A high load, impact resistant resistor

Abstract

The application relates to the technical field of resistors, and provides a high-load impact-resistant resistor which comprises a skin, an aluminum inner shell, a grid sandwich, a resistor body, an elastic core body, a packaging shell, a wind cooling module and an end fin, the packaging shell is arranged in the packaging shell, the end fin and the wind cooling module are fixedly arranged at two ends of the packaging shell respectively, the wind cooling module is fixedly connected with one end of the skin, the resistor body is arranged on the inner side of the aluminum inner shell, the grid sandwich is provided with a plurality of groups of cells, a circumferential groove and an axial groove, the flange is fixedly arranged between the end fin and the grid sandwich, the elastic core body is filled in the cells, the circumferential groove and the axial groove, under the impact deformation extrusion of the skin, the elastic core body further absorbs and dissipates impact energy through controllable plastic deformation, a rigid-flexible energy management mechanism is formed with the rigid grid framework, the overall toughness and energy dispersion performance are significantly improved, and the phenomena of waist contraction caused by transverse impact force and collapse caused by longitudinal high load are prevented.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of resistors, in particular to a high-load impact-resistant resistor. BACKGROUND

[0002] When the outdoor high-voltage power switch shunts current to the sub-module capacitor of zero voltage, the power switch needs to be provided with a starting resistor to prevent the starting current from being too large, which causes the problem of burning the fuse or tripping of the switch power supply. High-power resistors are widely used in energy consumption control systems powered by variable frequency motors, industrial motor starting, speed regulation, braking control systems, and neutral point grounding resistors in analog load and power distribution systems of various industrial electrical appliances. Among the existing high-power resistors, there are wire-wound resistors, thick-film resistors, and chip resistors.

[0003] After searching, the existing publication number CN114334320B discloses a high-load impact-resistant resistor, which includes an insulating column and a plurality of resistance core strips. The insulating column is in a long strip shape, and a plurality of receiving grooves are provided on the outer side of the insulating column in a circumferential direction. The resistance core strip is a V-shaped metal long strip, and a plurality of resistance core strips are embedded in different receiving grooves with their openings facing inward. The two end portions of the resistance core strip extend out of the receiving groove and are electrically connected to each other. The two side portions of the resistance core strip are bent outward to form a lock hook portion. The groove bottom of the receiving groove is provided with a bent hook groove, and the lock hook portion of the resistance core strip is embedded in the bent hook groove of the corresponding receiving groove to lock the resistance core strip in the radial direction. Compared with linear resistors, the resistance core strip has a larger current-carrying area and is stably fixed in the receiving groove in the radial direction. Different resistance core strips are separated and cannot be attracted to each other, have good insulation performance, and are not easy to deform or separate, and the structure is stable.

[0004] The existing resistor still has the following defects: (1) The traditional resistor shell is mostly single-layer or simple double-layer structure, and has single function, only focusing on heat dissipation or only focusing on protection, which is difficult to consider both; (2) Poor impact resistance, external impact (such as vibration and bumping) can easily cause the shell to deform or even damage the resistor, affecting reliability; (3) Limited heat dissipation path, relying on forced air cooling or simple water cooling, natural heat dissipation efficiency is low, and the energy consumption of the air cooling module is high. SUMMARY

[0005] The present application provides a high-load impact-resistant resistor, which solves the problems of poor impact resistance and single function of traditional resistors.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a high-load impact-resistant resistor, which includes a resistor body, a packaging shell, an air cooling module and an end cap, the packaging shell is arranged in the packaging shell, and the end cap and the air cooling module are fixedly arranged at both ends of the packaging shell. The packaging shell comprises:

[0007] A skin, the air-cooled module is fixedly connected with one end of the skin;

[0008] An aluminum inner shell, the resistor is arranged on the inner side of the aluminum inner shell, and the aluminum inner shell is provided with a flange structure at one end;

[0009] A grid sandwich is arranged between the skin and the aluminum inner shell, the grid sandwich is provided with a plurality of groups of cells, a circumferential groove and an axial groove, and the flange structure is fixedly arranged between the end cap and the grid sandwich;

[0010] An elastic core is filled in the cells, the circumferential groove and the axial groove.

