Alloy resistor material strip design method
Through a systematic design process and finished product verification, the consistency problem in the mass production of alloy resistors was solved, achieving high consistency and reliability of finished alloy resistors and improving the scientific nature and operability of the design process.
Patent Information
- Application Number
- CN202511865790.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-11
- Publication Date
- 2026-03-17
AI Technical Summary
In the existing technology, the mass production of alloy resistors suffers from poor consistency, resulting in significant dispersion in key parameters between different batches or even within the same batch of resistors, making it difficult to meet the requirements of high-precision current detection applications.
By establishing a systematic design process from downstream circuit application requirements to upstream material production, the design range of material width and thickness is deduced by using the resistance law formula, specifying material types and setting target ranges and manufacturing tolerances for resistivity, resistance per meter and TCR, forming material design specifications, and introducing a finished product verification process to ensure the effectiveness of the design specifications.
This achieves excellent batch consistency and individual stability of alloy resistor products, improves the scientific nature and repeatability of the design process, reduces design risks, and ensures high product reliability and operability.
Smart Images
Figure CN121687330A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of electronic component manufacturing technology, and more specifically, to a method for designing alloy resistor strips. Background Technology
[0002] As a core component for current sensing, the accuracy and stability of alloy resistors directly affect the reliability of circuit systems. In existing technologies, the research and development and production of alloy resistors typically involve multiple stages, including downstream designers and upstream material suppliers. Downstream designers primarily propose target parameters for the finished product based on theoretical calculations, while upstream material suppliers provide semi-finished material strips based on their own experience. This disconnected design model lacks systematic standards and precise transmission mechanisms, resulting in a lack of unified and clear quantitative guidance on key parameters such as the geometric dimensions and electrical properties of the material strips, as well as their manufacturing fluctuation range.
[0003] Therefore, alloy resistors produced under current technological conditions generally face the prominent problem of poor performance consistency in mass-produced products. Significant variations in key parameters such as resistance and temperature coefficient can easily occur between different batches, and even between individual resistors within the same batch, making it difficult to meet the stringent uniformity requirements of high-precision current sensing applications. This invention aims to solve the technical problem of how to systematically ensure the consistency of alloy resistor mass production from the design stage. Summary of the Invention
[0004] To address the problem of poor batch consistency in alloy resistors in existing technologies, this application provides a method for designing alloy resistor strips.
[0005] The alloy resistor strip design method provided in this application adopts the following technical solution: An alloy resistor strip design method includes the following steps: S1. Application Requirements Determination: Based on the application requirements of downstream circuits, determine the target range of nominal resistance value, target range of physical size, and type of operating current environment for the finished alloy resistors. S2. Derivation of basic parameters of the strip: Based on the target range of nominal resistance value and target range of physical size, the width design range and thickness design range of the alloy resistance strip are calculated by using the resistance law formula. S3. Material and Electrical Parameter Specification: Based on the operating current environment type and the results of step S2, specify the material type of the alloy resistance strip from the predetermined material library, and set the target range of resistivity, target range of resistance per meter, and target range of temperature coefficient of resistance (TCR) for the material type. S4. Assigning design tolerances: Assign corresponding manufacturing tolerance ranges to the width design range and thickness design range obtained in step S2, as well as the resistivity target range, meter resistance target range and resistance temperature coefficient (TCR) target range set in step S3. S5. Integration Output: The strip width, thickness, material type, resistivity, resistance per meter, TCR and their respective manufacturing tolerance ranges obtained from step S4 are integrated into a strip design specification. S6. Production guidance: Provide the material strip design specifications to upstream material suppliers to guide them in producing alloy resistance strips that meet the specifications.
