JP2020526042A - Anti-surge winding low temperature fuse resistor and manufacturing method thereof - Google Patents

Abstract

A fuse resistor, including an insulating rod, a first winding, a second winding, and a connecting wire. The insulating rod has a first end and a second end. The first winding is wound around the insulating rod from the first end, and one end of the first winding is electrically welded to the first cap. The second winding is wound around the insulating rod from the second end, and one end of the second winding is electrowelded to the second cap. The connecting wire is placed between the first and second windings, the melting point of the connecting wire is lower than the melting points of the first and second windings, and the first and second windings. Are separated from each other and electrically connected via a connecting wire. The fuse resistor further includes a first electrical cover layer that electrically connects one end of the first winding to the first cap and a second electrical cover layer that electrically connects one end of the second winding to the second cap. Strengthen the fixing of the first winding and the second winding, and enhance the surge resistance effect of the fuse resistor. [Selection diagram] Fig. 1

Description

The present disclosure relates to a fuse resistor and a manufacturing method thereof, and more particularly, to a surge resistance low temperature low temperature fuse resistor and a manufacturing method thereof.

When the circuit is operating normally, the fuse resistor acts as a fixed resistor. When the operating current exceeds the rated current, it blows like a fuse due to overheating to protect the circuit. Generally, the melting temperature of a winding fuse resistor is the melting point of the winding. However, considering the resistance value and other electrical characteristics, the winding material of the conventional fuse resistor is mainly made of a high melting point alloy. The fusing temperature is too high and there is a reddish process, which can burn or destroy the circuit and other components, affecting the circuit protection effect.

One aspect of the present disclosure is to provide an anti-surge winding cryogenic fuse resistor.

Embodiments of the present disclosure provide a fuse resistor that includes an insulating rod, a first winding, a second winding, and a connecting wire. The insulating rod has a first end and a second end. The first winding winds the insulating rod from the first end of the insulating rod. The second winding winds the insulating rod from the second end of the insulating rod. The connecting wire is arranged between the first winding and the second winding, the melting point of the connecting wire is lower than that of the first winding and the second winding, and the first winding and the second winding are They are separated from each other and are electrically connected via connecting wires.

According to some embodiments of the present disclosure, the fuse resistor further comprises a first insulating layer covering the first winding and the second winding, the first insulating layer exposing a portion of the insulating rod. It has an opening.

According to some embodiments of the present disclosure, the material of the first insulating layer comprises epoxy resin, silicone non-combustible paint, or enamel paint.

According to some embodiments of the present disclosure, the openings include slot openings to surround and partially expose the insulating rod.

According to some embodiments of the present disclosure, the openings include dot openings to partially expose the insulating rod.

According to some embodiments of the present disclosure, the connecting wire is in contact with the first winding and the second winding through the opening in the first insulating layer.

According to some embodiments of the present disclosure, a second insulating layer covering the first insulating layer and the connecting wire is provided to fill the opening of the first insulating layer.

According to some embodiments of the present disclosure, the material of the second insulating layer comprises epoxy resin, silicone non-combustible paint, or enamel paint.

According to some embodiments of the present disclosure, the fuse resistor further includes a first cap and a second cap, the first cap electrically welded from the first end of the insulating rod to the one end of the first winding. And the second cap is electrically welded from the second end of the insulating rod to one end of the second winding.

According to some embodiments of the present disclosure, a fuse resistor includes a first electrical cover layer electrically connecting one end of a first winding to a first cap and one end of a second winding to a second cap. And a second electrical cover layer for connection.

According to some embodiments of the present disclosure, the material of the first electrical cover layer and the second electrical cover layer comprises tin, copper, iron, silver, nickel, or alloys thereof, respectively.

According to some embodiments of the present disclosure, the thickness of the first electrical cover layer and the second electrical cover layer are each between 1 and 20 micrometers.

Another embodiment of the present disclosure provides a method of manufacturing a fuse resistor, the method including providing an insulating rod, winding a winding around the insulating rod, cutting the winding, and separating them from each other. Forming a first winding and a second winding, forming a connection wire, and electrically connecting the first winding to the second winding, wherein the melting point of the connection wire is And lower than the melting point of the second winding.

According to some embodiments of the present disclosure, a method of manufacturing a fuse resistor includes forming an insulating rod and a first insulating layer on the winding before cutting the winding, and forming an opening in the first insulating layer. And cutting the winding.

According to some embodiments of the present disclosure, the openings include slot openings to surround and partially expose the insulating rod.

According to some embodiments of the present disclosure, the openings include dot openings to partially expose the insulating rod.

According to some embodiments of the present disclosure, a method of manufacturing a fuse resistor includes forming a second insulating layer, covering a first insulating layer and a connecting wire, and filling an opening in the first insulating layer. Further includes.

According to some embodiments of the present disclosure, a method of manufacturing a fuse resistor includes forming a first cap on a first end of an insulating rod and forming a second cap on a second end of the insulating rod. Further comprising forming.

According to some embodiments of the present disclosure, a method of making a fuse resistor includes electrically welding one end of a winding to a first cap and electrically welding the other end of the winding to a second cap. Further includes.

According to some embodiments of the present disclosure, a method of making a fuse resistor includes electrically connecting one end of a first winding to a first cap using a first electrical cover layer, and a second electrical cover layer. The method further includes electrically connecting one end of the second winding to the second cap using the cover layer.

According to some embodiments of the present disclosure, the first electrical cover layer, the second electrical cover layer, and the connecting wire are formed together by the same process.

For the best understanding, it is recommended that the present disclosure be read with reference to the accompanying drawings and detailed description thereof. In order to comply with industry standards, the drawings in this patent specification are not necessarily drawn to scale. In some drawings, the dimensions may be intentionally enlarged or reduced to help the reader understand the contents.

FIG. 1 illustrates a fuse resistor according to an embodiment of the present disclosure.

FIG. 2 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure. FIG. 3 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure. FIG. 4 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure. FIG. 5 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure.

