Method for manufacturing a resistive element and resistive element obtained thereby

Abstract

To provide a manufacturing method of a resistive element capable of bonding a resistor and a terminal in a satisfactory state.SOLUTION: A first metal member 10 consisting of a copper-manganese-nickel alloy for general electric resistance and a second metal member 20 consisting of aluminum are prepared. The first metal member 10 and the second metal member 20 are adjacently disposed without a gap. In a state where a rotary tool 30 is inserted to the second metal member 20 in such a manner that an outer peripheral edge of the rotary tool 30 is substantially matched with a boundary 3 of the first metal member 10 and the second metal member 20, the rotary tool 30 is moved along the boundary 3, thereby providing a resistive element 1 in which the first metal member 10 and the second metal member 20 are bonded by frictional stir bonding, the first metal member 10 is defined as a resistive element main body 11, the second metal member 20 is defined as an electrode part 21 and the resistive element main body 11 and the electrode part 21 are bonded via an AL2Cu compound layer.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a resistance element that can be used, for example, in a shunt resistor or the like, and a resistance element obtained thereby.

Background Art

[0002] In recent years, in electric vehicles and smart meters that have begun to spread, a large current of several tens of A to several hundreds of A may flow. Such a large current can be measured at high speed, accurately, and inexpensively by a shunt resistor that converts the current into a voltage and measures it. Therefore, with the spread of electric vehicles and smart meters, the demand for shunt resistors is increasing.

[0003] For such shunt resistors, manganin (registered trademark), which has low temperature dependence of resistance value, is used as a resistance element. Terminals made of a metal such as copper are welded to the resistance element to form a resistor.

[0004] As prior art documents related to such a resistance element and its manufacturing method, the applicant is aware of the following Patent Documents 1 and 2.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

[0006] The above Patent Document 1 discloses a technique related to a resistor, and has the following description. 〔0017〕 In the above configuration, the resistor 11 is composed of a metal plate such as copper nickel, nichrome, or manganin. Further, the metal terminal 12 is formed in a plate shape from a metal having a higher electrical conductivity than the resistor 11, such as gold, silver, copper, or aluminum, and this plate-shaped metal terminal 12 is formed by being bent into a U shape so as to sandwich both ends of the resistor 11. And also, this metal terminal 12 is configured to be electrically connected to at least the upper and lower surfaces of the resistor 11.

[0007] The above Patent Document 2 discloses a technique related to a method for manufacturing a shunt resistor, and has the following description. 〔0002〕 It is known to join a long plate-shaped metal plate serving as an electrode to a long plate-shaped resistor, and cut out a predetermined shape from this joined plate material (welded plate material) to form a resistor. In this case, the resistor is usually a manganin metal alloy such as Cu (copper), Mn (manganese), or Ni (nickel), and the terminal plate is usually a copper plate. As a means for welding such dissimilar metals, a method using an electron beam is known. This method using an electron beam requires a vacuum chamber and a vacuum device because it is necessary to irradiate the joint (butting portion between the resistor and the terminal plate) with an electron beam in a vacuum, resulting in a large-sized and expensive welding device, and also having a problem of poor welding processing efficiency. 〔0003〕 Therefore, it has been proposed to use a laser beam for welding instead of an electron beam. Patent Document 1 discloses a method of irradiating a butting end face of a long plate-shaped resistor and a terminal plate with a laser beam from the outside to melt-join the contact portion between the resistor and the terminal plate. Among this type of resistors, so-called shunt resistors have been widely used in recent years. This shunt resistor is widely used for detecting current in electronic devices such as automobiles, etc., and in this case, it is desired that the resistance value is small and it can withstand a large current (large rated power).

Disclosure of the Invention

Problems to be Solved by the Invention

[0008] Patent Document 1 discloses a resistor formed by bending it into a U shape so as to sandwich metal terminals 12 at both ends of a resistor body 11. It is described that manganin (registered trademark) is used as the resistor body 11, and it is described that copper or aluminum is used as the metal constituting the metal terminal 12.

[0009] Patent Document 2 discloses a method for manufacturing a shunt resistor by welding a copper plate to a resistor body made of a manganin metal alloy. As means for performing the above welding, methods using an electron beam and methods using a laser beam are described.