[0006] By adopting the above technical solutions and establishing a systematic design process from downstream circuit application requirements to upstream material strip production specifications, abstract end-performance requirements are transformed into a series of specific and interrelated material strip technical parameters. This method first uses the resistance law formula to back-calculate the finished product resistance value and size requirements into the design range of material strip width and thickness, accurately transmitting macroscopic requirements to microscopic material specifications. Then, by pre-setting a material library including copper-nickel alloys, manganese-copper alloys, and nickel-chromium alloys, and specifying specific material types based on the operating current environment, it achieves targeted matching of material characteristics with circuit conditions. Furthermore, by systematically assigning specific manufacturing tolerance ranges to the geometric dimensions of the material strip—width and thickness—as well as key electrical parameters such as resistivity, resistance per meter, and total resistance (TCR), it provides proactive control and constraint over quality fluctuations during material strip production. Finally, by integrating all these quantitative parameters and their tolerances into a complete material strip design specification and directly guiding supplier production, it seamlessly transfers systematic design concepts to the manufacturing stage, thus bridging the gap between design and manufacturing. The synergistic application of this series of specific technical means effectively improves the consistency and reliability of alloy resistor performance from the design source.
[0007] Preferably, in step S1, the length of the target physical size range is 1.0-10.0 mm and the width is 0.5-5.0 mm.
[0008] By adopting the above technical solution, the mainstream product size specifications of alloy resistors to which this design method is applicable are clearly defined. This range accurately covers a variety of common surface mount resistor package sizes, from miniaturized to medium power load. This allows the subsequent derivation of material parameters, material selection, and tolerance assignment to be carried out within a scale that has been verified in practice and has mature technology. This ensures that the design method has clear targeting and good engineering feasibility in specific implementation.
[0009] Preferably, in step S2, the resistance law formula is: Where R represents the target resistance value of the finished alloy resistor; ρ represents the resistivity of the alloy resistor strip material; L represents the effective conduction length of the current in the finished alloy resistor; W represents the width of the alloy resistor strip; and T represents the thickness of the alloy resistor strip.
[0010] By adopting the above technical solution, a precise quantitative model was established for this core calculation step. The introduction of this specific formula provides a clear and universally accepted theoretical basis for the reverse calculation process from the target resistance value of the finished product to the key geometric dimensions of the strip, ensuring the scientific nature and repeatability of the parameter derivation process, and providing an accurate input basis for subsequent material specification and tolerance assignment steps.
[0011] Preferably, the length L in the resistance law formula ranges from 1.0 mm to 5.0 mm.
[0012] By adopting the above technical solution, specific design boundaries for key geometric parameters are provided. This defined range fully considers the actual physical dimensions of the current path in typical packaging structures of the alloy resistors, allowing the reverse calculation of the strip width and thickness to focus on a technically reasonable and easily achievable interval. This limitation effectively reduces the fluctuation range of design variables, laying a more reliable foundation for accurate calculation of strip dimensions and reasonable assignment of manufacturing tolerances in subsequent steps, thereby enhancing the certainty and operability of the entire design process.
[0013] Preferably, in step S3, the predetermined material library includes copper-nickel alloys, manganese-copper alloys, and nickel-chromium alloys.
[0014] By adopting the above technical solutions, these three metallic materials with specific electrical and thermal properties serve to provide a validated and limited set of optimal candidate materials for the material selection process. These three alloy materials are all recognized in the industry as mature materials suitable for manufacturing precision alloy resistors. Each of them has excellent resistance stability, low temperature coefficient of resistance, and good processing performance. This specific limitation allows the selection of material types to focus on options with reliable performance and strong process compatibility, avoiding the blindness and uncertainty of the selection range, thus laying the material foundation for obtaining alloy resistor strips with the expected electrical performance.
[0015] Preferably, in step S4, the manufacturing tolerance of the width design range is ±0.01mm to ±0.1mm, and the manufacturing tolerance of the thickness design range is ±0.005mm to ±0.05mm.
[0016] By adopting the above technical solution, the processing accuracy of the key geometric dimensions of the material strip is precisely controlled. This specific tolerance range is based on a profound understanding of the sensitivity of alloy resistor performance to geometric dimensions, and its stringency distinguishes it from conventional foil processing capabilities. This limitation ensures that the material strip maintains a preset cross-sectional area accuracy during subsequent forming processes such as stamping, etching, or laser cutting, thus providing crucial geometric dimensional assurance for achieving accurate and consistent resistance values in the final alloy resistor product.