FIG. 6 illustrates a fuse resistor according to another embodiment of the present disclosure.

FIG. 7 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to another embodiment of the present disclosure. FIG. 8 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to another embodiment of the present disclosure. FIG. 9 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to another embodiment of the present disclosure.

This disclosure provides many different embodiments or examples for implementing various features of this disclosure. For ease of explanation, this disclosure also describes examples of particular components and arrangements. These examples are provided for demonstration purposes only and are not intended to be limiting. For example, a method in which the first feature in the following description is on or above the second feature may include certain embodiments in which the first feature is in direct contact with the second feature, or the first feature and the second feature. Different embodiments may be included in which other features are formed between the first and second features such that the two features are not in direct contact. Additionally, various examples of the present disclosure use repetitive reference numbers and/or text annotations for the purpose of simplifying and clarifying the document, which repetitive reference numbers and annotations It does not prescribe the relationship between and.

Further, in the present disclosure, the spatially relative terms “beneath”, “below”, “lower”, “above”, “Upper,” “on,” etc. refer to one element or feature and another element or features, as shown in the figure, for ease of explanation. Describe the relative relationship. In addition to the angular orientations shown in the figures, these spatially relative terms are also used to describe possible angles and orientations of the device during use or operation. The angular orientation of the device can vary (in 90 degrees or other directions) and the spatially relative descriptions used in this disclosure can be interpreted as well.

Please refer to FIG. FIG. 1 is a diagram illustrating a fuse resistor according to an embodiment of the present disclosure. As shown in FIG. 1, the fuse resistor 1 of the present embodiment includes an insulating rod 10, a first winding 22, a second winding 24, and a connecting wire 26. The insulated wire 10 has a first end 101 and a second end 102. The insulating rod 10 of the present embodiment may include a ceramic rod, but the material is not limited to the ceramic material, and any insulating material such as glass fiber that can achieve the object of the present disclosure can be used. In addition, the insulating rod 10 of the present embodiment has a cylindrical shape, but is not limited to this.

The first winding 22 is wound around the insulating rod 10 from the first end 101, and the second winding 24 is wound around the insulating rod 10 from the second end 102. The windings 24 are not directly connected and have a gap between them. In some embodiments, the first winding 22 and the second winding 24 are spirally wound on the insulating rod 10. In some embodiments, the first winding 22 and the second winding 24 are spirally wound on the insulating rod 10. In some embodiments, the gap between the first winding 22 and the second winding 24 is between about 0.05 millimeters (mm) and about 2 millimeters. The connecting wire 26 is disposed between the first winding 22 and the second winding 24, and the length of the connecting wire 26 is equal to the first winding 22 and the second winding 24 in order to connect the first winding 22 and the second winding 24. It may be slightly larger than the gap between the one winding 22 and the second winding 24. The melting point of the connecting wire 26 is lower than the melting points of the first winding 22 and the second winding 24, the first winding 22 and the second winding 24 are separated from each other, and are electrically connected via the connecting wire 26. It

In the present embodiment, the material of the first winding 22 and the second winding 24 may include or be selected from materials having a melting point higher than that of the connecting wire 26. For example, the melting point of the first winding 22 and the second winding 24 is between about 800 and 1500 degrees Celsius, and the melting point of the connecting wire 26 is less than about 500 degrees Celsius, or less than about 300 degrees Celsius. obtain. It is between, but not limited to, about 200 degrees Celsius to 300 degrees Celsius. The materials of the first winding 22, the second winding 24 and the connecting wire 26 can be determined according to the electrical and safety specifications of the resistor. In some embodiments, the material of the first winding 22 and the second winding 24 can include or be selected from nickel copper alloys, or other suitable refractory conductive metals, or alloy materials. obtain. Also, the material of the connecting wire 26 may include or be selected from tin, copper, or other low melting point conductive metal, or alloy material. With the above configuration, when the operating current of the fuse resistor 2 of the present embodiment exceeds the rated current, the low melting point connection wire 26 has a low fusing temperature and a high fusing speed, so that the circuit is first protected in order to protect it. Fused. It is also worth noting that in normal operation, the operating temperature of the fuse resistor 1 is less than about 70 degrees, so that the connecting wire 26 having a low melting point does not affect the normal operation of the fuse resistor 1.

In some embodiments, the fuse resistor 1 can further include a first insulating layer 12 that covers the first winding 22 and the second winding 24. The first insulating layer 12 has an opening 12S that exposes a part of the insulating rod 10. In some embodiments, the material of the first insulating layer 12 can include or be selected from insulating paints such as epoxy resins or other insulating materials. In some embodiments, the connecting wire 26 is in contact with the first winding 22 and the second winding 24 through the opening 12S of the first insulating layer 12. In some embodiments, the openings 12S in the first insulating layer 12 can include slot openings that surround the insulating rod 10 and partially expose the insulating rod 10. In some embodiments, the width of the slot opening in the first insulating layer 12 is between, but not limited to, about 0.05 mm to about 2 mm.

In some embodiments, the fuse resistor 1 can further include a second insulating layer 14 that covers the first insulating layer 12 and the connection layer 26 and fills the opening 12S of the first insulating layer 12. In some embodiments, the material of the second insulating layer 14 can include or be selected from insulating paints such as epoxy resins, silicone non-combustible paints, enamel paints, or other insulating materials.

