A production process for synthetic resistor

Abstract

The present invention discloses a production process of a synthetic resistor, and relates to the technical field of synthetic resistor production, including that the synthetic resistor includes a resistor material arranged inside, a welding structure is arranged at both ends of the resistor material, a copper terminal is arranged at one end of the welding structure, and an insulating layer is arranged on the surface of the resistor material; the specific production process of the synthetic resistor includes the following steps: material welding: vacuum electron beam welding is adopted to weld the copper terminal and the resistor material with a certain resistivity together; stamping forming: stamping the resistor shape according to the product appearance structure, and the resistors are still connected in sheet form. The production process of a synthetic resistor disclosed by the present invention adopts an electrophoresis process to form an insulating layer of about 15μm on the surface of the resistor, which meets the insulation requirements of a normal synthetic resistor and greatly reduces the thickness of the synthetic resistor. Moreover, the electrophoresis temperature is generally about 40 degrees, which realizes the room temperature curing of the resistor and has no destructive effect on the resistor performance.

Description

Technical Field

[0001] The invention relates to the technical field of synthetic resistor production, and in particular to a production process of a synthetic resistor. Background Art

[0002] Composite resistors are resistors made of alloy materials. Compared with traditional carbon film resistors or metal oxide film resistors, composite resistors have some unique advantages and characteristics. As chip resistors, composite resistors need to be isolated from the alloy part by insulating materials in many applications. At present, the insulation isolation of composite resistors generally adopts plastic sealing equipment. After the epoxy resin is melted at high temperature, the epoxy resin adheres to the alloy part of the resistor to achieve insulation isolation of the alloy part.

[0003] The existing insulation material packaging method has disadvantages: first, the covering insulation material must be relatively thick, generally requiring more than 0.15mm, otherwise it is easy to cause inadequate coverage; second, the insulation material and the alloy have poor adhesion and are easy to fall off; third, the temperature during insulation material packaging is high, requiring a high temperature of about 190 degrees, which has a certain destructive effect on the synthetic resistor and affects the product performance. Therefore, in response to this series of problems that need to be solved urgently, it is particularly important to propose a production process for synthetic resistors to solve the shortcomings of the existing technology. Summary of the invention

[0004] The invention discloses a production process of a synthetic resistor, aiming to solve the technical problem that the resistance value of the existing synthetic resistor fluctuates greatly with the increase of temperature during use, and cannot meet the strict requirements of high-power measuring instruments and digital display devices on stability. Such fluctuation of the resistance value not only leads to reduced measurement accuracy, but also may cause equipment errors, thereby causing unreliable performance of the equipment and shortened service life.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A production process of a composite resistor, the composite resistor comprising a resistor material arranged inside, welding structures arranged at both ends of the resistor material, copper terminals arranged at one end of the welding structures, and an insulating layer arranged on the surface of the resistor material;

[0007] The specific production process of synthetic resistors includes the following steps:

[0008] Material welding: vacuum electron beam welding is used to weld the copper terminal and the resistance material with a certain resistivity together;

[0009] Stamping: Stamping the resistor shape according to the product appearance structure, and the resistors are still connected in sheets;

[0010] Resistance repair: Grind the alloy thickness or width to achieve the predetermined resistance value;

[0011] Electrophoresis: Using the electrophoresis process, an insulating layer of about 15μm is formed on the surface of the resistor;

[0012] Glue removal: remove excess insulation layer on terminal electrodes;

[0013] Silk screen printing: Print the logo on the insulation layer;

[0014] Punching: punching the sheet resistor strip into resistor particles;

[0015] Electroplating: Copper terminals are nickel-plated and tin-plated to improve corrosion resistance and welding performance;

[0016] Resistance inspection: Use a resistor meter to screen out products with unqualified resistance.

[0017] In a preferred embodiment, the material welding step specifically uses high-precision vacuum electron beam welding technology to firmly weld the copper terminal and the resistance material with a specific resistivity together to achieve a stable electrical connection. This welding method ensures good electrical conductivity and high temperature resistance.

