Three-dimensional arched ignition resistor element and method of manufacturing the same

Abstract

The invention provides a three-dimensional dome-shaped ignition resistance element and a manufacturing method thereof, comprising: a substrate, an alloy layer, a fuel container, and a side guide layer, the alloy layer is arranged on the first surface of the substrate, the alloy layer comprises a dome-shaped lead, a first connecting part and a second connecting part, the fuel container is defined between the dome-shaped lead and the substrate, the dome-shaped lead defines the volume of the fuel in the fuel container, the side guide layer is arranged on the alloy layer, and the side guide layer abuts the side surface of the substrate, the three-dimensional dome-shaped ignition resistance element is configured to reduce the ignition distance and / or increase the contact area with the fuel.

Description

Technical Field

[0001] This invention relates to the technical field of ignition resistor elements, and in particular to a three-dimensional arched ignition resistor element and its manufacturing method. Background Technology

[0002] When current passes through an ignition resistor element, electrical energy is converted into heat energy through the Joule effect. This heat energy is then conducted to the material to be burned through thermal conduction, raising the temperature to the ignition point for combustion. Alternatively, the element may generate a spark by heating up and melting, thus igniting the surrounding material to be burned.

[0003] However, traditional bridge wire ignition resistors have a small contact area between the bridge wire and the combustible material, requiring a longer ignition reaction time and a higher ignition voltage. Furthermore, the limited heat conduction range results in uneven heating of the combustible material, with only the area near the bridge wire reaching particularly high temperatures, failing to quickly ignite all the material. In addition, the bridge wire of traditional ignition resistors is prone to improper soldering, leading to cold solder joints and ignition failure. Moreover, the bridge wire at the ignition point of traditional bridge wire ignition resistors is very thin, making it susceptible to breakage after component loading or during transportation, resulting in ignition failure. Therefore, it is difficult to ensure the stability and ignition accuracy of traditional ignition resistor elements. Summary of the Invention

[0004] In view of this, the present invention provides a three-dimensional arched ignition resistor element, comprising:

[0005] substrate;

[0006] An alloy layer is disposed on a first surface of the substrate. The alloy layer includes an arched lead, a first connection portion and a second connection portion, with the arched lead located between the first connection portion and the second connection portion.

[0007] A combustible material receiving portion is located between the arched lead and the substrate, the arched lead defining a volume of a combustible material in the combustible material receiving portion; and

[0008] A side guide layer is disposed on the alloy layer and abuts against one side surface of the substrate;

[0009] The three-dimensional arched ignition resistor element is configured to reduce the ignition distance and / or increase the contact area with the material to be burned.

[0010] Preferably, the eccentricity of the arched lead wire is ε and 0 < ε < 1.

[0011] Preferably, the three-dimensional arched ignition resistor element further includes: a back electrode layer disposed on a second surface of the substrate, and the side conductor layer abutting the alloy layer, the substrate and the back electrode layer.

[0012] Preferably, the length of the arched lead is greater than the distance between the first connection and the second connection, and the arched lead is configured to reduce the ignition reaction time.

[0013] Preferably, the diameter of the arched lead wire is 50–250 μm.

[0014] Furthermore, the present invention also provides a method for manufacturing a three-dimensional arched ignition resistor element, comprising:

[0015] An alloy layer is disposed on a first surface of a substrate, and the alloy layer is etched to form an arched lead, a first connection portion, and a second connection portion. The arched lead is located between the first connection portion and the second connection portion, and the arched lead and the substrate define a volume of a combustible material within a combustible material receiving portion; and

[0016] A side guide layer is provided on the alloy layer, and the side guide layer abuts against one side surface of the substrate;

[0017] The three-dimensional arched ignition resistor element is configured to reduce the ignition distance and / or increase the contact area with the material to be burned.

[0018] Preferably, the eccentricity of the arched lead wire is ε and 0 < ε < 1.

[0019] Preferably, the manufacturing method further includes: forming a back electrode layer on a second surface of the substrate, and the side conductor layer abutting the alloy layer, the substrate and the back electrode layer.

