Ignition resistor and method for manufacturing the same

Abstract

An igniter resistor includes an ignition structure, an insulating substrate, a supporting base, a first conductive layer, and a second conductive layer. The ignition structure includes a first electrode portion, an ignition portion, and a second electrode portion. The first and second electrode portions are respectively joined to two opposite ends of the ignition portion. The insulating substrate is disposed on the ignition structure. The insulating substrate includes a filling portion, which includes an opening and a side wall surrounding the opening. The opening exposes the ignition portion. The opening can accommodate an ignition material. The supporting base is disposed under the ignition structure. The supporting base includes a first electrode and a second electrode, which correspond to the first electrode portion and the second electrode portion, respectively. The first electrode and the second electrode are respectively located on two opposite sides of the supporting base and the ignition structure. The first conductive layer electrically connects the first electrode portion and the first electrode. The second conductive layer electrically connects the second electrode portion and the second electrode. The ignition material can be accurately disposed on the ignition portion through the opening, so the ignition effect can be ensured, and the quality and reliability of the igniter resistor can be improved.

Description

Technical Field

[0001] The present disclosure relates to a resistor manufacturing technology, and more particularly to an igniter resistor and a manufacturing method thereof. Background Art

[0002] In the past, electronic ignition devices mainly provide ignition function by passing high voltage between two electrodes to generate arc discharge and spark. With the rapid development of technology, surface mount ignition resistors have been developed. Surface mount ignition resistors are designed with a narrow channel with low resistance value so that the narrow channel will fuse and spark when the digital voltage passes through it for a short time, thereby achieving the ignition function.

[0003] When manufacturing a traditional surface-mounted igniter resistor, the ignition device must first be glued to the circuit board, and then the ignition material such as pyrotechnic powder must be placed on the narrow channel. However, due to the small narrow channel, it is not easy to accurately place the ignition material on the narrow channel, and the position of the ignition material often deviates. The position deviation of the ignition material causes the ignition resistor to fail to ignite or have a poor effect. Summary of the invention

[0004] Therefore, the purpose of the present disclosure is to provide an igniter resistor and a manufacturing method thereof, wherein the insulating substrate includes a filling portion, and the openings of the filling portion are aligned to expose the ignition portion of the ignition structure. Thus, the ignition material can be accurately placed on the ignition portion through the opening, and the placement of the ignition material can be easily completed. Therefore, the application of the present disclosure can ensure the ignition effect of the igniter resistor, thereby improving the quality and reliability of the igniter resistor.

[0005] According to the above-mentioned purpose of the present disclosure, an igniter resistor is proposed. This igniter resistor includes an ignition structure, an insulating substrate, a supporting base, a first conductive layer, and a second conductive layer. The ignition structure includes a first electrode portion, an ignition portion, and a second electrode portion. The first electrode portion and the second electrode portion are respectively joined at two opposite ends of the ignition portion. The insulating substrate is disposed on the ignition structure. The insulating substrate includes a filling portion, and the filling portion includes an opening and a side wall surrounding the opening. The opening exposes the ignition portion. The opening is configured to accommodate an ignition material. The supporting base is disposed under the ignition structure. The supporting base includes a first electrode and a second electrode, which correspond to the first electrode portion and the second electrode portion, respectively. The first electrode and the second electrode are respectively located on two opposite sides of the supporting base with the ignition structure. The first conductive layer electrically connects the first electrode portion and the first electrode. The second conductive layer electrically connects the second electrode portion and the second electrode.

[0006] According to an embodiment of the present disclosure, the material of the ignition structure is nickel-chromium alloy, copper-nickel alloy, or copper.

[0007] According to an embodiment of the present disclosure, the thermal conductivity of the insulating substrate is equal to or less than 0.2 W / mK.

[0008] According to an embodiment of the present disclosure, the material of the insulating substrate is polyimide (PI), polycarbonate (PC), glass fiber, ceramic material, or FR4 grade material.

[0009] According to an embodiment of the present disclosure, the first conductive layer is disposed through the sidewall, the first electrode portion, the supporting base, and the first electrode, and the second conductive layer is disposed through the sidewall, the second electrode portion, the supporting base, and the second electrode.

[0010] According to an embodiment of the present disclosure, the ignition structure, the insulating substrate, and the supporting base constitute the main structure of the igniter resistor, and the first conductive layer covers the first side of the main structure, and the second conductive layer covers the second side of the main structure.

