Power type aluminum shell wire-wound resistor

Abstract

The utility model relates to the technical field of resistors, and discloses a power type aluminum shell wire-wound resistor which comprises an aluminum shell, a resistor core, a filling layer and a packaging assembly, the two ends of the resistor core are provided with embedded supporting structures which are fixed at the two ends of the ceramic framework through welding and are uniformly spaced from the inner wall of the aluminum shell to ensure that the resistor core is centered. An active heat dissipation structure is integrated in the filling layer, and rapid heat dissipation is achieved through the synergistic effect of a heat conduction material and the aluminum shell; c-shaped insulation supports are arranged on the two sides of the opening of the aluminum shell and fixedly connected with the side wall of the aluminum shell through rivets, mechanical support is provided, electrical contact is isolated, the outer sides of the C-shaped insulation supports are covered with silica gel packaging layers, and insulation, impact resistance and weather resistance are considered. A micro heat pipe array is welded to the outer surface of the aluminum shell, and heat is conducted out to external cooling fins through the phase change heat transfer principle. A temperature sensing switch is arranged on the inner wall of the aluminum shell, and when the temperature exceeds 120 DEG C, the fan is automatically triggered to start forced air cooling.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of resistor, specifically is a power type aluminum shell wire wound resistor. BACKGROUND

[0002] With the continuous development of science and technology, the industries such as industrial frequency conversion, energy storage, new energy, transportation and power supply are growing rapidly, which drives and promotes the accelerated development of modern power industrial control technology. In the energy storage market, power resistors can be used as pre-charging resistors to limit the impact current of the circuit during startup or initial power-on, thereby avoiding damage to elements such as capacitors, contactors, rectifier devices and motor controllers in the circuit caused by instantaneous high current. Although the pre-charging resistor can withstand a certain amount of current impact energy, instantaneous high energy or long energy duration may still cause damage to the pre-charging resistor, and in severe cases, the pre-charging resistor may be blown open due to excessive energy.

[0003] The existing power type aluminum shell wire wound resistor is mostly of the structure that the resistance core is installed in the aluminum shell, the silica sand is filled into the aluminum shell by using the sand filling process, the resistance core is fixed in the aluminum shell, and an insulation layer is attached to the inner wall of the resistance core and the aluminum shell to enhance the insulation performance of the resistor. The opening of the aluminum shell is sealed by cement on both sides, so that the silica sand and the resistance core are sealed in the aluminum shell.

[0004] Disadvantages:

[0005] 1. The resistance core is easy to deviate during the assembly and filling process, which causes uneven heating of the resistor and uneven heat dissipation of the aluminum shell.

[0006] 2. The silica sand inside the resistor is prone to loosen due to vibration impact during the use of the resistor, which in turn causes the resistance core to deviate.

[0007] 3. The sealing cement on both sides of the opening of the aluminum shell is prone to cracking due to vibration impact during the use of the resistor, which in turn causes the silica sand inside the resistor to leak and the resistance core to deviate.

[0008] Therefore, we propose a power type aluminum shell wire wound resistor to solve the above problems. Utility model content

[0009] The utility model aims at providing a power type aluminum shell wire wound resistor to solve the problem of uneven heating of the resistor and uneven heat dissipation of the aluminum shell caused by the deviation of the resistance core during the assembly and filling process of the existing power type aluminum shell wire wound resistor.

[0010] In order to solve the above technical problems, the utility model provides the following technical scheme:

[0011] A power type aluminum shell wire-wound resistor comprises an aluminum shell, a resistance core arranged inside the aluminum shell, a filling layer for pressure-resistant packaging, the resistance core is provided with an inlaid support structure at both ends, the inlaid support structure is a symmetrical rectangular structure, is fixedly connected to both ends of a ceramic framework of the resistance core, and keeps a middle distance with the inner wall of the aluminum shell, and the filling layer is connected with an active heat dissipation structure for rapid heat dissipation.