[0011] As a further scheme of the present application, a substrate structure is further included, the substrate structure includes a ring, an elastic piece and a counterbore, the elastic piece is connected between two groups of rings, one of the elastic pieces is in contact with the substrate structure below, and the other group of elastic pieces is arranged between the aluminum inner shell and the skin, and the group of elastic pieces is provided with a counterbore at the matching position of the aluminum inner shell.

[0012] As a further scheme of the present application, the aluminum inner shell is a cylindrical shell with both ends open, and the aluminum inner shell is provided with a flange structure at one end.

[0013] As a further scheme of the present application, the elastic core is a silicone rubber-based composite material, and a plurality of groups of air holes are arranged on the surface of the elastic core distributed in the cells.

[0014] As a further scheme of the present application, the surface of the closed end of the skin and the surface of the end cap are both provided with one-way ventilation holes.

[0015] As a further scheme of the present application, the surface of the flange structure, the surface of the closed end of the skin and the surface of the end cap are all provided with medium flow holes.

[0016] As a further scheme of the present application, the inner side of the aluminum inner shell is provided with an axial rib, the surface of the resistor is in contact with the axial rib, and the adjacent two groups of axial ribs are ventilation cavities.

[0017] As a further scheme of the present application, the radial distance between the elastic core and the skin is greater than the radial distance between the grid sandwich and the skin, and the medium flow hole on the surface of the end cap is in communication with the medium flow hole on the closed end of the skin.

[0018] As a further scheme of the present application, the air holes on the surface of the elastic core are all conical holes, and the caliber of the conical hole close to the aluminum inner shell is smaller than the caliber close to the skin.

[0019] As a further scheme of the present application, the grid sandwich is provided with a fastener at one end, and the fastener penetrates the end cap and the flange structure.

[0020] The beneficial effects of the present application are: (1) the skin as the first line of defense, preferentially occurs controllable plastic deformation (local indentation), crushing and absorbing impact energy, protecting the internal core structure, the grid sandwich provides rigid skeleton support, significantly enhances the longitudinal, circumferential bending, anti-twist, anti-radial deformation and anti-global buckling ability of the entire shell, effectively prevents the "waist shrinkage" and "collapse" phenomenon, divides it into several independent cells, realizes the regionalization of impact energy limitation;

[0021] (2) filling the elastic core made of silicone rubber-based composite material in the cells, circumferential grooves and axial grooves of the grid sandwich, on the one hand, under the impact deformation extrusion of the skin, the elastic core further absorbs and dissipates impact energy through controllable plastic deformation, forming a "rigid and flexible" energy management mechanism with the rigid grid skeleton, significantly improving the overall toughness and energy dispersion performance, on the other hand, it can improve the heat conduction path from the aluminum inner shell to the skin / external environment. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is the exploded view of the present application.

[0023] Figure 2 is the front view of the present application.

[0024] Figure 3 is the disassembly schematic diagram of the packaging shell of the embodiment of the present application.

[0025] Figure 4 is the front view of the grid sandwich of the embodiment of the present application.

[0026] Figure 5 is the front view of the elastic core of the embodiment of the present application.

[0027] Figure 6 is the front view of the grid sandwich and the elastic core after assembly of the embodiment of the present application.

[0028] Figure 7 is the top view of the packaging shell of the embodiment of the present application.

[0029] Figure 8 is the top view of the present application.

[0030] Figure 9 is the disassembly schematic diagram of the air-cooled module of the present application.

[0031] Figure 10 is the sectional view of the present application.

[0032] Figure 11 is the sectional view A-A of the present application.

[0033] Figure 12 is the sectional view B-B of the present application.

[0034] 1 - resistor body;

[0035] 2 - package shell, 21 - skin, 22 - aluminum inner shell, 221 - axial rib, 23 - grid sandwich, 231 - cell, 232 - circumferential groove, 233 - axial groove, 234 - fastener, 24 - elastic core, 241 - air hole;

[0036] 3 - air cooling module;

[0037] 4 - end cap;

[0038] 5 - substrate structure, 51 - ring, 52 - elastic piece, 53 - countersunk hole.

