WO2021085339A1 - Noise prevention resistor and manufacturing method thereof - Google Patents

Noise prevention resistor and manufacturing method thereof Download PDF

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Publication number
WO2021085339A1
WO2021085339A1 PCT/JP2020/039983 JP2020039983W WO2021085339A1 WO 2021085339 A1 WO2021085339 A1 WO 2021085339A1 JP 2020039983 W JP2020039983 W JP 2020039983W WO 2021085339 A1 WO2021085339 A1 WO 2021085339A1
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WIPO (PCT)
Prior art keywords
electromagnetic shield
shield member
resistance element
noise prevention
resonance
Prior art date
Application number
PCT/JP2020/039983
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French (fr)
Japanese (ja)
Inventor
瑞記 内盛
仁男 宮坂
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Koa株式会社
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Publication of WO2021085339A1 publication Critical patent/WO2021085339A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C13/00—Resistors not provided for elsewhere
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
    • H01C3/14—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids the resistive element being formed in two or more coils or loops continuously wound as a spiral, helical or toroidal winding
    • H01C3/20—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids the resistive element being formed in two or more coils or loops continuously wound as a spiral, helical or toroidal winding wound on cylindrical or prismatic base

Definitions

  • the present invention relates to a noise prevention resistor mounted on an ignition coil of an internal combustion engine such as an engine and a method for manufacturing the same.
  • the engine ignition device of a gasoline engine car ignites by passing a high-pressure current through the spark plug (spark plug) to discharge it, and sparking a compressed mixed gas of gasoline and air in the cylinder.
  • spark plug spark plug
  • spark plug In order to blow sparks by electric discharge, it is necessary to apply a voltage of 10 kV or more to the spark plug. Therefore, gasoline engine vehicles are equipped with an ignition coil that boosts the battery voltage.
  • the ignition coil is composed of a coil main body, a tubular insulating case, etc., and the coil main body is a primary coil housed in the insulating case, a secondary coil, a core (iron core) around which these coils are wound, and the like. It consists of an IC chip or the like that controls ignition.
  • a spring (connection terminal on the spark plug side) connected to the spark plug is housed in the tubular insulating case.
  • the inside of the coil body is filled with resin and sealed.
  • a noise prevention resistor (also called a noise prevention filter) is arranged in a tower portion between the coil body and the spring, and the noise is generated.
  • the coil body and the spark plug are electrically connected via a prevention resistor.
  • the high-voltage electric wire device described in Patent Document 1 has a columnar shape in which ferrite powder is mixed with silicone rubber or the like between the spark plug connection terminal and the output side terminal of the high-voltage cable. It discloses a technique for suppressing the emission of high-frequency noise by incorporating a resistor (concentrated resistor) formed by winding a metal resistance electric wire into an extrusion-molded magnetic powder-containing resin core.
  • a resistor concentrated resistor
  • noise is suppressed by the characteristics depending on the resistance value and the inductance value of the resistance wire (resistance wire) used, and the axial length dimension of the resistor body including the resistance element is lengthened. It is possible to improve the noise suppression effect by changing the diameter of the core material and the resistance wire.
  • the mounting space for the noise prevention resistor is limited in the engine ignition device, and mounting the noise prevention resistor with different lengths and dimensions requires a change in the mounting structure of the engine ignition device. Therefore, there is a problem that it is difficult to enhance the noise suppression effect while maintaining the outer size of the noise prevention resistor.
  • the present invention has been made in view of the above-mentioned problems, and an object of the present invention is to improve the noise suppression effect in a single noise suppression resistor without changing the axial length or the like. is there.
  • the present invention is a noise prevention resistor having an insulating core material and a resistance element in which a resistance wire is wound around the outer peripheral surface of the core material, and a pair of cap terminals are attached to both ends of the resistance element.
  • the electromagnetic shield member is formed so as to circulate around the axis of the resistance element at a predetermined position which is a part of the outer peripheral surface of the resistance element and is separated from the pair of cap terminals.
  • the predetermined position is a position deviated from the axial intermediate point of the resistance element.
  • it is characterized in that two resonance equivalent circuits having different resonance frequencies are formed with the single electromagnetic shield member formed at a predetermined position as a boundary.
  • the predetermined position is characterized in that the coupling coefficient between the inductance component of one of the two resonance equivalent circuits and the inductance component of the other resonance equivalent circuit is reduced.
  • a plurality of the predetermined positions are provided, and a plurality of resonance equivalent circuits having different resonance frequencies are formed with each of the electromagnetic shield members formed at each of the plurality of positions as a boundary.
  • the electromagnetic shield member is characterized in that it is formed at a position where the coupling coefficient between the inductance components of adjacent resonance equivalent circuits among the plurality of resonance equivalent circuits is reduced.
  • the resonance equivalent circuit is an LCR resonance circuit formed by a resistance component, an inductance component, and a capacitance component of the resistance element magnetically separated with the electromagnetic shield member as a boundary.
  • the electromagnetic shield member is characterized by being made of an annular metal.
  • the electromagnetic shield member is characterized by being a metal film formed on the surface of a heat-resistant resin layer. Further, for example, the electromagnetic shield member and the resistance wire are electrically insulated from each other.
  • the method for manufacturing the noise prevention resistor of the present invention includes a step of bundling fibrous insulators to form a long core material, and a step of winding a resistance wire around the outer peripheral surface of the core material.
  • the present invention comprises a step of mounting a pair of cap terminals at both ends in the axial direction of the resistance element, and mounting the electromagnetic shield member at a predetermined position separated from the pair of cap terminals.
  • the step of forming the electromagnetic shield member is carried out after the step of mounting the cap terminal.
  • at least one electromagnetic shield member is formed at a position deviated from the axial intermediate point of the resistance element.
  • the electromagnetic shield member is formed at each of a plurality of positions in the axial direction of the resistance element.
  • an electromagnetic shield member that covers a part of the outer peripheral surface of the resistance element in an annular shape around the axis, a plurality of resonance circuits having different resonance frequencies are formed in a single noise suppression resistor. , Noise suppression is possible in a wide band.
  • FIG. 1 (a) is an external perspective view of the noise prevention resistor according to the embodiment of the present invention
  • FIG. 1 (b) shows the resistor cut along the line of sight of XX'in FIG. 1 (a). It is a vertical sectional view.
  • FIG. 2A is an external perspective view of a noise prevention resistor in which an electromagnetic shield member is fixed to a resistance element by caulking
  • FIG. 2B is along the line of sight of YY'in FIG. 2A. It is a vertical cross-sectional view which cut the resistor.
  • It is external perspective view of the noise prevention resistor which concerns on another example which fixed the electromagnetic shield member by caulking.
  • It is external perspective view of the noise prevention resistor which concerns on further another example which fixed the electromagnetic shield member by caulking.
  • FIG. 1 It is a schematic diagram for demonstrating the separation mechanism of a resonance circuit by an electromagnetic shield member. It is a figure which shows an example of the simple equivalent circuit of the resistor provided with the electromagnetic shield member. It is a graph (image) which showed the result which showed the electrical characteristic of a noise-prevention resistor. It is a figure which shows another example of the simple equivalent circuit of the resistor provided with the electromagnetic shield member. It is a flowchart which shows an example of the manufacturing process of the noise prevention resistor which concerns on embodiment in time series. It is a figure which shows another example concerning the structure of the electromagnetic shield member. It is a figure which shows another example about the shape of the electromagnetic shield member. It is a figure which shows another example concerning the formation mode of the electromagnetic shield member to a resistance element. FIG.
  • FIG. 13 (a) is an external perspective view of the noise prevention resistor according to the modified example 5, and FIG. 13 (b) shows the resistor in the axial direction along the ZZ'arrow line of sight of FIG. 13 (a). It is a vertical cross-sectional view when it is cut into.
  • FIG. 1A is an external perspective view of a noise prevention resistor (hereinafter, also simply referred to as a resistor) 10 according to the present embodiment
  • FIG. 1B is an external perspective view of FIG. 1A. It is a vertical cross-sectional view when the resistor is cut in the axial direction along the arrow line of sight.
  • the resistor 10 is, for example, a noise prevention resistor mounted on an engine ignition device and functioning as a noise filter that effectively suppresses radiated noise such as ignition noise generated at the time of engine ignition.
  • the resistor 10 is attached to the core material 5, the resistance element (resistor) 2 in which the resistance wire 7 is wound around the outer peripheral surface of the core material 5, and both ends of the resistance element 2, and is electrically connected to the resistance wire 7.
  • the cap terminals 3a and 3b are provided, and an electromagnetic shield member (also referred to as a ring-shaped member) 8a formed at a position where a part of the outer peripheral surface of the resistance element 2 is rotated around an axis and does not come into contact with the cap terminal.
  • the core material 5 is a rod-shaped (cylindrical) member in which a large number of fibrous insulating materials made of glass, ferrite, resin, etc. are bound and fixed with epoxy resin, silicone resin, or the like.
  • the fiber diameter is several ⁇ m to several tens of ⁇ m, so if a bundle of a plurality of fibers is conveyed in a long state before cutting, the shape of the core material cannot be maintained and the glass fiber is curved. Therefore, as described above, the core material is impregnated with an epoxy resin, a silicone resin, or the like and heat-cured to maintain its shape.
  • the present invention is not limited to this, and for example, it does not have to be a fibrous insulator, and glass, ferrite, resin, or ceramic. You may use a member formed into a cylindrical shape such as.
  • the resistance wire 7 is, for example, a metal wire such as nickel / iron (Ni—Fe) wire, nickel (Ni) wire, copper / nickel (CN) wire, nickel / chromium (Ni—Cr) wire, and the resistance of the resistor. Select according to the value.
  • the wire diameter of the resistance wire 7 is about several tens of ⁇ m (for example, 30 to 60 ⁇ m), and the resistance wire 7 is continuously wound around the outer circumference of the core material 5 at a narrow pitch.
  • the metal wire may be used as it is, or a coated conductor wire having a resin coating on the surface of the metal wire may be used.
  • An insulating coating (also referred to as a resin coating) 6 made of resin is formed on the outer peripheral surface of the resistance element 2.
  • a resin coating 6 made of resin is applied and coated on the outer peripheral surface of the core material 5 around which the resistance wire 7 is wound.
  • the insulating coating 6 has a role of preventing unwinding of resistance wires and short-circuiting between resistance wires.
  • the resin coating as the insulating coating 6 has a role of fixing the resistance wire 7 as described above, but if the thickness thereof varies, the cap terminals 3a and 3b are press-fitted into the end portions of the outer peripheral surface of the resistance element 2. At that time, it is assumed that the insulating coating 6 is scraped by the openings 4a and 4b of the cap terminal. Therefore, the insulating coating 6 is thick enough to hide the resistance wire 7, for example.
  • the cap terminals 3a and 3b are made of a conductive metal such as iron or stainless steel, and the surface thereof is plated with copper, nickel or the like. As a result, the cap terminals 3a and 3b come into contact with the resistance wire 7 to ensure an electrical connection.
  • the cap terminals 3a and 3b have openings 4a and 4b and are formed in a bottomed tubular shape as a whole.
  • the cap terminals 3a and 3b are manufactured by, for example, deforming a metal plate material by a punch.
  • the cap terminals 3a and 3b are fixed by mechanically pushing (press-fitting) the cap terminals 3a and 3b in the axial direction with the openings 4a and 4b facing the axial ends of the resistance element 2. Even if the outer surface side portion is caulked in order to ensure the continuity between the cap terminals 3a and 3b and the resistance element 2 (resistance wire 7) and further to prevent the cap terminals 3a and 3b from coming off. Good.
  • the electromagnetic shield member 8a is a ring-shaped member having conductivity and low resistivity, for example, made of silver, copper, aluminum, iron, or the like. As shown in FIG. 1A, the electromagnetic shield member 8a covers a part of the outer peripheral surface of the resistance element 2 in which the resistance wire 7 is wound around the core material 5 in an annular shape without interruption around the axis thereof.