[0020] Preferably, the length of the arched lead is greater than the distance between the first connection and the second connection, and the arched lead is configured to reduce the ignition reaction time.

[0021] Preferably, the diameter of the arched lead wire is 50–250 μm.

[0022] The three-dimensional arched ignition resistor element of this invention defines the flammable material accommodating area through an arched lead, allowing the flammable material to cover the entire arched lead. This not only increases the contact surface between the three-dimensional arched ignition resistor element and the flammable material but also increases the volume of flammable material accommodated by the three-dimensional arched ignition resistor element. Therefore, when energized, the three-dimensional arched ignition resistor element can ensure uniform heating of the flammable material, reduce ignition reaction time and ignition distance, and improve the flammable material contact area, safe operating voltage, stability, ignition accuracy, and transportation safety of the three-dimensional arched ignition resistor element. Attached Figure Description

[0023] Figure 1 This is a flowchart of the manufacturing method of the three-dimensional arched ignition resistor element of the present invention.

[0024] Figure 2This is a cross-sectional view of the three-dimensional arched ignition resistor element of the present invention.

[0025] Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 This is a schematic diagram of the manufacturing method of the three-dimensional arched ignition resistor element of the present invention.

[0026] Figure 9 This is a top view of the first embodiment of the three-dimensional arched ignition resistor element of the present invention.

[0027] Figure 10 This is a top view of a second embodiment of the three-dimensional arched ignition resistor element of the present invention.

[0028] Attached icon number

[0029] 1-3: Three-dimensional arched ignition resistor element

[0030] 10:Substrate

[0031] 20: Adhesive layer

[0032] 30: Alloy layer

[0033] 31: Arched lead wire

[0034] 32: First connecting part

[0035] 33: Second connecting part

[0036] 40: Back electrode layer

[0037] 41: First back electrode

[0038] 42: Second back electrode

[0039] 50: Combustion-containing container

[0040] 60: Side guide layer

[0041] 61: First side conductor

[0042] 62: Second side conductor

[0043] 70: Outer electrode layer

[0044] 71: First external electrode

[0045] 72: Second external electrode

[0046] 80: Colloid

[0047] 90: Material to be combusted

[0048] D1: Distance to the upper arch

[0049] DR1: First Direction

[0050] DR2: Second Direction

[0051] θ: Angle of the upper arch

[0052] S01~S06: Steps Detailed Implementation

[0053] The following detailed description of various embodiments of the present invention, illustrated with accompanying drawings, will facilitate a better understanding by those skilled in the art. In addition to these detailed descriptions, the present invention can be widely implemented in other embodiments. Any easy substitutions, modifications, or equivalent changes to the described embodiments should be understood to be included within the scope of the present invention, and the scope of the patent should be defined by the claims. It should be noted that the drawings are for illustrative purposes only and do not represent the actual size or quantity of elements; some details may not be fully depicted for the sake of simplicity.

[0054] For the sake of simplicity, a rectangular three-dimensional arched ignition resistor element is used as an example, but it should be understood that it is used as an example and not to limit the invention. The three-dimensional arched ignition resistor element of the present invention can be implemented in any shape.

[0055] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 , Figure 1 This is a flowchart of the manufacturing method of the three-dimensional arched ignition resistor element of the present invention. Figure 2 This is a cross-sectional view of the three-dimensional arched ignition resistor element of the present invention. Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 This is a schematic diagram of the manufacturing method of the three-dimensional arched ignition resistor element of the present invention. Figure 9 This is a top view of the first embodiment of the three-dimensional arched ignition resistor element of the present invention. Figure 10 This is a top view of a second embodiment of the three-dimensional arched ignition resistor element of the present invention.

[0056] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8, Figure 9 , Figure 10 , Figure 1 This is a flowchart of the manufacturing method of the arched ignition resistor element of the present invention. Figure 2 This is a cross-sectional view of the three-dimensional arched ignition resistor element of the present invention. Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 This is a schematic diagram of the manufacturing method of the arched ignition resistor element of the present invention. Figure 9 This is a top view of the first embodiment of the three-dimensional arched ignition resistor element of the present invention. Figure 10 This is a top view of a second embodiment of the three-dimensional arched ignition resistor element of the present invention.