[0012] Preferably, the filling layer inside the aluminum shell fixes the resistance core through twice pouring processes, and the filling layer comprises cement poured between the inlaid support and the inner wall of the aluminum shell for the first time and a quartz sand filling layer covering the resistance core and the first pouring area for the second time.

[0013] Preferably, C-shaped insulating supports are arranged at both sides of the opening of the aluminum shell, and the C-shaped insulating supports are fixedly connected to the side walls of the aluminum shell.

[0014] Preferably, a silica gel packaging layer covers the outside of the C-shaped insulating supports, and the silica gel packaging layer completely covers rivets and extends to the edge of the opening of the aluminum shell.

[0015] Compared with the prior art, the power type aluminum shell wire-wound resistor has the following beneficial effects:

[0016] The power type aluminum shell wire-wound resistor in the first and second embodiments of the utility model greatly improves the heat dissipation efficiency and structural stability through optimized design, and effectively prevents damage caused by overheating. Firstly, from the working principle, the symmetrical rectangular inlaid support structure is fixed at both ends of the resistance core through welding, so that the resistance core is ensured to be centered and uniform heat dissipation channels are provided for the filling layer, thereby avoiding local overheating. The active heat dissipation structure integrated in the filling layer cooperates with the aluminum shell through a heat-conducting material to accelerate heat dissipation. The first pouring adopts cement to form a rigid support layer to limit displacement of the resistance core, and the second pouring uses quartz sand filling to provide high thermal conductivity and anti-vibration performance. The C-shaped insulating supports are fixed to the side walls of the aluminum shell through rivets, and the silica gel packaging layer outside the C-shaped insulating supports provides insulation, impact resistance and weather resistance to prevent high-temperature aging and internal pollution. The micro heat pipe array welded on the outer surface of the aluminum shell and the temperature sensing switch on the inner wall further enhance the heat dissipation capacity. When the internal temperature exceeds 120 DEG C, the temperature sensing switch triggers the fan controller to start forced air cooling, so that the active heat dissipation is supplemented when the passive heat dissipation is insufficient. The inlaid support structure simplifies the assembly process and improves the anti-vibration stability through the design of the rectangular support block and the magnetic attraction block, thereby effectively preventing the resistance core from deviating and the filling layer from loosening due to vibration impact, and significantly improving the heat dissipation efficiency and overall performance of the entire resistor. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 It is a schematic diagram of the overall external structure of the first embodiment of the utility model;

[0018] Figure 2The whole expansion structure schematic diagram of the embodiment one of the utility model;

[0019] Figure 3 The whole side view structure schematic diagram of the embodiment one of the utility model;

[0020] Figure 4 The whole external structure schematic diagram of the embodiment two of the utility model;

[0021] Figure 5 The whole side view structure schematic diagram of the embodiment two of the utility model;

[0022] Figure 6 The A place of the utility model's Figure 5 The enlarged structure schematic diagram of the A place.

[0023] 1, aluminum shell, 2, resistance core, 3, filling layer, 4, inlay support structure, 5, ceramic framework, 6, resistance wire, 7, outer electrode, 8, soldering leg lead, 9, C-shaped insulation support, 10, silica gel packaging layer, 11, micro heat pipe array, 12, heat pipe evaporation section, 13, heat pipe condensation section, 14, heat dissipation fin, 15, temperature sensing switch, 16, fan controller, 17, first magnetic suction block, 18, telescopic groove, 19, second magnetic suction block, 20, positioning groove, 21, support rib plate, 22, rectangular support block, 23, mica inner wall. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the utility model will be clearly and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the utility model.

[0025] Embodiment one:

[0026] Please refer to Figures 1-3 The utility model provides a technical scheme:

[0027] A power type aluminum shell wire-wound resistor, including aluminum shell 1, resistance core 2, filling layer 3 for pressure-resistant packaging and packaging assembly, the both ends of resistance core 2 are equipped with inlay support structure 4, the inlay support is symmetrical rectangular structure, it is fixed in the ceramic framework 5 both ends of resistance core 2 by welding, and with aluminum shell 1 inner wall keeps the middle distance, filling layer 3 inside is connected with the active heat dissipation structure for quick heat dissipation, resistance core 2 and aluminum shell 1 between be provided with mica inner wall 23 for insulation protection.

