Zero-waste welding type alloy chip resistor production process and alloy chip resistor thereof

Abstract

The invention discloses a zero-waste welding type alloy chip resistor production process and an alloy chip resistor thereof. The production process comprises the following steps that N alloy chip resistors are predicted to be produced, each alloy chip resistor comprises a base material and red copper, the length of the red copper is L, the width of the red copper is W, and the area S of a needed copper material is predicted to be equal to 2LWN; the method comprises the following steps: obtaining an infinitely extended copper material, segmenting the copper material to obtain N-1 large square blocks and two small square blocks, the length of each large square block being 2L, the length of each small square block being L, and the width of each large square block and the width of each small square block being W; n base materials are obtained, the N base materials are arranged at intervals in a linear mode, one large square block is placed between every two adjacent base materials, and one small square block is placed on each of the base materials on the edges of the two sides; welding to obtain a linear material belt; carrying out resistance adjustment, plastic packaging and lettering treatment on the base material in the linear material belt; and cutting the particles to obtain N alloy chip resistors. The problem of serious material waste can be solved, and loss is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of alloy chip resistors, and in particular to a production process of a zero-waste welding alloy chip resistor and an alloy chip resistor thereof. Background Art

[0002] like Figure 1 As shown in the figure, it is the old production process of the existing welding type alloy chip resistor, which is to weld two copper flat wires and one base material flat wire to form a single base material strip material, then punch out a single vertically arranged overall frame, and then go through a series of subsequent processes such as resistance adjustment-plastic sealing and printing-granule cutting-electroplating and package testing to make the product. Such old production process has serious material waste and high loss. Summary of the invention

[0003] The purpose of the present invention is to overcome the deficiencies in the prior art, provide a zero-waste welding alloy chip resistor production process and alloy chip resistor, solve the problem of serious material waste, and reduce losses.

[0004] The objective of the present invention is achieved through the following technical solutions:

[0005] A zero-waste welding alloy chip resistor production process comprises the following steps:

[0006] It is expected that N alloy chip resistors will be produced. Each alloy chip resistor includes a base material and copper soldered to both sides of the base material. The length of each copper is L and the width is W. The area of ​​copper required is S = 2LWN.

[0007] Get an infinitely extended copper material, and divide it into N-1 large square blocks and 2 small square blocks. The length of the large square block is 2L, the length of the small square block is L, and the width of the large square block and the small square block are both W;

[0008] Obtain N mother materials, and arrange the N mother materials in a straight line with intervals from each other, place a large square block between adjacent mother materials, and place a small square block on the mother materials at both sides of the edge;

[0009] Welding: N base materials, N-1 large square blocks, and 2 small square blocks are welded to obtain a straight material strip;

[0010] Carry out resistance adjustment, plastic sealing and printing on the parent material in the linear strip;

[0011] Cut the particles and cut the large square block in the linear material strip into two pieces to obtain N single-particle alloy chip resistors.

[0012] In one of the embodiments, the alloy chip resistor is electroplated.

[0013] In one of the embodiments, the alloy chip resistor is subjected to a test packaging process.

[0014] In one embodiment, a piece of copper material with an infinitely extended width of W is obtained, and is divided along the extension line of the copper material to obtain N large square blocks, and then one of the large square blocks is divided to obtain two small square blocks.

[0015] In one embodiment, a piece of copper material with an infinite extension width of B is obtained, and the infinite extension direction of the copper material is defined as the length direction, and the direction perpendicular to the length direction is defined as the width direction;

[0016] If the width of the copper material is B, and n=B / W is satisfied, and n is a positive integer, the arrangement is preferably performed in the width direction of the large copper plate based on W;

[0017] Then calculate the length of the copper material to be obtained, A=S / B=2LWN / nW=2LN / n. If the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to retain an integer;

[0018] The copper material to be divided having a length of A and a width of B is cut to obtain N large square blocks, and one of the large square blocks is then divided to obtain two small square blocks.

