High-wear-resistance linear circular-arc-shaped resistance sheet

Abstract

This invention provides a high-wear-resistant linear arc-shaped resistor sheet, comprising an insulating substrate, and further comprising a first conductive metal circuit layer, a second conductive metal circuit layer, a third conductive metal circuit layer, a fourth conductive metal circuit layer, a fifth conductive metal circuit layer, a sixth conductive metal circuit layer, a first carbon film resistor layer, and a second carbon film resistor layer. The second conductive metal circuit layer is connected to the sixth conductive metal circuit layer through the first carbon film resistor layer, and the third conductive metal circuit layer is connected to the fifth conductive metal circuit layer through the second carbon film resistor layer. A third carbon film resistor layer is disposed on the first carbon film resistor layer, and a fourth carbon film resistor layer is disposed on the second carbon film resistor layer. A vertically oriented anisotropic conductive adhesive layer is disposed on the first, third, and fourth conductive metal circuit layers in the area traversed by the brush. This significantly improves the sliding life while reducing costs.

Description

Technical Field

[0001] This utility model relates to the field of resistor sheet technology, specifically to a highly wear-resistant linear arc-shaped resistor sheet. Background Technology

[0002] Chinese patent application CN 218351223 U, published on January 20, 2023, discloses a high-precision rotary potentiometer structure. The structure includes a plastic base with an inner cavity on its top surface, a substrate with a resistive element, several conductive terminals, and a brush. The substrate is a high-temperature resistant plastic film for injection molding. The substrate edge has several connecting portions that are electrically connected to the conductive terminals. The substrate is integrally formed on the inner bottom surface of the inner cavity, and one end of each conductive terminal is correspondingly attached to the surface of the connecting portion and integrally formed within the base. The substrate, made of plastic film, has a very smooth surface and a certain degree of flexibility. On the one hand, this ensures uniform thickness of the printed resistive element, thereby improving the linear accuracy of the resistive element. On the other hand, the connecting portions between the conductive terminals and the substrate only make contact and conduction. Furthermore, the integral forming within the plastic base, due to the substrate's flexibility, forces the conductive terminals into close contact with the substrate under molding pressure. This not only significantly improves the reliability of the electrical connection but also eliminates the riveting process and the problems associated with it. The existing technology has the following drawbacks: its standard lifespan is only between 100,000 and 1 million cycles. To increase it to 1 million to 10 million cycles, the resistive element cannot meet the requirements due to wear. Another solution to extend lifespan is to improve the brush material, replacing common brush materials like aluminum alloy, phosphor bronze, and beryllium copper with hexa-element alloys (Pd, Ag, Cu, Au, Pt, Zn). This utilizes the strength, hardness, good elasticity, and low wear resistance of hexa-element alloys. However, using this method makes the cost of the brush itself higher than that of the entire potentiometer, resulting in low market acceptance and poor cost-effectiveness. Therefore, improvements are urgently needed. Utility Model Content

[0003] To address the above problems, this utility model provides a highly wear-resistant linear arc-shaped resistor sheet with a vertically oriented anisotropic conductive adhesive layer, which greatly improves the gliding life while reducing costs.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a high-wear-resistant linear arc-shaped resistor sheet, comprising an insulating substrate, and further comprising a first conductive metal circuit layer, a second conductive metal circuit layer, a third conductive metal circuit layer, a fourth conductive metal circuit layer, a fifth conductive metal circuit layer, a sixth conductive metal circuit layer, a first carbon film resistor layer, and a second carbon film resistor layer disposed on the insulating substrate. The second conductive metal circuit layer is connected to the sixth conductive metal circuit layer through the first carbon film resistor layer, and the third conductive metal circuit layer is connected to the fifth conductive metal circuit layer through the second carbon film resistor layer. Both the first and second carbon film resistor layers are arc-shaped. The first conductive metal circuit layer, the first carbon film resistor layer, and the second carbon film resistor layer are coaxially arc-shaped. A third carbon film resistor layer is disposed on the first carbon film resistor layer, and a fourth carbon film resistor layer is disposed on the second carbon film resistor layer. A vertically oriented anisotropic conductive adhesive layer is disposed on the first, third, and fourth conductive metal circuit layers in the area through which the brush slides.

[0005] Preferably, the first conductive metal circuit layer, the second conductive metal circuit layer, the third conductive metal circuit layer, the fourth conductive metal circuit layer, the fifth conductive metal circuit layer, and the sixth conductive metal circuit layer are all respectively set as silver layers.