[0057] The arched ignition resistor elements 1-3 of the present invention are provided with a substrate 10, an adhesive layer 20, an alloy layer 30, a back electrode layer 40, a side guide layer 60, and an outer electrode layer 70.

[0058] The manufacturing method of the arched ignition resistor elements 1 to 3 of the present invention is as follows:

[0059] Step S01: Print colloid 80 on the first surface of substrate 10, and sputter to form a back electrode layer 40 on the second surface of substrate 10. The back electrode layer 40 can be formed by sputtering, electroplating or printing. Both colloid 80 and back electrode layer 40 are parallel strip structures. The back electrode layer 40 is further provided with a first back electrode 41 and a second back electrode 42.

[0060] The substrate 10 is made of FR4 glass fiber substrate or ceramic substrate. The colloid 80 is made of polymer, such as acrylic polymer. The back electrode layer 40 is made of metal, such as copper or silver.

[0061] Step S02: Apply adhesive layer 20 to colloid 80 and attach alloy layer 30 to adhesive layer 20. Etch alloy layer 30 according to the required target resistance value to form arched lead 31, first connection portion 32 and second connection portion 33. Arched lead 31 is located between first connection portion 32 and second connection portion 33. First connection portion 32 is disposed relative to first back electrode 41 and second connection portion 33 is disposed relative to second back electrode 42.

[0062] The included angle θ of the arched lead 31 is 0° < θ < 90°. For every 1 degree increase in the included angle θ, the ignition distance increases by 2-5%, preferably 3.3%. The contact area between the arched lead 31 and the combustible material 90 increases by 1-5%, preferably 1.5%-2%. The ignition reaction time decreases by 1-5%. The semi-major axis of the arched lead 31 (i.e., half the distance between the first connecting part 32 and the second connecting part 33) is greater than the semi-minor axis (i.e., the upper arch distance D1), so that the eccentricity of the arched lead 31 is ε and 0 < ε < 1. The length of the arched lead is greater than the interval between the first connecting part 32 and the second connecting part 33. The upper arch distance D1 of the arched lead 31 is 0.2-1.1 mm, preferably 0.4-1.08 mm. The upper arch distance D1 of the arched lead 31 can reduce the ignition distance with the surrounding combustible material 90. The diameter of the arched lead 31 is 50-250μm, thereby increasing the contact area between the arched lead 31 and the combustible material 90, increasing the safe voltage used, and improving the transportation safety of the three-dimensional arched ignition resistor elements 1-3.

[0063] The material to be combusted (90) is gunpowder, such as ZPP, PETN, or KDNBF.

[0064] like Figure 9 and Figure 10 As shown, the arched lead 31 can be a bridge lead or an S-shaped lead.

[0065] The adhesive layer 20 is made of a polymer, such as epoxy resin adhesive. The alloy layer 30 is made of a nickel-chromium alloy (NiCr).

[0066] Step S03: Cut the substrate 10 into a strip structure with multiple three-dimensional arched ignition resistor elements along the first direction DR1.

[0067] Step S04: After attaching the first shield to the arched lead 31 and performing exposure and development, a side conductor layer 60 is sputtered onto the alloy layer 30. After removing the shield, a first side conductor 61 and a second side conductor 62 are formed. The first side conductor 61 is disposed opposite to the first connection portion 32 and abuts against the side surfaces of the first connection portion 32, the adhesive layer 20, the substrate 10, and the first back electrode 41. The second side conductor 62 is disposed opposite to the second connection portion 33 and abuts against the side surfaces of the second connection portion 33, the adhesive layer 20, the substrate 10, and the second back electrode 42. The material of the side conductor layer 60 is a nickel-chromium alloy (NiCr), copper (Cu), or nickel (Ni). The side conductor layer 60 helps to distribute current evenly, avoid local overheating or excessive stress, thereby improving the reliability of the resistor.