[0018] In a preferred embodiment, the stamping step is to use a stamping machine to accurately stamp the alloy material according to product design requirements to form a resistor shape that conforms to the resistor shape structure. During this process, the resistor elements maintain sheet connections to ensure overall stability in subsequent processing.

[0019] In a preferred embodiment, the resistance trimming step specifically adjusts the thickness or width of the alloy material through a grinding process to achieve a predetermined resistance value. This process requires precise control to ensure that the performance of each resistor meets the design standards.

[0020] In a preferred embodiment, the electrophoresis step specifically adopts an advanced electrophoretic coating process to uniformly form an insulating layer of about 15 μm thick on the surface of the resistor. This insulating layer not only provides electrical insulation, but also improves the corrosion resistance and service life of the resistor.

[0021] In a preferred embodiment, the debonding step specifically removes excess insulating material from the electrode terminals to ensure good electrical contact, which is crucial for subsequent welding performance.

[0022] In a preferred solution, the silk-screen printing step is specifically to perform silk-screen printing on the surface of the insulating layer to clearly mark the specifications, brand and other necessary information of the resistor for easy identification and use.

[0023] In a preferred embodiment, the punching step is to process the formed sheet resistor strips into independent resistors through a precise punching process. This process not only improves production efficiency, but also prepares for subsequent processing and packaging.

[0024] In a preferred embodiment, the electroplating step specifically involves electroplating the copper terminals, including nickel plating and tin plating, to improve their corrosion resistance and welding performance. This layer of metal coating can effectively prevent oxidation and ensure the reliability of the resistor during use.

[0025] In a preferred solution, the resistance inspection specifically uses a precision resistance instrument to screen all resistors to detect whether their resistance meets the standards. This link can timely eliminate unqualified products and ensure the stable quality of factory-produced resistors.

[0026] It can be seen from the above that the production process of a synthetic resistor provided by the present invention has the following technical effects.

[0027] First, the thickness of the insulating material film is greatly reduced, and only 15μm±5μm can meet the insulation requirements. The adhesion between the insulating material and the alloy material is increased, and it can be bent 90 degrees without falling off. There is no high-temperature damage during the resistor manufacturing process, and the product performance is stable.

[0028] Second: The electrophoresis process is used to form an insulating layer of about 15μm on the surface of the resistor. Under the action of the electric field, the granular epoxy resin is deposited on the surface of the charged synthetic resistor to form a uniform and dense film layer. The thickness of the insulating material is only about 15μm, which can meet the insulation requirements and greatly reduce the thickness of the synthetic resistor. Moreover, the electrophoresis temperature is generally around 40 degrees, which realizes the room temperature curing of the resistor without damaging the resistor performance.

[0029] Third: The electrophoresis process is used to greatly enhance the adhesion of the insulating layer on the resistor material. When the resistor material is squeezed and deformed, the insulating layer will not fall off the resistor material, thus ensuring the safety of the resistor material.

[0030] Fourthly: the nickel plating layer provides excellent anti-corrosion performance, which can effectively prevent the copper terminals from oxidizing in a humid or corrosive environment and extend the service life of the composite resistor. Nickel plating has good electrical conductivity and can maintain the electrical properties of the composite resistor to a certain extent. Tin plating has excellent wettability during the welding process and can form good solder joints to ensure a strong connection between the composite resistor and other circuit components. Tin plating can effectively prevent the oxidation of copper terminals and prevent poor contact problems in the welding structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a schematic diagram of the main structure of a production process for a synthetic resistor proposed by the present invention.

[0032] In the figure: 1. Resistor material; 2. Welding structure; 3. Copper terminal; 4. Insulation layer. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0034] The production process of a synthetic resistor disclosed in the present invention is mainly applied to existing synthetic resistors. During use, the resistance value of the synthetic resistor fluctuates greatly with the increase of temperature, and cannot meet the strict requirements of high-power measuring instruments and digital display devices for stability. Such fluctuation of resistance value not only leads to reduced measurement accuracy, but may also cause equipment errors, thereby resulting in unreliable performance of the equipment and shortened service life.