[0017] Preferably, in step S4, the manufacturing tolerance of the resistivity target range is ±5% to ±15%, the manufacturing tolerance of the meter resistance target range is ±2% to ±10%, and the manufacturing tolerance of the resistance temperature coefficient (TCR) target range is ±5 ppm / °C to ±20 ppm / °C.
[0018] By adopting the above technical solution, a systematic control over the quality fluctuations of key electrical performance parameters of the material strip is achieved. The specific tolerance ranges set for these parameters establish multi-level quality control standards targeting three interrelated yet independent key indicators: intrinsic material properties, resistance per unit length, and temperature stability. This constraint requires material suppliers to not only focus on dimensional accuracy during production but also to strictly control the material's compositional uniformity, grain structure, and heat treatment processes. This ensures that the final alloy resistor strip meets the requirements of high consistency and high stability in electrical performance, providing a reliable electrical characteristic foundation for manufacturing high-performance alloy resistors.
[0019] Preferably, in step S1, when the operating current environment type is alternating current, manganese copper alloy or nickel-chromium alloy is specified from the material library as the material type of the alloy resistance strip.
[0020] By adopting the above technical solution, abstract operating conditions are transformed into specific material selection instructions. This technical rule is established based on the fact that manganese-copper alloys and nickel-chromium alloys, compared to other alloys, possess lower magnetic induction intensity and superior eddy current loss suppression characteristics in alternating current fields. This specific constraint enables the design system to automatically respond to AC application scenarios, avoiding additional losses and temperature rise problems caused by the mismatch between the inherent electromagnetic properties of the materials and the working environment. This lays the material foundation for the stable and efficient operation of alloy resistors in AC circuits.
[0021] Preferably, the method further includes the following after step S6: S7. Finished Product Verification: Alloy resistor samples are made using alloy resistor strips produced according to the strip design specifications, and the alloy resistor samples are tested.
[0022] By adopting the above technical solution, this additional step serves as a bridge connecting theoretical design with the performance of actual finished products. By actually processing the material strip produced in accordance with specifications into resistor samples and testing them, the effectiveness of the technical solutions formed in all the aforementioned design stages can be directly verified. This technical means verifies whether the parameter settings and tolerance ranges in the design specifications are reasonable and whether they can ultimately lead to qualified resistor products, forming a complete technical closed loop from design, production to verification. This ensures the reliability and practicality of the entire design method and provides feedback based on measured data for continuous optimization of design specifications.
[0023] Preferably, in step S7, the test includes a temperature cycling test, with a test temperature range of -55°C to +155°C and a cycle count of 100 to 500 times.
[0024] By adopting the above technical solution, the durability of alloy resistor samples can be effectively evaluated using industry-recognized accelerated stress testing conditions. These specific testing conditions simulate the extreme temperature fluctuations and frequent thermal shocks that products may experience in harsh application environments. This can effectively stimulate potential defects in materials and structures. Performing this test can verify the robustness of the internal material interface bonding, the reliability of electrode connections, and the stability of the overall structure under thermal stress in resistor samples made from strips produced according to the aforementioned design specifications. This provides crucial experimental evidence for evaluating the long-term reliability of alloy resistors.
[0025] In summary, this application has the following beneficial effects: 1. This invention establishes a complete design process from application requirement analysis to material strip production guidance, and systematically assigns precise manufacturing tolerance ranges to the geometric dimensions and key electrical parameters of the material strip, forming a standardized design system. This method accurately transforms downstream performance requirements into quantifiable and controllable production indicators for upstream material strips, thereby providing a solid guarantee for excellent batch consistency and individual stability of alloy resistors from the source, effectively overcoming the performance dispersion problem caused by the disconnect of links in traditional design.