  • the electromagnetic shield member 8a is fixed to the resistance element 2 with a heat-resistant resin, an adhesive, or the like in order to prevent dropping, misalignment, and the like.
  • the resistance wire 7 and the electromagnetic shield member 8a are sufficiently electrically insulated in order to avoid a change in resistance value (lower resistance) due to the electromagnetic shield member 8a and an arc discharge between the resistance wire 7 and the electromagnetic shield 8a. It is desirable to be.
  • an insulating layer (resin) is interposed between the resistance wire 7 and the electromagnetic shield member 8a, or the inside of the electromagnetic shield member 8a is insulated to insulate.
  • FIG. 2A is an external perspective view of the noise prevention resistor 20 to which the electromagnetic shield member 8b is fixed by caulking
  • FIG. 2B is taken along the line of sight of YY'in FIG. 2A. It is a vertical cross-sectional view when the noise prevention resistor 20 is cut in the axial direction.
  • the noise prevention resistor 60 shown in FIG. 3 is caulked in a direction parallel to the axial direction of the resistance element 2 with respect to the electromagnetic shield member 8f.
  • the noise prevention resistor 70 shown in FIG. 4 has a structure in which the electromagnetic shield member 8g is caulked in a direction parallel to the axial direction of the resistance element 2, and the cap terminals 33a and 33b are also caulked.
  • the part that is not crimped may be deformed (warped) if it is strongly crimped. Therefore, like the electromagnetic shield member 8f of the noise prevention resistor 60 shown in FIG. 3, caulking is performed over the entire width direction, or the electromagnetic shield member 8g of the noise prevention resistor 70 shown in FIG. 4 is used. Squeeze at least the end in its width direction.
  • the warp of the electromagnetic shield member due to caulking can be reduced, and the entire electromagnetic shield member is in close contact with the resistance wire. As a result, it is possible to obtain the effect that arc discharge is unlikely to occur between the resistance wire and the electromagnetic shield member.
  • the electromagnetic shield member 8 g can be crimped and the cap terminals 33a and 33b can be crimped at the same time. Therefore, in addition to the above effects, the resistor can be manufactured. The process can be simplified.
  • the resistance element 2 such as the noise prevention resistors 10 and 20 according to the present embodiment has an annular shape that orbits the surface of the resistance element at a position not in contact with the cap terminals 3a and 3b mounted on both ends thereof.
  • Electromagnetic shield members 8a and 8b are arranged.
  • FIG. 5 is a schematic diagram for explaining the separation action (separation mechanism) of the resonance circuit by the electromagnetic shield members 8a and 8b.
  • the resonance circuit is separated by the electromagnetic shield members 8a and 8b described above.
  • a resonance circuit (referred to as RC1) corresponding to the part A and a resonance circuit (referred to as RC2) corresponding to the part B are formed.
  • FIG. 6 is an example of a simple equivalent circuit of resistors 10, 20, etc. provided with electromagnetic shield members 8a, 8b, etc.
  • the simple equivalent circuit 30 such as resistors 10 and 20 is a circuit in which resonance circuits RC1 and RC2 are connected in series.
  • the resistance component and the inductance component which depend on the number of turns of the resistance wire, the resistance wire material, etc., are electrically connected in series, and the stray capacitance generated between the resistance wires (between conductors) is generated. It is an LCR resonant circuit that becomes a capacitance component and is connected in parallel to these resistance components and inductance components.
  • the resistance wire 7 is uniformly wound from one end to the other end of the core material 5, and the electromagnetic shield members 8a and 8b are the shafts of the resistance element 2.
  • the number of turns of the resistance wire at the part A in FIG. 5 (N 1 ) and the number of turns of the resistance wire at the part B (N 2 ) are equal. Therefore, in the resonance circuits RC1 and RC2, the inductance components L1 and L2, the resistance components R1 and R2, and the capacitance components C1 and C2 can be regarded as being equal (equivalent), respectively.
  • the resonance circuits RC1 and RC2 have the same resonance characteristics, and the resistors 10, 20 and the like have deep resonance peaks due to the synergistic effect of the resonance characteristics of the resonance circuit RC1 and the resonance characteristics of the resonance circuit RC2. Has characteristics. As a result, a resonance peak is generated for a specific frequency, and the resonance peak cannot have a width.
  • a resistor with a high resistance value and a large inductance component has a large noise suppression effect, but when mounted on an engine ignition device as a noise prevention resistor, the resistance value is high and the ignition coil is lost. There is a problem that the engine output is reduced due to the increase in the engine output. Therefore, in an engine ignition device, a resistor having a low resistance value and a large inductance component is required.
  • the noise prevention resistor is provided with a width at the resonance peak in a desired frequency band while securing the above-mentioned inductance components L1 and L2. It is necessary to function as a noise filter.
  • the magnetic fluxes of the portions A and B separated by the electromagnetic shield members 8a and 8b do not match (the coupling of the inductance components L1 and L2 in FIG. 6).
  • the electromagnetic shield members 8a and 8b are arranged at predetermined positions (coefficient (M) approaches 0). That is, the electromagnetic shield members 8a and 8b are arranged and formed at positions deviated from the midpoint in the axial direction of the resistance element 2 and not touching the cap terminals 3a and 3b.
  • the first resonance equivalent circuit (RC1) is formed at the portion of the resistance element 2 between the electromagnetic shield members 8a and 8b and one of the cap terminals 3a of the pair of cap terminals, and further.
  • a second resonance equivalent circuit (RC2) is formed at a portion between the electromagnetic shield members 8a and 8b and the other cap terminal 3b of the pair of cap terminals, and the first resonance equivalent circuit and the second resonance equivalent circuit are formed.
  • the resonance frequency of the circuit is different.
  • the resonance peak of the resistor has a width. This is a characteristic of a phenomenon (double resonance phenomenon) in which a plurality of valleys of resonance frequencies (peaks) are formed by arranging a plurality of resonance circuits in close proximity to each other, and the width of the resonance point is widened.
  • FIG. 7 is a graph imagining the result of the electrical characteristics of the noise prevention resistor according to the present embodiment.
  • the horizontal axis of FIG. 7 is the frequency (MHz), and the vertical axis is the S21 characteristic (dB).
  • the S21 characteristic is an S parameter indicating the amount of attenuation of the signal that has passed through the noise suppression resistor.
  • an annular electromagnetic shield member orbiting the outer peripheral surface thereof is arranged at a position deviated from the axial intermediate point of the resistance element. Since the peak of the resonance point has a width, it can be seen that it has better filter characteristics (noise suppression effect) as compared with the conventional example.
  • the noise prevention resistors 10, 20, etc. are shown in FIG. It can be represented by a simple equivalent circuit.
  • L is an inductance component and k is a magnetic coupling coefficient.
  • FIG. 9 is a flowchart showing an example of the manufacturing process of the noise prevention resistor according to the present embodiment in chronological order.
  • the core material is molded in the first step (step S11 in FIG. 9).
  • glass fibers having a fiber diameter of several ⁇ m to several tens of ⁇ m are bundled, impregnated with an epoxy resin, a silicone resin, or the like, and formed into a long rod shape to form a core material.
  • step S13 resistance wires such as nickel / iron (Ni—Fe) wire, nickel (Ni) wire, copper / nickel (CN) wire, nickel / chromium (Ni—Cr) wire, etc. are formed on the outer peripheral surface of the core material. Wind continuously at a predetermined pitch. The resistance value of the resistor is adjusted according to the type (material) of the wire, the winding pitch, and the like.
  • step S15 the core material around which the resistance wire is wound is dried to cure the resin.
  • step S17 for example, an epoxy resin or a silicone resin having a thickness sufficient to hide the resistance wire is applied and coated on the outer peripheral surface of the core material obtained by winding the resistance wire and drying / curing as described above.
  • step S19 the resin coating is cured.
  • the drying and curing of step S15 may be performed at the same time in step S19.
  • step S21 the resistance wire is wound in the above step, and the long core material coated with the resin is cut together with the resistance wire to a predetermined size by a cutter or the like. As a result, individual pieces of the resistance element 2 (resistor) are manufactured.
  • the electromagnetic shield is placed at a predetermined position (position shifted from the axial center of the resistance element) so as to cover a part of the outer peripheral surface of the resistance element around which the resistance wire is wound without interruption around the axis. Form a member.
  • the electromagnetic shield member is, for example, a plate-shaped annular member having a width of 1 to 3 mm and a thickness of 0.1 to 0.6 mm in consideration of workability and the like.
  • the electromagnetic shield member may be composed of a linear thin metal wire from the viewpoint that the short-circuit current described above can be passed.
  • a thin metal wire is used, the ends of the thin metal wire are joined by welding or the like to form an annular ring-shaped member.
  • cap terminals 3a and 3b are attached to both ends of the resistance element 2.
  • the cap terminals 3a and 3b are mechanically pushed in the axial direction from both ends of the resistance element 2 to be temporarily fixed, and then the side surface portions of the cap terminals 3a and 3b are pressed from the outer peripheral surface thereof to be deformed (caulking). ), That makes the resistance wire 7 and the cap terminals 3a and 3b electrically conductive.
  • the cap terminals 3a and 3b may be press-fitted into both ends of the resistance element 2 to be mounted (fitted).
  • step S27 an inspection such as an appearance image inspection and a resistance value inspection of the noise prevention resistor manufactured through the above steps is performed.
  • the order of the step of forming the electromagnetic shield member in step S23 and the step of mounting the cap terminal in step S25 may be appropriately changed according to the shape, structure, etc. of the electromagnetic shield member to be formed, and the same step. May be performed at the same time.
  • the step of forming the electromagnetic shield member in step S23 is performed after the step of mounting the cap terminal in step S25, the position deviated from the axial intermediate point of the resistance element forming the electromagnetic shield member, that is, separated from the pair of cap terminals.
  • the predetermined position can be easily adjusted.
  • the curing method of the resin or the like in step S15 or the like described above may be any of curing at room temperature, heat curing (for example, 100 to 150 ° C.), or curing by ultraviolet irradiation. Further, from the viewpoint of shortening the drying time, the resin of the protective film formed on the entire outer surface of the resistor may be limited to the quick-drying urethane resin.
  • an electromagnetic shield member that covers a part of the outer peripheral surface of the resistance element without interruption is arranged around the axis thereof, and the resistance is resisted by the electromagnetic shield member. Separate the resonant circuit of the vessel (magnetically separate).
  • the electromagnetic shield member in a single resistor, by forming the electromagnetic shield member at a position where the resonance frequency of the resonance circuit is different, a plurality of resonance circuits are provided in one element of the resistor, and the resonance of the resistor is generated.
  • the peak has a width.
  • the noise suppression effect is achieved in a wide band while maintaining the external size of the noise prevention resistor without increasing the axial length of the resistor body or changing the diameter of the core material and the resistance wire. It is possible to obtain a noise suppression resistor having a function as a noise suppression filter.
  • the electromagnetic shield member is arranged so as to be offset from the axial center of the resistance element so that the resonance frequency is different with the electromagnetic shield member as a boundary.
  • the electromagnetic shield member is arranged so as to be offset from the axial center of the resistance element so that the resonance frequency is different with the electromagnetic shield member as a boundary.
  • a single electromagnetic shield member is formed on the resistance element, but a plurality of electromagnetic shield members are formed on the resistance element, and the resonance circuit of the resistor is divided at each electromagnetic shield member to divide the resonance frequency.
  • a first resonant circuit is formed, a second resonant circuit is formed at a portion between the two electromagnetic shield members, the other cap terminal 3b of the pair of cap terminals and the other of the two electromagnetic shield members.
  • a third resonance circuit is formed at a portion between the cap terminal 3b and the electromagnetic shield member adjacent to the cap terminal 3b, and the resonance frequencies of each of these three resonance circuits are different.
  • a metal member having an integral structure with continuous rings is used as the electromagnetic shield member, but the present invention is not limited to this.
