US3742422A - High voltage resistor - Google Patents

High voltage resistor Download PDF

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Publication number
US3742422A
US3742422A US00200765A US3742422DA US3742422A US 3742422 A US3742422 A US 3742422A US 00200765 A US00200765 A US 00200765A US 3742422D A US3742422D A US 3742422DA US 3742422 A US3742422 A US 3742422A
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US
United States
Prior art keywords
housing
high voltage
substrate
resistive path
lead wire
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00200765A
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English (en)
Inventor
A Rozema
C Osburn
Benthuysen J Van
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CTS Corp
Original Assignee
CTS Corp
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Filing date
Publication date
Application filed by CTS Corp filed Critical CTS Corp
Application granted granted Critical
Publication of US3742422A publication Critical patent/US3742422A/en
Anticipated expiration legal-status Critical
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C1/00—Details
    • H01C1/08—Cooling, heating or ventilating arrangements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C1/00—Details
    • H01C1/02—Housing; Enclosing; Embedding; Filling the housing or enclosure
    • H01C1/028—Housing; Enclosing; Embedding; Filling the housing or enclosure the resistive element being embedded in insulation with outer enclosing sheath
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S174/00—Electricity: conductors and insulators
    • Y10S174/08—Shrinkable tubes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49082—Resistor making
    • Y10T29/49085—Thermally variable