[0010] As a configuration of a resistor, it is common to combine a resistor body of manganin (registered trademark) with a copper metal terminal. This is because a resistor body combining manganin (registered trademark) and copper has merits such as a very small temperature coefficient of resistance at normal temperature, little secular change in resistance value and temperature coefficient of resistance, small thermoelectric power against copper, ease of rolling and fine wire processing, and ease of brazing and soldering. On the other hand, demerits such as poor corrosion resistance, slight processing affecting the characteristics, non-linearity of the temperature coefficient of resistance near normal temperature, and easy generation of a deteriorated layer on the surface due to heating are known.

[0011] Also, in a resistor as described above, the joining of manganin (registered trademark) and copper was mainly by electron beam welding, but electron beam welding requires a vacuum environment, and although laser beam welding has also been put into practical use, there is still a problem that the equipment is large and expensive.

[0012] Patent Document 1 describes using aluminum as the metal terminal 12, but it mechanically connects by sandwiching the resistor body 11 with the U-shaped bent metal terminal 12. For this reason, structural defects are inevitable at the joining interface between the metal terminal 12 and the resistor body 11, and there is a risk that various characteristics of the resistor body as described above cannot be obtained.

[0013] The present invention has been made for the purpose of solving the above problems. Provided are a method for manufacturing a resistive element in which a resistor and a metal terminal can be joined in an extremely good state with few defects, and a resistive element obtained thereby.

Means for Solving the Problems

[0014] In order to achieve the above object, the method for manufacturing a resistive element according to claim 1 employs the following configuration. Prepare a first metal member made of a copper-manganese-nickel alloy for general electrical resistance and a second metal member made of aluminum, Arrange the first metal member and the second metal member adjacent to each other so that there is substantially no gap therebetween, With the rotary tool inserted into the second metal member such that the outer peripheral edge of the rotary tool substantially coincides with the boundary between the first metal member and the second metal member, move the rotary tool along the boundary, Se Join the first metal member and the second metal member by friction stir welding When performing, by causing plastic flow only in the second metal member , Use the first metal member as the resistive element body and the second metal member as the electrode portion, and obtain a resistive element in which the resistive element body and the electrode portion are joined via an Al2Cu compound layer. Without mixing the copper-manganese-nickel alloy and the aluminum, in a film-like

[0015] The method for manufacturing a resistive element according to claim 2 employs the following configuration in addition to the configuration according to claim 1. Arrange an auxiliary metal material that at least covers the region along the boundary between the first metal member and the second metal member, Perform the friction stir welding by inserting the rotary tool into the second metal member in the region where the auxiliary metal material is present.

[0016] The method for manufacturing a resistive element according to claim 3 employs the following configuration in addition to the configuration according to claim 2. Arrange the auxiliary metal material above the first metal member and the second metal member that are arranged adjacent to each other, Perform the friction stir welding by inserting the rotary tool into the second metal member from above the auxiliary metal material.

[0017] The manufacturing method of the resistive element according to claim 4 adopted the following configuration in addition to the configuration according to claim 2 or 3. The auxiliary metal material is disposed below the adjacent first metal member and second metal member, and the friction stir welding is performed by inserting the rotary tool from above the second metal member to the auxiliary metal material through the second metal member.

[0018] The manufacturing method of the resistive element according to claim 5 adopted the following configuration in addition to the configuration according to any one of claims 2 to 4. The auxiliary metal material is made of substantially the same aluminum as the second metal member.

[0019] The manufacturing method of the resistive element according to claim 6 adopted the following configuration in addition to the configuration according to any one of claims 1 to 5. The copper-manganese-nickel alloy is Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, balance: Cu, and Cu + Ni + Mn is 98% by weight or more.

[0020] The resistive element according to claim 7 adopted the following configuration in order to achieve the above object. A resistive element body made of a copper-manganese-nickel alloy for general electric resistance, and an electrode portion made of aluminum joined to the resistive element body, wherein the resistive element body and the electrode portion The copper-manganese-nickel alloy and the aluminum are not mixed, in a film-like are joined via an Al2Cu compound layer.

[0021] The resistive element according to claim 8 adopted the following configuration in addition to the configuration according to claim 8. The copper-manganese-nickel alloy is Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, balance: Cu, and Cu + Ni + Mn is 98% by weight or more.