[0039] 6 - one-way vent hole;

[0040] 7 - medium flow hole. DETAILED DESCRIPTION

[0041] In order to make the purpose, technical scheme and advantages of the present application clearer, the present application will be further described in detail below in combination with the drawings and specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and do not limit the present application.

[0042] The specific implementation of the present application is described in detail below in combination with specific embodiments.

[0043] Please refer to Figures 1 to 12 In an embodiment of the present application, a high-load impact-resistant resistor includes a resistor body 1, a package shell 2, an air cooling module 3 and an end cap 4, the package shell 2 is arranged in the package shell 2, and the end cap 4 and the air cooling module 3 are fixedly arranged at both ends of the package shell 2, characterized in that the package shell 2 comprises:

[0044] The skin 21 is a single-opening cylindrical shell, the air cooling module 3 is fixedly connected with one end of the skin 21, and the skin 21 is made of aluminum material.

[0045] The aluminum inner shell 22 is a two-opening cylindrical shell, one end of the aluminum inner shell 22 is provided with a flange structure, the resistor body 1 is arranged on the inner side of the aluminum inner shell 22, the inner side of the aluminum inner shell 22 is provided with axial ribs 221, the surface of the resistor body 1 is in contact with the axial ribs 221, and the adjacent two groups of axial ribs 221 are vent cavities.

[0046] The grid sandwich 23 is arranged between the skin 21 and the aluminum inner shell 22, the grid sandwich 23 is provided with a plurality of groups of cells 231, a circumferential groove 232 and an axial groove 233, the flange structure is fixedly arranged between the end cap 4 and the grid sandwich 23, one end of the grid sandwich 23 is provided with a fastener 234, the fastener 234 penetrates the end cap 4 and the flange structure, the grid sandwich 23 is made of aluminum alloy or engineering plastic;

[0047] The elastic core 24 is filled in the cell 231, the circumferential groove 232 and the axial groove 233.

[0048] In the embodiment of the present application, the skin 21 serves as the first line of defense, preferentially occurs controllable plastic deformation (local depression), crushing and absorbing impact energy, protecting the internal core structure, the grid sandwich 23 provides a rigid skeleton support, significantly enhances the longitudinal, circumferential bending, anti-twisting, anti-radial deformation and anti-global buckling ability of the whole shell, effectively prevents the "waist shrinkage" and "collapse" phenomenon, divides it into a plurality of independent cells 231, realizes the regionalization of impact energy limitation. Local impact damage will be limited in a few cells 231, avoiding the overall structure failure, the aluminum inner shell 22 inside is provided with an axial rib 221, on the one hand, enhancing the structural stiffness, on the other hand, contacting the resistor 1 to form an efficient heat conduction path, and dividing the internal space into a ventilation cavity, optimizing the airflow, through the deformation of the sacrificial layer, the rigid grid support prevents collapse, the cell 231 design isolates the damage area, and the impact force is limited to the outside of the aluminum inner shell 22 to the greatest extent, ensuring the safety of the internal resistor 1. At the same time, the structure itself also enhances the overall mechanical strength.

[0049] Please refer to Figure 11 In another embodiment of the present application, the substrate structure 5 is also included, the substrate structure 5 includes a ring 51, an elastic member 52 and a counterbore 53, the elastic member 52 is connected between the two groups of rings 51, the lower part of the packaging shell 2 is in contact with one of the elastic members 52, and the other group of elastic members 52 is arranged between the aluminum inner shell 22 and the skin 21, and the group of elastic members 52 is provided with a counterbore 53 at the matching position of the aluminum inner shell 22, when the surface of the end cap 4 is impacted or bears high load, the elastic buffer of the ring 51 and the elastic member 52 plays a role in weakening the impact force, the counterbore 53 is designed to communicate the aluminum inner shell 22 and the grid sandwich 23 from the bottom, when the active heat dissipation is used by the air-cooled module 3, the airflow can be actively filled in the grid sandwich 23, and the elastic core 24 can be actively dried and moisture-proof treated in the case of humid and other harsh weather conditions.