[0019] In one embodiment, a piece of copper material with an infinite extension width of B is obtained, and the infinite extension direction of the copper material is defined as the length direction, and the direction perpendicular to the length direction is defined as the width direction;

[0020] If the width of the copper material is B, and satisfies n=B / 2L, and n is a positive integer, then L is used as the reference and the arrangement is preferentially performed in the width direction of the large copper plate;

[0021] Then calculate the length of the copper material to be obtained, A=S / B=2LWN / 2nL=WN / n. If the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to retain an integer;

[0022] The copper material to be divided having a length of A and a width of B is cut to obtain N large square blocks, and one of the large square blocks is then divided to obtain two small square blocks.

[0023] An alloy chip resistor is produced by the above-mentioned zero-waste welding type alloy chip resistor production process.

[0024] The invention discloses a zero-waste welding alloy chip resistor production process and the alloy chip resistor, which solves the problem of serious material waste and reduces loss. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0026] Figure 1 This is the old production process flow chart of the existing welding alloy chip resistor;

[0027] Figure 2 A schematic diagram of an alloy chip resistor according to an embodiment of the present invention;

[0028] Figure 3 This is a schematic diagram of a copper material with a width W that is infinitely extended in Example 1;

[0029] Figure 4 It is a schematic diagram of arranging the parent material, the large square block and the small square block;

[0030] Figure 5 A schematic diagram of welding a parent material, a large square block, and a small square block to obtain a straight strip;

[0031] Figure 6 A schematic diagram of adjusting the resistance of a linear strip;

[0032] Figure 7 A schematic diagram of plastic sealing and printing on a linear strip;

[0033] Figure 8 Schematic diagram of cutting a straight strip to obtain an alloy chip resistor;

[0034] Fig. 9 This is a schematic diagram of a copper material with a width B that is infinitely extended according to Embodiment 2;

[0035] Fig.10 This is a schematic diagram of a copper material with a width B that is infinitely extended in Example 3;

[0036] Fig.11 This is a schematic diagram of using a jig to weld a base material, a large square block, and a small square block. DETAILED DESCRIPTION

[0037] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0038] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only and do not represent the only implementation method.

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0040] The present invention discloses a zero-waste welding alloy chip resistor production process, comprising the following steps:

[0041] like Figure 2 As shown, it is expected to produce N alloy chip resistors 10, each alloy chip resistor 10 includes a base material 11 and red copper 12 welded to both sides of the base material, each red copper 12 has a length of L and a width of W, and the area of ​​the required copper material is expected to be S=2LWN;

[0042] like Figure 3 As shown, an infinitely extended copper material is obtained, and N-1 large square blocks 20 and 2 small square blocks 30 are obtained by cutting the copper material. The length of the large square block 20 is 2L, the length of the small square block 30 is L, and the widths of the large square block 20 and the small square block 30 are both W;

[0043] like Figure 4 As shown, N mother materials 11 are obtained, and the N mother materials 11 are arranged in a straight line with spacing from each other, a large square block 20 is placed between adjacent mother materials 11, and a small square block 30 is placed on the mother materials 11 at both sides of the edge;

[0044] like Figure 5 As shown, welding is performed by welding N base materials 11, N-1 large square blocks 20, and 2 small square blocks 30 to obtain a straight material strip;

[0045] like Figure 6 and Figure 7 As shown, the mother material 11 in the linear strip is subjected to resistance adjustment, plastic sealing, and printing processing;

[0046] like Figure 8 As shown, the particles are cut, and the large square block 20 in the linear material strip is cut into two parts to obtain N single-particle alloy chip resistors 10.

[0047] Furthermore, in the present invention, the alloy chip resistor 10 may be subjected to electroplating treatment and testing and packaging treatment.

[0048] Embodiment 1

[0049] like Figure 3 As shown, a piece of copper material with an infinitely extended width of W is obtained, and it is divided along the extension line direction of the copper material to obtain N large square blocks 20, and then one of the large square blocks 20 is divided to obtain two small square blocks 30.