[0028] The symmetrical rectangular inlaid support structure 4 is fixed at both ends of the resistance core 2 by welding, is embedded at both ends of the ceramic framework 5, and keeps a uniform distance from the inner wall of the aluminum shell 1, so as to ensure that the resistance core 2 is centered. The active heat dissipation structure is integrated in the filling layer 3, and the heat generated by the resistance core 2 is quickly transmitted to the shell through the cooperation of the heat-conducting material and the aluminum shell 1. The support structure fixes the position of the resistance core 2 and provides a uniform heat dissipation channel for the filling layer 3, so as to avoid local overheating.

[0029] Further, the filling layer 3 inside the aluminum shell 1 fixes the resistance core 2 through twice sealing processes, and the filling layer 3 includes cement that is first sealed between the inlaid support and the inner wall of the aluminum shell 1, and quartz sand that is secondly sealed to cover the resistance core 2 and the first sealing area.

[0030] The first sealing uses cement to fill the gap between the inlaid support and the inner wall of the aluminum shell 1, and a rigid support layer is formed after solidification to limit the displacement of the resistance core 2; the second sealing uses quartz sand to cover the resistance core 2 and the first sealing area, and the high thermal conductivity and fluidity of the quartz sand are used to fill the gap. The combination of rigid and flexible filling in the twice sealing processes enhances the structural stability and improves the overall heat dissipation efficiency.

[0031] Further, C-shaped insulating supports 9 are arranged on both sides of the opening of the aluminum shell 1, and the C-shaped insulating supports 9 are fixedly connected to the side wall of the aluminum shell 1 by rivets.

[0032] The C-shaped insulating supports 9 are arranged on both sides of the opening of the aluminum shell 1 and are fixed to the side wall of the aluminum shell 1 by rivets. The C-shaped structure wraps the opening edge of the aluminum shell 1, provides mechanical support, and insulates the internal circuit from electrical contact with the shell to prevent short circuits. The riveting ensures that the insulating support is closely attached to the aluminum shell 1, thereby improving the anti-shock performance.

[0033] Further, the C-shaped insulating supports 9 are covered with a silica gel sealing layer 10 on the outside, and the silica gel sealing layer 10 completely covers the rivets and extends to the opening edge of the aluminum shell 1. The silica gel layer is divided into three layers from the inside to the outside: (1) high-temperature-resistant silica gel directly covers the C-shaped support and the rivet to prevent high-temperature aging; (2) the middle layer of ceramic fiber woven mesh enhances the structural strength; and (3) the outer layer of fluororubber coating seals the whole and resists environmental corrosion. The three-layer composite structure takes into account insulation, impact resistance, and weather resistance, while sealing the opening of the aluminum shell 1 to prevent external pollutants from entering.

[0034] Further, the resistance core 2 includes a ceramic framework 5 and a wound resistance wire 6 outside the ceramic framework 5, one end of the ceramic framework 5 is provided with an external electrode 7, and the top of the external electrode 7 is provided with a solder leg lead 8.

[0035] The ceramic skeleton 5 is wound with resistance wire 6 on its surface, one end of which is welded with an external electrode 7, and the top of the external electrode 7 is connected with a soldering leg lead 8. The ceramic skeleton 5 provides insulation and high-temperature-resistant support, the resistance wire 6 and the external electrode 7 are connected by welding to realize low-impedance conduction, and the soldering leg lead 8 facilitates external circuit connection.

[0036] Further, the inlaid support structure 4 is provided with two groups and is arranged at both ends of the resistance core 2 for fixing the position of the resistance core 2, and the inlaid support structure 4 includes linearly distributed support rib plates 21, a plurality of support rib plates 21 are symmetrically distributed on both sides of the ceramic skeleton 5 of the resistance core 2 and have the same size, and one end of the support rib plate 21 away from the ceramic skeleton 5 is in contact with the inner wall of the aluminum shell 1.