  • the electromagnetic shield member 8c shown in FIG. 10 a part of the ring is formed into a separated shape, the separated portion C is formed into a structure having a step so that it can be engaged, and after being formed into a resistance element, they are formed. It may be configured to be joined.
  • the separated portions C are joined to each other by soldering, welding, or the like.
  • the electromagnetic shield member can be formed so as to cover a part of the outer peripheral portion of the resistance element without interruption.
  • the separated portions C of the electromagnetic shield member 8c may have a structure that simply fits into each other.
  • the shape of the electromagnetic shield member is not limited to the example shown in FIG. 1 and the like, and may be a ring-shaped member having a polygonal appearance, such as the electromagnetic shield member 8d shown in FIG.
  • the mode of forming the electromagnetic shield member on the resistance element is not limited to the above embodiment.
  • an insulating layer (resin layer) 31 is formed in an annular shape at a predetermined position on the outer peripheral surface of the resistance element 2 so as not to come into contact with the cap terminals 3a and 3b.
  • An electromagnetic shield member 8e made of a metal film may be formed on the upper surface of the insulating layer (resin layer) 31.
  • the insulating layer (resin layer) 31 is formed by printing, coating, shrinking of a heat-bonded tube, or the like. Alternatively, an insulating coating (resin coating) may be used.
  • the electromagnetic shield member 8e which is a metal film, is formed by printing, coating, pasting, transfer, or the like. As the resin used for the insulating layer 31, a highly heat-resistant resin is used. As a result, the insulating layer 31 has resistance to firing and curing of the metal film (electromagnetic shield member 8e).
  • FIG. 13 (a) is an external perspective view of the noise prevention resistor 80 according to the modified example 5, and FIG. 13 (b) is an axis of the resistor along the ZZ'arrow line of sight of FIG. 13 (a). It is a vertical cross-sectional view when cut in a direction.
  • the noise prevention resistor 80 of the cap terminals 43a and 43b, the cap terminal 43a is separated from the resistance wire 7 at the opening 45a, and the opening of the electromagnetic shield member 8g is opened.
  • It has a structure in which an expansion portion 45b is provided at an end portion on the side facing the portion 45a so as to be separated from the resistance wire 7.
  • the resonance frequencies of the two resonance equivalent circuits formed across the electromagnetic shield member 8g can be made different.
  • the sealing resin enters the inside of the expansion portion, so that arc discharge is less likely to occur.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)
  • Apparatuses And Processes For Manufacturing Resistors (AREA)

Abstract

In this noise prevention resistor 10, an electromagnetic shield member 8a, which covers a part of the outer peripheral surface of a resistance element 2 without interruption around the axis of the resistance element 2, is disposed at a position on the outer peripheral surface of the resistance element 2 where the resonance frequency of a resonance circuit is different. Thus, the electromagnetic shield member 8a magnetically separates the resonance circuit of a resistor. As a result, since a plurality of resonance equivalent circuits are provided in a single resistor element and the resonance peak of the resistor has a width, noise can be suppressed in a wider band than before while maintaining the length dimension and the like.

Description

雑音防止抵抗器およびその製造方法Noise suppression resistor and its manufacturing method
　本発明は、例えばエンジン等の内燃機関のイグニッションコイルに実装される雑音防止抵抗器およびその製造方法に関する。 The present invention relates to a noise prevention resistor mounted on an ignition coil of an internal combustion engine such as an engine and a method for manufacturing the same.
　ガソリンエンジン車のエンジン点火装置は、点火プラグ（スパークプラグ）に高圧電流を流して放電させ、シリンダー内のガソリンと空気の圧縮混合気体に火花を飛ばして着火している。放電により火花を飛ばすには、点火プラグに１０ｋＶ以上の電圧を印加する必要がある。そのため、ガソリンエンジン車はバッテリー電圧を昇圧するイグニッションコイルを備えている。 The engine ignition device of a gasoline engine car ignites by passing a high-pressure current through the spark plug (spark plug) to discharge it, and sparking a compressed mixed gas of gasoline and air in the cylinder. In order to blow sparks by electric discharge, it is necessary to apply a voltage of 10 kV or more to the spark plug. Therefore, gasoline engine vehicles are equipped with an ignition coil that boosts the battery voltage.
　イグニッションコイルは、コイル本体部、筒状の絶縁ケース等で構成され、コイル本体部は絶縁ケース内に収納された１次コイル、２次コイル、これらのコイルが巻きつけられたコア（鉄心）、点火制御を行うＩＣチップ等からなる。筒状の絶縁ケースには、スパークプラグに接続されたスプリング（スパークプラグ側の接続端子）が収納されている。コイル本体部内は樹脂を充填して封止される。 The ignition coil is composed of a coil main body, a tubular insulating case, etc., and the coil main body is a primary coil housed in the insulating case, a secondary coil, a core (iron core) around which these coils are wound, and the like. It consists of an IC chip or the like that controls ignition. A spring (connection terminal on the spark plug side) connected to the spark plug is housed in the tubular insulating case. The inside of the coil body is filled with resin and sealed.
　エンジン点火装置は、エンジン点火時に発生する高周波雑音（ノイズ）を抑制するため、例えばコイル本体部とスプリングとの間のタワー部内に雑音防止抵抗器（雑音防止フィルタとも言う）が配置され、その雑音防止抵抗器を介してコイル本体部とスパークプラグとが電気的に接続されている。 In the engine ignition device, in order to suppress high-frequency noise (noise) generated when the engine is ignited, for example, a noise prevention resistor (also called a noise prevention filter) is arranged in a tower portion between the coil body and the spring, and the noise is generated. The coil body and the spark plug are electrically connected via a prevention resistor.
　このような雑音防止抵抗器として、例えば特許文献１に記載の高圧電線装置は、点火プラグ接続端子と高圧ケーブルの出力側端末との間に、シリコーンゴム等にフェライト粉末を混合して円柱状に押出成形した磁性体粉末含有樹脂コアに金属抵抗電線を捲回してなる抵抗器（集中抵抗器）を組み込んで、高周波雑音の放射を抑制する技術を開示している。 As such a noise prevention resistor, for example, the high-voltage electric wire device described in Patent Document 1 has a columnar shape in which ferrite powder is mixed with silicone rubber or the like between the spark plug connection terminal and the output side terminal of the high-voltage cable. It discloses a technique for suppressing the emission of high-frequency noise by incorporating a resistor (concentrated resistor) formed by winding a metal resistance electric wire into an extrusion-molded magnetic powder-containing resin core.
特開平５－７４６２９号公報Japanese Unexamined Patent Publication No. 5-74629
　従来の雑音防止抵抗器は、使用する抵抗電線（抵抗線）の抵抗値とインダクタンス値に依拠した特性によりノイズを抑制しており、抵抗素子を含む抵抗器本体の軸方向の長さ寸法を長くする、芯材、抵抗線の径を変える等により、ノイズ抑制効果を向上させることは可能である。 In the conventional noise prevention resistor, noise is suppressed by the characteristics depending on the resistance value and the inductance value of the resistance wire (resistance wire) used, and the axial length dimension of the resistor body including the resistance element is lengthened. It is possible to improve the noise suppression effect by changing the diameter of the core material and the resistance wire.
　しかしながら、エンジン点火装置において雑音防止抵抗器の搭載スペースは限られており、長さ寸法等を変えた雑音防止抵抗器を搭載するには、エンジン点火装置の実装構造の変更を伴うことになる。したがって、雑音防止抵抗器の外形サイズを維持したままノイズ抑制効果を高めることは困難であるという問題がある。 However, the mounting space for the noise prevention resistor is limited in the engine ignition device, and mounting the noise prevention resistor with different lengths and dimensions requires a change in the mounting structure of the engine ignition device. Therefore, there is a problem that it is difficult to enhance the noise suppression effect while maintaining the outer size of the noise prevention resistor.
　本発明は、上述した課題に鑑みてなされたものであり、その目的とするところは、単一の雑音防止抵抗器において軸方向の長さ等を変更せずに雑音抑制効果を向上させることである。 The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to improve the noise suppression effect in a single noise suppression resistor without changing the axial length or the like. is there.
　上記の目的を達成し、上述した課題を解決する一手段として以下の構成を備える。すなわち、本発明は、絶縁性の芯材と、その芯材の外周面に抵抗線を巻回した抵抗素子とを有し、前記抵抗素子の両端に一対のキャップ端子を装着した雑音防止抵抗器であって、前記抵抗素子の外周表面の一部で、かつ前記一対のキャップ端子より離間した所定位置に、該抵抗素子の軸回りに周回する電磁シールド部材を形成したことを特徴とする。 The following configuration is provided as a means of achieving the above objectives and solving the above problems. That is, the present invention is a noise prevention resistor having an insulating core material and a resistance element in which a resistance wire is wound around the outer peripheral surface of the core material, and a pair of cap terminals are attached to both ends of the resistance element. The electromagnetic shield member is formed so as to circulate around the axis of the resistance element at a predetermined position which is a part of the outer peripheral surface of the resistance element and is separated from the pair of cap terminals.
　例えば前記所定位置は、前記抵抗素子の軸方向中間点からずれた位置であることを特徴とする。例えば、前記所定位置に形成した単一の前記電磁シールド部材を境界にして共振周波数の異なる２つの共振等価回路を形成したことを特徴とする。例えば前記所定位置は、前記２つの共振等価回路の一方の共振等価回路のインダクタンス成分と他方の共振等価回路のインダクタンス成分との結合係数を減少させる位置であることを特徴とする。例えば前記所定位置を複数設け、該複数の位置それぞれに形成した前記電磁シールド部材各々を境界にして共振周波数の異なる複数の共振等価回路を形成したことを特徴とする。また、例えば、前記電磁シールド部材は、前記複数の共振等価回路のうち隣接する共振等価回路のインダクタンス成分同士の結合係数を減少させる位置に形成されていることを特徴とする。例えば前記共振等価回路は、前記電磁シールド部材を境界にして磁気的に分離された前記抵抗素子の抵抗成分とインダクタンス成分と容量成分によって形成されるＬＣＲ共振回路であることを特徴とする。例えば前記電磁シールド部材は円環状の金属からなることを特徴とする。例えば前記電磁シールド部材は耐熱樹脂層の表面に形成した金属膜であることを特徴とする。さらには、例えば、前記電磁シールド部材と前記抵抗線は電気的に絶縁されていることを特徴とする。 For example, the predetermined position is a position deviated from the axial intermediate point of the resistance element. For example, it is characterized in that two resonance equivalent circuits having different resonance frequencies are formed with the single electromagnetic shield member formed at a predetermined position as a boundary. For example, the predetermined position is characterized in that the coupling coefficient between the inductance component of one of the two resonance equivalent circuits and the inductance component of the other resonance equivalent circuit is reduced. For example, a plurality of the predetermined positions are provided, and a plurality of resonance equivalent circuits having different resonance frequencies are formed with each of the electromagnetic shield members formed at each of the plurality of positions as a boundary. Further, for example, the electromagnetic shield member is characterized in that it is formed at a position where the coupling coefficient between the inductance components of adjacent resonance equivalent circuits among the plurality of resonance equivalent circuits is reduced. For example, the resonance equivalent circuit is an LCR resonance circuit formed by a resistance component, an inductance component, and a capacitance component of the resistance element magnetically separated with the electromagnetic shield member as a boundary. For example, the electromagnetic shield member is characterized by being made of an annular metal. For example, the electromagnetic shield member is characterized by being a metal film formed on the surface of a heat-resistant resin layer. Further, for example, the electromagnetic shield member and the resistance wire are electrically insulated from each other.