[0011] According to the above-mentioned purpose of the present disclosure, a method for manufacturing an igniter resistor is also proposed. In this method, a conductive sheet is provided, wherein the conductive sheet has a first surface and a second surface opposite to each other. The conductive sheet includes a plurality of ignition structures, each of which includes a first electrode portion, an ignition portion, and a second electrode portion, and the first electrode portion and the second electrode portion are respectively joined at two opposite ends of the ignition portion. An insulating substrate is bonded to the first surface of the conductive sheet, wherein the insulating substrate includes a plurality of filling portions corresponding to the ignition structures respectively. Each filling portion includes an opening and a side wall surrounding the opening. Bonding the insulating substrate includes aligning these openings with the ignition portion respectively. Each opening is configured to accommodate an ignition material. The first surface of the supporting base is bonded to the second surface of the conductive sheet. The supporting base includes a plurality of first electrodes and a plurality of second electrodes disposed on the second surface of the supporting base relative to the first surface. These first electrodes correspond to the first electrode portions respectively, and the second electrodes correspond to the second electrode portions respectively. A plurality of first conductive layers are formed to electrically connect the corresponding first electrode portions and the first electrodes respectively. A plurality of second conductive layers are formed to electrically connect the corresponding second electrode portions and the second electrodes respectively.

[0012] According to an embodiment of the present disclosure, the conductive sheet is a metal foil.

[0013] According to an embodiment of the present disclosure, the conductive sheet is made of nickel-chromium alloy, copper-nickel alloy, or copper.

[0014] According to an embodiment of the present disclosure, the thermal conductivity of the insulating substrate is equal to or less than 0.2 W / mK.

[0015] According to an embodiment of the present disclosure, the insulating substrate is made of polyimide, polycarbonate, glass fiber, ceramic material, or FR4 grade material.

[0016] According to one embodiment of the present disclosure, the formation of the first conductive layer and the second conductive layer includes: forming a plurality of first through holes respectively penetrating the side wall, the first electrode portion, the supporting base, and the first electrode; forming a plurality of second through holes respectively penetrating the side wall, the second electrode portion, the supporting base, and the second electrode; forming the first conductive layer to be filled in the first through holes respectively; and forming the second conductive layer to be filled in the second through holes respectively.

[0017] According to an embodiment of the present disclosure, after attaching the supporting base, the above method further includes a segmentation step to form a plurality of main structures of the igniter resistor. The above forming of the first conductive layer and the second conductive layer includes: forming the first conductive layer to cover the first side surfaces of the main structures respectively; and forming the second conductive layer to cover the second side surfaces of the main structures respectively. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to make the above and other objects, features, advantages and embodiments of the present disclosure more clearly understood, the accompanying drawings are described as follows:

[0019] Figure 1 A cross-sectional schematic diagram of an igniter resistor according to a first embodiment of the present disclosure is shown;

[0020] Figure 2 A cross-sectional schematic diagram of an igniter resistor according to a second embodiment of the present disclosure is shown;

[0021] Figure 3 A schematic top view of an insulating substrate according to an embodiment of the present disclosure is shown;

[0022] Figure 4 A schematic top view of a conductive sheet according to an embodiment of the present disclosure is shown;

[0023] Figure 5 A bottom view of a supporting base according to an embodiment of the present disclosure is shown;

[0024] FIG. 6A to FIG. 6D A partial cross-sectional schematic diagram showing various intermediate stages of a method for manufacturing an igniter resistor according to a first embodiment of the present disclosure;

[0025] Figure 7 A cross-sectional schematic diagram illustrating a method for manufacturing a first conductive layer and a second conductive layer of an igniter resistor according to a second embodiment of the present disclosure; and

[0026] Figure 8 A schematic diagram of an igniter resistance igniting ignition material according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0027] The following is a detailed discussion of the embodiments of the present disclosure. However, it is to be understood that the embodiments provide many applicable concepts that can be implemented in a variety of specific contexts. The embodiments discussed and disclosed are for illustration only and are not intended to limit the scope of the present disclosure. All embodiments of the present disclosure disclose a variety of different features, but these features can be implemented individually or in combination as needed.

[0028] In addition, the terms “first”, “second”, etc. used in this document do not particularly refer to an order or sequence, but are only used to distinguish elements or operations described with the same technical terminology.

[0029] The spatial relationship between two elements described in the present disclosure is applicable not only to the orientations shown in the drawings, but also to orientations not shown in the drawings, such as an inverted orientation. In addition, the "connection", "electrical connection" or similar terms between two components in the present disclosure are not limited to direct connection or electrical connection between the two components, but may also include indirect connection or electrical connection as required.

