KR100258965B1 - Metal register producing method - Google Patents

Abstract

PURPOSE: A method for making metallic register is provided to improve performance of a register by using a sodium oxide, an aluminum oxide and a silicon oxide as an insulating paste. CONSTITUTION: A substrate uses of stainless plate. The substrate cuts a predetermined size and cleans. The lower insulating layer is formed of the surface of the substrate, which uses an insulating paste such as a sodium oxide, an aluminum oxide and a silicon oxide. A composition ratio of each ingredients 10-25 by weight of sodium oxide, 10-30 by weight of aluminum oxide and 50-80 by weight of silicon oxide. The substrate, coated on the lower insulating layer, performs a plastic working. The paste mixing a silver power with a palladium power prints on the insulating layer, which dries, forms a resisting layer. The paste, mixing a silver power with a palladium power, coats on the resisting layer. The protecting membrane is formed by plastic working at 550-530°C.

Description

Manufacturing method of metal register

The present invention relates to a method of manufacturing a metal register for speed control of a vehicle blower and an air conditioner.

Conventionally, as a speed control resistor for a vehicle blower, an air conditioner, etc., it is provided on an insulated substrate, The resistor which melt | dissolves and cuts when an overcurrent flows, The some terminal connected to predetermined part of this resistor, and the heat which generate | occur | produces in this resistor It is known to have a heat radiating fin to radiate heat, and to fix a heat radiating plate on an insulating substrate, and to fix the heat radiating fin on the heat sink using adhesive materials such as soldering (Utility Model Publication Nos. 92-7514 and 95-3082, No. 92-7513, No. 93-7605, No. 62-14075, No. 62-147302, etc.).

However, since the metal resistors as described above attach heat radiating fins on the substrate, the manufacturing process is complicated and uneconomical, and since the substrate is made of a material such as ceramics, the heat dissipating fins do not attach the heat radiating fins because the substrate is overheated and damaged. As a result, they are not only bulky, difficult to thin, but also expensive to manufacture and time-consuming to mass produce.

In order to solve this problem, a substrate can be made compact and mass-produced by using a steel sheet, in particular, a stainless plate, as a substrate, applying a ceramic, in particular, an aluminum oxide paste, and firing it on the substrate. However, when coated with such a material, the softening point is only about 650 ° C., so that it is difficult to use it because it is deformed or swelled when forming a screen circuit. In order to solve this problem, Germany's Heraeus company sells a paste that can be used on steel sheets. Such a paste is composed of barium oxide, aluminum oxide and silica, and it is known that such a paste can be applied to a steel sheet and fired at about 850 ° C. However, in practice, such a paste is difficult to be used in a water-soluble resin because it is difficult to disperse in a general water-soluble resin, and thus the working environment is bad, and because the paste itself is expensive, the manufacturing cost is increased and the competitiveness is weak. In addition, coating the steel sheet with the paste, screen printing and then protective coating again requires firing at a low temperature, such as 550-600 ° C., to protect the screen circuitry, which is not suitable for baking at such a low temperature. There is this.

MEANS TO SOLVE THE PROBLEM As a result of earnestly researching in order to solve the said problem, the present inventor prepared the composition which improved dispersibility in water-soluble resin using the composition of sodium oxide, aluminum oxide, and silicon oxide as an insulation paste, and this is a well-known method on a board | substrate. And then fired at 890-940 ° C., printed thereon with a paste of a mixture of silver powder and palladium powder in a fixed ratio, dried, and then fired to form a resistive layer, followed by sodium oxide, aluminum oxide, Discovering that metal resistors can be manufactured in an economical and compact manner by eliminating conventional problems by coating titanium oxide and potassium oxide with a paste mixed with a resin and baking at 550-630 ° C. to form an upper protective film. The present invention has been completed.

It is an object of the present invention to provide a method of manufacturing a metal register.

The present invention also provides a paste for producing the metal register.

1 shows various patterns of the resistance element of the metal resistor of the present invention.