　また、本発明の雑音防止抵抗器の製造方法は、繊維状の絶縁物を結束して長尺の芯材を成形する工程と、前記芯材の外周面に抵抗線を巻回する工程と、前記抵抗線が巻回された芯材を所定寸法に切断して抵抗素子を形成する工程と、前記抵抗素子の外周表面の一部を該抵抗素子の軸回りに周回する電磁シールド部材を形成する工程と、前記抵抗素子の軸方向両端部に一対のキャップ端子を装着する工程とを備え、前記一対のキャップ端子より離間した所定位置に前記電磁シールド部材を装着することを特徴とする。 Further, the method for manufacturing the noise prevention resistor of the present invention includes a step of bundling fibrous insulators to form a long core material, and a step of winding a resistance wire around the outer peripheral surface of the core material. A step of cutting the core material around which the resistance wire is wound to a predetermined size to form a resistance element, and forming an electromagnetic shield member that orbits a part of the outer peripheral surface of the resistance element around the axis of the resistance element. The present invention comprises a step of mounting a pair of cap terminals at both ends in the axial direction of the resistance element, and mounting the electromagnetic shield member at a predetermined position separated from the pair of cap terminals.
　例えば、前記キャップ端子の装着工程の後に前記電磁シールド部材の形成工程を実施することを特徴とする。例えば、前記抵抗素子の軸方向中間点からずれた位置に前記電磁シールド部材を少なくとも１つ形成することを特徴とする。また、例えば、前記抵抗素子の軸方向の複数個所それぞれに前記電磁シールド部材を形成することを特徴とする。 For example, it is characterized in that the step of forming the electromagnetic shield member is carried out after the step of mounting the cap terminal. For example, at least one electromagnetic shield member is formed at a position deviated from the axial intermediate point of the resistance element. Further, for example, the electromagnetic shield member is formed at each of a plurality of positions in the axial direction of the resistance element.
　本発明によれば、抵抗素子の外周表面の一部を軸回りに環状に覆う電磁シールド部材を形成して、単一の雑音防止抵抗器に共振周波数の異なる複数の共振回路を形成することで、広帯域において雑音抑制が可能となる。 According to the present invention, by forming an electromagnetic shield member that covers a part of the outer peripheral surface of the resistance element in an annular shape around the axis, a plurality of resonance circuits having different resonance frequencies are formed in a single noise suppression resistor. , Noise suppression is possible in a wide band.
図１（ａ）は、本発明の実施形態に係る雑音防止抵抗器の外観斜視図、図１（ｂ）は、図１（ａ）のＸ－Ｘ´矢視線に沿って抵抗器を切断した縦断面図である。FIG. 1 (a) is an external perspective view of the noise prevention resistor according to the embodiment of the present invention, and FIG. 1 (b) shows the resistor cut along the line of sight of XX'in FIG. 1 (a). It is a vertical sectional view. 図２（ａ）は、電磁シールド部材をカシメ加工により抵抗素子に固定した雑音防止抵抗器の外観斜視図、図２（ｂ）は、図２（ａ）のＹ－Ｙ´矢視線に沿って抵抗器を切断した縦断面図である。FIG. 2A is an external perspective view of a noise prevention resistor in which an electromagnetic shield member is fixed to a resistance element by caulking, and FIG. 2B is along the line of sight of YY'in FIG. 2A. It is a vertical cross-sectional view which cut the resistor. 電磁シールド部材をカシメ加工により固定した他の例に係る雑音防止抵抗器の外観斜視図である。It is external perspective view of the noise prevention resistor which concerns on another example which fixed the electromagnetic shield member by caulking. 電磁シールド部材をカシメ加工により固定した、さらなる他の例に係る雑音防止抵抗器の外観斜視図である。It is external perspective view of the noise prevention resistor which concerns on further another example which fixed the electromagnetic shield member by caulking. 電磁シールド部材による共振回路の分離メカニズムを説明するための模式図である。It is a schematic diagram for demonstrating the separation mechanism of a resonance circuit by an electromagnetic shield member. 電磁シールド部材を設けた抵抗器の簡易等価回路の一例を示す図である。It is a figure which shows an example of the simple equivalent circuit of the resistor provided with the electromagnetic shield member. 雑音防止抵抗器の電気的特性を示す結果を表したグラフ（イメージ）である。It is a graph (image) which showed the result which showed the electrical characteristic of a noise-prevention resistor. 電磁シールド部材を設けた抵抗器の簡易等価回路の他の例を示す図である。It is a figure which shows another example of the simple equivalent circuit of the resistor provided with the electromagnetic shield member. 実施形態に係る雑音防止抵抗器の製造工程の一例を時系列で示すフローチャートである。It is a flowchart which shows an example of the manufacturing process of the noise prevention resistor which concerns on embodiment in time series. 電磁シールド部材の構造に関する他の例を示す図である。It is a figure which shows another example concerning the structure of the electromagnetic shield member. 電磁シールド部材の形状に関する他の例を示す図である。It is a figure which shows another example about the shape of the electromagnetic shield member. 抵抗素子への電磁シールド部材の形成態様に関する他の例を示す図である。It is a figure which shows another example concerning the formation mode of the electromagnetic shield member to a resistance element. 図１３（ａ）は、変形例５に係る雑音防止抵抗器の外観斜視図であり、図１３（ｂ）は、図１３（ａ）のＺ－Ｚ´矢視線に沿って抵抗器を軸方向に切断したときの縦断面図である。FIG. 13 (a) is an external perspective view of the noise prevention resistor according to the modified example 5, and FIG. 13 (b) shows the resistor in the axial direction along the ZZ'arrow line of sight of FIG. 13 (a). It is a vertical cross-sectional view when it is cut into.
　以下、本発明に係る実施形態について添付図面を参照して詳細に説明する。図１（ａ）は、本実施形態に係る雑音防止抵抗器（以下、単に抵抗器ともいう）１０の外観斜視図であり、図１（ｂ）は、図１（ａ）のＸ－Ｘ´矢視線に沿って抵抗器を軸方向に切断したときの縦断面図である。 Hereinafter, embodiments according to the present invention will be described in detail with reference to the accompanying drawings. FIG. 1A is an external perspective view of a noise prevention resistor (hereinafter, also simply referred to as a resistor) 10 according to the present embodiment, and FIG. 1B is an external perspective view of FIG. 1A. It is a vertical cross-sectional view when the resistor is cut in the axial direction along the arrow line of sight.
　本実施形態に係る抵抗器１０は、例えば、エンジン点火装置に搭載され、エンジン点火時に発生するイグニッションノイズ等の放射ノイズを効果的に抑制するノイズフィルタとして機能する雑音防止抵抗器である。 The resistor 10 according to the present embodiment is, for example, a noise prevention resistor mounted on an engine ignition device and functioning as a noise filter that effectively suppresses radiated noise such as ignition noise generated at the time of engine ignition.
　抵抗器１０は、芯材５と、芯材５の外周表面に抵抗線７を巻き付けた抵抗素子（抵抗体）２と、抵抗素子２の両端部に装着され、抵抗線７と電気的に接続されたキャップ端子３ａ，３ｂと、抵抗素子２の外周表面の一部を軸回りに周回し、キャップ端子に接触しない位置に形成した電磁シールド部材（リング状部材ともいう）８ａとを備える。 The resistor 10 is attached to the core material 5, the resistance element (resistor) 2 in which the resistance wire 7 is wound around the outer peripheral surface of the core material 5, and both ends of the resistance element 2, and is electrically connected to the resistance wire 7. The cap terminals 3a and 3b are provided, and an electromagnetic shield member (also referred to as a ring-shaped member) 8a formed at a position where a part of the outer peripheral surface of the resistance element 2 is rotated around an axis and does not come into contact with the cap terminal.
　芯材５は、ガラス、フェライト、樹脂等からなる繊維状の絶縁物を多数、結束し、エポキシ樹脂、シリコーン樹脂等により固着した棒状（円柱状）の部材である。ガラス繊維の場合、その繊維径が数μｍ～数十μｍであるため、複数本合わせた束を切断前の長尺状態で搬送すると、芯材の形状を維持できずに湾曲する。そのため、上記のように芯材にエポキシ樹脂、シリコーン樹脂等を含浸させて加温硬化し、形状を維持する。 The core material 5 is a rod-shaped (cylindrical) member in which a large number of fibrous insulating materials made of glass, ferrite, resin, etc. are bound and fixed with epoxy resin, silicone resin, or the like. In the case of glass fiber, the fiber diameter is several μm to several tens of μm, so if a bundle of a plurality of fibers is conveyed in a long state before cutting, the shape of the core material cannot be maintained and the glass fiber is curved. Therefore, as described above, the core material is impregnated with an epoxy resin, a silicone resin, or the like and heat-cured to maintain its shape.
　なお、芯材５としてガラス繊維束を採用した場合、コスト・高耐熱性の点で優れるが、これに限定されず、例えば繊維状の絶縁物でなくてもよく、ガラス、フェライト、樹脂、セラミック等を円柱形状に成形した部材を使用してもよい。 When a glass fiber bundle is used as the core material 5, it is excellent in terms of cost and high heat resistance, but the present invention is not limited to this, and for example, it does not have to be a fibrous insulator, and glass, ferrite, resin, or ceramic. You may use a member formed into a cylindrical shape such as.
　抵抗線７は、例えば、ニッケル・鉄（Ｎｉ－Ｆｅ）線、ニッケル（Ｎｉ）線、銅・ニッケル（ＣＮ）線、ニッケル・クロム（Ｎｉ－Ｃｒ）線等の金属線を、抵抗器の抵抗値に応じて選択する。抵抗線７の線径は、数十μｍ程度（例えば、３０～６０μｍ）で、狭ピッチで連続的に芯材５の外周に巻き付ける。 The resistance wire 7 is, for example, a metal wire such as nickel / iron (Ni—Fe) wire, nickel (Ni) wire, copper / nickel (CN) wire, nickel / chromium (Ni—Cr) wire, and the resistance of the resistor. Select according to the value. The wire diameter of the resistance wire 7 is about several tens of μm (for example, 30 to 60 μm), and the resistance wire 7 is continuously wound around the outer circumference of the core material 5 at a narrow pitch.
　抵抗線７は、金属線をそのまま使用してもよいし、金属線の表面に樹脂被覆を施した被覆導線を用いてもよい。 As the resistance wire 7, the metal wire may be used as it is, or a coated conductor wire having a resin coating on the surface of the metal wire may be used.
　抵抗素子２の外周表面には、樹脂による絶縁被覆（樹脂コーティングともいう）６が形成されている。ここでは、抵抗線７を巻き付けた芯材５の外周表面にエポキシ樹脂、シリコーン樹脂等を塗布コーティングする。絶縁被覆６には、抵抗線の巻き戻りや、抵抗線間のショートを防止する役割がある。 An insulating coating (also referred to as a resin coating) 6 made of resin is formed on the outer peripheral surface of the resistance element 2. Here, an epoxy resin, a silicone resin, or the like is applied and coated on the outer peripheral surface of the core material 5 around which the resistance wire 7 is wound. The insulating coating 6 has a role of preventing unwinding of resistance wires and short-circuiting between resistance wires.
　絶縁被覆６としての樹脂コーティングは、上記のように抵抗線７を固定する役割を有するが、その厚みにばらつきがあると、抵抗素子２の外周表面の端部にキャップ端子３ａ，３ｂを圧入する際、キャップ端子の開口部４ａ，４ｂにより絶縁被覆６が削られることも想定される。そこで、絶縁被覆６は、例えば抵抗線７が隠れる程度の厚みとする。 The resin coating as the insulating coating 6 has a role of fixing the resistance wire 7 as described above, but if the thickness thereof varies, the cap terminals 3a and 3b are press-fitted into the end portions of the outer peripheral surface of the resistance element 2. At that time, it is assumed that the insulating coating 6 is scraped by the openings 4a and 4b of the cap terminal. Therefore, the insulating coating 6 is thick enough to hide the resistance wire 7, for example.