[0037] Further, the particle surface of the quartz sand filling layer 3 is coated with nano-silicon dioxide adhesive, and the adhesive content is 0.5% to 1.5%; in the sand filling process, a high-frequency vibration table is used to apply 20-50Hz vertical vibration to the aluminum shell 1, and a vacuum negative pressure device is used to adsorb quartz sand particles to enhance the compactness.

[0038] The quartz sand particle surface is coated with nano-silicon dioxide adhesive, and the particles are closely arranged by high-frequency vibration during pouring and sealing, and vacuum negative pressure adsorption further eliminates air bubbles. This process forms a high-compactness filling layer 3, which improves the heat conduction performance and enhances the overall structure integrity.

[0039] The silica gel packaging layer 10 is a gradient composite structure, including an inner layer covering the C-shaped insulation support 9, the inner layer being made of a high-temperature-resistant silica gel layer; a middle layer embedded in the inner layer silica gel, which uses a ceramic fiber woven mesh; and an outer layer completely covering the middle layer and the inner layer, which uses a fluororubber coating.

[0040] Example Two:

[0041] Please refer to Figures 4-6 , and further combined with Example One, it is further obtained that the aluminum shell 1 is welded with a micro heat pipe array 11 on its outer surface, the evaporation section 12 of the heat pipe is embedded in the inner wall of the aluminum shell 1, and the condensation section 13 extends to the external heat dissipation fins 14; the evaporation section 12 of the heat pipe is embedded in the inner wall of the aluminum shell 1 to directly absorb internal heat; the condensation section 13 extends to the external heat dissipation fins 14 to increase the heat dissipation area through the fins.

[0042] The heat pipe uses the principle of phase change heat transfer to efficiently transfer the heat in the high-temperature internal area to the external environment, thereby reducing the internal temperature rise of the aluminum shell 1.

[0043] Further, the inner wall of the aluminum shell 1 is provided with a temperature sensing switch 15, and the temperature sensing switch 15 is connected with an external fan controller 16 through a wire, so that when the internal temperature of the aluminum shell 1 is greater than 120℃, the fan is triggered to start forced air cooling.

[0044] The temperature sensing switch 15 is installed on the inner wall of the aluminum shell 1. When the temperature exceeds 120℃, the external fan controller 16 is triggered to start forced air cooling through the wire. This design automatically supplements active cooling when passive cooling is insufficient, preventing the resistor from being damaged by overheating.

[0045] Further, the inlaid support structure 4 includes a rectangular support block 22 that is slidingly fitted inside the aluminum shell 1. The support block is provided with telescopic grooves 18 on both sides perpendicular to the direction of the aluminum shell 1. The telescopic grooves 18 are provided with first magnetic attraction blocks 17 that are slidingly connected inside the telescopic grooves 18 and have an inclined chamfer at one end close to the ceramic substrate, which facilitates the entry of the first magnetic attraction blocks 17 into the aluminum shell 1. The aluminum shell 1 is provided with positioning grooves 20 at both ends, and the positioning grooves 20 are provided with second magnetic attraction blocks 19. When the telescopic grooves 18 are aligned with the positioning grooves 20, the second magnetic attraction blocks 19 attract the first magnetic attraction blocks 17 to slide out of the telescopic grooves 18, so that the first magnetic attraction blocks 17 are located between the telescopic grooves 18 and the positioning grooves 20, achieving positioning of the support block. The end of the ceramic substrate is fixedly connected to the middle of the support block, and the support block fixes the resistance core 2 in the middle of the aluminum shell 1.