In some embodiments, the fuse resistor 1 can further include a first cap 32 and a second cap 34. The first cap 32 covers the first end 101 of the insulating rod 10 and is electrically connected to the first winding 22, and the second cap 34 covers the second end 102 of the insulating rod 10 and the second winding. Electrically connected to 24. In some embodiments, the material of the first cap 32 and the second cap 34 can include iron, steel, aluminum, copper, other metals, alloys, or graphite materials. In some embodiments, one end of the first winding 22 may be first welded to the first cap 32 and one end of the second winding 24 may be first welded to the second cap 34. In some embodiments, the fuse resistor 1 includes a first electrical cover layer 361 that electrically connects one end of the first winding 22 to the first cap 32 and one end of the second winding 24 to the second cap 34. It may further include a second electrical cover layer 362 for electrical connection. In some embodiments, the materials of first electrical cover layer 361 and second electrical cover layer 362 can include, but are not limited to, tin, copper, iron, silver, nickel, or other alloys. In some embodiments, the first electrical cover layer 361 and the second electrical cover layer 362 can be formed by, but not limited to, electroplating. In some embodiments, the first electrical cover layer 361, the second electrical cover layer 362, and the connecting wire 26 can be manufactured by the same process to simplify the manufacturing procedure. In some embodiments, the thicknesses of the first electrical cover layer 361 and the second electrical cover layer 362 are between about 1 micrometer and about 20 micrometers, respectively, but are not limited thereto. Under surge shock conditions, approximately 90% or more of the damage to conventional wound resistors occurs at the weld between the winding and the cap, resulting in an open circuit failure. Therefore, the first electric cover layer 361 and the second electric cover layer 362 can be used to reinforce the welded portions of the first winding 22 and the second winding 24, respectively, and increase the hardness of the welded portions, resulting in poor production. Rate, and further improve the reliability of the weld point. The welding strength of the first winding 22 and the second winding 24 is ensured by the first electric cover layer 361 and the second electric cover layer 362, and may enhance the anti-surge effect of the fuse resistor 1. it can.

In some embodiments, the fuse resistor 1 extends outwardly from the first cap 32 and electrically connects the first wire 42 to the first cap 32, and outwardly from the second cap 34 to the second cap 34. And a second wire 44 electrically connected to. The first wire 42 and the second wire 44 can be electrically connected to an external circuit such as a printed circuit board.

See Table 1. The results of the fusing test of the fuse resistor in the comparative example and the embodiment of the present disclosure are listed in Table 1.

In the fusing test of Table 1, the resistance value specifications of the fuse resistor of the comparative example and the fuse resistor of the embodiment of the present disclosure are both 1Ω, and the power specification is 2 watts (W). The first winding and the second winding of the fuse resistor of the comparative example are directly connected, and the first winding and the second winding of the fuse resistor in the embodiment of the present disclosure are electrically connected through a low melting point connection wire. To be done. For example, the material of the connecting wires is tin and can be formed by electroplating. As shown in Table 1, the error between the resistance values of the fuse resistor of the comparative example and the fuse resistor of the embodiment of the present disclosure is within the allowable error range (±5%), and the fusing power is increased by 40 times. In the set state, the fusing time and the fusing temperature of the fuse resistor according to the embodiment of the present disclosure are lower than those of the fuse resistor according to the comparative example, and the fuse resistor according to the embodiment of the present disclosure has an effect of protecting the circuit. Proof that it will be enhanced.

Please refer to FIGS. 2 to 5 are schematic diagrams showing a method for manufacturing a fuse resistor according to an embodiment of the present disclosure. As shown in FIG. 2, an insulating rod 10 is provided. The insulating rod 10 has a first end 101 and a second end 102. Then, the winding 21 is wound around the insulating rod 10. In some embodiments, the first cap 32 and the second cap 34 may be formed on both sides of the insulating rod 10, but outside the first cap 32 and the second cap 34, the first wire 42 and the second cap 42, respectively. The wire 44 can be formed outward. In some embodiments, the ends of winding 21 can be welded to first cap 32 and second cap 34, respectively, by electrical welding. For example, one end of the winding wire 21 is first electrically welded to the first cap 32, then the winding wire 21 is wound around the insulating rod 10, and then the other end of the winding wire 21 is electrically welded to the second cap 34. be able to.

As shown in FIG. 3, the first insulating layer 12 is formed on the insulating rod 10 and the winding wire 21. Next, as shown in FIG. 4, the opening 12S is formed in the first insulating layer 12, the winding 21 is cut, and the first winding 22 and the second winding 24 which are separated from each other are formed. In some embodiments, the opening 12S in the first insulating layer 12 is a slot opening that surrounds the insulating rod 10 and partially exposes the insulating rod 10. In some embodiments, forming the slot opening in the first insulating layer 12 and forming the cut in the winding 21 can be performed simultaneously. In some embodiments, forming the slot opening in the first insulating layer 12 and cutting the winding 21 can be performed using a cutting tool, but is not limited thereto. As shown in FIG. 5, a connecting wire 26 that electrically connects the first winding 22 and the second winding 24 is formed. In some embodiments, connecting wire 26 may be formed by electroplating, immersion tin bath, or other suitable process. In some embodiments, a first electrical cover layer 361 is provided to enhance the strength of the weld between the first winding 22 and the first cap 32 and the weld between the second winding 24 and the second cap 34. Electrically connecting (eg, electroplating) one end of the first winding 22 to the first cap 32 and using the second electrical cover layer 362 to connect one end of the second winding 24 to the second cap. An electrical connection (eg, electroplating) to 34 can be made to increase the reliability of the weld point. As shown in FIG. 1, then, the second insulating layer 14 is formed so as to cover the first insulating layer 12 and the connection wire 26, and the openings 12S of the first insulating layer 12 are filled with the second insulating layer 14 to form an embodiment of the present disclosure. The fuse resistor 1 is manufactured.

The fuse resistor of the present disclosure is not limited to the embodiments described above and may have other different embodiments. To simplify the description and facilitate comparison between the embodiments of the present disclosure, the same components in the following embodiments are denoted by the same reference numerals. In order to more easily compare the differences between the embodiments, the following description details the differences between the different embodiments and does not repeat the same features and related details.