[0035] A production process of a synthetic resistor, the synthetic resistor comprising a resistor material 1 arranged inside, welding structures 2 arranged at both ends of the resistor material 1, copper terminals 3 arranged at one end of the welding structures 2, and an insulating layer 4 arranged on the surface of the resistor material 1;

[0036] The specific production process of synthetic resistors includes the following steps:

[0037] Material welding: vacuum electron beam welding is used to weld the copper terminal 3 and the resistance material 1 having a certain resistivity together;

[0038] Stamping: Stamping the resistor shape according to the product appearance structure, and the resistors are still connected in sheets;

[0039] Resistance repair: Grind the alloy thickness or width to achieve the predetermined resistance value;

[0040] Electrophoresis: Using the electrophoresis process, an insulating layer of about 15 μm is formed on the surface of the resistor 4;

[0041] Glue removal: remove the excess insulating layer on the terminal electrode 4;

[0042] Silk screen printing: Print the logo on the insulating layer 4;

[0043] Punching: punching the sheet resistor strip into resistor particles;

[0044] Electroplating: Copper terminals 3 are nickel-plated and tin-plated to improve corrosion resistance and welding performance;

[0045] Resistance inspection: Use a resistor meter to screen out products with unqualified resistance.

[0046] The material welding step specifically adopts high-precision vacuum electron beam welding technology to firmly weld the copper terminal 3 and the resistance material 1 with a specific resistivity together to achieve a stable electrical connection. This welding method ensures good electrical conductivity and high temperature resistance.

[0047] The stamping step is to use a stamping machine to accurately stamp the alloy material according to product design requirements to form a resistor shape that conforms to the resistor shape structure. During this process, the resistor elements maintain sheet connections to ensure overall stability in subsequent processing.

[0048] The resistor trimming step specifically adjusts the thickness or width of the alloy material through a grinding process to achieve a predetermined resistance value. This process requires precise control to ensure that the performance of each resistor meets the design standards.

[0049] The electrophoresis step specifically adopts an advanced electrophoretic coating process to uniformly form an insulating layer 4 with a thickness of about 15 μm on the surface of the resistor. This insulating layer 4 not only provides electrical insulation, but also improves the corrosion resistance and service life of the resistor.

[0050] In this embodiment, an electrophoresis process is used to form an insulating layer 4 of about 15 μm on the surface of the resistor. Under the action of the electric field, the granular epoxy resin is deposited on the charged surface of the synthetic resistor to form a uniform and dense film layer. The thickness of the insulating material is only about 15 μm, which can meet the insulation requirements, greatly reducing the thickness of the synthetic resistor. Moreover, the electrophoresis temperature is generally around room temperature 25 degrees, and the curing can be performed at a low temperature of about 120 degrees or at room temperature, without damaging the resistor performance.

[0051] Furthermore, the electrophoresis process is used to greatly enhance the adhesion of the insulating layer 4 on the resistor material 1 . When the resistor material 1 is squeezed and deformed, the insulating layer 4 will not fall off the resistor material 1 , thereby ensuring the safety of the resistor material 1 .

[0052] The debonding step specifically removes excess insulating material from the electrode terminals to ensure good electrical contact, which is critical to subsequent welding performance.

[0053] The silk-screen printing step specifically involves silk-screen printing on the surface of the insulating layer 4 to clearly mark the specifications, brand and other necessary information of the resistor for easy identification and use.

[0054] The punching step is to process the formed sheet resistor strips into independent resistors through a precise punching process. This process not only improves production efficiency, but also prepares for subsequent processing and packaging.

[0055] The electroplating step specifically involves electroplating the copper terminal 3, including nickel plating and tin plating, to improve its corrosion resistance and welding performance. This layer of metal coating can effectively prevent oxidation and ensure the reliability of the resistor during use.