Advantages of the Invention

[0022] The method for manufacturing a resistive element according to claim 1 first prepares a first metal member made of a copper-manganese-nickel alloy for general electric resistance and a second metal member made of aluminum. Next, the first metal member and the second metal member are arranged adjacent to each other so that there is substantially no gap. Then, with the outer peripheral edge of the rotary tool substantially coinciding with the boundary between the first metal member and the second metal member, the rotary tool is inserted into the second metal member and moved along the boundary, thereby joining the first metal member and the second metal member by friction stir welding. Thereby, a resistive element is obtained in which the first metal member serves as a resistive element body and the second metal member serves as an electrode portion. By the friction stir welding, plastic flow occurs in the second metal member and adheres to the boundary with the first metal member, and the first metal member and the second metal member are joined. At this time, plastic flow occurs only in the second metal member, and almost no plastic flow occurs in the first metal member. Further, since the resistive element body and the electrode portion are joined via an Al2Cu compound layer, a very good joining state with few defects such as mixing of two types of metals and voids can be obtained. That is, by generating the Al2Cu compound layer, aluminum and copper are metallically bonded. Moreover, the Al2Cu compound layer is formed in a film shape at the joining interface without mixing of two types of metals, and the electrical resistance value of the joined portion is stabilized. Furthermore, if the thickness of the Al2Cu compound layer is made as thin as about 1 micron, the joined portion is less likely to break brittlely.

[0023] The method for manufacturing a resistive element according to claim 2 arranges an auxiliary metal material that at least covers a region along the boundary between the first metal member and the second metal member. Then, the friction stir welding is performed by inserting the rotary tool into the second metal member in a region where the auxiliary metal material exists. By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material is added to the plastic flow to supplement the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with few defects such as the mixture of two types of metals and voids can be obtained. Also, even if the first metal member and the second metal member are thin plates (for example, about 2 mm or less), a good bonding state can be obtained by the auxiliary metal material holding the first metal member and the second metal member.

[0024] The method for manufacturing a resistance element according to claim 3 arranges the auxiliary metal material above the first metal member and the second metal member arranged adjacent to each other. Then, the friction stir welding is performed by inserting the rotary tool into the second metal member from above the auxiliary metal material. By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material is added to the plastic flow to supplement the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with few defects such as the mixture of two types of metals and voids can be obtained. Also, even if the first metal member and the second metal member are thin plates (for example, about 2 mm or less), a good bonding state can be obtained by the auxiliary metal material holding the first metal member and the second metal member.

[0025] The method for manufacturing a resistance element according to claim 4 arranges the auxiliary metal material below the first metal member and the second metal member arranged adjacent to each other. Then, the friction stir welding is performed by inserting the rotary tool into the second metal member from above the second metal member until it reaches the auxiliary metal material. By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material is added to the plastic flow to supplement the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with few defects such as the mixture of two types of metals and voids can be obtained. Further, even if the first metal member and the second metal member are thin plates (for example, about 2 mm or less), a good bonding state can be obtained by the auxiliary metal material holding the first metal member and the second metal member.

[0026] The method for manufacturing a resistance element according to claim 5 uses, as the auxiliary metal material, aluminum substantially the same as the second metal member. By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material is added to the plastic flow to supplement the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with few defects such as the mixture of two types of metals and voids can be obtained.

[0027] The method for manufacturing a resistance element according to claim 6 has the copper-manganese-nickel alloy containing Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, and the balance: Cu, with Cu + Ni + Mn being 98% by weight or more. For this reason, the resistance element can be constituted by a copper-manganese-nickel alloy circulating in the market, and a product of a certain quality can be obtained at low cost.

[0028] The resistive element according to claim 7 includes a resistive element body made of a copper-manganese-nickel alloy for general electric resistance, and an electrode portion made of aluminum joined to the resistive element body. The resistive element body and the electrode portion are joined via an Al2Cu compound layer. Therefore, an extremely good joining state with few defects such as a mixture of two types of metals and voids can be obtained. That is, by generating the Al2Cu compound layer, aluminum and copper are metallically bonded. Moreover, without mixing two types of metals, the Al2Cu compound layer is formed in a film shape at the joining interface, and the electrical resistance value of the joined portion is stabilized. Further, if the thickness of the Al2Cu compound layer is made as thin as about 1 micron, the joined portion is less likely to be brittlely fractured.

[0029] In the resistive element according to claim 8, the copper-manganese-nickel alloy has Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, and the balance: Cu, and Cu + Ni + Mn is 98% by weight or more. Therefore, the resistive element can be formed of a copper-manganese-nickel alloy that circulates in the market, and a product of a certain quality can be obtained at low cost.

Brief Description of the Drawings

[0030]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0031] Next, embodiments for carrying out the present invention will be described.