[0026] 2. The method in this invention provides a clear theoretical basis and material selection rules for the design process by explicitly defining the resistance law formula used for parameter calculation and the value range of its key variables, and by constructing a dedicated material library associated with the type of operating current environment. This design makes the determination of material selection and technical parameters no longer dependent on personal experience, but driven by clear technical rules and quantitative relationships, significantly improving the scientific nature and repeatability of the design process, and reducing the design risks introduced by improper selection or fuzzy calculations.
[0027] 3. This invention constructs a closed-loop system of design, production, and verification by introducing a finished product verification step into the method flow and specifying test items including rigorous temperature cycling. This step allows the effectiveness of the strip design specifications to be practically verified, thereby enabling timely detection of design deviations and providing feedback for optimization. This not only improves the reliability confidence of the final product but also makes the entire design method a dynamic system capable of self-improvement and continuous optimization. Attached Figure Description
[0028] Figure 1 This is a flowchart of the preparation process of an alloy resistance strip design method provided in this application. Detailed Implementation
[0029] The present application will be further described in detail below with reference to embodiments and comparative examples.
[0030] Technical concept: In the traditional design and production model of alloy resistors, a technological gap exists between downstream finished product designers and upstream raw material suppliers. Finished product designers typically only propose the final target resistance parameters, while upstream suppliers provide semi-finished raw materials based on experience. There is a lack of a design bridge that systematically and quantitatively transmits the finished product performance requirements to the key characteristic parameters of the raw material. This disconnect directly leads to a lack of unified and precise specifications for the key geometric dimensions, material electrical parameters, and necessary manufacturing tolerances of the raw material, thus becoming a core bottleneck restricting the performance consistency of mass-produced alloy resistors.
[0031] This technical solution aims to construct a systematic design methodology connecting downstream applications and upstream manufacturing. Its core concept lies in establishing a standardized, interconnected design process. First, downstream application requirements are translated into precise calculations of fundamental parameters such as strip width and thickness. Then, by defining a dedicated material library and establishing matching rules between material types and operating current environments, precise material selection is achieved. Most importantly, validated and quantified manufacturing tolerance ranges are systematically assigned to all key geometric dimensions and electrical parameters, forming an executable strip design specification. Finally, by guiding upstream production and incorporating this specification into the finished product verification process, a complete closed loop from design to verification is formed, ensuring the quality uniformity of alloy resistance strips at the source and fundamentally resolving batch consistency issues. Example
[0032] This application provides a method for designing alloy resistance strips. S1. Application Requirements Determination: Based on the application requirements of downstream circuits, determine the target range of nominal resistance value, target range of physical size, and type of operating current environment for the finished alloy resistors. The physical dimension target range has a length of 5.0 mm and a width of 2.5 mm.
[0033] When the operating current environment type is alternating current, manganese copper alloy or nickel-chromium alloy is specified from the material library as the material type of the alloy resistance strip.
[0034] S2. Derivation of basic parameters of the strip: Based on the target range of nominal resistance value and target range of physical size, the width design range and thickness design range of the alloy resistance strip are calculated by using the resistance law formula. The law of resistance is as follows: Where R represents the target resistance value of the finished alloy resistor; ρ represents the resistivity of the alloy resistor strip material; L represents the effective conduction length of the current in the finished alloy resistor; W represents the width of the alloy resistor strip; and T represents the thickness of the alloy resistor strip.
[0035] In the resistance law formula, the length L is taken as 3.0 mm.
[0036] S3. Material and Electrical Parameter Specification: Based on the operating current environment type and the results of step S2, specify the material type of the alloy resistance strip from the predetermined material library, and set the target range of resistivity, target range of resistance per meter, and target range of temperature coefficient of resistance (TCR) for the material type. The planned material library includes copper-nickel alloys, manganese-copper alloys, and nickel-chromium alloys.
[0037] The target range for resistance per meter is set to 2.0 Ω / m, and the target range for temperature coefficient of resistance (TCR) is set to ±20 ppm / °C.
[0038] S4. Assigning design tolerances: Assign corresponding manufacturing tolerance ranges to the width design range and thickness design range obtained in step S2, as well as the resistivity target range, meter resistance target range and resistance temperature coefficient (TCR) target range set in step S3. The manufacturing tolerance for the width design range is ±0.05mm, and the manufacturing tolerance for the thickness design range is ±0.025mm.