[0030] Please refer to Figure 1 , which illustrates a cross-sectional schematic diagram of an igniter resistor according to the first embodiment of the present disclosure. The igniter resistor 100a is a surface mount type igniter resistor. In some examples, the igniter resistor 100a may mainly include an insulating substrate 110, an ignition structure 120, a supporting base 130, a first conductive layer 140, and a second conductive layer 150.

[0031] The insulating substrate 110 has a first surface 110a and a second surface 110b opposite to each other. The insulating substrate 110 includes a filling portion 112. The filling portion 112 may mainly include an opening 114 and a side wall 116. The opening 114 extends from the first surface 110a of the insulating substrate 110 to the second surface 110b and penetrates the insulating substrate 110. The opening 114 is configured to accommodate an ignition material. The side wall 116 may, for example, be a ring-shaped structure and surround the opening 114 to facilitate the loading of the ignition material. In some examples, in addition to being non-conductive, the insulating substrate 110 also has the characteristic of poor thermal conductivity. For example, the thermal conductivity of the insulating substrate 110 is equal to or less than about 0.2 W / mK. In some exemplary examples, the material of the insulating substrate 110 is polyimide, polycarbonate, glass fiber, ceramic material, or FR4 grade material.

[0032] The ignition structure 120 has a first surface 120a and a second surface 120b respectively located at two opposite sides of the ignition structure 120. The insulating substrate 110 is disposed on the ignition structure 120, and the second surface 110b of the insulating substrate 110 can be, for example, attached to the first surface 120a of the ignition structure 120. The ignition structure 120 includes a first electrode portion 122, a second electrode portion 124, and an ignition portion 126. The first electrode portion 122 and the second electrode portion 124 are respectively joined to two opposite ends of the ignition portion 126. When the insulating substrate 110 is disposed on the first surface 120a of the ignition structure 120, the opening 114 of the filling portion 112 is aligned with the ignition portion 126, and the ignition portion 126 is exposed. The opposite sides of the side wall 116 of the filling portion 112 are respectively overlapped on the first electrode portion 122 and the second electrode portion 124. Thus, the filling portion 112 can define a containing space on the ignition structure 120 for filling the ignition material.

[0033] Please refer to Figure 4 , which shows a top view of a conductive sheet according to an embodiment of the present disclosure. The conductive sheet 300 includes a plurality of ignition structures 120. Figure 4 In the example shown, the ignition structure 120 is an I-shaped structure, that is, the width of the ignition portion 126 located between the first electrode portion 122 and the second electrode portion 124 is smaller than the width of the first electrode portion 122 and the width of the second electrode portion 124. Here, the width of the first electrode portion 122 and the width of the second electrode portion 124 refer to the average width of the first electrode portion 122 and the average width of the second electrode portion 124, respectively. The shape of the ignition structure disclosed herein is not limited to the above example, and it is only necessary that the radial dimension of the ignition portion is smaller than the radial dimension of the electrode portions on both sides. For example, the ignition structure may also be an S-shaped structure. In some exemplary examples, the ignition structure 120 is an integrally formed structure. However, the ignition structure 120 may not be an integrally formed structure. The material of the ignition structure 120 is a conductive material, such as a metal material. For example, the material of the ignition structure 120 is a nickel-chromium alloy, a copper-nickel alloy, or copper.

[0034] The supporting base 130 also has a first surface 130a and a second surface 130b opposite to each other. The supporting base 130 is disposed under the ignition structure 120, and the first surface 130a of the supporting base 130 can be, for example, attached to the second surface 120b of the ignition structure 120, and together with the insulating substrate 110 and the ignition structure 120, form the main structure 160 of the igniter resistor 100a. The supporting base 130 includes a first electrode 132 and a second electrode 134. The first electrode 132 and the second electrode 134 are disposed on the second surface 130b of the supporting base 130, and are thus located on two opposite sides of the supporting base 130 with the ignition structure 120. The first electrode 132 and the second electrode 134 are disposed separately from each other. The first electrode 132 and the second electrode 134 correspond to the first electrode portion 122 and the second electrode portion 124 of the ignition structure 120 , respectively. That is, the first electrode portion 122 and the second electrode portion 124 are stacked on the first electrode 132 and the second electrode 134 , respectively.

[0035] The support base 130 is an insulating base and preferably has a poor thermal conductivity. In some exemplary examples, the material of the support base 130 is glass fiber or FR4 grade material. The material of the first electrode 132 and the second electrode 134 can be a metal with good electrical conductivity. For example, the material of the first electrode 132 and the second electrode 134 can be silver or copper.