[0032] 〔Process〕 FIG. 1 is a diagram for explaining a first embodiment of a method for manufacturing a resistive element according to the present invention. (A) shows the state as viewed from the front, and (B) shows the state as viewed from above.

[0033] In this manufacturing method, first, a first metal member 10 made of a copper-manganese-nickel alloy for general electrical resistance and a second metal member 20 made of aluminum are prepared.

[0034] The copper-manganese-nickel alloy constituting the first metal member 10 has Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, and the balance: Cu, and those with Cu + Ni + Mn of 98% by weight or more can preferably be used. For example, those defined as copper manganese GCM44 for general electrical resistance in JIS C 2532 or those distributed as manganin (registered trademark) can be used.

[0035] As the aluminum constituting the first metal member 10, various aluminum-based materials (including alloys) used as terminal materials for electrical connection can be used.

[0036] In the illustrated example, both the first metal member 10 and the second metal member 20 have a quadrangular shape (square or rectangle).

[0037] Next, the first metal member 10 and the second metal member 20 are arranged adjacent to each other so that there is substantially no gap. In the illustrated example, the first metal member 10 and the second metal member 20, which are each a quadrangular plate, are placed on a base 40, and their sides are butted against each other. A boundary 3 is formed at the butted portion of the first metal member 10 and the second metal member 20.

[0038] The base 40 is a quadrangle slightly larger than the state where the first metal member 10 and the second metal member 20 are butted against each other. In this example, a gap 41 is formed in the base 40 along the boundary 3 of the butted first metal member 10 and second metal member 20.

[0039] Next, with the outer peripheral edge of the rotary tool 30 substantially coinciding with the boundary 3 between the first metal member 10 and the second metal member 20, while the rotary tool 30 is inserted into the second metal member 20, the rotary tool 30 is moved along the boundary 3 to join the first metal member 10 and the second metal member 20 by friction stir welding.

[0040] FIG. 2 shows a state in which a pair of the second metal members 20 are joined to both sides of the first metal member 10 by the above-described friction stir welding. (A) is a plan view, and (B) is a view seen from the front.

[0041] In this way, the resistance element 1 can be obtained with the first metal member 10 as the resistance element body 11 and the second metal member 20 as the electrode portion 21.

[0042] As described above, the first metal member 10 constituting the resistance element body 11 is made of a copper-manganese-nickel alloy for general electrical resistance. Preferably, as the copper-manganese-nickel alloy, Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, balance: Cu, and a material in which Cu + Ni + Mn is 98% by weight or more can be used. The second metal member 20 constituting the electrode portion 21 is aluminum. Then, by the action of friction stir, copper in the first metal member 10 (copper-manganese-nickel alloy) reacts with the second metal member 20 (aluminum), and a compound layer is formed at the interface between the two. Thereby, the resistance element body 11 and the electrode portion 21 are joined via the Al2Cu compound layer.

[0043] 〔Effect of the First Embodiment〕 The manufacturing method of the resistance element according to the first embodiment first prepares a first metal member 10 made of a copper-manganese-nickel alloy for general electric resistance and a second metal member 20 made of aluminum. Next, the first metal member 10 and the second metal member 20 are arranged adjacent to each other so that there is substantially no gap. Next, with the outer peripheral edge of the rotary tool 30 substantially coinciding with the boundary 3 between the first metal member 10 and the second metal member 20, the rotary tool 30 is inserted into the second metal member 20, and the rotary tool 30 is moved along the boundary 3, thereby joining the first metal member 10 and the second metal member 20 by friction stir welding. Thereby, a resistance element is obtained in which the first metal member 10 serves as a resistance element body 11 and the second metal member 20 serves as an electrode portion 21. By the friction stir welding, plastic flow occurs in the second metal member 20 and adheres to the boundary 3 with the first metal member 10, and the first metal member 10 and the second metal member 20 are joined. At this time, plastic flow occurs only in the second metal member 20, and hardly any plastic flow occurs in the first metal member 10. In addition, since the resistance element body 11 and the electrode portion 21 are joined via an Al2Cu compound layer, an extremely good joining state with few defects such as mixing of two types of metals and voids can be obtained. That is, by generating the Al2Cu compound layer, aluminum and copper are metallically bonded. Moreover, the Al2Cu compound layer is formed in a film shape at the joining interface without mixing of two types of metals, and the electrical resistance value of the joining portion is stabilized. Furthermore, if the thickness of the Al2Cu compound layer is made as thin as about 1 micron, the joining portion is less likely to break brittlely.