[0039] The manufacturing tolerances for the resistivity target range are ±10%, the resistance per meter target range are ±5%, and the temperature coefficient of resistance (TCR) target range are ±10 ppm / °C.
[0040] S5. Integration Output: The strip width, thickness, material type, resistivity, resistance per meter, TCR and their respective manufacturing tolerance ranges obtained from step S4 are integrated into a strip design specification. S6. Production guidance: Provide the material strip design specifications to upstream material suppliers to guide them in producing alloy resistance strips that meet the specifications.
[0041] S7. Finished Product Verification: Alloy resistor samples are made using alloy resistor strips produced according to the strip design specifications, and the alloy resistor samples are tested.
[0042] The test included a temperature cycling test, with a test temperature of 55°C and 300 cycles.
[0043] Example 2 This application provides a method for designing alloy resistance strips, including the following steps: S1. Application Requirements Determination: Based on the application requirements of downstream circuits, determine the target range of nominal resistance value, target range of physical size, and type of operating current environment for the finished alloy resistors. The physical size target range has a length of 1.0 mm and a width of 0.5 mm.
[0044] When the operating current environment type is alternating current, manganese copper alloy or nickel-chromium alloy is specified from the material library as the material type of the alloy resistance strip.
[0045] S2. Derivation of basic parameters of the strip: Based on the target range of nominal resistance value and target range of physical size, the width design range and thickness design range of the alloy resistance strip are calculated by using the resistance law formula. The law of resistance is as follows: Where R represents the target resistance value of the finished alloy resistor; ρ represents the resistivity of the alloy resistor strip material; L represents the effective conduction length of the current in the finished alloy resistor; W represents the width of the alloy resistor strip; and T represents the thickness of the alloy resistor strip.
[0046] In the resistance law formula, the length L is taken as 1.0 mm.
[0047] S3. Material and Electrical Parameter Specification: Based on the operating current environment type and the results of step S2, specify the material type of the alloy resistance strip from the predetermined material library, and set the target range of resistivity, target range of resistance per meter, and target range of temperature coefficient of resistance (TCR) for the material type. The planned material library includes copper-nickel alloys, manganese-copper alloys, and nickel-chromium alloys.
[0048] The target range for resistance per meter is set to 0.5 Ω / m, and the target range for temperature coefficient of resistance (TCR) is set to ±15 ppm / °C.
[0049] S4. Assigning design tolerances: Assign corresponding manufacturing tolerance ranges to the width design range and thickness design range obtained in step S2, as well as the resistivity target range, meter resistance target range and resistance temperature coefficient (TCR) target range set in step S3. The manufacturing tolerance for the width design range is ±0.01mm, and the manufacturing tolerance for the thickness design range is ±0.005mm.
[0050] The manufacturing tolerances for the resistivity target range are ±5%, the resistance per meter target range are ±2%, and the temperature coefficient of resistance (TCR) target range are ±5 ppm / °C.
[0051] S5. Integration Output: The strip width, thickness, material type, resistivity, resistance per meter, TCR and their respective manufacturing tolerance ranges obtained from step S4 are integrated into a strip design specification. S6. Production guidance: Provide the material strip design specifications to upstream material suppliers to guide them in producing alloy resistance strips that meet the specifications.
[0052] S7. Finished Product Verification: Alloy resistor samples are made using alloy resistor strips produced according to the strip design specifications, and the alloy resistor samples are tested.
[0053] The test included a temperature cycling test, with a test temperature of -55°C and 100 cycles.
[0054] Example 3 This application provides a method for designing alloy resistance strips, including the following steps: S1. Application Requirements Determination: Based on the application requirements of downstream circuits, determine the target range of nominal resistance value, target range of physical size, and type of operating current environment for the finished alloy resistors. The physical dimension target range has a length of 10.0 mm and a width of 5.0 mm.
