Igniter Resistor Fabrication Using Punched Alloy Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for fabricating resistors in igniters face challenges in controlling resistance due to difficulties in etching certain alloy materials, leading to uneven thickness and potential ignition failures or poor firing effects.
Innovation Solution
A method involving punching alloy components with specific shapes, such as dumbbell or S-shapes, to create resistors with uniform size and stable shape, using nickel-chromium alloy and surface mount technology on an aluminum oxide substrate, with electrodes made of nickel and tin, and optionally forming a protective layer and using an adhesive layer to ensure proper connection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etching is used to fabricate resistors from alloy materials, then the resistor shape can be formed, but the resistance cannot be controlled precisely due to uneven thickness
Solution Approach 1:
The patent replaces the chemical etching process with a mechanical punching process to form resistor components from alloy materials. The punching method uses a punching module with a punching cavity that mechanically cuts the alloy material according to the resistor shape, eliminating the need for chemical etching and achieving uniform thickness without the complexity of etching difficult-to-etch alloys.
2Manufacturing precision
If punching is used to fabricate resistors, then uniform size and stable shape can be achieved, but additional process steps are required
Solution Approach 1:
The patent combines multiple functions into the punching module: the punching cavity forms the resistor shape, the punching process simultaneously creates the narrow region and electrically connecting regions, and the module can be reused for consistent production. This integration reduces overall process complexity compared to separate steps for shaping, thinning, and assembling.
Solution Approach 2:
The punching module is designed in advance with the precise geometry of the resistor component, including the narrow region and electrically connecting regions. This preliminary design of the punching cavity ensures that each punched resistor component is formed with the correct dimensions and shape, eliminating the need for subsequent adjustment or correction steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the fabrication of resistors with consistent resistance and improved firing performance by controlling the size and shape of the channel portions, ensuring reliable ignition with desired time and energy.
Implementation Method 1
punching an alloy material to obtain a plurality of alloy components
Implementation Method 2
disposing an adhesive layer over the substrate before disposing the alloy components on the substrate
Implementation Method 3
Resistors in igniter are fused by subjecting electric current to pass through a narrow region of the resistors with a capacitor after charging, thereby achieving igniting
Data Source
AI summary
A method of fabricating resistors in igniter is provided. The method includes punching an alloy material to obtain a plurality of alloy components. The alloy components are disposed on a substrate, and electrodes are disposed on the substrate. Resistors in igniter are obtained by disposing electrodes on the substrate such that two electrically connecting regions of each alloy component are physically contacting and electrically connecting to the electrodes, respectively. The resulting resistors in igniter have uniform size and stable shape hence showing great ignition performance.