[0036] The first conductive layer 140 electrically connects the first electrode portion 122 of the ignition structure 120 and the first electrode 132. Figure 1 In the example shown, the main structure 160 has a first through hole 162. The first through hole 162 extends from the first surface 110a of the insulating substrate 110, through the insulating substrate 110, the first electrode portion 122 of the ignition structure 120, and the supporting base 130 to the first electrode 132. In other words, the first through hole 162 penetrates the side wall 116 of the insulating substrate 110 above the first electrode portion 122, the first electrode portion 122, and the supporting base 130, and exposes a portion of the first electrode 132. In some examples, the first through hole 162 penetrates the first electrode 132. The axial direction of the first through hole 162 may be, for example, substantially perpendicular to the main structure 160. The first conductive layer 140 is filled in the first through hole 162 to connect the first electrode portion 122 and the first electrode 132, thereby achieving electrical connection between the first electrode portion 122 and the first electrode 132. The material of the first conductive layer 140 may be metal, such as copper or a copper alloy.

[0037] The second conductive layer 150 electrically connects the second electrode portion 124 of the ignition structure 120 and the second electrode 134. The main structure 160 further has a second through hole 164. The second through hole 164 extends from the first surface 110a of the insulating substrate 110, through the insulating substrate 110, the second electrode portion 124 of the ignition structure 120, and the supporting base 130 to the second electrode 134. That is, the second through hole 164 penetrates the side wall 116 of the insulating substrate 110 above the second electrode portion 124, the second electrode portion 124, and the supporting base 130, and exposes a portion of the second electrode 134. In some examples, the second through hole 164 penetrates the second electrode 134. The axial direction of the second through hole 164 can also be substantially perpendicular to the main structure 160. The second conductive layer 150 is filled in the second through hole 164 to connect the second electrode portion 124 and the second electrode 134, thereby electrically connecting the second electrode portion 124 and the second electrode 134. The material of the second conductive layer 150 may be metal, such as copper or copper alloy.

[0038] By placing the insulating substrate 110 having the filling portion 112 on the ignition structure 120 and aligning the opening 114 of the filling portion 112 with the ignition portion 126 of the ignition structure 120, the ignition material can be accurately placed on the ignition portion 126. Therefore, the reliability of the igniter resistor 100a can be improved, and the ignition effect can be enhanced.

[0039] Please refer to Figure 2 , which shows a cross-sectional schematic diagram of an igniter resistor according to a second embodiment of the present disclosure. The structure of the igniter resistor 100b of this embodiment is substantially the same as the structure of the igniter resistor 100a described above, and the difference between the two is that the first conductive layer 170 and the second conductive layer 180 of the igniter resistor 100b are not disposed in the main structure 160.

[0040] The main structure 160 has a first side surface 160a and a second side surface 160b. The first side surface 160a and the second side surface 160b may be, for example, located at two opposite sides of the main structure 160, respectively. The first conductive layer 170 covers the first side surface 160a of the main structure 160. The first conductive layer 170 extends at least from the first electrode portion 122 of the ignition structure 120 to the first electrode 132, and simultaneously connects the first electrode portion 122 and the first electrode 132, thereby electrically connecting the first electrode portion 122 and the first electrode 132. The second conductive layer 180 covers the second side surface 160b of the main structure 160. The second conductive layer 180 extends at least from the second electrode portion 124 of the ignition structure 120 to the second electrode 134, and simultaneously connects the second electrode portion 124 and the second electrode 134, thereby achieving electrical connection between the second electrode portion 124 and the second electrode 134.

[0041] Please refer to Figures 3 to 6D ,in Figure 3 and Figure 5 A schematic top view of an insulating substrate and a schematic bottom view of a supporting base according to an embodiment of the present disclosure are respectively shown. FIG. 6A to FIG. 6D A partial cross-sectional schematic diagram of various intermediate stages of a method for manufacturing an igniter resistor according to a first embodiment of the present disclosure is shown. Fig.6D The igniter resistor shown is 100A, which can provide Figure 3 The insulating substrate 200 shown in FIG. Figure 4 The conductive sheet 300 shown, and Figure 5 The supporting base 400 is shown. In this embodiment, the order of providing the insulating substrate 200, the conductive sheet 300, and the supporting base 400 can be adjusted according to actual process requirements. In some exemplary examples, the insulating substrate 200 can be provided first, the conductive sheet 300 can be provided, and then the supporting base 400 can be provided.