Definitions

  • a high voltage electrical resistor comprises a resistive path supported on a dielectric hollow cylindrical substrate, termination means electrically connected to the resistive path, an insulation system and a heat dissipation system.
  • the high voltage end of the substrate is spaced from the wall of an insulative jacket by means of projections extending radially inwardly from the wall.
  • the low voltage end of the substrate is spaced from the wall of the jacket by means of a heat dissipating mounting member.
  • the termination means include insulated lead wires electrically connected to the resistive path with a lead wire adjacent the high voltage end of the substrate passing through a tubular projection of the jacket.
  • a heat shrunk sleeve forms a tight seal between the tubular projection and the lead wire.
  • Dielectric material fills the space between the substrate and the jacket forming a moisture impervious barrier around the resistive path and improving the dielectric strength of the resistor.
  • the prior inventions sought to replace the typical prior art circuit arrangement wherein a resistor module comprising a plurality of series connected fixed volume electrical resistors had been connected across a power supply of 20,000 or more volts.
  • the inventions of the above-identified applications eliminated the need for separate resistors by providing a single discrete high ohmic value resistor for use in a high voltage circuit application such that the precision, stability and quality thereof was determined by the characteristics of a single continuous resistive path.
  • Still another object of the present invention is to provide a tapped resistor wherein the substrate provides a continuous heat transfer path through the taps.
  • the present invention is concerned with an improved high voltage electrical resistor comprising a resistive path supported on a ceramic substrate, termination means electrically connected to the resistive path, and an insulation system.
  • the substrate provides a uniform and continuous heat dissipation path between the ends of the resistive path.
  • a thermally conductive heat dissipating mounting member is arranged in close proximity to the surface of the substrate.
  • An insulative jacket having an aperture in one end and an opening in the other end surrounds the substrate.
  • the termination means include an insulated lead wire electrically connected to the resistive path adjacent the high voltage end which projects through the aperture and substantially seals the aperture.
  • a plurality of projections extend from the interior wall of the housing into engagement with the substrate to maintain the resistive path at the high voltage end spaced from the wall of the housing.
  • the point of electrical connection between the insulated lead wire and the resistive path is also spaced from the wall of the housing by positioning the point relative to the projections.
  • the thermally conductive heat dissipating member provides means for maintaining the resistive path at the low voltage end spaced from the wall of housing.
  • Dielectric material is positioned between the resistive path and the wall of the housing thereby providing a moisture impervious barrier around the resistive path. The material also surrounds the termination thereby providing strain relief and means for preventing high voltage corona when the termination is connected to a high potential in the range of 20,000 volts or more.
  • FIG. 1 is an isometric view of the high voltage resistor made in accord with the present invention
  • FIG. 2 is a sectional view taken on the line IIII of FIG. 1;
  • FIG. 3 is a sectional view taken on the line IIIIII of FIG. 2 assuming FIG. 2 to be shown in full;
  • FIG. 4 is an exploded isometric view of the high voltage resistor shown in FIG. 1 with parts broken away to better disclose features of the present invention.
  • the preferred embodiment of the present invention comprises a high voltage resistor 10 comprising a jacket or cylindrical housing 11 of a dielectric material such as polypropylene having an aperture 12 in one end and an opening 13 in the other end.
  • a hollow cylindrical substrate 14 formed of a ceramic type material such as steatite or alumina is disposed within the housing 11 and has resistance means in the form of resistance material 16 defining a serpentine resistive path deposited by a printing or other suitable. process onto an outer surface of the sub strate 14.
  • the resistive path is comprised of an intersticed mass of inert electricallynonconductive particles uniformly distributed throughout the resistive path and a conductive phase forming an interstitial mass within the intersticed mass of the inert electrically nonconductive particles.
  • the uniformly spaced inert electrically nonconductive particles typically have an average size of 0.1 to 10 microns with the conductive phase filling the spaces between adjacent ones of the inert electrically nonconductive particles.
  • a binder bonds together the inert electrically nonconductive particles and the conductive phase.
  • the resistive path has a resistivity of l megohm per square and a voltage coefficient of 400 parts per million per volt per square of resistive path.
  • the resistance composition used in making the resistive path is similar to the resistance composition disclosed in the co-pending application Ser. No. 803,688 filed on Mar. 3, 1969, by L. J. Brady and entitled Electrical Resistance Elements, Their Composition, and Method of Manufacture. It will, however, be understood that resistance compositions other than those being disclosed in said co-pending application may also be used in the practice of the present invention.
  • the illustrated termination means includes two solderable conductive pads 17, 118 deposited adjacent the ends of the resistive path in electrical connection therewith and having insulated lead wires 21, 22 soldered thereto.
  • a third or additional solderable conductive pad 23 is deposited on the substrate intersecting the resistive path to provide the desired ratio between the resulting two portions of resistive pathand an insulated lead wire 22 is soldered to the pad.
  • the end of the substrate having the lead wire 117 secured thereto is referred to as the high voltage end whereas the other end of the substrate is referred to as the low voltage end.
  • solderable conductive pad 26 is deposited adjacent the low voltage end and positioning means in the form of a heat dissipating mounting member 27 is connected thereto by a deposit of solder.