[0044] In the manufacturing method of the resistance element according to the first embodiment, in the copper-manganese-nickel alloy, Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, the balance: Cu, and Cu + Ni + Mn is 98% by weight or more. Therefore, the resistance element can be formed of a copper-manganese-nickel alloy that circulates in the market, and a product of a certain quality can be obtained at low cost.

[0045] The resistance element of the first embodiment includes a resistance element body 11 made of a copper-manganese-nickel alloy for general electrical resistance, and an electrode portion 21 made of aluminum joined to the resistance element body 11. The resistance element body 11 and the electrode portion 21 are joined via an Al2Cu compound layer. Therefore, an extremely good joint state with few defects such as a mixture of two types of metals and voids can be obtained. That is, by forming the Al2Cu compound layer, aluminum and copper are metallically bonded. Moreover, without mixing two types of metals, the Al2Cu compound layer is formed in a film shape at the joint interface, and the electrical resistance value of the joint portion is stabilized. Further, if the thickness of the Al2Cu compound layer is made as thin as about 1 micron, the joint portion is less likely to be brittlely fractured.

[0046] In the resistance element of the first embodiment, the copper-manganese-nickel alloy has Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, and the balance: Cu, and Cu + Ni + Mn is 98% by weight or more. Therefore, the resistance element can be formed of a copper-manganese-nickel alloy that circulates in the market, and a product of a certain quality can be obtained at low cost.

[0047] FIG. 3 is a diagram for explaining a second embodiment of the method for manufacturing the resistance element of the present invention. (A) is a first example, (B) is a second example, and (C) is a third example.

[0048] In the second embodiment, auxiliary metal materials 50A / 50B are arranged to cover at least a region along the boundary 3 between the first metal member 10 and the second metal member 20. Then, the friction stir welding is performed by inserting the rotary tool 30 into the second metal member 20 in a region where the auxiliary metal materials 50A / 50B are present.

[0049] By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material is added to the plastic flow to compensate for the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good joint state with few defects such as a mixture of two types of metals and voids can be obtained.

[0050] In the second embodiment, the auxiliary metal materials 50A / 50B can be made of substantially the same aluminum as the second metal member 20.

[0051] By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material is added to the plastic flow to compensate for the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with less mixing of two types of metals and fewer defects such as voids can be obtained.

[0052] FIG. 3(A) shows a first example of the second embodiment.

[0053] In this example, the auxiliary metal material 50A is disposed above the first metal member 10 and the second metal member 20 which are adjacently arranged. Also, the auxiliary metal material 50B is disposed below the first metal member 10 and the second metal member 20. The lower auxiliary metal material 50B is fitted into a groove 42 formed in the base 40A. Then, the rotary tool 30 is inserted into the second metal member 20 from above the auxiliary metal material 50A to the auxiliary metal material 50B to perform the friction stir welding.

[0054] FIG. 3(B) shows a second example of the second embodiment.

[0055] In this example, the auxiliary metal material 50A is disposed above the first metal member 10 and the second metal member 20 which are adjacently arranged, and the friction stir welding is performed by inserting the rotary tool 30 into the second metal member 20 from above the auxiliary metal material 50A.

[0056] FIG. 3(C) shows a third example of the second embodiment.

[0057] In this example, the auxiliary metal material 50B is disposed below the adjacent first metal member 10 and the second metal member 20, and the friction stir welding is performed by inserting the rotary tool 30 into the second metal member 20 from above the second metal member 20 to the auxiliary metal material 50B.

[0058] 〔Effects of the Second Embodiment〕 In the method for manufacturing a resistance element according to the second embodiment, an auxiliary metal material 50A / 50B that at least covers a region along the boundary 3 between the first metal member 10 and the second metal member 20 is disposed. Then, the friction stir welding is performed by inserting the rotary tool 30 into the second metal member 20 in a region where the auxiliary metal material 50A / 50B exists. By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material 50A / 50B participates in the plastic flow to compensate for the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with few defects such as mixing of two types of metals and voids can be obtained. Also, even if the first metal member 10 and the second metal member 20 are thin plates (for example, about 2 mm or less), a good bonding state can be obtained by the auxiliary metal material 50A / 50B holding the first metal member 10 and the second metal member 20.

[0059] In the method for manufacturing a resistance element according to the second embodiment, the auxiliary metal material 50A / 50B is made of substantially the same aluminum as the second metal member 20. By doing so, even if the material scatters due to intense plastic flow, the auxiliary metal material 50A / 50B participates in the plastic flow to compensate for the material, and as a result, the generation of voids can be significantly reduced. Therefore, an extremely good bonding state with few defects such as mixing of two types of metals and voids can be obtained.