　キャップ端子３ａ，３ｂは、例えば、鉄、ステンレス等の導電性を有する金属からなり、その表面に銅、ニッケル等のめっきが施されている。これにより、キャップ端子３ａ，３ｂは抵抗線７と接触して電気的な接続が確保される。 The cap terminals 3a and 3b are made of a conductive metal such as iron or stainless steel, and the surface thereof is plated with copper, nickel or the like. As a result, the cap terminals 3a and 3b come into contact with the resistance wire 7 to ensure an electrical connection.
　キャップ端子３ａ，３ｂは、開口部４ａ，４ｂを有するとともに全体が有底筒型に形成されている。キャップ端子３ａ，３ｂは、例えば、金属製の板材をパンチにより変形させて製造する。 The cap terminals 3a and 3b have openings 4a and 4b and are formed in a bottomed tubular shape as a whole. The cap terminals 3a and 3b are manufactured by, for example, deforming a metal plate material by a punch.
　キャップ端子３ａ，３ｂは、開口部４ａ，４ｂを抵抗素子２の軸方向端部に対向させた状態で、キャップ端子３ａ，３ｂを軸方向に機械的に押し込み（圧入し）固定する。キャップ端子３ａ，３ｂと抵抗素子２（抵抗線７）の導通を確実にするため、さらには、キャップ端子３ａ，３ｂの抜けを防止するために、その外表面側部にカシメ加工を施してもよい。 The cap terminals 3a and 3b are fixed by mechanically pushing (press-fitting) the cap terminals 3a and 3b in the axial direction with the openings 4a and 4b facing the axial ends of the resistance element 2. Even if the outer surface side portion is caulked in order to ensure the continuity between the cap terminals 3a and 3b and the resistance element 2 (resistance wire 7) and further to prevent the cap terminals 3a and 3b from coming off. Good.
　電磁シールド部材８ａは、導電性があり抵抗率の低い、例えば、銀、銅、アルミニウム、鉄等からなるリング状部材である。電磁シールド部材８ａは、図１（ａ）に示すように、芯材５に抵抗線７を巻き付けた抵抗素子２の外周表面の一部を、その軸回りに途切れることなく環状に覆っている。電磁シールド部材８ａは、落下、位置ずれ等を防止するため耐熱性樹脂や接着剤等により抵抗素子２に固着する。 The electromagnetic shield member 8a is a ring-shaped member having conductivity and low resistivity, for example, made of silver, copper, aluminum, iron, or the like. As shown in FIG. 1A, the electromagnetic shield member 8a covers a part of the outer peripheral surface of the resistance element 2 in which the resistance wire 7 is wound around the core material 5 in an annular shape without interruption around the axis thereof. The electromagnetic shield member 8a is fixed to the resistance element 2 with a heat-resistant resin, an adhesive, or the like in order to prevent dropping, misalignment, and the like.
　抵抗線７と電磁シールド部材８ａは、電磁シールド部材８ａによる抵抗値の変化（低抵抗化）や抵抗線７と電磁シールド８ａとの間におけるアーク放電を回避するため、電気的に十分に絶縁されていることが望ましい。例えば、抵抗線７と電磁シールド部材８ａとの間に絶縁層（樹脂）を介在させる、あるいは電磁シールド部材８ａの内部に絶縁加工を施す等により絶縁する。 The resistance wire 7 and the electromagnetic shield member 8a are sufficiently electrically insulated in order to avoid a change in resistance value (lower resistance) due to the electromagnetic shield member 8a and an arc discharge between the resistance wire 7 and the electromagnetic shield 8a. It is desirable to be. For example, an insulating layer (resin) is interposed between the resistance wire 7 and the electromagnetic shield member 8a, or the inside of the electromagnetic shield member 8a is insulated to insulate.
　なお、電磁シールド部材８ａの抵抗素子２への固定方法は、上述した接着剤等に限定されず、例えば、カシメ加工により抵抗素子２に固定してもよい。図２（ａ）は、カシメ加工で電磁シールド部材８ｂを固定した雑音防止抵抗器２０の外観斜視図であり、図２（ｂ）は、図２（ａ）のＹ－Ｙ´矢視線に沿って雑音防止抵抗器２０を軸方向に切断したときの縦断面図である。 The method of fixing the electromagnetic shield member 8a to the resistance element 2 is not limited to the adhesive or the like described above, and may be fixed to the resistance element 2 by, for example, caulking. FIG. 2A is an external perspective view of the noise prevention resistor 20 to which the electromagnetic shield member 8b is fixed by caulking, and FIG. 2B is taken along the line of sight of YY'in FIG. 2A. It is a vertical cross-sectional view when the noise prevention resistor 20 is cut in the axial direction.
　カシメ加工で電磁シールド部材を固定した雑音防止抵抗器の他の例として、図３に示す雑音防止抵抗器６０は、電磁シールド部材８ｆに対して抵抗素子２の軸方向に平行な方向にカシメ加工を施した構造を有する。また、図４に示す雑音防止抵抗器７０は、電磁シールド部材８ｇに対して抵抗素子２の軸方向に平行な方向にカシメ加工を施すとともに、キャップ端子３３ａ，３３ｂにもカシメ加工を施した構造を有する。 As another example of the noise prevention resistor in which the electromagnetic shield member is fixed by caulking, the noise prevention resistor 60 shown in FIG. 3 is caulked in a direction parallel to the axial direction of the resistance element 2 with respect to the electromagnetic shield member 8f. Has a structure that has been subjected to. Further, the noise prevention resistor 70 shown in FIG. 4 has a structure in which the electromagnetic shield member 8g is caulked in a direction parallel to the axial direction of the resistance element 2, and the cap terminals 33a and 33b are also caulked. Has.
　電磁シールド部材の一部のみ（例えば、幅方向の中央部のみ）にカシメ加工を施した場合、強くかしめるとカシメ加工を施さない部分が変形（反ってしまう）可能性がある。そこで、図３に示す雑音防止抵抗器６０の電磁シールド部材８ｆのように、その幅方向全体に渡ってカシメ加工を施す、あるいは、図４に示す雑音防止抵抗器７０の電磁シールド部材８ｇのように、その幅方向の少なくとも端部をかしめる。 If only a part of the electromagnetic shield member (for example, only the central part in the width direction) is crimped, the part that is not crimped may be deformed (warped) if it is strongly crimped. Therefore, like the electromagnetic shield member 8f of the noise prevention resistor 60 shown in FIG. 3, caulking is performed over the entire width direction, or the electromagnetic shield member 8g of the noise prevention resistor 70 shown in FIG. 4 is used. Squeeze at least the end in its width direction.
　こうすることによって、カシメ加工による電磁シールド部材の反りを低減でき、電磁シールド部材全体が抵抗線に密着する。その結果、抵抗線と電磁シールド部材間においてアーク放電が起こりにくいという効果が得られる。 By doing so, the warp of the electromagnetic shield member due to caulking can be reduced, and the entire electromagnetic shield member is in close contact with the resistance wire. As a result, it is possible to obtain the effect that arc discharge is unlikely to occur between the resistance wire and the electromagnetic shield member.
　特に、図４に示す雑音防止抵抗器７０の場合、電磁シールド部材８ｇのカシメ加工とキャップ端子３３ａ，３３ｂのカシメ加工とを同時に行なうことができるので、上記の効果に加えて、抵抗器の製造工程を簡素化できる。 In particular, in the case of the noise prevention resistor 70 shown in FIG. 4, the electromagnetic shield member 8 g can be crimped and the cap terminals 33a and 33b can be crimped at the same time. Therefore, in addition to the above effects, the resistor can be manufactured. The process can be simplified.
　次に、本実施形態に係る雑音防止抵抗器の電気的特性等について詳細に説明する。上述したように、本実施形態に係る雑音防止抵抗器１０，２０等の抵抗素子２には、その両端に装着したキャップ端子３ａ，３ｂに接しない位置に、抵抗素子の表面を周回する環状の電磁シールド部材８ａ，８ｂが配置されている。 Next, the electrical characteristics and the like of the noise prevention resistor according to the present embodiment will be described in detail. As described above, the resistance element 2 such as the noise prevention resistors 10 and 20 according to the present embodiment has an annular shape that orbits the surface of the resistance element at a position not in contact with the cap terminals 3a and 3b mounted on both ends thereof. Electromagnetic shield members 8a and 8b are arranged.
　雑音防止抵抗器１０，２０等において、環状の電磁シールド部材８ａ，８ｂは、抵抗器の共振等価回路を分離（分断）させる作用を有する。図５は、電磁シールド部材８ａ，８ｂによる共振回路の分離作用（分離メカニズム）を説明するための模式図である。 In the noise prevention resistors 10, 20, etc., the annular electromagnetic shield members 8a, 8b have an action of separating (dividing) the resonance equivalent circuit of the resistor. FIG. 5 is a schematic diagram for explaining the separation action (separation mechanism) of the resonance circuit by the electromagnetic shield members 8a and 8b.
　図５に示すように、抵抗素子２のコイル状の抵抗線７で発生した磁束（図中の矢印線）は、電磁シールド部材８ａ，８ｂを通過しようとすると、逆起電力によって、電磁シールド部材８ａ，８ｂに短絡電流が流れ、磁束の増加を打ち消す磁束が発生する。その結果、磁束は電磁シールド部材８ａ，８ｂを通過しづらくなり、抵抗素子（抵抗器）は、電磁シールド部材８ａ，８ｂを境に磁気的に分離される（疎結合となる）。 As shown in FIG. 5, when the magnetic flux (arrow line in the figure) generated by the coiled resistance wire 7 of the resistance element 2 tries to pass through the electromagnetic shield members 8a and 8b, the electromagnetic shield member is caused by the counter electromotive force. A short-circuit current flows through 8a and 8b, and a magnetic flux that cancels the increase in magnetic flux is generated. As a result, it becomes difficult for the magnetic flux to pass through the electromagnetic shield members 8a and 8b, and the resistance element (resistor) is magnetically separated (loosely coupled) at the electromagnetic shield members 8a and 8b.
　図５の抵抗素子２の軸方向において、電磁シールド部材８ａ，８ｂを境にして一方端側を部位Ａ、他方端側を部位Ｂとすると、上述した電磁シールド部材８ａ，８ｂによる共振回路の分離により、部位Ａに対応する共振回路（ＲＣ１とする）と、部位Ｂに対応する共振回路（ＲＣ２とする）とが形成される。 In the axial direction of the resistance element 2 of FIG. 5, assuming that one end side is a portion A and the other end side is a portion B with the electromagnetic shield members 8a and 8b as boundaries, the resonance circuit is separated by the electromagnetic shield members 8a and 8b described above. As a result, a resonance circuit (referred to as RC1) corresponding to the part A and a resonance circuit (referred to as RC2) corresponding to the part B are formed.
　図６は、電磁シールド部材８ａ，８ｂ等を設けた抵抗器１０，２０等の簡易等価回路の一例である。図６に示すように抵抗器１０，２０等の簡易等価回路３０は、共振回路ＲＣ１，ＲＣ２が直列に接続された回路となる。 FIG. 6 is an example of a simple equivalent circuit of resistors 10, 20, etc. provided with electromagnetic shield members 8a, 8b, etc. As shown in FIG. 6, the simple equivalent circuit 30 such as resistors 10 and 20 is a circuit in which resonance circuits RC1 and RC2 are connected in series.
　共振回路ＲＣ１，ＲＣ２は、抵抗線のターン数、抵抗線材料等に依存する抵抗成分とインダクタンス成分とが電気的に直列に接続され、さらに、抵抗線間（導体間）等に生じる浮遊容量がキャパシタンス成分となって、これら抵抗成分とインダクタンス成分に対して並列に接続されたＬＣＲ共振回路である。 In the resonant circuits RC1 and RC2, the resistance component and the inductance component, which depend on the number of turns of the resistance wire, the resistance wire material, etc., are electrically connected in series, and the stray capacitance generated between the resistance wires (between conductors) is generated. It is an LCR resonant circuit that becomes a capacitance component and is connected in parallel to these resistance components and inductance components.