[0006] Preferably, the thickness of the first conductive metal circuit layer, the second conductive metal circuit layer, the third conductive metal circuit layer, the fourth conductive metal circuit layer, the fifth conductive metal circuit layer, and the sixth conductive metal circuit layer is set to 8-12 μm.

[0007] Preferably, the film thickness of the first carbon film resistive layer and the second carbon film resistive layer is set to 10-15 μm.

[0008] Preferably, the film thickness of the third carbon film resistive layer and the fourth carbon film resistive layer is set to 16-24 μm.

[0009] Preferably, the thickness of the vertical anisotropic conductive adhesive layer is set to 5–8 μm.

[0010] The beneficial effects of this utility model are as follows: The first conductive metal circuit layer, the third carbon film resistor layer, and the fourth carbon film resistor layer are covered with a vertically oriented anisotropic conductive adhesive layer in the area through which the brush slides. Utilizing the principle of vertical conductivity, when the brush slides on it, the contact point is connected to the underlying carbon film or silver film through the vertically oriented anisotropic conductive adhesive, forming a circuit output. The vertically oriented anisotropic conductive adhesive has good wear resistance, thus greatly improving the sliding life while reducing costs, achieving a sliding life of 1 million to 1000 cycles. Attached Figure Description

[0011] Figure 1 This is a top view of the present invention (showing the relative structural relationships of the insulating substrate, the first conductive metal circuit layer, the second conductive metal circuit layer, the third conductive metal circuit layer, the fourth conductive metal circuit layer, the fifth conductive metal circuit layer, and the sixth conductive metal circuit layer).

[0012] Figure 2 This is a top view of the present invention (showing the structural relationship between the first carbon film resistive layer and the second carbon film resistive layer).

[0013] Figure 3 This is a top view of the present invention (showing the structural relationship between the third carbon film resistive layer and the fourth carbon film resistive layer).

[0014] Figure 4 This is a top view of the present invention (showing the structural relationship of the vertical anisotropic conductive adhesive layer).

[0015] Figure 5 This is a schematic diagram illustrating the functional implementation of this utility model (showing a partial connection between the conductive metal circuit layer and the carbon film resistor layer; the arrow indicates the direction of conduction).

[0016] The reference numerals in the attached figures are: insulating substrate 10, fourth carbon film resistive layer 11, third carbon film resistive layer 12, brush 13, first conductive metal circuit layer 16, second conductive metal circuit layer 17, fourth conductive metal circuit layer 19, fifth conductive metal circuit layer 18, vertical anisotropic conductive adhesive layer 20, sixth conductive metal circuit layer 23, first carbon film resistive layer 22, second carbon film resistive layer 21, and third conductive metal circuit layer 24. Detailed Implementation

[0017] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the implementation of the present invention is not limited thereto.

[0018] like Figure 1-5As shown, this embodiment provides a high-wear-resistant linear arc-shaped resistor sheet, including an insulating substrate 10, and further including a first conductive metal circuit layer 16, a second conductive metal circuit layer 17, a third conductive metal circuit layer 24, a fourth conductive metal circuit layer 19, a fifth conductive metal circuit layer 18, a sixth conductive metal circuit layer 23, a first carbon film resistor layer 22, and a second carbon film resistor layer 21 printed on the insulating substrate 10. The second conductive metal circuit layer 17 is connected to the sixth conductive metal circuit layer 23 through the first carbon film resistor layer 22, and the third conductive metal circuit layer 24 is connected to the fifth conductive metal circuit layer 23 through the second carbon film resistor layer 21. The conductive metal circuit layer 18 is connected; the first carbon film resistor layer 22 and the second carbon film resistor layer 21 are both set in an arc shape; the first conductive metal circuit layer 16, the first carbon film resistor layer 22, and the second carbon film resistor layer 21 are set in a coaxial arc shape; a third carbon film resistor layer 12 is covered on the first carbon film resistor layer 22, and a fourth carbon film resistor layer 11 is covered on the second carbon film resistor layer 21; the first conductive metal circuit layer 16, the third carbon film resistor layer 12, the fourth carbon film resistor layer 11, and the fourth conductive metal circuit layer 19 are covered with a vertically oriented anisotropic conductive adhesive layer 20 in the area through which the brush 13 slides.