[0046] The support block is positioned by the interaction of the first magnetic attraction blocks 17 in the telescopic grooves 18 on both sides and the second magnetic attraction blocks 19 in the positioning grooves 20 of the aluminum shell 1. During installation, the support block is slid into the aluminum shell 1. When the telescopic grooves 18 are aligned with the positioning grooves 20, the magnetic attraction force causes the first magnetic attraction blocks 17 to slide out and be clamped into the positioning grooves 20, achieving automatic locking of the support block. The inclined chamfer design facilitates the sliding of the magnetic attraction blocks into the positioning grooves 20, and the middle of the support block fixes the ceramic framework 5, ensuring quick positioning and centering of the resistance core 2. This structure simplifies the assembly process and improves the anti-shock stability.

[0047] Working principle of example one:

[0048] The power type aluminum shell wire-wound resistor in the embodiment one works in the following way: first, the resistance core 2 is fixed at both ends by welding a symmetrical rectangular inlaid support structure 4 which is embedded into the ceramic framework 5 at both ends and keeps a uniform distance with the inner wall of the aluminum shell 1, ensuring that the resistance core 2 is centered. The active heat dissipation structure is integrated in the filling layer 3, which cooperates with the aluminum shell 1 through the heat-conducting material to quickly transfer the heat generated by the resistance core 2 to the outer shell. The first pouring uses cement to fill the gap between the inlaid support and the inner wall of the aluminum shell 1, and after solidification, a rigid support layer is formed to limit the displacement of the resistance core 2; the second pouring uses quartz sand to cover the resistance core 2 and the first pouring area, and the high thermal conductivity and fluidity of the quartz sand are used to fill the gaps. The C-shaped insulation support 9 is fixedly connected with the side wall of the aluminum shell 1 through rivets, and the silicone encapsulation layer 10 covering the outside of the C-shaped insulation support 9 provides insulation, impact resistance and weather resistance. The ceramic framework 5 of the resistance core 2 is wound with resistance wire 6, one end of which is welded with an external electrode 7, and the external electrode 7 is connected with a solder leg lead 8 at the top, facilitating external circuit connection. The inlaid support structure 4 fixes the position of the resistance core 2 through the linearly distributed support rib plates 21, and at the same time provides uniform heat dissipation channels for the filling layer 3, avoiding local overheating.

[0049] The working principle of the embodiment two is as follows:

[0050] The embodiment two further enhances the heat dissipation capacity on the basis of the embodiment one. The aluminum shell 1 is welded with a micro heat pipe array 11 on the outer surface, the evaporation section 12 of the heat pipe is embedded into the inner wall of the aluminum shell 1, the condensation section 13 extends to the external heat dissipation fins 14, and the heat in the internal high temperature area is efficiently conducted to the external environment by using the phase change heat transfer principle. The inner wall of the aluminum shell 1 is provided with a temperature sensing switch 15, which triggers the external fan controller 16 to start forced air cooling when the temperature inside the aluminum shell 1 exceeds 120℃, so as to supplement the passive heat dissipation in an active heat dissipation mode. In addition, the inlaid support structure 4 is designed through the rectangular support blocks 22 and the magnetic attraction blocks, which simplifies the assembly process and improves the anti-seismic stability. The above improvements jointly improve the heat dissipation efficiency and overall performance of the resistor, preventing damage caused by overheating.

[0051] Although the specific embodiments of the utility model have been shown and described, it can be understood by those skilled in the art that various changes, modifications, replacements and variations can be made to these specific embodiments without departing from the principles and spirits, and the scope of the utility model is defined by the appended claims and their equivalents.

Claims

1. A power type aluminum shell wirewound resistor comprising an aluminum shell (1), a resistor core (2) disposed inside the aluminum shell (1), and a filling layer (3) for pressure-proof packaging, characterized in that: The resistance core (2) is provided with an inlaid support structure (4) at both ends, the inlaid support is a symmetrical rectangular structure, and is fixedly connected to the ceramic framework (5) at both ends of the resistance core (2) and keeps a middle distance with the inner wall of the aluminum shell (1); the filling layer (3) is internally connected with an active heat dissipation structure for rapid heat dissipation, and the resistance core (2) and the aluminum shell (1) are provided with a mica inner wall (23) for insulation protection.