　ここで、抵抗器１０，２０等において芯材５の一方端部から他方端部に渡って抵抗線７が一様に巻かれており、かつ、電磁シールド部材８ａ，８ｂが抵抗素子２の軸方向の中間点に配置されている場合、図５の部位Ａでの抵抗線の巻き数（Ｎ１）と部位Ｂでの抵抗線の巻き数（Ｎ２）とが等しいことになる。よって、共振回路ＲＣ１，ＲＣ２において、インダクタンス成分Ｌ１，Ｌ２、抵抗成分Ｒ１，Ｒ２、キャパシタンス成分Ｃ１，Ｃ２がそれぞれ等しい（等価）と見做すことができる。 Here, in the resistors 10, 20, and the like, the resistance wire 7 is uniformly wound from one end to the other end of the core material 5, and the electromagnetic shield members 8a and 8b are the shafts of the resistance element 2. When arranged at the midpoint in the direction, the number of turns of the resistance wire at the part A in FIG. 5 (N 1 ) and the number of turns of the resistance wire at the part B (N 2 ) are equal. Therefore, in the resonance circuits RC1 and RC2, the inductance components L1 and L2, the resistance components R1 and R2, and the capacitance components C1 and C2 can be regarded as being equal (equivalent), respectively.
　この場合、共振回路ＲＣ１，ＲＣ２が同一の共振特性を有することになり、共振回路ＲＣ１の共振特性と共振回路ＲＣ２の共振特性との相乗効果により、抵抗器１０，２０等は深い共振ピークを有する特性を持つ。その結果、特定の周波数に対する共振ピークが生じ、共振ピークに幅を持たせることができない。 In this case, the resonance circuits RC1 and RC2 have the same resonance characteristics, and the resistors 10, 20 and the like have deep resonance peaks due to the synergistic effect of the resonance characteristics of the resonance circuit RC1 and the resonance characteristics of the resonance circuit RC2. Has characteristics. As a result, a resonance peak is generated for a specific frequency, and the resonance peak cannot have a width.
　電気的特性の観点からは、抵抗値が高く、インダクタンス成分の大きい抵抗器はノイズ抑制効果は大きいが、雑音防止用抵抗器としてエンジン点火装置に搭載した場合、抵抗値が高いためイグニッションコイルの損失が大きくなり、それによりエンジン出力が低下するという問題がある。よって、エンジン点火装置では、抵抗値が低く、かつインダクタンス成分の大きい抵抗器が求められる。 From the viewpoint of electrical characteristics, a resistor with a high resistance value and a large inductance component has a large noise suppression effect, but when mounted on an engine ignition device as a noise prevention resistor, the resistance value is high and the ignition coil is lost. There is a problem that the engine output is reduced due to the increase in the engine output. Therefore, in an engine ignition device, a resistor having a low resistance value and a large inductance component is required.
　そこで、軸方向の長さと径寸法が限られた雑音防止抵抗器において、上記のインダクタンス成分Ｌ１，Ｌ２を確保しながら、その雑音防止抵抗器を、所望の周波数帯において共振ピークに幅を持たせたノイズフィルタとして機能させる必要がある。 Therefore, in a noise prevention resistor having a limited axial length and diameter, the noise prevention resistor is provided with a width at the resonance peak in a desired frequency band while securing the above-mentioned inductance components L1 and L2. It is necessary to function as a noise filter.
　これらの観点から、本実施形態に係る雑音防止抵抗器１０，２０等は、電磁シールド部材８ａ，８ｂを境に分かれる部位Ａ，Ｂの磁束が一致しない（図６のインダクタンス成分Ｌ１，Ｌ２の結合係数（Ｍ）が０に近づく）所定位置に電磁シールド部材８ａ，８ｂを配置する。すなわち、抵抗素子２の軸方向の中間点からずれた位置であって、キャップ端子３ａ，３ｂに触れない位置に電磁シールド部材８ａ，８ｂを配置し、形成する。 From these viewpoints, in the noise prevention resistors 10, 20 and the like according to the present embodiment, the magnetic fluxes of the portions A and B separated by the electromagnetic shield members 8a and 8b do not match (the coupling of the inductance components L1 and L2 in FIG. 6). The electromagnetic shield members 8a and 8b are arranged at predetermined positions (coefficient (M) approaches 0). That is, the electromagnetic shield members 8a and 8b are arranged and formed at positions deviated from the midpoint in the axial direction of the resistance element 2 and not touching the cap terminals 3a and 3b.
　こうすることで、抵抗素子２のうち、電磁シールド部材８ａ，８ｂと、一対のキャップ端子の一方のキャップ端子３ａとの間の部位において第１の共振等価回路（ＲＣ１）が形成され、さらに、電磁シールド部材８ａ，８ｂと、一対のキャップ端子の他方のキャップ端子３ｂとの間の部位において第２の共振等価回路（ＲＣ２）が形成され、これら第１の共振等価回路と第２の共振等価回路の共振周波数が異なる。 By doing so, the first resonance equivalent circuit (RC1) is formed at the portion of the resistance element 2 between the electromagnetic shield members 8a and 8b and one of the cap terminals 3a of the pair of cap terminals, and further. A second resonance equivalent circuit (RC2) is formed at a portion between the electromagnetic shield members 8a and 8b and the other cap terminal 3b of the pair of cap terminals, and the first resonance equivalent circuit and the second resonance equivalent circuit are formed. The resonance frequency of the circuit is different.
　このように、単一の抵抗器である雑音防止抵抗器１０，２０等には、インダクタンス成分、抵抗成分等が相違し、それぞれが異なる共振特性を有する複数の共振回路（ＲＣ１，ＲＣ２）が形成されるので、抵抗器の共振ピークが幅を持つことになる。これは、複数の共振回路が近接して配置されることで、共振周波数（ピーク）の谷間が複数形成されて、共振点の幅が広がる現象（複共振現象）による特性である。 As described above, a plurality of resonance circuits (RC1, RC2) having different inductance components, resistance components, etc., and each having different resonance characteristics are formed in the noise prevention resistors 10, 20, etc., which are a single resistor. Therefore, the resonance peak of the resistor has a width. This is a characteristic of a phenomenon (double resonance phenomenon) in which a plurality of valleys of resonance frequencies (peaks) are formed by arranging a plurality of resonance circuits in close proximity to each other, and the width of the resonance point is widened.
　図７は、本実施形態に係る雑音防止抵抗器の電気的特性の結果をイメージしたグラフである。図７の横軸は周波数（ＭＨｚ）、縦軸はＳ２１特性（ｄＢ）である。Ｓ２１特性は、雑音防止抵抗器を通過した信号の減衰量を示すＳパラメータである。 FIG. 7 is a graph imagining the result of the electrical characteristics of the noise prevention resistor according to the present embodiment. The horizontal axis of FIG. 7 is the frequency (MHz), and the vertical axis is the S21 characteristic (dB). The S21 characteristic is an S parameter indicating the amount of attenuation of the signal that has passed through the noise suppression resistor.
　図７より、本実施形態に係る雑音防止抵抗器（図７の実施例）は、抵抗素子の軸方向中間点からずれた位置に、その外周表面を周回する環状の電磁シールド部材を配置することで、共振点のピークが幅を持つため、従来例と比較して良好なフィルタ特性（ノイズ抑制効果）を有することが分かる。 From FIG. 7, in the noise prevention resistor (example of FIG. 7) according to the present embodiment, an annular electromagnetic shield member orbiting the outer peripheral surface thereof is arranged at a position deviated from the axial intermediate point of the resistance element. Since the peak of the resonance point has a width, it can be seen that it has better filter characteristics (noise suppression effect) as compared with the conventional example.
　なお、雑音防止抵抗器１０，２０等において、電磁シールド部材により分断された２つの共振回路のインダクタンス成分が磁気結合されると考えた場合、雑音防止抵抗器１０，２０等は、図８に示す簡易等価回路で表すことができる。図８において、Ｌはインダクタンス成分、ｋは磁気の結合係数である。 When it is considered that the inductance components of the two resonance circuits separated by the electromagnetic shield member are magnetically coupled in the noise prevention resistors 10, 20, etc., the noise prevention resistors 10, 20, etc. are shown in FIG. It can be represented by a simple equivalent circuit. In FIG. 8, L is an inductance component and k is a magnetic coupling coefficient.
　次に、本実施形態に係る雑音防止抵抗器の製造方法について説明する。図９は、本実施形態に係る雑音防止抵抗器の製造工程の一例を時系列で示すフローチャートである。 Next, a method of manufacturing the noise suppression resistor according to the present embodiment will be described. FIG. 9 is a flowchart showing an example of the manufacturing process of the noise prevention resistor according to the present embodiment in chronological order.
　最初の工程（図９のステップＳ１１）において芯材を成形する。ここでは、上述したように、繊維径が数μｍ～数十μｍ程度のガラス繊維等を束ねてエポキシ樹脂、シリコーン樹脂等を含浸させ、長尺の棒状に成形して芯材とする。 The core material is molded in the first step (step S11 in FIG. 9). Here, as described above, glass fibers having a fiber diameter of several μm to several tens of μm are bundled, impregnated with an epoxy resin, a silicone resin, or the like, and formed into a long rod shape to form a core material.
　ステップＳ１３において、芯材の外周表面に、例えばニッケル・鉄（Ｎｉ－Ｆｅ）線、ニッケル（Ｎｉ）線、銅・ニッケル（ＣＮ）線、ニッケル・クロム（Ｎｉ－Ｃｒ）線等の抵抗線を所定のピッチで連続的に巻き付ける。抵抗器の抵抗値は、線材の種類（材料）、巻き付けピッチ等により調整する。 In step S13, resistance wires such as nickel / iron (Ni—Fe) wire, nickel (Ni) wire, copper / nickel (CN) wire, nickel / chromium (Ni—Cr) wire, etc. are formed on the outer peripheral surface of the core material. Wind continuously at a predetermined pitch. The resistance value of the resistor is adjusted according to the type (material) of the wire, the winding pitch, and the like.
　ステップＳ１５において、抵抗線を巻回した芯材を乾燥させて樹脂を硬化させる。続くステップＳ１７において、上記のように抵抗線を巻き付けて乾燥・硬化させた芯材の外周表面に、例えば、抵抗線が隠れる程度の厚みのエポキシ樹脂またはシリコーン樹脂等を塗布コーティングする。そして、ステップＳ１９で、樹脂コーティングを硬化させる。なお、ステップＳ１５の乾燥・硬化は、ステップＳ１９において同時に行なってもよい。 In step S15, the core material around which the resistance wire is wound is dried to cure the resin. In the subsequent step S17, for example, an epoxy resin or a silicone resin having a thickness sufficient to hide the resistance wire is applied and coated on the outer peripheral surface of the core material obtained by winding the resistance wire and drying / curing as described above. Then, in step S19, the resin coating is cured. The drying and curing of step S15 may be performed at the same time in step S19.
　ステップＳ２１において、上記の工程で抵抗線が巻回され、樹脂でコーティングされた長尺の芯材を抵抗線ごとカッター等により所定寸法に切断する。これにより、抵抗素子２（抵抗体）の個片を作製する。 In step S21, the resistance wire is wound in the above step, and the long core material coated with the resin is cut together with the resistance wire to a predetermined size by a cutter or the like. As a result, individual pieces of the resistance element 2 (resistor) are manufactured.
　続くステップＳ２３では、抵抗線が巻回された抵抗素子の外周表面の一部を、その軸回りに途切れることなく覆うように、所定位置（抵抗素子の軸方向中心からずらした位置）に電磁シールド部材を形成する。 In the following step S23, the electromagnetic shield is placed at a predetermined position (position shifted from the axial center of the resistance element) so as to cover a part of the outer peripheral surface of the resistance element around which the resistance wire is wound without interruption around the axis. Form a member.