[0055] When the operating current environment type is alternating current, manganese copper alloy or nickel-chromium alloy is specified from the material library as the material type of the alloy resistance strip.
[0056] S2. Derivation of basic parameters of the strip: Based on the target range of nominal resistance value and target range of physical size, the width design range and thickness design range of the alloy resistance strip are calculated by using the resistance law formula. The law of resistance is as follows: Where R represents the target resistance value of the finished alloy resistor; ρ represents the resistivity of the alloy resistor strip material; L represents the effective conduction length of the current in the finished alloy resistor; W represents the width of the alloy resistor strip; and T represents the thickness of the alloy resistor strip.
[0057] In the resistance law formula, the length L is taken as 5.0 mm.
[0058] S3. Material and Electrical Parameter Specification: Based on the operating current environment type and the results of step S2, specify the material type of the alloy resistance strip from the predetermined material library, and set the target range of resistivity, target range of resistance per meter, and target range of temperature coefficient of resistance (TCR) for the material type. The planned material library includes copper-nickel alloys, manganese-copper alloys, and nickel-chromium alloys.
[0059] The target range for resistance per meter is set to 5.0 Ω / m, and the target range for temperature coefficient of resistance (TCR) is set to ±30 ppm / °C.
[0060] S4. Assigning design tolerances: Assign corresponding manufacturing tolerance ranges to the width design range and thickness design range obtained in step S2, as well as the resistivity target range, meter resistance target range and resistance temperature coefficient (TCR) target range set in step S3. The manufacturing tolerance for the width design range is ±0.1mm, and the manufacturing tolerance for the thickness design range is ±0.05mm.
[0061] The manufacturing tolerances for the resistivity target range are ±15%, the resistance per meter target range are ±10%, and the temperature coefficient of resistance (TCR) target range are ±20 ppm / °C.
[0062] S5. Integration Output: The strip width, thickness, material type, resistivity, resistance per meter, TCR and their respective manufacturing tolerance ranges obtained from step S4 are integrated into a strip design specification. S6. Production guidance: Provide the material strip design specifications to upstream material suppliers to guide them in producing alloy resistance strips that meet the specifications.
[0063] S7. Finished Product Verification: Alloy resistor samples are made using alloy resistor strips produced according to the strip design specifications, and the alloy resistor samples are tested.
[0064] The tests included a temperature cycling test, with a test temperature of 155°C and 500 cycles.
[0065] Comparative Example 1 The only difference between this comparative example and Example 1 is that in step S3, the predetermined material library no longer includes manganese-copper alloy and nickel-chromium alloy, but is composed of copper-nickel alloy and iron-chromium-aluminum alloy.
[0066] Comparative Example 2 The only difference between this comparative example and Example 1 is that the technical rule in step S1, "wherein, when the working current environment type is AC, manganese copper alloy or nickel chromium alloy is specified from the material library as the material type of the alloy resistance strip," is deleted.
[0067] Comparative Example 3 The only difference between this comparative example and Example 1 is that the entire step S4 is deleted, and in step S5, the target values of the parameters obtained in steps S2 and S3 are directly integrated without including any manufacturing tolerance range.
[0068] Comparative Example 4 The only difference between this comparative example and Example 1 is that in step S4, only the width and thickness are given manufacturing tolerances, but no manufacturing tolerances are given for the target range of resistivity, the target range of resistance per meter, and the target range of temperature coefficient of resistance (TCR).
[0069] I. Test Item 1: Resistance Drift Rate Test under Multiple Temperature Cycling Ten alloy resistor samples from Examples 1-3 and Comparative Examples 1-4 were selected and manufactured according to their respective design specifications. The initial resistance values of the samples were ensured to be within their respective nominal resistance target ranges. The initial resistance value R0 of each sample was recorded and numbered using a high-precision resistance tester.