  • This construction enables the heat dissipating mounting member 27 to dissipate relatively large amounts of heat away from the substrate during use of the resistor. It will be appreciated that the resistive path could be electrically connected to the solderable conductive pad 26 secured to the heat dissipating mounting member 27 whereby the heat dissipating mounting member 27 could also serve as termination means.
  • the heat dissipating mounting member 27 is provided with tubular centering means 28 defining the walls of a central aperture 29 projecting into the interior of the hollow substrate M to thereby center the substrate relative to the heat dissipating mounting member 27.
  • Frictional gripping means 31 extend from the heat dissipating mounting member into engagement with the interior wall of the cylindrical housing 11 to position the substrate 314 relative to the housing.
  • a latching tab 32 projects outwardly from the tubular centering means 28 having an angled portion 33 bent at an angle to the heat dissipating mounting member 27 and a lateral portion 34 extending outwardly of the housing from the angled portion 33.
  • a screw tab 36 also extends from the heat dissipating mounting member 27 having a hole therein for receiving a bolt or screw to secure the resistor to the mounting panel.
  • the tip 35 of the lateral portion 341 is disposed such that the distance between the tip 35 and a plane through the in terface of the heat dissipating mounting member is less than the thickness of the mounting panel.
  • positioning means in the form of a plurality of projections or fins 37 extend from the interior wall of the housing adjacent the aperture 12 into engagement with the substrate 14 adjacent the high voltage end.
  • a locating lug 38 projects from the exterior of the housing to enable external determination of the position of the fins 37.
  • two of the fins 37a, 37b project from the housing a distance greater than the distance a third fin 370 projects therefrom.
  • the high voltage end of the sub strate is inserted into the housing with the point of electrical connection 39 between the insulated lead wire 21 and the solderable conductive pad 17 being positioned between the two fins 37a, 37b, thus ensuring spacing between the point of electrical connection 39 and the wall of the housing.
  • the aperture T2 in the end of the housing is defined by a tubular projection 40 and is substantially sealed by introducing the insulated lead wire 21 therethrough. in order to provide ease of assembly it is necessary to have some tolerance between the tubular projection 40 and the insulated lead wire 21.
  • a heat shrinkable sleeve 41 is disposed over the tubular projection 40 and insulated lead wire 21 and heat shrunk to tightly seal the aperture.
  • the tubular projection 436) can be spin welded to the insulation of the insulated lead wire 21 in order to tightly seal the aperture.
  • the insulated lead wire 24 forming the tap and the insulated lead wire 22 secured to the low voltage end of the resistor are disposed in the space between the substrate 14 and the housing wall and inserted into individual lead break outs 42, 43, 45 adjacent the opening in the housing.
  • strain relief is provided since a force exerted on the lead wires 22, 24 will be in a direction different from the direction in which the lead wires 22, 24! are secured to the solderable conductive pads 118, 23. Since each of the lead wires 22, 24 has a separate break out, the possibility of shorting between the lead wires 22, 243 is minimized due to their physical separation.
  • the heat dissipating mounting member 29 When the high voltage end of the substrate 14 is positioned in engagement with the fins 37, the heat dissipating mounting member 29 is dis posed with its frictional gripping means 311 frictionally engaging the wall of the housing, thus positioning the substrate 14 so as to provide a space between the resistive path and the wall of the housing.
  • dielectric material 44 such as a polyurethane is inserted through the aperture 29 in the heat dissipating mounting member 27 whereby-the material passes through the center of the substrate and fills the space between the resistive path and the walls of the housing 11.
  • the lead break outs 42, 43, 45 provide vents for the escape of gases forming during insertion of the dielectric material 44. Since the point of electrical connection 39 between the insulated lead wire 21 and the solderable conductive pad 17 at the high voltage end of the substrate is spaced from the wall of the housing, the dielectric material also surrounds the point of electrical connection 39.
  • the dielectric material cures it forms a rigid moisture impervious barrier around the resistive path and insulated lead wires. In surrounding the insulated lead wires, the dielectric material adheres to the insulation of the lead wires and provides strain relief.
  • the dielectric strength of the resistor can be increased by tapering the crosssectional width of the housing wall such that the width of the wall is greater at the high voltage end.
  • the voltages applied to the high voltage end of the resistor during operation are sufficiently high to cause high voltage corona to occur around the resistive path in the absence of some corona prevention means.
  • atmospheric nitrogen will combine with water vapor to form nitrous acid and atmospheric oxygen will form ozone. Since both of these materials are extremely chemically active with materials such as the resistance material and insulation, it is necessary to provide some means for both preventing the formation of high voltage corona around the resistive path and eliminating the formation of nitrous acid and ozone in the event corona does occur.
  • By providing a uniform voltage gradient along a resistive path devoid of abrupt changes the likelihood of corona occurring is reduced.
  • the dielectric material 44 serves as a dielectric barrier between adjacent turns of the serpentine path further reducing the likelihood of corona occurring. Even if corona occurs the dielectric material 44 forms a moisture impervious barrier around the resistive path thus preventing the presence of atmospheric nitrogen and oxygen in the area where corona occurs. Since the dielectric material is filled from the low voltage end of the substrate 14, it will be appreciated that the maximum density of the material will be at the high voltage end of the substrate thus reducing the possibility of gas pockets forming adjacent thehigh voltage end and improving the dielectric strength at the pads.