Please refer to FIG. FIG. 6 is a schematic diagram illustrating a fuse resistor according to another embodiment of the present disclosure. As shown in FIG. 6, unlike the fuse resistor 1 of FIG. 1, the opening 12S of the first insulating layer 12 of the fuse resistor 2 of the present embodiment has a dot opening that partially exposes the insulating rod 10. Including. In some embodiments, the shape of the dot openings can include any regular or irregular geometric shape. In some embodiments, the width or diameter of the dot openings is between but not limited to about 0.05 mm to about 2 mm. In the present embodiment, the material of the first insulating layer 12 may include or be selected from insulating paints such as epoxy resin, silicone non-flammable paint, enamel paint, or other insulating material. The connection wire 26 is in contact with the first winding 22 and the second winding 24 through the opening 12S of the first insulating layer 12. The second insulating layer 14 covers the first insulating layer 12 and the connection layer 26 and fills the opening 12S of the first insulating layer 12. In the present embodiment, the material of the second insulating layer 14 may include or be selected from insulating paints such as epoxy resin, silicone non-flammable paint, enamel paint, or other insulating material. The insulating rod 10, the first winding 22, the second winding 24, the connection layer 26, the first cap 32, the second cap 34, the first electric cover layer 361, and the second electric cover of the fuse resistor 2 in the present embodiment. The location, connection method, materials, and other properties of components such as layer 362, first wire 42, and second wire 44 are similar to those of fuse resistor 1 of FIG. 1 and will not be repeated here.

Please refer to FIGS. 7 to 9 are schematic views showing a method of manufacturing a fuse resistor according to another embodiment of the present disclosure. As shown in FIG. 2, an insulating rod 10 is provided. The insulating rod 10 has a first end 101 and a second end 102. Then, the winding 21 is wound around the insulating rod 10. In some embodiments, the first cap 32 and the second cap 34 may be formed on both sides of the insulating rod 10, but outside the first cap 32 and the second cap 34, the first wire 42 and the second cap 42, respectively. The wire 44 can be formed outward. In some embodiments, the ends of winding 21 can be welded to first cap 32 and second cap 34, respectively, by electrical welding. For example, one end of the winding wire 21 is first electrically welded to the first cap 32, then the winding wire 21 is wound around the insulating rod 10, and then the other end of the winding wire 21 is electrically welded to the second cap 34. be able to. Subsequently, the first insulating layer 12 is formed on the insulating rod 10 and the winding wire 21.

As shown in FIG. 8, the opening 12S is formed in the first insulating layer 12, the winding 21 is cut, and the first winding 22 and the second winding 24 which are separated from each other are formed. In some embodiments, the opening 12S of the first insulating layer 12 is a dot opening that partially exposes the insulating rod 10. In some embodiments, forming the dot openings in the first insulating layer 12 and forming the cuts in the windings 21 can be performed simultaneously. In some embodiments, for example, forming the dot openings in the first insulating layer 12 and cutting the windings 21 can be performed using a cutting tool. As shown in FIG. 9, connecting wires 26 are formed in the dot openings to electrically connect the first winding 22 to the second winding 24. In some embodiments, connecting wire 26 may be formed by electroplating, immersion tin bath, or other suitable process. In some embodiments, a first electrical cover layer 361 is provided to enhance the strength of the weld between the first winding 22 and the first cap 32 and the weld between the second winding 24 and the second cap 34. Electrically connecting (eg, electroplating) one end of the first winding 22 to the first cap 32 and using the second electrical cover layer 362 to connect one end of the second winding 24 to the second cap. An electrical connection (eg, electroplating) to 34 can be made to increase the reliability of the weld point. As shown in FIG. 6, then, the second insulating layer 14 is formed so as to cover the first insulating layer 12 and the connecting wire 26, and the opening 12S of the first insulating layer 12 is filled with the second insulating layer 14 to form the embodiment of the present disclosure. The fuse resistor 2 is manufactured.

In the fuse resistor of the present disclosure, since the first winding and the second winding are electrically connected using the connecting wire, the fusing temperature and the fusing speed of the resistor can be controlled, and the application range and safety of the resistor can be improved. Improve. In addition, in the fuse resistor of the present disclosure, the electrical cover layer is used to reinforce the weld point between the winding and the cap, increasing the hardness of the weld, avoiding loosening of the winding, and manufacturing failure. To reduce. Therefore, the fuse resistor of the present disclosure has a failure rate of the surge resistant welding point of less than 0.1 ppm. The fuse resistor of the present disclosure can improve the anti-surge effect of the fuse resistor, and can be applied to circuits such as anti-surge circuits of automobiles and motorcycles, spark plugs, and ignition systems.

Although this disclosure has been described in considerable detail with reference to its specific embodiments, these descriptions and illustrations are not intended to limit this disclosure. Those skilled in the art can make various changes and can replace equivalent elements in the embodiments without departing from the spirit and scope of the present disclosure as defined in the appended claims. Will be clearly understood by.

The present disclosure relates to a fuse resistor and a manufacturing method thereof, and more particularly, to a surge resistance low temperature low temperature fuse resistor and a manufacturing method thereof.

When the circuit is operating normally, the fuse resistor acts as a fixed resistor. When the operating current exceeds the rated current, it blows like a fuse due to overheating to protect the circuit. Generally, the melting temperature of a winding fuse resistor is the melting point of the winding. However, considering the resistance value and other electrical characteristics, the winding material of the conventional fuse resistor is mainly made of a high melting point alloy. The fusing temperature is too high and there is a reddish process, which can burn or destroy the circuit and other components, affecting the circuit protection effect.

One aspect of the present disclosure is to provide an anti-surge winding cryogenic fuse resistor.

Embodiments of the present disclosure provide an insulating rod, a first winding, second winding, and a fuse resistor comprising a connection. The insulating rod has a first end and a second end. The first winding winds the insulating rod from the first end of the insulating rod. The second winding winds the insulating rod from the second end of the insulating rod. The connecting part is arranged between the first winding and the second winding, the melting point of the connecting part is lower than the melting points of the first winding and the second winding, and the first winding and the second winding are They are separated from each other and are electrically connected via a connecting portion .

According to some embodiments of the present disclosure, the fuse resistor further comprises a first insulating layer covering the first winding and the second winding, the first insulating layer exposing a portion of the insulating rod. It has an opening.