2. A power type aluminium shell wirewound resistor according to claim 1, characterized in that: The filling layer (3) in the aluminum shell (1) fixes the resistance core (2) through twice pouring processes, and the filling layer (3) comprises cement poured between the inlaid support and the inner wall of the aluminum shell (1) for the first time and a quartz sand filling layer (3) covering the resistance core (2) and the first pouring area for the second time.

3. A power type aluminium-clad wire-wound resistor according to claim 2, characterised in that: The aluminum shell (1) is provided with C-shaped insulation supports (9) on both sides of the opening, and the C-shaped insulation supports (9) are fixedly connected with the side wall of the aluminum shell (1).

4. A power type aluminium-clad wire-wound resistor according to claim 3, characterised in that: The C-shaped insulation supports (9) are covered with a silica gel packaging layer (10) on the outside, and the silica gel packaging layer (10) extends to the opening edge of the aluminum shell (1).

5. A power type aluminum shell wirewound resistor according to claim 1, characterized in that: The resistance core (2) comprises a ceramic framework (5) and a wound resistance wire (6) outside the ceramic framework (5), one end of the ceramic framework (5) is provided with an external electrode (7), and the top of the external electrode (7) is provided with a solder leg lead (8).

6. A power type aluminum shell wirewound resistor according to claim 1, characterized in that: The aluminum shell (1) is welded with a micro heat pipe array (11) on the outer surface, the evaporation section (12) of the heat pipe is embedded in the inner wall of the aluminum shell (1), and the condensation section (13) extends to the external heat dissipation fins (14).

7. A power type aluminium-clad wirewound resistor according to claim 6, characterised in that: The inner wall of the aluminum shell (1) is provided with a temperature sensing switch (15), the temperature sensing switch (15) is connected with an external fan controller (16) through a wire, and when the temperature in the aluminum shell (1) is greater than 120 DEG C, the fan is triggered to start forced air cooling.

8. The power-type aluminum shell wirewound resistor according to claim 4, characterized in that: The inlaid support structure (4) has two groups and is arranged at both ends of the resistance core (2) to fix the position of the resistance core (2), the inlaid support structure (4) comprises linearly distributed support rib plates (21), a plurality of support rib plates (21) are the same in size and symmetrically distributed on both sides of the ceramic framework (5) of the resistance core (2), and one end of the support rib plate (21) away from the ceramic framework (5) abuts against the inner wall of the aluminum shell (1).

9. A power type aluminium-clad wire-wound resistor according to claim 8, characterised in that: The inlaid support structure (4) comprises a rectangular support block (22), the support block is in sliding fit with the inside of the aluminum shell (1), the support block is provided with an expansion slot (18) perpendicular to the direction of the aluminum shell (1) on both sides, the expansion slot (18) is provided with a first magnetic block (17) inside, the first magnetic block (17) is in sliding connection inside the expansion slot (18) and is provided with an inclined chamfer at one end close to the ceramic substrate, which is beneficial to entering the inside of the aluminum shell (1), the aluminum shell (1) is provided with a positioning slot (20) at both ends, the positioning slot (20) is provided with a second magnetic block (19) inside, when the expansion slot (18) is aligned with the positioning slot (20), the second magnetic block (19) attracts the first magnetic block (17) to slide out of the expansion slot (18), so that the first magnetic block (17) is located between the expansion slot (18) and the positioning slot (20), the positioning of the support block is realized, the end of the ceramic substrate is fixedly connected with the middle of the support block, and the support block fixes the resistance core (2) in the middle of the aluminum shell (1).

10. A power type aluminium shell wirewound resistor according to claim 4, characterised in that: The particle surface of the quartz sand filling layer (3) is coated with nano-silica binder, the silica gel packaging layer (10) is a gradient composite structure, including an inner layer covering the C-shaped insulation support (9), the material of the inner layer is a high-temperature-resistant silica gel layer; a middle layer embedded in the silica gel of the inner layer, which adopts a ceramic fiber woven mesh; and an outer layer completely covering the middle layer and the inner layer, which adopts a fluorine rubber coating.

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