[0050] In this embodiment, the width of the infinitely extended copper material is exactly W. The infinitely extended copper material can be regarded as a long and thin whole roll of material strip, and the material strip can be unwound and used when needed.

[0051] However, in actual production activities, the materials received from suppliers are usually large plates with very large widths. If the large plates are cut to obtain slender strips with a width of W, and then the slender strips are divided to obtain a number of large square blocks 20 and small square blocks 30, this will complicate the production process, reduce production efficiency and poor production quality.

[0052] In order to cope with the above-mentioned large sheet materials, the present invention proposes Embodiment 2 and Embodiment 3 to solve the technical problems brought about.

[0053] Embodiment 2

[0054] like Fig. 9 As shown, a piece of copper material with an infinite extension width of B is obtained, and the infinite extension direction of the copper material is taken as the length direction, and the direction perpendicular to the length direction is the width direction;

[0055] If the width of the copper material is B, and n=B / W is satisfied, and n is a positive integer, the large copper plate is preferably arranged in the width direction based on W; it should be noted that in this embodiment, n is a positive integer, that is, the copper material with a width of B can just accommodate n rows of large square blocks with a size of W as a reference;

[0056] Then calculate the length of the copper material to be obtained: A=S / B=2LWN / nW=2LN / n. If the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to an integer; for example, if the ratio of N / n is 5.1, the decimal part of the comparison value is rounded up to an integer, thereby obtaining a value of 6; for another example, if the ratio of N / n is 5.9, the decimal part of the comparison value is rounded up to an integer, thereby obtaining a value of 6.

[0057] The copper material to be divided having a length of A and a width of B is cut to obtain N large square blocks, and one of the large square blocks is then divided to obtain two small square blocks.

[0058] As can be seen from the above, during the processing, there is a small square block 30 at each end of the straight material strip, for a total of two small square blocks 30, and the length of the small square block 30 is exactly half the length of the large square block 20. Therefore, one of the large square blocks can be divided into two to obtain two small square blocks to meet the requirements.

[0059] Embodiment 3

[0060] like Fig.10 As shown, a piece of copper material with an infinite extension width of B is obtained, and the infinite extension direction of the copper material is taken as the length direction, and the direction perpendicular to the length direction is the width direction;

[0061] If the width of the copper material is B, and n=B / 2L is satisfied, and n is a positive integer, then the large copper plate is preferably arranged in the width direction based on L; it should be noted that in this embodiment, n is a positive integer, that is, the copper material with a width of B can just accommodate n rows of large square blocks with a size of 2L as the reference;

[0062] Then calculate the length of the copper material to be obtained: A=S / B=2LWN / 2nL=WN / n. If the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to an integer; for example, if the ratio of N / n is 5.1, the decimal part of the comparison value is rounded up to an integer, thereby obtaining a value of 6; for another example, if the ratio of N / n is 5.9, the decimal part of the comparison value is rounded up to an integer, thereby obtaining a value of 6.

[0063] The copper material to be divided having a length of A and a width of B is cut to obtain N large square blocks, and one of the large square blocks is then divided to obtain two small square blocks.

[0064] In the second and third embodiments, if the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to retain the integer. In this way, although there will be some more large square blocks than expected, these extra large square blocks are not waste. These large square blocks can continue to be used in the next batch of production process, and the materials can be fully utilized.

[0065] In the second and third embodiments, the large sheet material can be laser cut or punched to obtain a large square block. In the second and third embodiments, in some special cases, when the large sheet material is arranged in the width direction, a surplus may be generated, and the surplus cannot completely accommodate a large square block. During the operation, the surplus can be separated out first and reserved for use by other alloy chip resistors that meet the size requirements.