According to some embodiments of the present disclosure, the material of the first insulating layer comprises epoxy resin, silicone non-combustible paint, or enamel paint.

According to some embodiments of the present disclosure, the openings include slot openings to surround and partially expose the insulating rod.

According to some embodiments of the present disclosure, the openings include dot openings to partially expose the insulating rod.

According to some embodiments of the present disclosure, the connection portion is in contact with the first winding and the second winding through the opening of the first insulating layer.

According to some embodiments of the present disclosure, a second insulating layer covering the first insulating layer and the connection portion is provided, and the opening of the first insulating layer is filled.

According to some embodiments of the present disclosure, the material of the second insulating layer comprises epoxy resin, silicone non-combustible paint, or enamel paint.

According to some embodiments of the present disclosure, the fuse resistor further includes a first cap and a second cap, the first cap electrically welded from the first end of the insulating rod to the one end of the first winding. And the second cap is electrically welded from the second end of the insulating rod to one end of the second winding.

According to some embodiments of the present disclosure, a fuse resistor includes a first electrical cover layer electrically connecting one end of a first winding to a first cap and one end of a second winding to a second cap. And a second electrical cover layer for connection.

According to some embodiments of the present disclosure, the material of the first electrical cover layer and the second electrical cover layer comprises tin, copper, iron, silver, nickel, or alloys thereof, respectively.

According to some embodiments of the present disclosure, the thickness of the first electrical cover layer and the second electrical cover layer are each between 1 and 20 micrometers.

Another embodiment of the present disclosure provides a method of manufacturing a fuse resistor, the method including providing an insulating rod, winding a winding around the insulating rod, cutting the winding, and separating them from each other. Forming a first winding and a second winding, forming a connecting portion , and electrically connecting the first winding to the second winding, the melting point of the connecting portion is the first winding. And lower than the melting point of the second winding.

According to some embodiments of the present disclosure, a method of manufacturing a fuse resistor includes forming an insulating rod and a first insulating layer on the winding before cutting the winding, and forming an opening in the first insulating layer. And cutting the winding.

According to some embodiments of the present disclosure, the openings include slot openings to surround and partially expose the insulating rod.

According to some embodiments of the present disclosure, the openings include dot openings to partially expose the insulating rod.

According to some embodiments of the present disclosure, the manufacturing method of the fuse resistor, forming a second insulating layer, covering the first insulating layer and connecting portion, the filling in the openings of the first insulating layer Further includes.

According to some embodiments of the present disclosure, a method of manufacturing a fuse resistor includes forming a first cap on a first end of an insulating rod and forming a second cap on a second end of the insulating rod. Further comprising forming.

According to some embodiments of the present disclosure, a method of making a fuse resistor includes electrically welding one end of a winding to a first cap and electrically welding the other end of the winding to a second cap. Further includes.

According to some embodiments of the present disclosure, a method of making a fuse resistor includes electrically connecting one end of a first winding to a first cap using a first electrical cover layer, and a second electrical cover layer. The method further includes electrically connecting one end of the second winding to the second cap using the cover layer.

According to some embodiments of the present disclosure, the first electric cover layer, the second electrical cover layer, and the connecting portion is formed with the same process.

For the best understanding, it is recommended that the present disclosure be read with reference to the accompanying drawings and detailed description thereof. In order to comply with industry standards, the drawings in this patent specification are not necessarily drawn to scale. In some drawings, the dimensions may be intentionally enlarged or reduced to help the reader understand the contents.

FIG. 1 illustrates a fuse resistor according to an embodiment of the present disclosure.

FIG. 2 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure. FIG. 3 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure. FIG. 4 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure. FIG. 5 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to an embodiment of the present disclosure.

FIG. 6 illustrates a fuse resistor according to another embodiment of the present disclosure.

FIG. 7 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to another embodiment of the present disclosure. FIG. 8 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to another embodiment of the present disclosure. FIG. 9 is a schematic diagram illustrating a method of manufacturing a fuse resistor according to another embodiment of the present disclosure.

This disclosure provides many different embodiments or examples for implementing various features of this disclosure. For ease of explanation, this disclosure also describes examples of particular components and arrangements. These examples are provided for demonstration purposes only and are not intended to be limiting. For example, a method in which the first feature in the following description is on or above the second feature may include certain embodiments in which the first feature is in direct contact with the second feature, or the first feature and the second feature. Different embodiments may be included in which other features are formed between the first and second features such that the two features are not in direct contact. Additionally, various examples of the present disclosure use repetitive reference numbers and/or text annotations for the purpose of simplifying and clarifying the document, which repetitive reference numbers and annotations It does not prescribe the relationship between and.

Further, in the present disclosure, the spatially relative terms “beneath”, “below”, “lower”, “above”, “Upper,” “on,” etc. refer to one element or feature and another element or features, as shown in the figure, for ease of explanation. Describe the relative relationship. In addition to the angular orientations shown in the figures, these spatially relative terms are also used to describe possible angles and orientations of the device during use or operation. The angular orientation of the device can vary (in 90 degrees or other directions) and the spatially relative descriptions used in this disclosure can be interpreted as well.

Please refer to FIG. FIG. 1 is a diagram illustrating a fuse resistor according to an embodiment of the present disclosure. As shown in FIG. 1, the fuse resistor 1 of the present embodiment includes an insulating rod 10, a first winding 22, a second winding 24, and a connecting portion 26. The insulated wire 10 has a first end 101 and a second end 102. The insulating rod 10 of the present embodiment may include a ceramic rod, but the material is not limited to the ceramic material, and any insulating material such as glass fiber that can achieve the object of the present disclosure can be used. In addition, the insulating rod 10 of the present embodiment has a cylindrical shape, but is not limited to this.