[0042] Please also refer to Figure 3 and Fig. 6A , the insulating substrate 200 has a first surface 200a and a second surface 200b opposite to each other. The insulating substrate 200 includes a plurality of filling portions 112. Each filling portion 112 includes an opening 114 and a side wall 116 surrounding the opening 114. Each opening 114 extends from the first surface 200a of the insulating substrate 200 to the second surface 200b, and is a through hole that penetrates the insulating substrate 200. The opening 114 is used to accommodate the ignition material, so the space for filling the ignition material can be clearly defined by the filling portion 112. These filling portions 112 can be arranged according to a default rule. For example, these filling portions 112 can be arranged at a certain interval. In some exemplary examples, the filling portions 112 can be arranged in an array. In some examples, the insulating substrate 200 is non-conductive and has the characteristic of poor thermal conductivity. The thermal conductivity of the insulating substrate 200 can be, for example, equal to or less than about 0.2 W / mK. In some exemplary examples, the insulating substrate 200 is made of polyimide, polycarbonate, fiberglass, ceramic material, or FR4 grade material.

[0043] The size and shape of the conductive sheet 300 may be the same as the size and shape of the insulating substrate 200, for example. Figure 4 As shown, the conductive sheet 300 includes a plurality of ignition structures 120. In some examples, when manufacturing the conductive sheet 300, a metal foil may be provided first, and then a portion of the metal foil may be removed by etching, for example, to form the ignition structure 120. The material of the conductive sheet 300 may be, for example, a nickel-chromium alloy, a copper-nickel alloy, or copper. Fig. 6A The conductive sheet 300 has a first surface 300 a and a second surface 300 b , wherein the first surface 300 a and the second surface 300 b are respectively located at two opposite sides of the conductive sheet 300 .

[0044] The number of the ignition structures 120 may be the same as the number of the filling portions 112. In addition, the positions of the ignition structures 120 correspond to the positions of the filling portions 112 of the insulating substrate 200, respectively. Therefore, the arrangement rule of the ignition structures 120 is the same as the arrangement rule of the filling portions 112. Each ignition structure 120 includes a first electrode portion 122, an ignition portion 126, and a second electrode portion 124. In some examples, the first electrode portion 122 and the second electrode portion 124 are respectively joined at opposite ends of the ignition portion 126 to form an I-shaped structure. In other examples, the ignition structure may be other shapes, such as an S-shaped shape, in which the radial dimension of the ignition portion is smaller than the radial dimension of the electrode portions on both sides.

[0045] Please also refer to Figure 5 and Figure 6B The supporting base 400 has a first surface 400a and a second surface 400b opposite to each other. The supporting base 400 includes a plurality of first electrodes 132 and a plurality of second electrodes 134. The first electrodes 132 correspond to the second electrodes 134 respectively, so the first electrodes 132 and the second electrodes 134 have the same number. The first electrodes 132 and the second electrodes 134 are both disposed on the second surface 400b of the supporting base 400. Each first electrode 132 and the corresponding second electrode 134 are disposed separately and opposite to each other.

[0046] The number of the first electrodes 132 and the corresponding second electrodes 134 may be the same as the number of the ignition structures 120 and the number of the filling portions 112. In addition, the positions of the first electrodes 132 and the corresponding second electrodes 134 correspond to the positions of the filling portions 112 of the insulating substrate 200 and the positions of the ignition structures 120 of the conductive sheet 300. Therefore, the arrangement rule of the first electrodes 132 and the corresponding second electrodes 134 is the same as the arrangement rule of the filling portions 112 and the arrangement rule of the ignition structures 120. The positions of the first electrodes 132 and the second electrodes 134 correspond to the positions of the first electrode portions 122 and the second electrode portions 124 of the corresponding ignition structures 120, respectively.

[0047] The support base 400 is an insulating base and has a poor thermal conductivity. The material of the support base 400 can be, for example, glass fiber or FR4 grade material. In some examples, the first electrode 132 and the second electrode 134 can be made by low-temperature silver paste printing or chemical plating. The material of the first electrode 132 and the second electrode 134 can be a metal with good conductivity, such as silver or copper.