  • a solderable conductive pad 26 is deposited on the low voltage end of the substrate and a heat dissipating mounting member 27 having an aperture 29 therein is soldered to the solderable conductive pad 26 with the aperture 29 in communication with the interior of the substrate 14.
  • the point of electrical connection 39 between the insulated lead wire 21 at the high voltage end of the substrate and the solderable conductive pad 17 is accurately positioned relative to fins 37 projecting from the inner wall of the housing by means of a locating lug 38 projecting outwardly from the exterior of the housing.
  • the point of electrical connection 39 is guaranteed to be centered between two of the projections 37 and spaced from the wall of the housing.
  • a heat shrinkable sleeve 41 is positioned over a tubular projection 40 defining the aperture 12 and over the insulated lead wire 21 and heat shrunk into tight engagement with the tubular projection and insulated lead wire.
  • the tubular projection can be spin welded to the insulation of the insulated lead wire 21.
  • Dielectric material 44 is then injected into the housing through the aperture in the heat dissipating mounting member 27 whereby the material passes through the hollow substrate and enters the space between the resistive path and the housing.
  • a high voltage resistor comprising a cylindrical housing of dielectric material having an inner wall extending longitudinally of the housing, a high heat resistant dielectric cylindrical substrate disposed within said housing, the substrate being provided with a cylindrical opening extending longitudinally through the substrate, a resistive path supported on the substrate, termination means electrically connected to the resistive path, said resistive path having a high voltage end and a low voltage end, positioning means for maintaining said high voltage end of the resistive path spaced from the wall of said housing, said positioning means being provided with at least one opening between said high voltage end of said resistive path and the wall of said housing, the cylindrical opening in the substrate communicating with the one opening, and dielectric material disposed between said resistive path and the wall of said housing and forming a moisture impervious barrier around said resistive path.
  • said positioning means comprises a plurality of projections extending from said housing into engagement with said substrate.
  • thermoly conductive bonding material secures the mounting member and substrate in fixed assembled relationship, said bonding material providing a thermally conductive path for dissipating heat from the substrate to the mounting member.
  • said housing has an aperture in one end and an opening in the other end, said termination means including an in sulated lead wire electrically connected to said resistive path adjacent said high voltage end and projecting through said aperture, said lead wire substantially sealing said aperture.
  • the high voltage resistor of claim 8 wherein said housing is provided with a tubular projection defining said aperture, and said tubular projection is welded to the insulation of said insulated wire.
  • the high voltage resistor of claim 8 wherein second positioning means is provided for maintaining the resistive path at said low voltage end spaced from the wall of said housing and comprises a mounting member electrically connected to said resistance path.
  • termination means includes an insulated lead wire electrically connected to the resistive path adjacent said high voltage end, the point of electrical connection between the insulated lead wire and the resistive path being positioned between two of said projections.
  • termination means includes a tap comprising an insulated lead wire electrically connected to the resistivepath intermediate the high voltage end and the low voltage end, said substrate providing a continuous heat transfer path from said high voltage end to said low voltage end.
  • termination means includes an insulated lead wire electrically connected to said resistive path adjacent said high voltage end, said projections spacing the point of electrical connection between the lead wire and the resistive path fromthe wall of the housing, said dielectric material surrounding the point of electrical connection.
  • a high voltage resistor comprising a cylindrical housing of dielectric material, a high heat resistant dielectric cylindrical substrate disposed within said housing, a resistive path supported on the substrate, termination means electrically connected to the resistive path, said substrate having a high voltage end and a low voltage end, said housing having an aperture in one end and an opening in the other end, a plurality of projections extending from said housing adjacent said one end into engagement with said substrate adjacent said high voltage end whereby said resistive path at said high voltage end is spaced from the wall of the housing, said termination means including an insulated lead wire electrically connected to said resistive path adjacent said high voltage end, said insulated lead wire passing through and substantially sealing said aperture, a mounting member bearing against said low voltage end and frictionally engaging the housing adjacent said other end maintaining the resistive path at said low voltage end spaced from the wall of the housing, and dielectric material positioned between said resistive path and the wall of said housing, said dielectric material forming a moisture impervious barrier around said resistive path.
  • a mounting bracket having an aperture therein to one end of said substrate with said aperture being in communication with the interior of said substrate, centering said substrate relative to the walls of a cylindrical housing of dielectric material having an aperture in one end and an opening, of sufficient size to receive said substrate in the other end,
  • step of applying termination means to said resistive path comprises securing an insulated lead wire to the other end of said substrate in electrical connection with said resistive path.
  • step of centering the substrate relative to the walls of a cylindrical housing comprises nesting the other end of the substrate against a plurality of projections in the housing with said insulated lead wire disposed between two of said projections.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Details Of Resistors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
US00200765A 1971-11-22 1971-11-22 High voltage resistor Expired - Lifetime US3742422A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US20076571A 1971-11-22 1971-11-22