The first winding 22 is wound around the insulating rod 10 from the first end 101, and the second winding 24 is wound around the insulating rod 10 from the second end 102. The windings 24 are not directly connected and have a gap between them. In some embodiments, the first winding 22 and the second winding 24 are spirally wound on the insulating rod 10. In some embodiments, the first winding 22 and the second winding 24 are spirally wound on the insulating rod 10. In some embodiments, the gap between the first winding 22 and the second winding 24 is between about 0.05 millimeters (mm) and about 2 millimeters. The connecting portion 26 is arranged between the first winding 22 and the second winding 24, and the length of the connecting portion 26 is the It may be slightly larger than the gap between the one winding 22 and the second winding 24. The melting point of the connecting portion 26 is lower than the melting points of the first winding 22 and the second winding 24, the first winding 22 and the second winding 24 are separated from each other, and are electrically connected via the connecting portion 26. It

In the present embodiment, the materials of the first winding 22 and the second winding 24 may include or be selected from materials having a melting point higher than that of the connecting portion 26. For example, the melting points of the first winding 22 and the second winding 24 are between about 800 and 1500 degrees Celsius, and the melting point of the connecting portion 26 is less than about 500 degrees Celsius, or less than about 300 degrees Celsius. obtain. It is between, but not limited to, about 200 degrees Celsius to 300 degrees Celsius. The material of the first winding 22, the second winding 24, and the connecting portion 26 can be determined according to the electrical and safety specifications of the resistor. In some embodiments, the material of the first winding 22 and the second winding 24 can include or be selected from nickel copper alloys, or other suitable refractory conductive metals, or alloy materials. obtain. Further, the material of the connecting portion 26, tin, copper or other low melting conductive metal or may comprise an alloy material, or may be selected from them. With the above configuration, when the operating current of the fuse resistor 2 of the present embodiment exceeds the rated current, the low melting point connecting portion 26 has a low fusing temperature and a high fusing speed. Therefore, first, in order to protect the circuit. Fused. It is also worth noting that in normal operation, the operating temperature of the fuse resistor 1 is less than about 70 degrees, so that the connecting portion 26 having a low melting point does not affect the normal operation of the fuse resistor 1.

In some embodiments, the fuse resistor 1 can further include a first insulating layer 12 that covers the first winding 22 and the second winding 24. The first insulating layer 12 has an opening 12S that exposes a part of the insulating rod 10. In some embodiments, the material of the first insulating layer 12 can include or be selected from insulating paints such as epoxy resins or other insulating materials. In some embodiments, the connecting portion 26 is in contact with the first winding 22 and the second winding 24 through the opening 12S of the first insulating layer 12. In some embodiments, the openings 12S in the first insulating layer 12 can include slot openings that surround the insulating rod 10 and partially expose the insulating rod 10. In some embodiments, the width of the slot opening in the first insulating layer 12 is between, but not limited to, about 0.05 mm to about 2 mm.

In some embodiments, the fuse resistor 1 can further include a second insulating layer 14 that covers the first insulating layer 12 and the connection layer 26 and fills the opening 12S of the first insulating layer 12. In some embodiments, the material of the second insulating layer 14 can include or be selected from insulating paints such as epoxy resins, silicone non-combustible paints, enamel paints, or other insulating materials.

In some embodiments, the fuse resistor 1 can further include a first cap 32 and a second cap 34. The first cap 32 covers the first end 101 of the insulating rod 10 and is electrically connected to the first winding 22, and the second cap 34 covers the second end 102 of the insulating rod 10 and the second winding. Electrically connected to 24. In some embodiments, the material of the first cap 32 and the second cap 34 can include iron, steel, aluminum, copper, other metals, alloys, or graphite materials. In some embodiments, one end of the first winding 22 may be first welded to the first cap 32 and one end of the second winding 24 may be first welded to the second cap 34. In some embodiments, the fuse resistor 1 includes a first electrical cover layer 361 that electrically connects one end of the first winding 22 to the first cap 32 and one end of the second winding 24 to the second cap 34. It may further include a second electrical cover layer 362 for electrical connection. In some embodiments, the materials of first electrical cover layer 361 and second electrical cover layer 362 can include, but are not limited to, tin, copper, iron, silver, nickel, or other alloys. In some embodiments, the first electrical cover layer 361 and the second electrical cover layer 362 can be formed by, but not limited to, electroplating. In some embodiments, the first electric cover layer 361, the second electric cover layer 362 and the connecting portion 26, in order to simplify the manufacturing steps can be produced by the same process. In some embodiments, the thicknesses of the first electrical cover layer 361 and the second electrical cover layer 362 are between about 1 micrometer and about 20 micrometers, respectively, but are not limited thereto. Under surge shock conditions, approximately 90% or more of the damage to conventional wound resistors occurs at the weld between the winding and the cap, resulting in an open circuit failure. Therefore, the first electric cover layer 361 and the second electric cover layer 362 can be used to reinforce the welded portions of the first winding 22 and the second winding 24, respectively, and increase the hardness of the welded portions, resulting in poor production. Rate, and further improve the reliability of the weld point. The welding strength of the first winding 22 and the second winding 24 is ensured by the first electric cover layer 361 and the second electric cover layer 362, and may enhance the anti-surge effect of the fuse resistor 1. it can.

In some embodiments, the fuse resistor 1 extends outwardly from the first cap 32 and electrically connects the first wire 42 to the first cap 32, and outwardly from the second cap 34 to the second cap 34. And a second wire 44 electrically connected to. The first wire 42 and the second wire 44 can be electrically connected to an external circuit such as a printed circuit board.

See Table 1. The results of the fusing test of the fuse resistor in the comparative example and the embodiment of the present disclosure are listed in Table 1.

In the fusing test of Table 1, the resistance value specifications of the fuse resistor of the comparative example and the fuse resistor of the embodiment of the present disclosure are both 1Ω, and the power specification is 2 watts (W). The first winding and the second winding of the fuse resistor of the comparative example are directly connected, and the first winding and the second winding of the fuse resistor in the embodiment of the present disclosure are electrically connected via the low melting point connection portion. To be done. For example, the material of the connection part is tin may be formed by electroplating. As shown in Table 1, the error between the resistance values of the fuse resistor of the comparative example and the fuse resistor of the embodiment of the present disclosure is within the allowable error range (±5%), and the fusing power is increased by 40 times. In the set state, the fusing time and the fusing temperature of the fuse resistor according to the embodiment of the present disclosure are both lower than those of the fuse resistor according to the comparative example, and the fuse resistor according to the embodiment of the present disclosure has an effect of protecting the circuit. Proof that it will be enhanced.