　電磁シールド部材は、加工性等を考慮して、例えば幅が１～３ｍｍ、厚さが０．１～０．６ｍｍの板状の環状部材である。電磁シールド部材の厚さは、キャップ端子の部材の厚さと同等、あるいは、それよりも薄くすることで、雑音防止抵抗器をエンジン点火装置へ搭載する際に引っ掛かる等の不都合を回避できる。 The electromagnetic shield member is, for example, a plate-shaped annular member having a width of 1 to 3 mm and a thickness of 0.1 to 0.6 mm in consideration of workability and the like. By making the thickness of the electromagnetic shield member equal to or thinner than the thickness of the cap terminal member, it is possible to avoid inconveniences such as being caught when the noise prevention resistor is mounted on the engine ignition device.
　一方、電気的な特性から、上述した短絡電流を流せればよいという観点に立った場合、電磁シールド部材を線状の金属細線で構成してもよい。金属細線を使用した場合、金属細線の端部同士は溶接等により接合して円環状にしたリング状部材にする。 On the other hand, from the viewpoint of electrical characteristics, the electromagnetic shield member may be composed of a linear thin metal wire from the viewpoint that the short-circuit current described above can be passed. When a thin metal wire is used, the ends of the thin metal wire are joined by welding or the like to form an annular ring-shaped member.
　ステップＳ２５において、抵抗素子２の両端にキャップ端子３ａ，３ｂを装着する。例えば、抵抗素子２の両端部より軸方向にキャップ端子３ａ，３ｂを機械的に押し込み、仮固定した後、キャップ端子３ａ，３ｂの側面部を、その外周面から押圧して変形する（カシメ加工）ことで、抵抗線７とキャップ端子３ａ，３ｂを電気的に導通させる。なお、キャップ端子３ａ，３ｂを抵抗素子２の両端に圧入して装着（嵌合）してもよい。 In step S25, cap terminals 3a and 3b are attached to both ends of the resistance element 2. For example, the cap terminals 3a and 3b are mechanically pushed in the axial direction from both ends of the resistance element 2 to be temporarily fixed, and then the side surface portions of the cap terminals 3a and 3b are pressed from the outer peripheral surface thereof to be deformed (caulking). ), That makes the resistance wire 7 and the cap terminals 3a and 3b electrically conductive. The cap terminals 3a and 3b may be press-fitted into both ends of the resistance element 2 to be mounted (fitted).
　ステップＳ２７において、上記の工程を経て作製された雑音防止抵抗器の外観画像検査、抵抗値検測等の検査を行なう。 In step S27, an inspection such as an appearance image inspection and a resistance value inspection of the noise prevention resistor manufactured through the above steps is performed.
　なお、上記ステップＳ２３の電磁シールド部材の形成工程と、ステップＳ２５のキャップ端子の装着工程は、形成する電磁シールド部材の形状、構造等に応じて、適宜、その順序を入れ替えてもよく、同一工程において同時に行なってもよい。ステップＳ２３の電磁シールド部材の形成工程を、ステップＳ２５のキャップ端子の装着工程の後に行なうと、電磁シールド部材を形成する抵抗素子の軸方向中間点からずれた位置、すなわち一対のキャップ端子より離間した所定位置の調整が容易になる。 The order of the step of forming the electromagnetic shield member in step S23 and the step of mounting the cap terminal in step S25 may be appropriately changed according to the shape, structure, etc. of the electromagnetic shield member to be formed, and the same step. May be performed at the same time. When the step of forming the electromagnetic shield member in step S23 is performed after the step of mounting the cap terminal in step S25, the position deviated from the axial intermediate point of the resistance element forming the electromagnetic shield member, that is, separated from the pair of cap terminals. The predetermined position can be easily adjusted.
　上記のステップＳ１５等における樹脂等の硬化方法は、室温による硬化、加熱硬化（例えば１００～１５０℃）、あるいは紫外線照射による硬化のいずれでもよい。また、乾燥時間を短縮する観点から、抵抗器の外表面全体に形成する保護膜の樹脂として速乾性のウレタン樹脂に限定して使用してもよい。 The curing method of the resin or the like in step S15 or the like described above may be any of curing at room temperature, heat curing (for example, 100 to 150 ° C.), or curing by ultraviolet irradiation. Further, from the viewpoint of shortening the drying time, the resin of the protective film formed on the entire outer surface of the resistor may be limited to the quick-drying urethane resin.
　以上説明したように、本実施形態に係る雑音防止抵抗器は、抵抗素子の外周表面の一部の所定位置に、その軸回りに途切れることなく覆う電磁シールド部材を配置し、電磁シールド部材によって抵抗器の共振回路を分離する（磁気的に分離する）。 As described above, in the noise prevention resistor according to the present embodiment, an electromagnetic shield member that covers a part of the outer peripheral surface of the resistance element without interruption is arranged around the axis thereof, and the resistance is resisted by the electromagnetic shield member. Separate the resonant circuit of the vessel (magnetically separate).
　すなわち、単一の抵抗器において、共振回路の共振周波数が異なるような位置に電磁シールド部材を形成することで、抵抗器一素子の中に複数の共振回路を持つことになり、抵抗器の共振ピークが幅を持つ。 That is, in a single resistor, by forming the electromagnetic shield member at a position where the resonance frequency of the resonance circuit is different, a plurality of resonance circuits are provided in one element of the resistor, and the resonance of the resistor is generated. The peak has a width.
　その結果、抵抗器本体の軸方向の長さ寸法を長くすることなく、あるいは芯材、抵抗線の径を変えることなく、雑音防止抵抗器の外形サイズを維持したまま、広い帯域においてノイズ抑制効果を向上させ、雑音防止フィルタとしての機能を有する雑音防止抵抗器を得ることができる。 As a result, the noise suppression effect is achieved in a wide band while maintaining the external size of the noise prevention resistor without increasing the axial length of the resistor body or changing the diameter of the core material and the resistance wire. It is possible to obtain a noise suppression resistor having a function as a noise suppression filter.
　本願発明は上述した実施形態に限定されず、種々の変形が可能である。 The invention of the present application is not limited to the above-described embodiment, and various modifications are possible.
＜変形例１＞
　上記の実施形態では、電磁シールド部材の位置を抵抗素子の軸方向中心からずらして配置することで、電磁シールド部材を境に共振周波数を異ならせる構成としたが、共振周波数を異ならせる手段は、これに限定されない。例えば、電磁シールド部材を境にして抵抗線の巻き数、抵抗線の線径等（インダクタンス値）を変える、キャップ端子の深さ方向の寸法を変える（抵抗線の有効長を変える）、あるいは、電磁シールド部材の幅方向の面積を変える（電磁シールド部材に段差を形成し、厚みを変える）ことで、その電磁シールド部材とキャップ端子間に形成される容量成分を変える等の方法によって、共振周波数を異ならせるようにしてもよい。 <Modification example 1>
In the above embodiment, the electromagnetic shield member is arranged so as to be offset from the axial center of the resistance element so that the resonance frequency is different with the electromagnetic shield member as a boundary. Not limited to this. For example, changing the number of turns of the resistance wire, the wire diameter of the resistance wire (inductance value), etc. (inductance value) with the electromagnetic shield member as the boundary, changing the dimension in the depth direction of the cap terminal (changing the effective length of the resistance wire), or Resonance frequency by changing the width direction area of the electromagnetic shield member (forming a step on the electromagnetic shield member and changing the thickness) to change the capacitance component formed between the electromagnetic shield member and the cap terminal. May be different.
＜変形例２＞
　上記の実施形態では、抵抗素子に単一の電磁シールド部材を形成したが、抵抗素子に複数の電磁シールド部材を形成し、各電磁シールド部材を境に抵抗器の共振回路を分断して共振周波数を異ならせる構成としてもよい。例えば、互いに離間した２個の電磁シールド部材を抵抗素子に形成した場合、インダクタンス成分、抵抗成分等が異なり、共振周波数も異なる３つの共振回路が隣接して配置されることになり、共振ピークがさらなる幅を持つ周波数特性が得られる。 <Modification 2>
In the above embodiment, a single electromagnetic shield member is formed on the resistance element, but a plurality of electromagnetic shield members are formed on the resistance element, and the resonance circuit of the resistor is divided at each electromagnetic shield member to divide the resonance frequency. May be configured to be different. For example, when two electromagnetic shield members separated from each other are formed in a resistance element, three resonance circuits having different inductance components, resistance components, etc., and different resonance frequencies are arranged adjacent to each other, resulting in resonance peaks. Frequency characteristics with a wider range can be obtained.
　具体的には、抵抗素子のうち、一対のキャップ端子３ａ，３ｂの一方のキャップ端子３ａと、２個の電磁シールド部材のうち一方のキャップ端子３ａに隣接する電磁シールド部材との間の部位において第１の共振回路が形成され、２個の電磁シールド部材間の部位において第２の共振回路が形成され、一対のキャップ端子の他方のキャップ端子３ｂと、２個の電磁シールド部材のうち他方のキャップ端子３ｂに隣接する電磁シールド部材との間の部位において第３の共振回路が形成され、これら３つの共振回路それぞれの共振周波数が異なる。 Specifically, in the portion of the resistance element between one cap terminal 3a of the pair of cap terminals 3a and 3b and the electromagnetic shield member adjacent to one cap terminal 3a of the two electromagnetic shield members. A first resonant circuit is formed, a second resonant circuit is formed at a portion between the two electromagnetic shield members, the other cap terminal 3b of the pair of cap terminals and the other of the two electromagnetic shield members. A third resonance circuit is formed at a portion between the cap terminal 3b and the electromagnetic shield member adjacent to the cap terminal 3b, and the resonance frequencies of each of these three resonance circuits are different.
＜変形例３＞
　上記の実施形態では、電磁シールド部材としてリングが連続する一体構造の金属製部材を使用したが、これに限定されない。例えば、図１０に示す電磁シールド部材８ｃのように、リングの一部を分離した形状とし、その分離された部位Ｃが係合可能に段差を有する構造にして、抵抗素子に形成後、それらを接合させる構成としてもよい。 <Modification example 3>
In the above embodiment, a metal member having an integral structure with continuous rings is used as the electromagnetic shield member, but the present invention is not limited to this. For example, as in the electromagnetic shield member 8c shown in FIG. 10, a part of the ring is formed into a separated shape, the separated portion C is formed into a structure having a step so that it can be engaged, and after being formed into a resistance element, they are formed. It may be configured to be joined.
　すなわち、図１０に示す電磁シールド部材８ｃは、抵抗素子に対して配置する位置を決めた後、はんだ、溶接等により、分離された部位Ｃを相互に接合する。こうすることで、抵抗素子の外周部の一部を途切れることなく覆うように電磁シールド部材を形成できる。電磁シールド部材８ｃの分離された部位Ｃは単に相互にはめ込むだけの構造としてもよい。 That is, after determining the position of the electromagnetic shield member 8c shown in FIG. 10 with respect to the resistance element, the separated portions C are joined to each other by soldering, welding, or the like. By doing so, the electromagnetic shield member can be formed so as to cover a part of the outer peripheral portion of the resistance element without interruption. The separated portions C of the electromagnetic shield member 8c may have a structure that simply fits into each other.
　また、電磁シールド部材の形状は、図１等に示す例に限定されず、例えば、図１１に示す電磁シールド部材８ｄのように、外観が多角形状であるリング状部材としてもよい。 Further, the shape of the electromagnetic shield member is not limited to the example shown in FIG. 1 and the like, and may be a ring-shaped member having a polygonal appearance, such as the electromagnetic shield member 8d shown in FIG.