[0048] In some examples, such as Fig. 6AAs shown, after the insulating substrate 200 and the conductive sheet 300 are provided, the second surface 200b of the insulating substrate 200 can be bonded to the first surface 300a of the conductive sheet 300. When bonding the insulating substrate 200 and the conductive sheet 300, the opening 114 of the filling portion 112 of the insulating substrate 200 is aligned with the ignition portion 126 of the corresponding ignition structure 120 on the conductive sheet 300, so that the opening 114 can expose the ignition portion 126. At this time, the opposite sides of the side wall 116 of the filling portion 112 can be respectively overlapped on the first electrode portion 122 and the second electrode portion 124 of the ignition structure 120.

[0049] Next, the first surface 400a of the support base 400 can be bonded to the second surface 300b of the conductive sheet 300. When the support base 400 is bonded to the conductive sheet 300, the first electrode 132 of the support base 400 is overlapped with the first electrode portion 122 of the ignition structure 120 of the conductive sheet 300, and the second electrode 134 is overlapped with the second electrode portion 124 of the ignition structure 120. Each filling portion 112, the ignition structure 120 overlapped with it, and part of the support base 400 form a Fig.6D The main structure 160 of the igniter resistor 100a.

[0050] In the above embodiment, the insulating substrate 200 is first laminated with the conductive sheet 300, and then the supporting base 400 is laminated with the conductive sheet 300. However, the present disclosure is not limited thereto, and the conductive sheet 300 and the supporting base 400 may also be laminated first, and then the insulating substrate 200 and the conductive sheet 300 are laminated. In some examples, the lamination method of the insulating substrate 200, the conductive sheet 300, and the supporting base 400 may include combining the insulating substrate 200, the conductive sheet 300, and the supporting base 400 into one body by vacuum pressing.

[0051] Next, a first conductive layer 140 and a second conductive layer 150 may be formed in the main structure 160 of each igniter resistor 110a, such as Fig.6D In some examples, such as Figure 6C As shown, when manufacturing the first conductive layer 140, a first through hole 162 may be formed in each main structure 160. The first through hole 162 may, for example, penetrate the sidewall of the filling portion 112 located on the first electrode portion 122, the first electrode portion 122, the supporting base 400 under the first electrode portion 122, and the first electrode 132. Then, a plurality of first conductive layers 140 are formed by, for example, chemical plating to fill the first through holes 162 respectively, so as to electrically connect the first electrode portion 122 of each main structure 160 with the first electrode 132.

[0052] Similarly, when manufacturing the second conductive layer 150, the second through hole 164 may be formed in each main structure 160 first. The second through hole 164 may, for example, penetrate the side wall of the filling portion 112 located on the second electrode portion 124, the second electrode portion 124, the supporting base 400 under the second electrode portion 124, and the second electrode 134. Then, a plurality of second conductive layers 150 are formed by, for example, chemical plating to fill the second through holes 164 respectively, so as to electrically connect the second electrode portion 124 of each main structure 160 with the second electrode 134. The first conductive layer 140 and the second conductive layer 150 may be manufactured together.

[0053] After the first conductive layer 140 and the second conductive layer 150 are completed, a segmentation step may be performed to separate the main structure 160, thereby substantially completing the manufacture of the igniter resistor 100a. Fig.6D As shown. The insulating substrate 110 of the main structure 160 is a part of the insulating substrate 200, and the supporting base 130 is a part of the supporting base 400. In the above example, the first conductive layer 140 and the second conductive layer 150 of each igniter resistor 110a are first formed, and then the segmentation step is performed. This embodiment can also perform the segmentation step first, and separate the main structure 160, and then form the first conductive layer 140 and the second conductive layer 150 of each igniter resistor 110a.

[0054] Please refer to Figure 7 , which illustrates a cross-sectional schematic diagram of a method for manufacturing a first conductive layer and a second conductive layer of an igniter resistor according to a second embodiment of the present disclosure. After the insulating substrate 200, the conductive sheet 300, and the supporting base 400 are stacked, a Figure 6B After the structure shown in FIG. 1 is formed, a segmentation step is first performed to cut out a plurality of main structures 160. Figure 7 As shown, each main structure 160 has a first side surface 160 a and a second side surface 160 b. The first side surface 160 a and the second side surface 160 b may be located at two opposite sides of the main structure 160 , for example.

[0055] The first conductive layer 170 and the second conductive layer 180 of each main structure 160 are formed by, for example, a method for making the terminal of a general resistor element. For example, the first conductive layer 170 can be formed by vacuum sputtering to cover the first side surface 160a of the main structure 160, and the second conductive layer 180 can be formed to cover the second side surface 160b of the main structure 160. The first conductive layer 170 at least extends from the first electrode portion 122 to the first electrode 132 to electrically connect the first electrode portion 122 and the first electrode 132. The second conductive layer 180 at least extends from the second electrode portion 124 to the second electrode 134 to electrically connect the second electrode portion 124 and the second electrode 134.