Please refer to FIGS. 2 to 5 are schematic diagrams showing a method for manufacturing a fuse resistor according to an embodiment of the present disclosure. As shown in FIG. 2, an insulating rod 10 is provided. The insulating rod 10 has a first end 101 and a second end 102. Then, the winding 21 is wound around the insulating rod 10. In some embodiments, the first cap 32 and the second cap 34 may be formed on both sides of the insulating rod 10, but outside the first cap 32 and the second cap 34, the first wire 42 and the second cap 42, respectively. The wire 44 can be formed outward. In some embodiments, the ends of winding 21 can be welded to first cap 32 and second cap 34, respectively, by electrical welding. For example, one end of the winding wire 21 is first electrically welded to the first cap 32, then the winding wire 21 is wound around the insulating rod 10, and then the other end of the winding wire 21 is electrically welded to the second cap 34. be able to.

As shown in FIG. 3, the first insulating layer 12 is formed on the insulating rod 10 and the winding wire 21. Next, as shown in FIG. 4, the opening 12S is formed in the first insulating layer 12, the winding 21 is cut, and the first winding 22 and the second winding 24 which are separated from each other are formed. In some embodiments, the opening 12S in the first insulating layer 12 is a slot opening that surrounds the insulating rod 10 and partially exposes the insulating rod 10. In some embodiments, forming the slot opening in the first insulating layer 12 and forming the cut in the winding 21 can be performed simultaneously. In some embodiments, forming the slot opening in the first insulating layer 12 and cutting the winding 21 can be performed using a cutting tool, but is not limited thereto. As shown in FIG. 5, a connecting portion 26 that electrically connects the first winding 22 and the second winding 24 is formed. In some embodiments, the connection portion 26, electroplating, may be formed by dipping the tin bath or other suitable processes. In some embodiments, a first electrical cover layer 361 is provided to enhance the strength of the weld between the first winding 22 and the first cap 32 and the weld between the second winding 24 and the second cap 34. Electrically connecting (eg, electroplating) one end of the first winding 22 to the first cap 32 and using the second electrical cover layer 362 to connect one end of the second winding 24 to the second cap. An electrical connection (eg, electroplating) to 34 can be made to increase the reliability of the weld point. As shown in FIG. 1, then, the second insulating layer 14 is formed so as to cover the first insulating layer 12 and the connecting portion 26, and the opening 12S of the first insulating layer 12 is filled with the second insulating layer 14 to realize the embodiment of the present disclosure. The fuse resistor 1 is manufactured.

The fuse resistor of the present disclosure is not limited to the embodiments described above and may have other different embodiments. To simplify the description and facilitate comparison between the embodiments of the present disclosure, the same components in the following embodiments are denoted by the same reference numerals. In order to more easily compare the differences between the embodiments, the following description details the differences between the different embodiments and does not repeat the same features and related details.

Please refer to FIG. FIG. 6 is a schematic diagram illustrating a fuse resistor according to another embodiment of the present disclosure. As shown in FIG. 6, unlike the fuse resistor 1 of FIG. 1, the opening 12S of the first insulating layer 12 of the fuse resistor 2 of the present embodiment has a dot opening that partially exposes the insulating rod 10. Including. In some embodiments, the shape of the dot openings can include any regular or irregular geometric shape. In some embodiments, the width or diameter of the dot openings is between but not limited to about 0.05 mm to about 2 mm. In the present embodiment, the material of the first insulating layer 12 may include or be selected from insulating paints such as epoxy resin, silicone non-flammable paint, enamel paint, or other insulating material. The connecting portion 26 is in contact with the first winding 22 and the second winding 24 through the opening 12S of the first insulating layer 12. The second insulating layer 14 covers the first insulating layer 12 and the connection layer 26 and fills the opening 12S of the first insulating layer 12. In the present embodiment, the material of the second insulating layer 14 may include or be selected from insulating paints such as epoxy resin, silicone non-flammable paint, enamel paint, or other insulating material. The insulating rod 10, the first winding 22, the second winding 24, the connection layer 26, the first cap 32, the second cap 34, the first electric cover layer 361, and the second electric cover of the fuse resistor 2 in the present embodiment. The location, connection method, materials, and other properties of components such as layer 362, first wire 42, and second wire 44 are similar to those of fuse resistor 1 of FIG. 1 and will not be repeated here.

Please refer to FIGS. 7 to 9 are schematic views showing a method of manufacturing a fuse resistor according to another embodiment of the present disclosure. As shown in FIG. 2, an insulating rod 10 is provided. The insulating rod 10 has a first end 101 and a second end 102. Then, the winding 21 is wound around the insulating rod 10. In some embodiments, the first cap 32 and the second cap 34 may be formed on both sides of the insulating rod 10, but outside the first cap 32 and the second cap 34, the first wire 42 and the second cap 42, respectively. The wire 44 can be formed outward. In some embodiments, the ends of winding 21 can be welded to first cap 32 and second cap 34, respectively, by electrical welding. For example, one end of the winding wire 21 is first electrically welded to the first cap 32, then the winding wire 21 is wound around the insulating rod 10, and then the other end of the winding wire 21 is electrically welded to the second cap 34. be able to. Subsequently, the first insulating layer 12 is formed on the insulating rod 10 and the winding wire 21.