[0050] Please refer to Figure 11Further, the radial distance between the elastic core 24 and the skin 21 is greater than the radial distance between the grid sandwich 23 and the skin 21, the medium flow holes 7 on the surface of the end cap 4 are in communication with the medium flow holes 7 on the closed end of the skin 21, the elastic core 24 is a silicon rubber-based composite material, a plurality of groups of air holes 241 are arranged on the surface of the elastic core 24 distributed in the cell 231, the flange structure, the closed end of the skin 21 and the surface of the end cap 4 are all provided with medium flow holes 7, the design of the medium flow holes 7 can, on one hand, form a negative pressure in the shell when the airflow generated by the operation of the air cooling module 3, accelerate the hot air to be discharged through the medium flow holes 7, and strengthen heat dissipation, on the other hand, when the skin 21 is impacted and extruded to the elastic core 24, the internal air is forced to be quickly discharged through the holes, so that the pressure is prevented from increasing sharply to damage the structure, and part of the impact energy is dissipated.

[0051] Please refer to Figure 11 Further, the air holes 241 on the surface of the elastic core 24 are all conical holes, and the diameter of the conical hole close to the aluminum inner shell 22 is smaller than the diameter of the conical hole close to the skin 21.

[0052] In the embodiment of the application, the elastic core 24 made of a silicon rubber-based composite material is filled in the cell 231, the circumferential groove 232 and the axial groove 233 of the grid sandwich 23, on one hand, when the skin 21 is impacted and deformed and extruded, the elastic core 24 can further absorb and dissipate impact energy through controllable plastic deformation, and a “rigid-flexible” energy management mechanism is formed with the rigid grid framework, so that the overall toughness and energy dispersion performance are significantly improved, on the other hand, the heat conduction path from the aluminum inner shell 22 to the skin 21 / external environment can be improved, the design of the air holes 241 on the surface of the elastic core 24 can significantly increase the contact surface area between the elastic core 24 and the internal flowing air, and the conical air holes 241 (small opening inside and large opening outside) on the surface of the elastic core 24 can prevent liquid water (condensed water droplets) from penetrating into the interior (towards the aluminum inner shell 22). Under the action of gravity, the water droplets will adhere to the large-diameter end and flow downward to the bottom of the skin 21, so that moisture accumulation in the elastic core 24 is avoided.

[0053] Working principle: when the air cooling module 3 works, the airflow enters the aluminum inner shell 22 from the one-way vent hole 6 on the closed end or the bottom of the skin 21, and then the heat generated by the resistor body 1 is discharged from the one-way vent hole 6 at the end cap 4 along the vent cavity between the axial ribs 221.

[0054] The skin 21 and the aluminum inner shell 22 are high-strength double-layer panels with a light-weight grid sandwich 23 in between. When subjected to external impact, the skin 21, as the outermost structure, acts as a "sacrificial layer" to break the impact object and deform (local indentation in the cell 231 area) to absorb energy, thus protecting the safety of the internal structure. When the cell 231 area is locally impacted or the skin 21 is locally indented, the design of multiple independent cells 231 can limit the damage to a single or a few cells 231 when locally impacted, thus avoiding overall structural failure. The internal elastic core 24 absorbs impact energy through controlled plastic deformation, in combination with the rigid support of the grid sandwich 23, to improve the toughness and energy dissipation or dispersion performance of the overall structure, thus maximizing the limitation of impact force on the outside of the aluminum inner shell 22. The rigid support of the grid sandwich 23 and the axial ribs 221 on the inside of the aluminum inner shell 22 can increase the longitudinal and circumferential bending resistance, radial deformation resistance, and overall buckling resistance, preventing the occurrence of waist shrinkage due to transverse impact force and collapse due to longitudinal high load.

[0055] The design of the surface pores 241 of the elastic core 24 and the flange structure, the closed end of the skin 21, and the surface of the end cap 4 are provided with medium flow holes 7, which have the following technical effects:

[0056] Impact pressure relief. When locally impacted, the deformation of the skin 21 and the elastic core 24 forces the internal air to be discharged from the medium flow holes 7, thus playing a role in pressure relief and energy dispersion.

[0057] Improved heat dissipation. The heat generated by the resistor can be transferred from the aluminum inner shell 22 to the grid sandwich 23 and the elastic core 24. When air naturally flows from both ends of the resistor, the hot air inside the shell can be quickly discharged from the medium flow holes 7 under the action of negative pressure, and the surface pores 241 of the elastic core 24 can increase the contact area with air, thus improving the natural heat dissipation capacity without the intervention of the air-cooled module 3.