Example

[0060] FIG. 4 shows a cross-sectional micrograph of the resistance element 1 of the example.

[0061] The resistance element 1 of the above embodiment was obtained under the following conditions. ▽ First metal member 10: Copper-manganese-nickel alloy for general electric resistance (Mn: 10 to 13 wt%, Ni: 1 to 4 wt%, balance: Cu, where Cu + Ni + Mn is 98 wt% or more) (plate thickness 3 mm) ▽ Second metal member 20: Aluminum (plate thickness 3 mm) ▽ Friction stir welding: Rotating tool diameter: 6 mm Rotation speed: 2000 rpm Travel speed: 200 mm / min Auxiliary metal material: Aluminum

[0062] The two photos have different magnifications. In either photo, the phase visible on the left side of the screen is the copper-manganese-nickel alloy, and the phase visible on the right side of the screen is aluminum.

[0063] As can be seen from the figure, by joining the first metal member 10 (resistance element body 11) and the second metal member 20 (electrode portion 21) by the above-described friction stir welding, in the resistance element 1, the resistance element body 11 and the electrode portion 21 are joined via an Al2Cu compound layer. The thickness of the Al2Cu compound layer was about 1 micron, which was thin.

[0064] 〔Modification〕 Although the above has described particularly preferred embodiments of the present invention, the present invention is not intended to be limited to the illustrated embodiments, and can be implemented in various forms, and the present invention is intended to include various modifications.

Explanation of Signs

[0065] 1: Resistance element 3: Boundary 10: First metal member 11: Resistance element body 20: Second metal member 21: Electrode portion 30: Rotating tool 40: Base 41: Gap 42: Groove 50A: Auxiliary metal material 50B: Auxiliary metal material

Claims

1. Prepare a first metal member made of a copper-manganese-nickel alloy for general electric resistance and a second metal member made of aluminum, Arrange the first metal member and the second metal member adjacent to each other so that there is substantially no gap therebetween, With the rotary tool inserted into the second metal member, move the rotary tool along the boundary while the outer peripheral edge of the rotary tool substantially coincides with the boundary between the first metal member and the second metal member, and when joining the first metal member and the second metal member by friction stir welding, cause plastic flow only in the second metal member, Using the first metal member as the resistor element body, the second metal member as the electrode portion, and without mixing the copper-manganese-nickel alloy and the aluminum, a resistor element is obtained in which the resistor element body and the electrode portion are joined via a film-like AL ２ Cu compound layer A method for manufacturing a resistance element, characterized by the above.

2. Arrange an auxiliary metal material that at least covers a region along the boundary between the first metal member and the second metal member, Perform the friction stir welding by inserting the rotary tool into the second metal member in a region where the auxiliary metal material is present. The method for manufacturing a resistance element according to Claim 1.

3. Arrange the auxiliary metal material above the first metal member and the second metal member that are arranged adjacent to each other, Perform the friction stir welding by inserting the rotary tool into the second metal member from above the auxiliary metal material. The method for manufacturing a resistance element according to Claim 2.

4. Arrange the auxiliary metal material below the first metal member and the second metal member that are arranged adjacent to each other, Perform the friction stir welding by inserting the rotary tool into the second metal member from above the second metal member to the auxiliary metal material. The method for manufacturing a resistance element according to Claim 2 or 3.

5. Use aluminum that is substantially the same as the second metal member as the auxiliary metal material. The method for manufacturing a resistance element according to any one of Claims 2 to 4.

6. The copper-manganese-nickel alloy contains Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, and the balance: Cu, and Cu + Ni + Mn is 98% by weight or more. The method for manufacturing a resistance element according to any one of Claims 1 to 5.

7. A resistance element body made of a copper-manganese-nickel alloy for general electric resistance, And an electrode portion made of aluminum joined to the resistance element body. The resistance element body and the electrode portion are joined via a film-like Al ２ Cu compound layer in which the copper-manganese-nickel alloy and the aluminum are not mixed ２ together A resistance element, characterized by the above.

8. The copper-manganese-nickel alloy contains Mn: 10 to 13% by weight, Ni: 1 to 4% by weight, and the balance: Cu, and Cu + Ni + Mn is 98% by weight or more. The resistance element according to Claim 7.

Images