As shown in FIG. 8, the opening 12S is formed in the first insulating layer 12, the winding 21 is cut, and the first winding 22 and the second winding 24 which are separated from each other are formed. In some embodiments, the opening 12S of the first insulating layer 12 is a dot opening that partially exposes the insulating rod 10. In some embodiments, forming the dot openings in the first insulating layer 12 and forming the cuts in the windings 21 can be performed simultaneously. In some embodiments, for example, forming the dot openings in the first insulating layer 12 and cutting the windings 21 can be performed using a cutting tool. As shown in FIG. 9, a connecting portion 26 is formed in the dot opening in order to electrically connect the first winding wire 22 to the second winding wire 24. In some embodiments, the connection portion 26, electroplating, may be formed by dipping the tin bath or other suitable processes. In some embodiments, a first electrical cover layer 361 is provided to enhance the strength of the weld between the first winding 22 and the first cap 32 and the weld between the second winding 24 and the second cap 34. Electrically connecting (eg, electroplating) one end of the first winding 22 to the first cap 32 and using the second electrical cover layer 362 to connect one end of the second winding 24 to the second cap. An electrical connection (eg, electroplating) to 34 can be made to increase the reliability of the weld point. As shown in FIG. 6, then, the second insulating layer 14 is formed so as to cover the first insulating layer 12 and the connection portion 26, and the opening 12S of the first insulating layer 12 is filled with the second insulating layer 14 to form the second embodiment The fuse resistor 2 is manufactured.

In the fuse resistor of the present disclosure, since the first winding and the second winding are electrically connected using the connection portion , the fusing temperature and fusing speed of the resistor can be controlled, and the application range and safety of the resistor can be improved. Improve. In addition, in the fuse resistor of the present disclosure, the electrical cover layer is used to reinforce the weld point between the winding and the cap, increasing the hardness of the weld, avoiding loosening of the winding, and manufacturing failure. To reduce. Therefore, the fuse resistor of the present disclosure has a failure rate of the surge resistant welding point of less than 0.1 ppm. The fuse resistor of the present disclosure can improve the anti-surge effect of the fuse resistor, and can be applied to circuits such as anti-surge circuits of automobiles and motorcycles, spark plugs, and ignition systems.

Although this disclosure has been described in considerable detail with reference to its specific embodiments, these descriptions and illustrations are not intended to limit this disclosure. Those skilled in the art can make various changes and can replace equivalent elements in the embodiments without departing from the spirit and scope of the present disclosure as defined in the appended claims. Will be clearly understood by.

Claims (21)

A fuse resistor,
Including an insulating rod having a first end and a second end,
A first winding that winds the insulating rod from the first end of the insulating rod;
The second winding and the upper connecting wire around which the insulating rod is wound from the second end of the insulating rod are arranged between the first winding and the second winding,
The melting point of the connection wire is lower than the melting points of the first winding and the second winding,
The first winding and the second winding are separated from each other,
A fuse resistor electrically connected through the connection wire. The fuse resistor according to claim 1, further comprising a first insulating layer, the first insulating layer covering the first winding and the second winding, and the first insulating layer having an opening exposing a part of an insulating rod. .. The fuse resistor according to claim 2, wherein the material of the first insulating layer includes an epoxy resin, a silicone nonflammable paint, or an enamel paint. The fuse resistor according to claim 2, wherein the opening includes a slot opening, and the opening is partially exposed by surrounding the insulating rod. The fuse resistor according to claim 2, wherein the opening includes a dot opening to partially expose the insulating rod. The fuse resistor according to claim 2, wherein the connection wire is in contact with the first winding and the second winding through the opening of the first insulating layer. The fuse resistor according to claim 6, further comprising a second insulating layer covering the first insulating layer and the connection wire, the second insulating layer filling the opening of the first insulating layer. The fuse resistor according to claim 7, wherein the material of the second insulating layer includes an epoxy resin, a silicone nonflammable paint, or an enamel paint. Further comprising a first cap and a second cap, wherein the first cap covers from the first end of the insulating rod and is electrically connected to one end of the first winding, and the second cap is the insulating rod. The fuse resistor according to claim 1, wherein the fuse resistor is covered from the second end portion and electrically connected to one end of the second winding. The first electrical cover layer electrically connecting one end of the first winding to the first cap, and the second electrical cover layer electrically connecting one end of the second winding to the second cap. Fuse resistor described. The fuse resistor according to claim 10, wherein the materials of the first electrical cover layer and the second electrical cover layer each include tin, copper, iron, silver, nickel, or alloys thereof. 11. The fuse resistor of claim 10, wherein the first electrical cover layer and the second electrical cover layer each have a thickness between 1 and 20 micrometers. A method of manufacturing a fuse resistor,
Provide insulation rod,
Winding a wire around the insulating rod,
Cutting the winding to form a first winding and a second winding separated from each other, and further forming a connecting wire for electrically connecting the first winding to the second winding;
The method of manufacturing a fuse resistor, wherein the melting point of the connection wire is lower than the melting points of the first winding and the second winding. Forming a first insulating layer on the insulating rod and the winding before cutting the winding;
The method of manufacturing a fuse resistor according to claim 13, further comprising: forming an opening in the first insulating layer and cutting the winding. 15. The method of manufacturing a fuse resistor according to claim 14, wherein the opening includes a slot opening, and the opening is partially exposed by surrounding the insulating rod. The method of manufacturing a fuse resistor according to claim 14, wherein the opening includes a dot opening, and the insulating rod is partially exposed. Forming a second insulating layer,
Covering the first insulating layer and the connecting wire,
15. The method of manufacturing a fuse resistor according to claim 14, further comprising filling the opening of the first insulating layer. 14. The method of manufacturing a fuse resistor according to claim 13, further comprising covering the first cap from the first end of the insulating rod and covering the second cap from the second end of the insulating rod. 19. The method of manufacturing a fuse resistor according to claim 18, further comprising electrically welding one end of the winding to the first cap and electrically welding the other end of the winding. Electrically connecting one end of the first winding to the first cap using a first electrical cover layer, and using one end of the second winding to the second cap using a second electrical cover layer. 20. The method of manufacturing a fuse resistor of claim 19, further comprising electrically connecting. 21. The method of claim 20, wherein the first electrical cover layer, the second electrical cover layer, and the connecting wire are formed together by the same process.

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