[0070] The experimental setup included a programmable high and low temperature chamber and a data acquisition-type resistance meter. The temperature cycling program was set as follows: first, the temperature was lowered from room temperature (25℃) to -55℃, held for 2 hours, and the resistance value R1 was measured and recorded; then, the temperature was raised to 25℃, held for 1 hour, and the resistance value R2 was measured and recorded; next, the temperature was raised to 55℃, held for 2 hours, and the resistance value R3 was measured and recorded; then, the temperature was raised to 155℃, held for 2 hours, and the resistance value R4 was measured and recorded; finally, the temperature was lowered to 25℃, held for 1 hour, and the resistance value R5 was measured and recorded. This constituted one complete cycle, which was executed 500 times. After each cycle, the resistance drift rate of each sample was calculated using the following formula: After the experiment, the maximum resistance drift rate, average resistance drift rate, and number of samples with drift rates exceeding the standard were counted for all samples in 500 cycles.
[0071] II. Test Item 2: Temperature Rise-Resistance Co-stability Test under Long-Term Loading of Rated Current The samples from test item 1 are used, but it is necessary to ensure that the samples are not physically damaged after temperature cycling test. First, calculate the rated operating current I of each sample based on the nominal resistance value of each sample and the common power requirements of the downstream circuit. The rated current of Examples 1-3 and Comparative Examples 1-4 are respectively set to AC for their operating current environment type.
[0072] The experimental setup included an adjustable AC power supply, a contact-type temperature rise tester, and a high-precision resistance tester. Each sample was fixed on an insulating heat sink substrate, connected to the AC power supply, and a rated current I was applied. Simultaneously, the temperature at the center point of the sample surface was monitored using the temperature rise tester. The sample surface temperature Tt and real-time resistance Rt were recorded every hour for 1000 hours. During the experiment, the initial temperature rise ΔT0 was recorded, representing the difference between the temperature one hour after the current was applied and the ambient temperature of 25°C. The temperature rise ΔT0 at 1000 hours was also recorded. 1000 Calculate the temperature rise change ΔT = ΔT 1000 -ΔT0, and simultaneously calculate the resistance drift rate (R) over 1000 hours. t -R0) / R0×100%.
[0073] III. Experimental Data Results The resistance drift rate test results (after 500 cycles) of each embodiment and comparative example under multiple temperature cycles are shown in Table 1.
[0074] Table 1:
[0075] The temperature rise and resistance stability test results (1000 hours) under long-term loading of rated current for each embodiment and comparative example are shown in Table 2.
[0076] Table 2:
[0077] IV. Data Analysis and Conclusions As can be seen from Examples 1-3 and Comparative Example 1, along with Tables 1 and 2, when the composition of the material library changes, particularly by removing key alloy types suitable for AC environments and introducing mismatched alternative materials, the overall performance of the alloy resistance strips declines significantly. As the fundamental determinant of the electrothermal characteristics of resistance, improper material selection directly leads to the deterioration of the resistance element's loss characteristics under alternating current, resulting in heat accumulation and resistance instability. This fully demonstrates that constructing a dedicated material library for specific operating current environments is a prerequisite for achieving high-performance product design, and the matching of materials to operating conditions is fundamental.
[0078] As can be seen from Examples 1-3 and Comparative Example 2, along with Tables 1 and 2, simply having a correct material library is insufficient. Without clear technical rules linking the type of operating current environment to specific materials in the library, the design process will lack crucial decision-making support. Even if the material library contains suitable options, vague or missing selection rules can lead to blind material application, failing to ensure automatic locking of the optimal solution under specific operating conditions. Consequently, the performance of the final product becomes highly dependent on the designer's individual experience, making it impossible to achieve stable and reproducible superior performance.
[0079] As can be seen from Examples 1-3 and Comparative Example 3, along with Tables 1 and 2, completely eliminating the systematic tolerance assignment step and only transmitting target parameter values without constraints on manufacturing fluctuation ranges poses the most serious challenge to product performance consistency. If inherent deviations in the manufacturing process are not effectively regulated and controlled, theoretically precise designs will become uncontrollable in actual production. The dispersion of various key parameters will superimpose and amplify each other, ultimately leading to an excessively wide performance distribution range in mass-produced products, severely deviating from design expectations. This demonstrates that systematic tolerance control is the core element for achieving industrial consistency.