Publications (1)

Publication Number Publication Date
US3742422A true US3742422A (en) 1973-06-26

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Application Number Title Priority Date Filing Date
US00200765A Expired - Lifetime US3742422A (en) 1971-11-22 1971-11-22 High voltage resistor

Country Status (7)

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US (1) US3742422A (enExample)
AU (1) AU468635B2 (enExample)
CA (1) CA967655A (enExample)
DE (1) DE2257060C2 (enExample)
FR (1) FR2160919B1 (enExample)
GB (1) GB1418915A (enExample)
IT (1) IT975758B (enExample)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3858147A (en) * 1972-12-14 1974-12-31 R Caddock Non-inductive film-type cylindrical resistor
US3889362A (en) * 1973-10-29 1975-06-17 Robertshaw Controls Co Method of making electrical resistance element
EP0516112A3 (en) * 1991-05-28 1993-06-02 Chiung-Hsiang Yang Ptc semiconductor heating means having fully clad casing
US5247158A (en) * 1992-07-17 1993-09-21 Watlow Electric Manufacturing Company Electrical heater
US5627343A (en) * 1994-08-03 1997-05-06 Xl Technologies, Inc. Re-enterable conduit sealing assembly
US7161461B1 (en) * 2006-03-07 2007-01-09 Delphi Technologies, Inc. Injection molded trim resistor assembly
CN104183341A (zh) * 2014-08-22 2014-12-03 南京南瑞继保电气有限公司 一种电阻器、散热器、以及电阻器与散热器组合设备
US20150184887A1 (en) * 2013-12-26 2015-07-02 Save The World Air, Inc. Electrical interconnect and method
CN112038024A (zh) * 2020-08-26 2020-12-04 周晓燕 一种双电阻芯电阻器

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4122331A1 (de) * 1991-04-22 1992-10-29 Asea Brown Boveri Spannungswandler fuer eine mittel- oder hochspannungsanlage

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2635162A (en) * 1949-02-25 1953-04-14 Aerovox Corp Electrical resistance
DE1120583B (de) * 1959-03-20 1961-12-28 Siemens Ag Hochspannungsmesswiderstand
US3105218A (en) * 1961-06-30 1963-09-24 Fischer & Co H G Electric resistor
US3105219A (en) * 1962-02-19 1963-09-24 H G Fischer & Co Inc Electric resistor
GB1076252A (en) * 1962-11-16 1967-07-19 Nat Res Dev Improvements in or relating to high voltage resistors for use in potential dividers
US3169237A (en) * 1963-01-04 1965-02-09 Mclvin A Thom Electrical resistor device
US3579819A (en) * 1969-03-24 1971-05-25 Cts Corp Method of making a resistor

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3858147A (en) * 1972-12-14 1974-12-31 R Caddock Non-inductive film-type cylindrical resistor
US3889362A (en) * 1973-10-29 1975-06-17 Robertshaw Controls Co Method of making electrical resistance element
EP0516112A3 (en) * 1991-05-28 1993-06-02 Chiung-Hsiang Yang Ptc semiconductor heating means having fully clad casing
US5247158A (en) * 1992-07-17 1993-09-21 Watlow Electric Manufacturing Company Electrical heater
US5627343A (en) * 1994-08-03 1997-05-06 Xl Technologies, Inc. Re-enterable conduit sealing assembly
US6009610A (en) * 1994-08-03 2000-01-04 Brandolf; Henry E. Re-enterable conduit sealing assembly and method
US7161461B1 (en) * 2006-03-07 2007-01-09 Delphi Technologies, Inc. Injection molded trim resistor assembly
US20150184887A1 (en) * 2013-12-26 2015-07-02 Save The World Air, Inc. Electrical interconnect and method
CN104183341A (zh) * 2014-08-22 2014-12-03 南京南瑞继保电气有限公司 一种电阻器、散热器、以及电阻器与散热器组合设备
WO2016026470A1 (zh) * 2014-08-22 2016-02-25 南京南瑞继保电气有限公司 一种电阻器、散热器、以及电阻器与散热器组合设备
CN104183341B (zh) * 2014-08-22 2017-12-05 南京南瑞继保电气有限公司 一种电阻器、散热器、以及电阻器与散热器组合设备
AU2015306506B2 (en) * 2014-08-22 2019-01-17 Nr Electric Co., Ltd Resistor, heat dissipater, and combinatory device of resistor and heat dissipater
US10381138B2 (en) 2014-08-22 2019-08-13 Nr Electric Co., Ltd Resistor, a heat dissipater and a combinatory device of resistor and heat dissipater
CN112038024A (zh) * 2020-08-26 2020-12-04 周晓燕 一种双电阻芯电阻器

Also Published As

Publication number Publication date
FR2160919B1 (enExample) 1978-09-08
GB1418915A (en) 1975-12-24
FR2160919A1 (enExample) 1973-07-06
IT975758B (it) 1974-08-10
DE2257060A1 (de) 1973-05-24
AU4884572A (en) 1974-05-16
CA967655A (en) 1975-05-13
AU468635B2 (en) 1976-01-15
DE2257060C2 (de) 1982-04-29

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