Figure 2 shows the configuration of the reliability test equipment of the metal resistor.

Hereinafter, the present invention will be described in detail.

In the present invention, a stainless plate is used as the substrate. The substrate is cut to a predetermined size and washed, and then a lower insulator layer is formed. The lower insulator layer uses a paste obtained by dispersing a composition of sodium oxide, aluminum oxide and silicon oxide in a water soluble resin. The composition ratio of each component is composed of 10-25 parts by weight of sodium oxide (Na ₂ O), 10-30 parts by weight of aluminum oxide (Al ₂ O ₃ ) and 50-80 parts by weight of silicon oxide (SiO ₂ ). It is preferable to use fine powder of 250 mesh or more in size. In the case where the particles are larger than the above-mentioned size, they are used by grinding with a ball mill or the like. If the amount of sodium oxide in the composition exceeds the above range, the amount of aluminum oxide or silicon oxide is relatively small, so that the composition is calcined, and then the stability is lowered, and the coating layer swells and is carbonized to cause degeneration. If it is less than the above range, it is not preferable because the dispersibility is poor in the water-soluble resin. If the amount of aluminum oxide and silicon oxide exceeds the above range, the dispersibility is poor in the water-soluble resin, and if the amount is less than the above range, the coated surface is swelled or the stability is not preferable.

The composition is sufficiently dispersed by mixing the water-soluble acrylic resin in 1 to 5 parts by weight based on the composition, and then sprayed by controlling the amount of water to enable spraying, drying at 180 to 220 ° C, and then calcining at 880 to 930 ° C A lower insulator layer is formed on the substrate.

A resistive element paste layer is formed on the substrate thus obtained. The resistance paste layer is composed mainly of silver powder and palladium, and if necessary, a small amount of lead oxide, cadmium oxide, bismuth oxide, and the like are mixed in order to improve adhesion, and the polyester resin is butyl cellulose, which is a solvent. After dissolving in sol acetate at a ratio of 1.2-2: 1, a mixture of silver powder and palladium powder was added thereto to prepare a paste, which was printed on one side of the substrate obtained above, and then subjected to about 30 at 180 to 230 캜. After drying for about 30 minutes, baking was carried out at 810 to 860 ° C for about 30 minutes to form a resistive element paste layer. The composition ratio of silver powder and palladium depends on the desired resistance value, but it is preferable to mix silver powder: palladium powder = 6-3: 1 for the metal resistor of a general passenger car and a commercial vehicle, and it is preferable to mix with silver powder and palladium It is preferable that content of resin shall be 7: 3-8: 2.

In order to protect the resistive element paste layer of the board | substrate obtained above, a protective film is formed on a resistive element paste layer.

This protective film prepares a mixture of fine sodium oxide, aluminum oxide, silica, titanium oxide and potassium oxide of 250 mesh or more, respectively. Meanwhile, 12 to 20 parts by weight of butyl carbitol were mixed with 0.8 to 1.2 parts by weight of dibutyl phthalate, and then 1.2 to 2.0 parts by weight of acrylic resin and 1.5 to 2.5 parts by weight of ethyl cellulose were added thereto to prepare a resin mixture. The mixture is mixed well here to make a uniform paste dispersion. The paste is applied onto the resistive element paste layer, dried in an oven at about 180-230 ° C. for about 30 minutes, and then fired at 600-620 ° C. for about 30 minutes to produce a metal resistor. The component ratio of the mixture is preferably sodium oxide: aluminum oxide: silica: titanium oxide: potassium oxide = 10-30: 1-10: 20-50: 10-30: 10-20 (parts by weight). Here, the purpose of using sodium oxide, aluminum oxide and silica is the same as the purpose of the lower insulating paste composition, and titanium oxide and potassium oxide are included in order not to change the resistance to lower the heating temperature. In the process of forming the protective film, the firing temperature of 600-620 ° C. may cause the resistance element to denature when firing at a temperature higher than this. If the temperature is lower than this temperature, the formation layer may be broken or partially damaged. Since there is a possibility of falling, there is a problem that performance as a protective film cannot be guaranteed.