[0019] In a preferred embodiment, the first conductive metal circuit layer 16, the second conductive metal circuit layer 17, the third conductive metal circuit layer 24, the fourth conductive metal circuit layer 19, the fifth conductive metal circuit layer 18, and the sixth conductive metal circuit layer 23 are all silver layers. The thickness of the first conductive metal circuit layer 16, the second conductive metal circuit layer 17, the third conductive metal circuit layer 24, the fourth conductive metal circuit layer 19, the fifth conductive metal circuit layer 18, and the sixth conductive metal circuit layer 23 is set to 8–12 μm. The film thickness of the first carbon film resistor layer 22 and the second carbon film resistor layer 21 is set to 10–15 μm. The film thickness of the third carbon film resistor layer 12 and the fourth carbon film resistor layer 11 is set to 16–24 μm. The thickness of the vertical anisotropic conductive adhesive layer 20 is set to 5–8 μm.

[0020] In this embodiment, the first conductive metal circuit layer, the third carbon film resistor layer, the fourth carbon film resistor layer, and the fourth conductive metal circuit layer are covered with a vertically oriented anisotropic conductive adhesive layer in the area traversed by the brush through printing or hot pressing. Utilizing the principle of vertical conductivity, when the brush slides on it, the contact points are connected vertically to the underlying carbon film or silver film through the vertically oriented anisotropic conductive adhesive, forming a circuit output. The main materials of the vertically oriented anisotropic conductive adhesive are resin and conductive particles, thus exhibiting excellent wear resistance. Therefore, while reducing costs, the sliding life is greatly improved, achieving a sliding life of 1 million to 1000 cycles.

[0021] The above embodiments illustrate only one implementation of the present utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present utility model, and these all fall within the protection scope of the present utility model. Therefore, the protection scope of the present utility model patent should be determined by the appended claims.

Claims

1. A high-wear-resistant linear arc-shaped resistor sheet, comprising an insulating substrate (10), and further comprising a first conductive metal circuit layer (16), a second conductive metal circuit layer (17), a third conductive metal circuit layer (24), a fourth conductive metal circuit layer (19), a fifth conductive metal circuit layer (18), a sixth conductive metal circuit layer (23), a first carbon film resistor layer (22), and a second carbon film resistor layer (21) disposed on the insulating substrate (10), wherein the second conductive metal circuit layer (17) is connected to the sixth conductive metal circuit layer (23) through the first carbon film resistor layer (22), and the third conductive metal circuit layer (24) is connected to the fifth conductive metal circuit layer (18) through the second carbon film resistor layer (21); the first carbon film resistor layer (22) and the second carbon film resistor layer (21) are both configured as arc-shaped; the first conductive metal circuit layer (16) and the first carbon film resistor layer (22) and the second carbon film resistor layer (21) are configured as coaxial arc-shaped; characterized in that, A third carbon film resistive layer (12) is disposed on the first carbon film resistive layer (22), and a fourth carbon film resistive layer (11) is disposed on the second carbon film resistive layer (21); a vertically oriented anisotropic conductive adhesive layer (20) is disposed on the first conductive metal circuit layer (16), the third carbon film resistive layer (12), the fourth carbon film resistive layer (11), and the fourth conductive metal circuit layer (19) in the area through which the brush (13) slides.

2. The high wear-resistant linear arc-shaped resistor sheet according to claim 1, characterized in that, The first conductive metal circuit layer (16), the second conductive metal circuit layer (17), the third conductive metal circuit layer (24), the fourth conductive metal circuit layer (19), the fifth conductive metal circuit layer (18), and the sixth conductive metal circuit layer (23) are all set as silver layers.

3. The high wear-resistant linear arc-shaped resistor sheet according to claim 1, characterized in that, The thickness of the first conductive metal circuit layer (16), the second conductive metal circuit layer (17), the third conductive metal circuit layer (24), the fourth conductive metal circuit layer (19), the fifth conductive metal circuit layer (18), and the sixth conductive metal circuit layer (23) is set to 8-12 μm.

4. The high wear-resistant linear arc-shaped resistor sheet according to claim 1, characterized in that, The thickness of the first carbon film resistive layer (22) and the second carbon film resistive layer (21) is set to 10-15 μm.

5. The high wear-resistant linear arc-shaped resistor sheet according to claim 1, characterized in that, The thickness of the third carbon film resistive layer (12) and the fourth carbon film resistive layer (11) is set to 16-24 μm.

6. The high wear-resistant linear arc-shaped resistor sheet according to claim 1, characterized in that, The thickness of the vertical anisotropic conductive adhesive layer (20) is set to 5-8 μm.

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