＜変形例４＞
　抵抗素子への電磁シールド部材の形成態様は、上記の実施形態に限定されない。例えば、図１２に示す雑音防止抵抗器４０のように、抵抗素子２の外周表面であって、キャップ端子３ａ，３ｂに接触しない所定位置に環状に絶縁層(樹脂層)３１を形成し、その絶縁層(樹脂層)３１の上面に金属膜からなる電磁シールド部材８ｅを形成してもよい。 <Modification example 4>
The mode of forming the electromagnetic shield member on the resistance element is not limited to the above embodiment. For example, as in the noise prevention resistor 40 shown in FIG. 12, an insulating layer (resin layer) 31 is formed in an annular shape at a predetermined position on the outer peripheral surface of the resistance element 2 so as not to come into contact with the cap terminals 3a and 3b. An electromagnetic shield member 8e made of a metal film may be formed on the upper surface of the insulating layer (resin layer) 31.
　絶縁層(樹脂層)３１は、印刷、塗布、熱圧着チューブの縮小等により形成する。あるいは、絶縁被覆（樹脂コーティング）でもよい。金属膜である電磁シールド部材８ｅは、印刷、塗布、貼り付け、転写等により形成する。絶縁層３１に使用する樹脂は、高耐熱性の樹脂を用いる。これにより絶縁層３１は、金属膜（電磁シールド部材８ｅ）の焼成、硬化に対して耐性を有する。 The insulating layer (resin layer) 31 is formed by printing, coating, shrinking of a heat-bonded tube, or the like. Alternatively, an insulating coating (resin coating) may be used. The electromagnetic shield member 8e, which is a metal film, is formed by printing, coating, pasting, transfer, or the like. As the resin used for the insulating layer 31, a highly heat-resistant resin is used. As a result, the insulating layer 31 has resistance to firing and curing of the metal film (electromagnetic shield member 8e).
＜変形例５＞
　変形例５として、上記の変形例１において説明した電磁シールド部材とキャップ端子間に形成される容量成分を変える方法の一例について説明する。 <Modification 5>
As a modification 5, an example of a method of changing the capacitance component formed between the electromagnetic shield member and the cap terminal described in the above modification 1 will be described.
　図１３（ａ）は、変形例５に係る雑音防止抵抗器８０の外観斜視図であり、図１３（ｂ）は、図１３（ａ）のＺ－Ｚ´矢視線に沿って抵抗器を軸方向に切断したときの縦断面図である。図１３（ａ）に示すように雑音防止抵抗器８０は、一方のキャップ端子４３ａ，４３ｂのうち、キャップ端子４３ａがその開口部４５ａにおいて抵抗線７と離間し、電磁シールド部材８ｇのうち、開口部４５ａと対向する側の端部に拡張部４５ｂを設けて抵抗線７と離間させた構造を有する。 13 (a) is an external perspective view of the noise prevention resistor 80 according to the modified example 5, and FIG. 13 (b) is an axis of the resistor along the ZZ'arrow line of sight of FIG. 13 (a). It is a vertical cross-sectional view when cut in a direction. As shown in FIG. 13A, in the noise prevention resistor 80, of the cap terminals 43a and 43b, the cap terminal 43a is separated from the resistance wire 7 at the opening 45a, and the opening of the electromagnetic shield member 8g is opened. It has a structure in which an expansion portion 45b is provided at an end portion on the side facing the portion 45a so as to be separated from the resistance wire 7.
　このようにキャップ端子４３ａと電磁シールド部材８ｇとに、抵抗線７より離間させた部分（拡張部）を形成することで、雑音防止抵抗器８０に容量成分を付与する。これにより、電磁シールド部材８ｇによって分断された２つの共振回路のうち、一方の共振回路のキャパシタンス成分（Ｃ）を、拡張部を形成しない場合に比べて大きくすることができる。 By forming a portion (expansion portion) separated from the resistance wire 7 in the cap terminal 43a and the electromagnetic shield member 8g in this way, a capacitance component is imparted to the noise prevention resistor 80. As a result, the capacitance component (C) of one of the two resonant circuits divided by the electromagnetic shield member 8g can be increased as compared with the case where the expansion portion is not formed.
　その結果、例えば電磁シールド部材８ｇを抵抗素子２の軸方向の中央部に形成しても、電磁シールド部材８ｇを挟んで形成される２つの共振等価回路の共振周波数を異ならせることができる。 As a result, for example, even if the electromagnetic shield member 8g is formed at the central portion in the axial direction of the resistance element 2, the resonance frequencies of the two resonance equivalent circuits formed across the electromagnetic shield member 8g can be made different.
　さらには、イグニッションコイルへ雑音防止抵抗器８０を搭載したときに拡張部の内部に封止樹脂が入り込むため、アーク放電が起こりにくくなる。 Furthermore, when the noise prevention resistor 80 is mounted on the ignition coil, the sealing resin enters the inside of the expansion portion, so that arc discharge is less likely to occur.
２　抵抗素子（抵抗体）
３ａ，３ｂ，３３ａ，３３ｂ，４３ａ，４３ｂ　キャップ端子
４ａ，４ｂ，４５ａ　開口部
５　芯材
６　絶縁被覆（樹脂コーティング）
７　抵抗線
８ａ～８ｇ　電磁シールド部材
１０，２０，４０，６０，７０，８０　雑音防止抵抗器
３０，５０　抵抗器の簡易等価回路
３１　絶縁層(樹脂層)
４５ｂ　拡張部

  2 Resistor element (resistor)
3a, 3b, 33a, 33b, 43a, 43b Cap terminals 4a, 4b, 45a Opening 5 Core material 6 Insulation coating (resin coating)
7 Resistor wire 8a-8g Electromagnetic shield member 10, 20, 40, 60, 70, 80 Noise prevention resistor 30, 50 Simple equivalent circuit of resistor 31 Insulation layer (resin layer)
45b extension

Claims (12)

  1. 　絶縁性の芯材と、その芯材の外周面に抵抗線を巻回した抵抗素子とを有し、前記抵抗素子の両端に一対のキャップ端子を装着した雑音防止抵抗器であって、
    　前記抵抗素子の外周表面の一部で、かつ前記一対のキャップ端子より離間した所定位置に、該抵抗素子の軸回りに周回する電磁シールド部材を形成したことを特徴とする雑音防止抵抗器。     A noise-preventing resistor having an insulating core material and a resistance element in which a resistance wire is wound around the outer peripheral surface of the core material, and a pair of cap terminals are attached to both ends of the resistance element.
    A noise prevention resistor characterized in that an electromagnetic shield member that circulates around the axis of the resistance element is formed at a predetermined position that is a part of the outer peripheral surface of the resistance element and is separated from the pair of cap terminals.
  2. 　前記所定位置は前記抵抗素子の軸方向中間点からずれた位置であることを特徴とする請求項１に記載の雑音防止抵抗器。 The noise prevention resistor according to claim 1, wherein the predetermined position is a position deviated from the axial intermediate point of the resistance element.
  3. 　前記所定位置に形成した単一の前記電磁シールド部材を境界にして共振周波数の異なる２つの共振等価回路を形成したことを特徴とする請求項１に記載の雑音防止抵抗器。 The noise prevention resistor according to claim 1, wherein two resonance equivalent circuits having different resonance frequencies are formed with the single electromagnetic shield member formed at the predetermined position as a boundary.
  4. 　前記所定位置は、前記２つの共振等価回路の一方の共振等価回路のインダクタンス成分と他方の共振等価回路のインダクタンス成分との結合係数を減少させる位置であることを特徴とする請求項３に記載の雑音防止抵抗器。 The third aspect of claim 3, wherein the predetermined position is a position for reducing the coupling coefficient between the inductance component of one of the two resonance equivalent circuits and the inductance component of the other resonance equivalent circuit. Noise prevention resistor.
  5. 　前記所定位置を複数設け、該複数の位置それぞれに形成した前記電磁シールド部材各々を境界にして共振周波数の異なる複数の共振等価回路を形成したことを特徴とする請求項１に記載の雑音防止抵抗器。 The noise prevention resistor according to claim 1, wherein a plurality of the predetermined positions are provided, and a plurality of resonance equivalent circuits having different resonance frequencies are formed with each of the electromagnetic shield members formed at each of the plurality of positions as a boundary. vessel.
  6. 　前記電磁シールド部材は、前記複数の共振等価回路のうち隣接する共振等価回路のインダクタンス成分同士の結合係数を減少させる位置に形成されていることを特徴とする請求項５に記載の雑音防止抵抗器。 The noise prevention resistor according to claim 5, wherein the electromagnetic shield member is formed at a position where the coupling coefficient between the inductance components of adjacent resonance equivalent circuits is reduced among the plurality of resonance equivalent circuits. ..
  7. 　前記共振等価回路は、前記電磁シールド部材を境界にして磁気的に分離された前記抵抗素子の抵抗成分とインダクタンス成分と容量成分によって形成されるＬＣＲ共振回路であることを特徴とする請求項３～６のいずれか１項に記載の雑音防止抵抗器。 3. The resonance equivalent circuit is an LCR resonance circuit formed by a resistance component, an inductance component, and a capacitance component of the resistance element magnetically separated with the electromagnetic shield member as a boundary. The noise prevention resistor according to any one of 6.
  8. 　前記電磁シールド部材は円環状の金属からなることを特徴とする請求項１～６のいずれか１項に記載の雑音防止抵抗器。 The noise prevention resistor according to any one of claims 1 to 6, wherein the electromagnetic shield member is made of an annular metal.
  9. 　前記電磁シールド部材は樹脂層の表面に形成した金属膜であることを特徴とする請求項１～６のいずれか１項に記載の雑音防止抵抗器。 The noise prevention resistor according to any one of claims 1 to 6, wherein the electromagnetic shield member is a metal film formed on the surface of a resin layer.
  10. 　前記電磁シールド部材と前記抵抗線は電気的に絶縁されていることを特徴とする請求項１～６のいずれか１項に記載の雑音防止抵抗器。 The noise prevention resistor according to any one of claims 1 to 6, wherein the electromagnetic shield member and the resistance wire are electrically insulated.
  11. 　繊維状の絶縁物を結束して長尺の芯材を成形する工程と、
    　前記芯材の外周面に抵抗線を巻回する工程と、
    　前記抵抗線が巻回された芯材を所定寸法に切断して抵抗素子を形成する工程と、
    　前記抵抗素子の外周表面の一部を該抵抗素子の軸回りに周回する電磁シールド部材を形成する工程と、
    　前記抵抗素子の軸方向両端部に一対のキャップ端子を装着する工程と、
    を備え、
    　前記一対のキャップ端子より離間した所定位置に前記電磁シールド部材を形成することを特徴とする雑音防止抵抗器の製造方法。     The process of bundling fibrous insulators to form a long core material,
    The process of winding a resistance wire around the outer peripheral surface of the core material and
    A step of cutting the core material around which the resistance wire is wound to a predetermined size to form a resistance element, and
    A step of forming an electromagnetic shield member that orbits a part of the outer peripheral surface of the resistance element around the axis of the resistance element.
    The process of mounting a pair of cap terminals on both ends of the resistance element in the axial direction,
    With
    A method for manufacturing a noise prevention resistor, which comprises forming the electromagnetic shield member at a predetermined position separated from the pair of cap terminals.
  12. 　前記抵抗素子の軸方向中間点からずれた位置に前記電磁シールド部材を少なくとも１つ形成することを特徴とする請求項１１に記載の雑音防止抵抗器の製造方法。

          The method for manufacturing a noise prevention resistor according to claim 11, wherein at least one electromagnetic shield member is formed at a position deviated from an axial intermediate point of the resistance element.
PCT/JP2020/039983 2019-10-31 2020-10-23 Noise prevention resistor and manufacturing method thereof WO2021085339A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5889901U (en) * 1981-12-11 1983-06-17 株式会社アドバンテスト Moisture-proof fixed resistor
JPH01130501U (en) * 1988-02-29 1989-09-05
JP2013143417A (en) * 2012-01-10 2013-07-22 Koa Corp Resistor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5889901U (en) * 1981-12-11 1983-06-17 株式会社アドバンテスト Moisture-proof fixed resistor
JPH01130501U (en) * 1988-02-29 1989-09-05
JP2013143417A (en) * 2012-01-10 2013-07-22 Koa Corp Resistor

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