Hereinafter, the present invention will be described in more detail as examples. However, the present invention is not limited by this embodiment.

Example 1

The SUS steel sheet prepared in the shape shown in FIG. 1 is washed and prepared.

(1) Formation of Insulation Layer

Grind with a ball mill and disperse 100 g of a mixture of sodium oxide: aluminum oxide: silica = 15: 20: 65 (weight ratio) in a 250 mesh mixture to 3 g of acrylic resin, and add 50 ml of water so that spray coating can be applied to the insulating paste. Ready.

The insulating paste was spray sprayed onto the substrate, dried in an oven at 200 ° C. for 30 minutes, and then fired at 900-910 ° C. for 30 minutes. The thickness of the insulating paste layer on the substrate thus obtained was 120 µm.

(2) Formation of Resistance Element Paste Layer

First, a polyester resin was dissolved in butylcellulsolve acetate, a solvent, in a ratio of 1.4: 1, and then a paste was prepared by mixing a 6: 1 mixture of silver powder and palladium in a 250 mesh passage in a ratio of 7: 3 to the solution. Then, this screen-printed to the shape having the size and length shown in Figure 1 on one surface of the substrate obtained above, dried for 30 minutes in an oven at about 200 ℃, and then baked for 30 minutes at 850 ℃ to form a resistive element paste layer Formed. The thickness of the resistive element paste layer thus obtained was about 15 μm.

At this time, the resistance value is adjusted according to the width and length of the printed paste.

That is, the resistance value is different depending on the shape as shown in Figure 1, the resistance value of each terminal is as shown in Table 1. This resistance value is a setting reference according to the capacity of the air conditioner of the vehicle air conditioner manufacturer, and this resistance value is calculated by the following equation.

L / b ÷ 100

(Wherein L represents the length of the resistance pattern, b represents the width of the resistance pattern)

(3) Formation of protective film of resistive element paste layer

First, 15 parts by weight of butyl carbitol and 1.0 part by weight of dibutyl phthalate were mixed, 1.5 parts by weight of an acrylic resin and 2 parts by weight of ethylcellulose were added thereto, followed by sufficient mixing to prepare a resin mixture.

On the other hand, a mixture of sodium oxide: aluminum oxide: silica: titanium oxide: potassium oxide = 10-30: 1-10: 20-50: 10-30: 10-20 (parts by weight) of 250 mesh passes in the resin mixture After the addition, the mixture was sufficiently stirred to prepare a uniform paste. The paste was applied onto the resistive element paste layer, dried in an oven at about 200 ° C. for about 30 minutes, and fired at about 610 ° C. for about 30 minutes to prepare a metal resistor. . The thickness of the resistive element paste protective film layer thus obtained was about 20 μm.

Example 2

A metal resistor was manufactured in the same manner except that 2 parts by weight of lead oxide was added to the paste in order to enhance adhesion in the formation of the resistive element paste layer of Example 1.

Test Example 1

Using the test piece obtained according to the method of Example 1 was carried out the following test items.

1) Reliability Test

Reliability test is a commercial test equipment consisting of a power supply (DC), a multi-tester, a stopwatch, a recorder shown in Figure 2, the test method under the conditions of a DC power supply (DC 12V) at room temperature as follows. That is, as shown in FIG. 2 in the motor (blower) lock state, a direct current 12V was applied to the blower motor to measure the temperature fuse short circuit time for each mode. At this time, the criterion is shorted within 3 minutes.

The results are shown in Table 1.