[0066] In the present invention, mainly based on the production plan, the number of alloy chip resistors 10 to be produced is known in advance, and combined with the size parameters of the current alloy chip resistors 10, the usage of copper material is calculated, and then the copper material with accurate usage amount is divided and processed to achieve full utilization of copper material and reduce waste.

[0067] The present invention also discloses an alloy chip resistor 10, which is produced by the above-mentioned zero-waste welding type alloy chip resistor production process.

[0068] In the present invention, if Fig.11 As shown, a jig 40 is also used to weld the base material 11, the large square block 20, and the small square block 30. In each row, a number of base materials 11, large square blocks 20, and two small square blocks are placed, and the base material 11 is located between two adjacent large square blocks 20. Two small square blocks are placed at both ends of each row, so as to obtain a straight line strip; it can be seen that there are several rows of straight line strips in a jig 40, and the laser welding points in each column are aligned, so that the laser head can sweep all the laser welding points in a tortuous way in a straight line (such as Fig.11 This laser welding efficiency is very high.

[0069] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A zero-waste welding alloy chip resistor production process, characterized in that: The steps include: It is expected that N alloy chip resistors will be produced. Each alloy chip resistor includes a base material and copper soldered to both sides of the base material. The length of each copper is L and the width is W. The area of ​​copper required is S = 2LWN. Get an infinitely extended copper material, and divide it into N-1 large square blocks and 2 small square blocks. The length of the large square block is 2L, the length of the small square block is L, and the width of the large square block and the small square block are both W; Obtain N mother materials, and arrange the N mother materials in a straight line with intervals from each other, place a large square block between adjacent mother materials, and place a small square block on the mother materials at both sides of the edge; Welding: N base materials, N-1 large square blocks, and 2 small square blocks are welded to obtain a straight material strip; Carry out resistance adjustment, plastic sealing and printing on the parent material in the linear strip; Cut the particles and cut the large square block in the linear material strip into two pieces to obtain N single-particle alloy chip resistors.

2. The zero-waste welding alloy chip resistor production process according to claim 1, characterized in that: Electroplating treatment is performed on alloy chip resistors.

3. The zero-waste welding alloy chip resistor production process according to claim 3, characterized in that: The alloy chip resistors are tested and packaged.

4. The zero-waste welding alloy chip resistor production process according to claim 1, characterized in that: Obtain an infinitely extended copper material with a width of W, split it along the extension line of the copper material to obtain N large square blocks, and then split one of the large square blocks into two small square blocks.

5. The zero-waste welding alloy chip resistor production process according to claim 1, characterized in that: Obtain an infinitely extended copper material with a width of B, and let the infinite extension direction of the copper material be the length direction, and the direction perpendicular to the length direction be the width direction; If the width of the copper material is B, and n=B / W is satisfied, and n is a positive integer, the arrangement is preferably performed in the width direction of the large copper plate based on W; Then calculate the length of the copper material to be obtained, A=S / B=2LWN / nW=2LN / n. If the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to retain an integer; The copper material to be divided having a length of A and a width of B is cut to obtain N large square blocks, and one of the large square blocks is then divided to obtain two small square blocks.

6. The zero-waste welding alloy chip resistor production process according to claim 1, characterized in that: Obtain an infinitely extended copper material with a width of B, and let the infinite extension direction of the copper material be the length direction, and the direction perpendicular to the length direction be the width direction; If the width of the copper material is B, and satisfies n=B / 2L, and n is a positive integer, then L is used as the reference and the arrangement is preferentially performed in the width direction of the large copper plate; Then calculate the length of the copper material to be obtained, A=S / B=2LWN / 2nL=WN / n. If the ratio of N / n has a decimal part, the decimal part of the ratio of N / n is rounded up to retain an integer; The copper material to be divided having a length of A and a width of B is cut to obtain N large square blocks, and one of the large square blocks is then divided to obtain two small square blocks.

7. An alloy chip resistor, characterized in that: The invention is produced by the zero-waste welding alloy chip resistor production process described in any one of claims 1 to 6.

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