[0080] As can be seen from Examples 1-3 and Comparative Example 4, and in conjunction with Tables 1 and 2, even with strict tolerance control over the geometric dimensions of the strip, neglecting the tolerance management of the material's inherent electrical parameters cannot guarantee the uniformity of the final product's performance. If the intrinsic properties of the alloy material, such as resistivity, microresistivity, and TCR, fluctuate excessively, even with highly consistent geometry, the differences in the material's inherent properties will lead to different electrothermal behaviors in the resistive element. This indicates that geometric accuracy and tolerance control of electrical properties are an inseparable whole; both must work synergistically to achieve precise control over the performance of the finished product.
[0081] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.
Claims
1. A method of designing an alloy resistor tape strip, characterized by: The method comprises the following steps: S1, application requirement determination: according to the application requirement of the downstream circuit, the nominal resistance value target range, the physical size target range and the working current environment type of the alloy resistor finished product are determined; S2, derivation of the basic parameters of the material strip: based on the nominal resistance value target range and the physical size target range, the width design range and the thickness design range of the alloy resistor material strip are calculated by using the resistance law formula; S3, material and electrical parameter designation: according to the working current environment type and the result of step S2, the material type of the alloy resistor material strip is designated from the predetermined material library, and the resistivity target range, the meter resistance target range and the TCR target range of the material type are set; S4, design tolerance assignment: the width design range and the thickness design range obtained in step S2, and the resistivity target range, the meter resistance target range and the TCR target range set in step S3 are respectively assigned with corresponding manufacturing tolerance ranges; S5, integration output: the width, thickness, material type, resistivity, meter resistance, TCR and their respective manufacturing tolerance ranges of the material strip after step S4 are integrated to form a material strip design specification; S6, production guidance: the material strip design specification is provided to the upstream material supplier to guide the production of the alloy resistor material strip meeting the specification.
2. The method of designing an alloy ribbon according to claim 1, wherein: In step S1, the length of the physical size target range is 1.0-10.0 mm, and the width is 0.5-5.0 mm.
3. The method of designing an alloy ribbon according to claim 1, wherein: In step S2, the resistance law formula is: Wherein, R represents the target resistance value of the alloy resistor product; p represents the resistivity of the alloy resistor strip material; L represents the effective conduction length of the current in the alloy resistor product; W represents the width of the alloy resistor strip; and T represents the thickness of the alloy resistor strip.
4. The method of designing an alloy ribbon according to claim 3, wherein: The length L in the resistance law formula ranges from 1.0 mm to 5.0 mm.
5. The method of designing an alloy ribbon according to claim 1, wherein: In step S3, the predetermined material library includes copper-nickel alloy, manganese-copper alloy and nickel-chromium alloy.
6. The method of designing an alloy ribbon according to claim 1, wherein: In step S4, the manufacturing tolerance of the width design range is ±0.01 mm to ±0.1 mm, and the manufacturing tolerance of the thickness design range is ±0.005 mm to ±0.05 mm.
7. The method of designing an alloy ribbon according to claim 1, wherein: In step S4, the manufacturing tolerance of the resistivity target range is ±5% to ±15%, the manufacturing tolerance of the meter resistance target range is ±2% to ±10%, and the manufacturing tolerance of the TCR target range is ±5 ppm / °C to ±20 ppm / °C.
8. The method of designing an alloy ribbon according to claim 1, wherein: In step S1, when the working current environment type is alternating current, manganese-copper alloy or nickel-chromium alloy is designated from the material library as the material type of the alloy resistor material strip.
9. The method of designing an alloy ribbon according to claim 1, wherein: The method further comprises the following steps after step S6: S7, finished product verification: alloy resistor samples are made using the alloy resistor material strip produced according to the material strip design specification, and the alloy resistor samples are tested.
10. The method of designing an alloy ribbon according to claim 9, wherein: In step S7, the test includes a temperature cycle test, the test temperature range is -55°C to +155°C, and the cycle number is 100 to 500 times.