TABLE 1

Sample NO Terminal resistance Short time Current (A) Hi-MH Hi-ML Mi-Lo Hi-MH Hi-ML Hi-lo standard 0.29 ± 10% 1.08 ± 10% 2.240 ± 10% Within 3 minutes Tolerance 0.261-0.319 0.972-1.188 2.016-2.464 # One 0.297 1.069 2.184 26 seconds 6.3 # 2 0.306 1.092 2.184 24 sec 6.2 # 3 0.310 1.006 0.062 22 seconds 6.5 # 4 0.306 1.026 0.069 45 seconds 4.4 # 5 0.310 1.074 0.168 1 minute 11 seconds 4.0 # 6 0.303 1.012 2.075 45 seconds 4.2 # 7 0.312 1.012 0.071 1 minute 3.7 # 8 0.317 1.079 2.191 1 minute 10 seconds 3.5 # 9 0.303 1.010 2.180 59 seconds 3.6

In Table 1, Hi-MH represents the degree of resistance from high to medium high, Hi-ML represents the degree of resistance from high to medium low, and Hi-Lo represents the degree of low to high resistance. The register prepared in Example 1, and # 7 to # 9 are the registers obtained in Example 2.

It can be seen from the above test examples that the metal registers of the present invention are all highly reliable.

2) thermal shock test

Thermal shock test was performed using the metal resistors of Table 1. In the thermal shock test, one cycle was maintained for 5 minutes at room temperature, 1 hour at 85 ° C, and 1 hour at room temperature for 5 minutes -40 ° C.

3) High temperature operation test

The stability of the resistor was tested when the power supply voltage was maintained at 13.5 ± 0.5 ° C., test temperature 60 ° C., and test time 72 hours.

4) Low temperature operation test

The stability of the resistor was tested when the power supply voltage was maintained at 13.5 ± 0.5 ° C, test temperature of −30 ° C, and test time of 72 hours.

5) Normal humidity test

The humidity stability of the resistor was tested for 96 hours at a supply voltage of 13.5 ± 0.5 ° C, a test temperature of 60 ° C, and a humidity of 95%. There was no abnormality.

From the above test, it was confirmed that the metal resistor of the present invention had no floating phenomenon and cracks, had excellent insulation and breakdown voltage characteristics, and had excellent resistance characteristics at high or low temperatures.

The metal resistor of the present invention described above is a useful invention which is lightweight, inexpensive and easy to manufacture in large quantities, and has excellent performance as a resistor, compared to using a conventional ceramic plate or having a heat radiating fin attached thereto.

Claims (4)

Using a composition of sodium oxide, aluminum oxide and silicon oxide as an insulating paste, a composition having high dispersibility in a water-soluble resin was applied onto a substrate, calcined at 890-940 ° C., and then a mixture of a silver powder and a palladium powder was placed thereon. After printing with a paste, drying and firing to form a resistive layer, coating with a paste obtained by mixing sodium oxide, aluminum oxide, titanium oxide and potassium oxide with a resin, and firing at 550-630 ° C. to form an upper protective film. A method of manufacturing a metal resistor, characterized in that. The method of claim 1, 10-25 parts by weight of fine powdered sodium oxide (Na ₂ O), 10-30 parts by weight of aluminum oxide (Al ₂ O ₃ ) and silicon oxide (SiO ₂ ) 50-80 as an insulating paste. A method in which parts by weight are mixed and dispersed in 1 to 5 parts by weight of a water-soluble acrylic resin. The method according to claim 1, wherein the paste composition for forming a resistive layer is obtained by dispersing a silver powder and a palladium powder 6: 1 mixture in a 1.4: 1 mixture of butylcellulsolve acetate of a polyester resin. 2. The protective layer forming paste composition according to claim 1, wherein 1.5 parts by weight of acrylic resin and 2 parts by weight of ethylcellulose are added to the mixture of 15 parts by weight of butyl carbitol and 1.0 parts by weight of dibutyl phthalate, and the mixture is sufficiently mixed to pass 250 mesh through the resin mixture. Sodium oxide: aluminum oxide: silica: titanium oxide: potassium oxide = 10-30: 1-10: 20-50: 10-30: 10-20 parts by weight.

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