mounted without adding a complicated process.

  In addition, if a stopper is formed on the ring as in the second configuration example, it stops at an appropriate location, and therefore can be manufactured with high accuracy. Therefore, it will not be pushed further inward.

(Second Embodiment)
Next, a second embodiment of the present invention will be described. FIG. 7A is a perspective view of a winding resistor in which the ring described in the first configuration example (FIG. 1) of the first embodiment does not have a stopper structure.

  FIG. 7B is a diagram showing a configuration example of the winding resistor according to the present embodiment, and a gap having a width in the circumferential direction at least at one place in the circumferential direction of the ring of FIG. 21 is formed. This ring is referred to as a C-type ring. The C-shaped ring does not require the first and second rings 11a and 11b to be formed into a cylindrical shape in advance, and can be mounted by winding a metal plate around a predetermined location on the outer periphery of the cap terminals 7a and 7b. The ring inner diameter has the advantage that strict dimensional accuracy is not required. The width of the gap 21 is equally spaced in the extending direction of the insulator 3 in FIG. 7B, but the shape of the interval is not limited to such an equally spaced shape. Further, the position, width, number, etc. of the gaps may not be the same in the first and second rings 11a, 11b at both ends. Further, the connection portion 15 of the resistance wire 5 may be provided in the cap region.

(Third embodiment)
In the third embodiment of the present invention, a structure in which the shapes of the through holes 13c of the first and second rings 11a and 11b are different will be described. In the second embodiment shown in FIG. 7B, the stopper structure is not provided as shown in FIG. That is, the openings at the side ends of the first and second rings 11a and 11b have a substantially circular shape that exposes almost the entire end surfaces of the first and second cap terminals 7a and 7b.

  On the other hand, as shown in FIGS. 8 (a) and 8 (b), the winding resistor according to the third embodiment of the present invention has a stopper structure as shown in FIG. 3 (b). .

  8A, as shown in FIGS. 2 and 3B, the openings 11a-2 and 11b-2 at the side ends of the first and second rings 11a and 11b are the first and second openings 11a and 11b, respectively. It has a substantially circular shape that exposes only a part of the end face of the second cap terminals 7a, 7b.

  In FIG. 8B, the openings 11a-3 and 11b-3 of the first and second rings 11a and 11b have a rectangular shape that exposes only a part of the end surfaces of the cap terminals 7a and 7b. is there. The first and second stoppers 13a-1, 13a-2, 13b-1, 13b-2 provided in the first and second rings 11a, 11b are formed with through holes 13c by punching a cap-like member or the like. You may do it.

  In the rings shown in FIGS. 8 (a) and 8 (b), the air is easy to escape during press-fitting, and the performance is stable, and the first and second stoppers 13a-1, 13a-2, 13b during press-fitting. -1, 13b-2 has the advantage of having the function. In addition, there is an advantage that a region where the first and second lead wires 17a and 17b are connected is easily understood.

(Fourth embodiment)
In the fourth embodiment of the present invention, a structure in which the shape of the stopper formed on the first and second rings 11a and 11b is different from that shown in FIGS. 8A and 8B will be described. FIG. 9A and FIG. 9B are perspective views showing a ring stopper structure according to the present embodiment. In FIG. 9A, the first and second rings 11a and 11b have the same through-hole 13c as in FIGS. 7A and 7B, and a part of the opening edge of the through-hole 13c. Claw-shaped stoppers 13a-3, 13a-4, 13b-3, 13b-4 extending toward the center of the through hole 13c. In the drawing, a plurality of stoppers (two in the drawing) are provided, but the present invention is not limited to this. Regarding the shape, for example, in the figure, the claw-shaped stoppers 13a-3, 13a-4, 13b-3, and 13a-4 have the same width in the length direction, but the width and length of each claw are different. Also good.

  The structure shown in FIG. 9A can be realized, for example, by forming two notches in the circumferential direction from the structure of FIG. In FIG.9 (b), it extends toward the center part of opening part 11a-4, 11b-4 from the opening edge part of opening part 11a-4, 11b-4 of 1st and 2nd ring 11a, 11b, respectively. A plurality of (two in the figure) a pair of claw-shaped first and second stoppers 13a-5, 13a-6, 13b-5, and 13b-6 are provided. At this time, the peripheral edge portions of the cap terminals 7a and 7b are exposed from between the first and second stoppers 13a-5 and 13a-6, 13b-5 and 13b-6.

  The structure shown in FIG. 9B is two notches extending in the circumferential direction exposing the end faces 7a-2 and 7b-2 of the first and second cap terminals 7a and 7b from the structure of FIG. 8A. This can be realized by forming.

  First and second stoppers 13a-3, 13a-4, 13b-3, 13b-4 or 13a-5, 13a-6, 13b-5, 13b provided on the first and second rings 11a, 11b -6 may be formed by forming a through hole 13c by punching a cap-shaped member or the like.

  Moreover, you may provide the notch which exposes a partial area | region of the side surface of 1st and 2nd cap terminal 7a, 7b in a part of circumferential direction of 1st and 2nd ring 11a, 11b.

  The rings shown in FIGS. 9A and 9B have the advantage that air easily escapes during press-fitting and stabilizes the performance, and the advantage of improving the function as a stopper during press-fitting. Further, the press-fitting depth (the width of the exposed portion not covered by the first and second rings) can be finely adjusted by the bending position of the claw-shaped portion.

  In the above-described embodiment, the configuration and the like illustrated in the accompanying drawings are not limited to these, and can be appropriately changed within a range in which the effect of the present invention is exhibited. In addition, various modifications can be made without departing from the scope of the object of the present invention.

  For example, a resistance film element such as a metal film resistance, a metal oxide film resistance, or a carbon film resistance can be used.

  Each component of the present invention can be arbitrarily selected, and an invention having a selected configuration is also included in the present invention.

  The present invention is applicable to resistors.

A1, A2 ... Winding resistor 3 ... Insulator (core)
5 ... Resistance wire (winding)
7a, 7b ... 1st and 2nd cap terminal 11a, 11b ... 1st and 2nd ring 11a-1, 11b-1 ... Opening part 13a, 13b ... 1st and 2nd stopper 13c ... Through-hole 17a, 17b. First and second lead wires

Claims (5)

A columnar resistive element;
First and second cap terminals provided at both ends of the resistance element;
A first ring and a second ring provided on the outer peripheral side of each of the first and second cap terminals, and exposing a partial region of each end surface and side surface of the first and second cap terminals. Resistor. The resistance element is a winding resistance element in which a resistance wire is wound around a cylindrical insulator,
The first and second end portions that terminate the resistance wire are respectively connected to outer surfaces of the first and second cap terminals exposed from the first and second rings. The resistor described.   3. The resistor according to claim 1, wherein the first and second rings are formed shallower than a depth of the resistance element in a length direction of the first and second cap terminals.   The resistor according to any one of claims 1 to 3, wherein the first and second rings include stoppers that are in contact with respective end surfaces of the first and second cap terminals or a peripheral portion thereof.   The resistor according to any one of claims 1 to 4, wherein first and second lead wires are connected to end faces of the first and second cap terminals.

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