[0068] Step S05: After attaching the second shield to the arched lead 31 and performing exposure and development, the substrate 10 is granulated along the second direction DR2 to cut the substrate 10 into individual three-dimensional arched ignition resistor elements. The first shield and the second shield can be the same or different shields.

[0069] Step S06: Electroplating an outer electrode layer 70 on the side conductor layer and back electrode layer 40, removing the second shield to form a first outer electrode 71 and a second outer electrode 72, and removing the colloid 80 to form a combustible material receiving portion 50. The first outer electrode 71 abuts against the first side conductor 61 and the first back electrode 41, and the second outer electrode 72 abuts against and covers the second side conductor 62 and the second back electrode 42, shortening the conductive path, reducing inductance, crosstalk, and noise generation, and protecting each component layer from sulfur gas and moisture intrusion. The material of the outer electrode layer 70 is a nickel-tin composite metal layer.

[0070] The printing, coating, sputtering, exposure, development and electroplating processes used in this invention can be performed using existing technologies to achieve the same effect. For the sake of brevity, this invention will not be described in detail.

[0071] The three-dimensional arched ignition resistor element of this invention defines the flammable material accommodating area through an arched lead, allowing the flammable material to cover the entire arched lead. This not only increases the contact surface between the three-dimensional arched ignition resistor element and the flammable material but also increases the volume of flammable material accommodated by the three-dimensional arched ignition resistor element. Therefore, when energized, the three-dimensional arched ignition resistor element can ensure uniform heating of the flammable material, reduce ignition reaction time and ignition distance, and improve the flammable material contact area, safe operating voltage, stability, ignition accuracy, and transportation safety of the three-dimensional arched ignition resistor element.

Claims

1. A three-dimensional arched ignition resistor element, characterized in that, It includes: substrate; An alloy layer is disposed on the first surface of the substrate. The alloy layer includes an arched lead, a first connection portion and a second connection portion, with the arched lead located between the first connection portion and the second connection portion. A combustible material receiving portion is located between the arched lead and the substrate, the arched lead defining the volume of the combustible material in the combustible material receiving portion; and A side guide layer is disposed on the alloy layer and abuts against the side surface of the substrate; The three-dimensional arched ignition resistor element is configured to reduce the ignition distance and / or increase the contact area with the material to be burned.

2. The three-dimensional arched ignition resistor element according to claim 1, characterized in that, The eccentricity of the arched lead wire is ε and 0 < ε < 1.

3. The three-dimensional arched ignition resistor element according to claim 1, characterized in that, It also includes: a back electrode layer disposed on the second surface of the substrate, and the side conductor layer abutting the alloy layer, the substrate and the back electrode layer.

4. The three-dimensional arched ignition resistor element according to claim 1, characterized in that, The length of the arched lead is greater than the distance between the first connection and the second connection, and the arched lead is configured to reduce the ignition reaction time.

5. The three-dimensional arched ignition resistor element according to claim 1, characterized in that, The diameter of the arched lead wire is 50–250 μm.

6. A method for manufacturing a three-dimensional arched ignition resistor element, characterized in that, It includes: An alloy layer is formed on a first surface of a substrate, and the alloy layer is etched to form an arched lead, a first connection portion, and a second connection portion. The arched lead is located between the first connection portion and the second connection portion, and the arched lead and the substrate define the volume of the combustible material within the combustible material receiving portion; and A side guide layer is provided on the alloy layer, and the side guide layer abuts against the side surface of the substrate; The three-dimensional arched ignition resistor element is configured to reduce the ignition distance and / or increase the contact area with the material to be burned.

7. The manufacturing method according to claim 6, characterized in that, The eccentricity of the arched lead wire is ε and 0 < ε < 1.

8. The manufacturing method according to claim 6, characterized in that, It also includes: a back electrode layer disposed on the second surface of the substrate, and the side conductor layer abutting the alloy layer, the substrate and the back electrode layer.

9. The manufacturing method according to claim 6, characterized in that, The length of the arched lead is greater than the distance between the first connection and the second connection, and the arched lead is configured to reduce the ignition reaction time.

10. The manufacturing method according to claim 6, characterized in that, The diameter of the arched lead wire is 50–250 μm.

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