[0056] When applied, the igniter resistor can be placed on the component or circuit board using the adhesive layer, and the igniter material can be filled on the igniter resistor. Figure 8 , which is a schematic diagram of an igniter resistor igniting an ignition material according to an embodiment of the present disclosure. In some examples, the igniter resistor 100b can be fixed to the circuit board 500 using an adhesive material 190, and the first electrode 132 and the second electrode 134 of the igniter resistor 100b are electrically connected to the circuit on the circuit board 500. The adhesive material 190 can be formed by, for example, plating to join the igniter resistor 100b and the circuit board 500. The adhesive material 190 can be, for example, a nickel-tin alloy.

[0057] The ignition material 600 is filled into the opening 114 of the filling portion 112. Since the opening 114 of the filling portion 112 is aligned with the ignition portion 126 of the ignition structure 120, the ignition material 600 can be accurately placed on the ignition portion 126. After the circuit board 500 is energized, the ignition portion 126 can generate sparks to ignite the ignition material 600 on the ignition portion 126, thereby generating a reaction such as explosion.

[0058] The above embodiment is a process for simultaneously manufacturing multiple igniter resistors 100a and 100b. The igniter resistors 100a and 100b disclosed in the present invention can also be manufactured in a single manner. After the insulating substrate 110, the ignition structure 120, and the supporting base 130 of the main structure 160 of the igniter resistor 100a or 100b are stacked in sequence, the first conductive layer 140 and the second conductive layer 150, or the first conductive layer 170 and the second conductive layer 180 can be manufactured in the manner of the above example.

[0059] From the above embodiments, it can be seen that the advantage of the present disclosure is that the insulating substrate of the igniter resistor of the present disclosure includes a filling portion, and the openings of the filling portion are aligned to expose the ignition portion of the ignition structure, so the ignition material can be accurately placed on the ignition portion through the opening, and the placement of the ignition material can be easily completed. Therefore, the application of the present disclosure can ensure the ignition effect of the igniter resistor, thereby improving the quality and reliability of the igniter resistor.

[0060] Although the present disclosure has been disclosed as above by way of embodiments, it is not intended to limit the present disclosure. A person skilled in the art may make various changes and modifications without departing from the spirit and scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be determined by the definition of the appended claims.

[0061]

Explanation of symbols

[0062] 100A: Ignition resistor

[0063] 100b: Ignition resistor

[0064] 110: Insulation substrate

[0065] 110a: first surface

[0066] 110b: Second surface

[0067] 112: Filling part

[0068] 114: Opening

[0069] 116: Side wall

[0070] 120: Ignition structure

[0071] 120a: first surface

[0072] 120b: Second surface

[0073] 122: first electrode portion

[0074] 124: Second electrode portion

[0075] 126: Ignition Department

[0076] 130: Bearing base

[0077] 130a: first surface

[0078] 130b: Second surface

[0079] 132: first electrode

[0080] 134: Second electrode

[0081] 140: first conductive layer

[0082] 150: second conductive layer

[0083] 160: Main structure

[0084] 160a: first side

[0085] 160b: Second side

[0086] 162: First through hole

[0087] 164: Second through hole

[0088] 170: first conductive layer

[0089] 180: second conductive layer

[0090] 190: Next material

[0091] 200: Insulation substrate

[0092] 200a: first surface

[0093] 200b: second surface

[0094] 300: Conductive sheet

[0095] 300a: first surface

[0096] 300b: second surface

[0097] 400: Bearing base

[0098] 400a: first surface

[0099] 400b: second surface

[0100] 500: Circuit board

[0101] 600: Ignition material

[0102] 700: Electric current.

Claims

1. An igniter resistor, characterized in that: The igniter resistor contains: The ignition structure comprises a first electrode portion, an ignition portion, and a second electrode portion, wherein the first electrode portion and the second electrode portion are respectively connected to two opposite ends of the ignition portion; An insulating substrate is disposed on the ignition structure, wherein the insulating substrate comprises a filling portion, the filling portion comprises an opening and a side wall surrounding the opening, the opening exposes the ignition portion, the opening is configured to accommodate an ignition material, and two opposite sides of the side wall are respectively overlapped on the first electrode portion and the second electrode portion; A supporting base is disposed under the ignition structure, wherein the supporting base comprises a first electrode and a second electrode, the first electrode portion is stacked on the first electrode, the second electrode portion is stacked on the second electrode, and the first electrode and the second electrode and the ignition structure are respectively located on two opposite sides of the supporting base; A first conductive layer electrically connecting the first electrode portion and the first electrode, wherein the first conductive layer extends from the side wall of the insulating substrate through the first electrode portion of the ignition structure and the supporting base to the first electrode; as well as The second conductive layer electrically connects the second electrode portion and the second electrode, wherein the second conductive layer extends from the side wall of the insulating substrate through the second electrode portion of the ignition structure and the supporting base to the second electrode.