[0058] Moisture-proof. When air enters the surface of the elastic core 24 from the medium flow holes 7 at the upper end or water droplets condense on the surface of the elastic core 24, the conical structure of the air holes 241 can organize the water droplets to stay in the air holes 241, thus forcing them to flow to the lower end and be discharged from the medium flow holes 7. The air flow in the medium flow holes 7 can also be used to avoid moisture accumulation, reduce the risk of mold and corrosion, and prolong the heat preservation and energy absorption effect of the internal materials.

[0059] For those skilled in the art, although several embodiments and examples of the present application are described, these embodiments and examples are presented as examples and are not intended to limit the scope of the application. These new embodiments can be implemented in other various ways, and various omissions, substitutions, changes can be made without departing from the spirit of the application.

[0060] In addition, it should be understood that although the present specification is described in terms of embodiments, not every embodiment contains only one independent technical solution, and the description of the specification is only for the sake of clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each example can be appropriately combined to form other embodiments that those skilled in the art can understand.

Claims

1. A high-load shock resistant resistor, comprising a resistive element (1), a package housing (2), a cooling module (3), and end caps (4), wherein the resistive element (1) is disposed within the package housing (2), and the end caps (4) and the cooling module (3) are respectively fixedly disposed at both ends of the package housing (2), characterized in that, The packaging shell (2) comprises: a skin (21), one end of which is fixedly connected with the air-cooled module (3); an aluminum inner shell (22), the resistor body (1) is arranged on the inner side of the aluminum inner shell (22), one end of the aluminum inner shell (22) is provided with a flange structure, the aluminum inner shell (22) is a cylindrical shell with two open ends, one end of the aluminum inner shell (22) is provided with a flange structure, and the skin (21) is a cylindrical shell with a single opening; a grid sandwich (23) arranged between the skin (21) and the aluminum inner shell (22), the grid sandwich (23) is provided with a plurality of groups of cells (231), a circumferential groove (232) and an axial groove (233), the flange structure is fixedly arranged between the end cap (4) and the grid sandwich (23), and the closed end of the skin (21) and the surface of the end cap (4) are both provided with one-way ventilation holes (6); an elastic core (24), the elastic core (24) is filled in the cells (231), the circumferential groove (232) and the axial groove (233), the elastic core (24) is a silicone rubber-based composite material, and the surface of the elastic core (24) distributed in the cells (231) is provided with a plurality of groups of air holes (241); the flange structure, the closed end of the skin (21) and the surface of the end cap (4) are all provided with medium flow holes (7); the air holes (241) on the surface of the elastic core (24) are all tapered holes, and the aperture of the tapered hole close to the aluminum inner shell (22) is smaller than the aperture close to the skin (21).

2. A high load, impact resistant resistor according to claim 1, wherein, It also includes a substrate structure (5), the substrate structure (5) includes a ring (51), an elastic member (52) and a countersunk hole (53), the elastic member (52) is connected between the two groups of rings (51), the lower part of the packaging shell (2) is in contact with one of the elastic members (52), and the other group of elastic members (52) is arranged between the aluminum inner shell (22) and the skin (21), and the group of elastic members (52) is provided with a countersunk hole (53) at the matching position of the aluminum inner shell (22).

3. A high load, impact resistant resistor according to claim 2, wherein, The inner side of the aluminum inner shell (22) is provided with an axial rib (221), the surface of the resistor body (1) is in contact with the axial rib (221), and the adjacent two groups of axial ribs (221) are ventilation cavities.

4. A high load, impact resistant resistor according to claim 3, wherein, The radial distance between the elastic core (24) and the skin (21) is greater than the radial distance between the grid sandwich (23) and the skin (21), and the medium flow holes (7) on the surface of the end cap (4) are in communication with the medium flow holes (7) on the closed end of the skin (21).

5. A high load, impact resistant resistor according to claim 4, wherein, One end of the grid sandwich (23) is provided with a fastener (234), and the fastener (234) penetrates the end cap (4) and the flange structure.

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