[0056] The resistance inspection specifically involves screening all resistors using a precision resistance instrument to detect whether their resistance meets the standards. This step can promptly eliminate unqualified products and ensure the stable quality of factory-made resistors.

[0057] In this embodiment, the nickel plating layer provides excellent anti-corrosion performance, which can effectively prevent the copper terminal 3 from oxidizing in a humid or corrosive environment, thereby extending the service life of the composite resistor. Nickel plating has good electrical conductivity and can maintain the electrical properties of the composite resistor to a certain extent. Tin plating has excellent wettability during the welding process and can form good solder joints to ensure a strong connection between the composite resistor and other circuit elements. Tin plating can effectively prevent the copper terminal 3 from oxidizing and prevent the welding structure 2 from having poor contact problems, which is crucial to maintaining the performance stability of the composite resistor.

[0058] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A production process for a synthetic resistor, characterized in that: The composite resistor comprises a resistor material (1) arranged inside, welding structures (2) are arranged at both ends of the resistor material (1), copper terminals (3) are arranged at one end of each of the welding structures (2), and an insulating layer (4) is arranged on the surface of the resistor material (1); The production process of synthetic resistors includes the following steps: Material welding: vacuum electron beam welding is used to weld the copper terminal (3) and the resistance material (1) having a certain resistivity together; Stamping: Stamping the resistor shape according to the product appearance structure, and the resistors are still connected in sheets; Resistance repair: Grind the alloy thickness or width to achieve the predetermined resistance value; Electrophoresis: Using the electrophoresis process, an insulating layer of about 15 μm is formed on the surface of the resistor (4); Glue removal: removing the excess insulating layer on the terminal electrodes (4); Silk screen printing: printing a logo on the insulating layer (4); Punching: punching the sheet resistor strip into resistor particles; Electroplating: Copper terminals (3) are nickel-plated and tin-plated to improve corrosion resistance and welding performance; Resistance inspection: Use a resistor meter to screen out products with unqualified resistance.

2. The production process of a synthetic resistor according to claim 1, characterized in that: The material welding step specifically adopts high-precision vacuum electron beam welding technology to firmly weld the copper terminal (3) and the resistance material (1) with a specific resistivity together to achieve a stable electrical connection.

3. The production process of a synthetic resistor according to claim 1, characterized in that: The stamping step is to use a stamping machine to accurately stamp the alloy material according to product design requirements to form a resistor shape that conforms to the resistor shape structure. During this process, the resistor elements maintain sheet connections.

4. The production process of a synthetic resistor according to claim 1, characterized in that: The resistance repairing step specifically adjusts the thickness or width of the alloy material through a grinding process to achieve a predetermined resistance value.

5. The production process of a synthetic resistor according to claim 1, characterized in that: The electrophoresis step specifically adopts an advanced electrophoresis coating process to uniformly form an insulating layer (4) with a thickness of about 15 μm on the surface of the resistor. This insulating layer (4) not only provides electrical insulation, but also improves the corrosion resistance and service life of the resistor.

6. The production process of a synthetic resistor according to claim 1, characterized in that: The debonding step specifically removes excess insulating material on the electrode terminals to ensure good electrical contact.

7. The production process of a synthetic resistor according to claim 1, characterized in that: The silk screen printing step specifically involves performing silk screen printing on the surface of the insulating layer (4).

8. The production process of a synthetic resistor according to claim 1, characterized in that: The punching step is specifically to process the formed sheet-shaped resistor strips into independent resistors through a precise punching process.

9. The production process of a synthetic resistor according to claim 1, characterized in that: The electroplating step specifically involves electroplating the copper terminal (3), including nickel plating and tin plating, to improve its corrosion resistance and welding performance. This layer of metal coating can effectively prevent oxidation and ensure the reliability of the resistor during use.

10. The production process of a synthetic resistor according to claim 1, characterized in that: The resistance inspection specifically involves screening all resistors using a precision resistance instrument to detect whether their resistance meets the standards. This step can promptly eliminate unqualified products and ensure the stable quality of the factory-produced resistors.

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