2. The igniter resistor according to claim 1, characterized in that The material of the ignition structure is nickel-chromium alloy, copper-nickel alloy, or copper.

3. The igniter resistor according to claim 1, characterized in that The thermal conductivity of the insulating substrate is equal to or less than 0.2 W / mK.

4. The igniter resistor according to claim 1, characterized in that The insulating substrate is made of polyimide, polycarbonate, glass fiber, ceramic material, or FR4 grade material.

5. The igniter resistor according to claim 1, characterized in that The first conductive layer is disposed through the sidewall, the first electrode portion, the supporting base, and the first electrode; and The second conductive layer penetrates the side wall, the second electrode portion, the supporting base, and the second electrode.

6. The igniter resistor according to claim 1, characterized in that The ignition structure, the insulating substrate, and the supporting base constitute the main structure of the igniter resistor, and the first conductive layer covers the first side of the main structure, and the second conductive layer covers the second side of the main structure.

7. A method for manufacturing an igniter resistor, characterized in that: The method includes: A conductive sheet is provided, wherein the conductive sheet has a first surface and a second surface opposite to each other, the conductive sheet includes a plurality of ignition structures, each of the ignition structures includes a first electrode portion, an ignition portion, and a second electrode portion, the first electrode portion and the second electrode portion are respectively connected to two opposite ends of the ignition portion; Laminating an insulating substrate to the first surface of the conductive sheet, wherein the insulating substrate comprises a plurality of filling portions respectively corresponding to the ignition structures, each of the filling portions comprises an opening and a side wall surrounding the opening, laminating the insulating substrate comprises aligning the opening of each of the filling portions with the corresponding ignition portion of the ignition structure, and aligning two opposite sides of the side wall of each of the filling portions respectively on the first electrode portion and the second electrode portion of the corresponding ignition structure, and each of the openings is configured to accommodate an ignition material; Laminating the first surface of the supporting base to the second surface of the conductive sheet, wherein the supporting base comprises a plurality of first electrodes and a plurality of second electrodes disposed on the second surface of the supporting base opposite to the first surface, the first electrodes respectively correspond to the first electrode portions, and the second electrodes respectively correspond to the second electrode portions; forming a plurality of first conductive layers electrically connecting the corresponding first electrode portions and the first electrodes respectively, wherein the first conductive layers extend from the side walls, through the first electrode portions of the ignition structures and the supporting base to the first electrodes respectively; and A plurality of second conductive layers are formed to electrically connect the corresponding second electrode portions and the second electrodes respectively, wherein the second conductive layers extend from the side walls, through the second electrode portions of the ignition structures and the supporting base, to the second electrodes respectively.

8. The method according to claim 7, characterized in that The conductive sheet is a metal foil.

9. The method according to claim 7, characterized in that The conductive sheet is made of nickel-chromium alloy, copper-nickel alloy, or copper.

10. The method according to claim 7, characterized in that The thermal conductivity of the insulating substrate is equal to or less than 0.2 W / mK.

11. The method according to claim 7, characterized in that The insulating substrate is made of polyimide, polycarbonate, glass fiber, ceramic material, or FR4 grade material.

12. The method according to claim 7, characterized in that Forming the first conductive layers and the second conductive layers includes: Forming a plurality of first through holes respectively penetrating the side walls, the first electrode portions, the supporting base, and the first electrodes; Forming a plurality of second through holes respectively penetrating the side walls, the second electrode portions, the supporting base, and the second electrodes; forming the first conductive layers to fill the first through holes respectively; and The second conductive layers are formed to fill the second through holes respectively.

13. The method according to claim 7, characterized in that After attaching the supporting base, the method further comprises a segmentation step to form a plurality of main structures of a plurality of igniter resistors, wherein forming the first conductive layers and the second conductive layers comprises: forming the first conductive layers to respectively cover a plurality of first side surfaces of the main structures; and The second conductive layers are formed to respectively cover a plurality of second side surfaces of the main structures.

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