Patent Application
20210398717
The present invention relates to a noise-preventing resistor mounted on an ignition plug of an internal-combustion engine, for example, and a manufacturing method thereof.
An engine ignition device of gasoline engine automobiles is ignited by applying a high-voltage current to an ignition plug (spark plug) so as to discharge, thereby spark igniting a compressed gas mixture of gasoline and air within a cylinder. Since a voltage of 10 kV or greater is required for ignition through discharge, the gasoline engine car is provided with an ignition coil for boosting the battery voltage.
The ignition coil is configured by a coil main body made up of a primary coil, a secondary coil, a core (iron core) around which these coils are wound, and an IC chip for controlling ignition etc. housed in an insulation case; a spring (connection terminal on the spark plug side) connected to a spark plug, a tubular insulation case housing the spring, etc. The coil main body is filled with resin and sealed.
Such engine ignition device has a noise-preventing resistor arranged within a tower part between the coil main body part and the spring, for example, and the coil main body part and the spark plug are electrically connected via the noise-preventing resistor, so as to control high frequency noise generating at the time of engine ignition.
On the other hand, slight warping of cap terminals of the noise-preventing resistor may occur due to fluctuation in dimensions at the time of formation and/or caulking when fitting the cap terminals to the resistive element made of an insulative core, a resistance wire, and an insulative coating. In that case, contact between a high voltage output terminal and the spring may be unstable, possibly leading to conduction failure as a result.
It is also important to secure sufficient conduction between the resistive element and the cap terminals of the noise-preventing resistor. Patent Document 1 discloses a noise-preventing resistor including a wire wound resistor constituted by an insulative core, conductor coils, paired metal caps, and a resin coating member, wherein protrusions which are facing the inner periphery of the side surfaces of the metal caps and perpendicular (along axial direction Z) to the winding direction of the conductor coils, are formed in the side part inner circumferential surfaces of the metal caps.
The wire wound resistor disclosed in Patent Document 1 has the protrusions formed in the side part inner circumferential surfaces of the metal caps in order to secure electrical conduction between the metal caps and the conductor coils while preventing exposure of the conductor coils. In this wire wound resistor, when inserting the metal caps into the winding structure, the protrusions break the resin coating covering the conductor coils from the outer circumference side so that the metal caps make direct contact with the conductor coils.
With such a structured wire wound resistor, residue of the broken resin coating remains inside of and near the openings of the cap terminals, and may carbonize at the time of supplying power, leading to adverse effects on electrical performance of the resistor. Moreover, problems that the cap terminals end up opening due to repeated thermal expansion of the resin coating, causing a cap terminal to fall off and/or resin to get caught between a cap terminal and a conductor coil, and eventually leading to conduction failure, etc. are possible.
Furthermore, according to Patent Document 1, when the conductor coils are cut due to press-fitting of the protrusions, there is a possibility that ends of the conductor coils will stick out from the cap terminals, thereby causing a defect such as a short circuit due to the coils touching each other. There is also a problem that the cap terminals disclosed in Patent Document 1 are difficult to manufacture, leading to complicated manufacturing and processing.
In light of these problems, the present invention aims to provide a noise-preventing resistor preventing cap terminals from coming off, and securing conduction between the cap terminals and the resistance wire, and a manufacturing method thereof.
The present invention aims to resolve the above problems, and includes the following structure, for example, as means for achieving the above aim. That is, the present invention is a noise-preventing resistor, including a resistive element, which comprises an insulative core, a resistance wire wound around an outer circumferential surface of the core, and an insulative coating, which covers an outer circumferential surface of the core and that of the resistance wire; and paired cap terminals attached to either end of the resistive element. It further includes peeled regions provided by removing the insulative coating in a plurality of places of the outer circumferential surface covered by the cap terminals, resulting in exposing the resistance wire.
For example, it is characterized in that the peeled regions are regions made by cutting part of the insulative coating and part of the resistance wire including the upper part positioned underneath the insulative coating. It is characterized in that, for example, the peeled regions have any one of a form extending linearly in the axial direction of the resistive element while having a predetermined width, form extending diagonally in the axial direction, form extending in a zig zag form in the axis direction, or form in an island-like shape. It is further characterized in that one end parts of the peeled regions reach an axial edge of the core, and the other end parts are positioned inside of the cap terminals. It is further characterized in that the peeled regions are arranged nearly equidistant without facing each other in the radial direction when viewing the resistive element from the axial direction. It is further characterized in that the peeled regions have a form extending along the circumference of the resistive element while having a predetermined width. It is yet further characterized in that the resistance wire and the cap terminals are electrically conductive within the peeled regions.
The present invention is a manufacturing method of a noise-preventing resistor having paired cap terminals attached to either end. The manufacturing method is characterized by including the steps of: binding fibrous insulating material so as to form a long core; winding a resistance wire around an outer circumferential surface of the core; applying an insulative coating to outer circumferential surfaces of the core and the resistance wire; cutting the core around which the resistance wire is wound to a predetermined length so as to form a resistive element; removing the insulative coating from a plurality of places in regions of the outer circumferential surface of the resistive element covered by the cap terminals so as to form peeled regions exposing the resistance wire; and attaching the cap terminals to either end of the resistive element in which the peeled regions are formed.
For example, it is characterized in that the peeled regions are made by cutting part of the insulative coating and part of the resistance wire including the upper part positioned underneath the insulative coating. It is characterized in that, for example, the cutting is carried out from a predetermined position separated axially from an end surface of the resistive element toward the other end surface side. It is further characterized in that, for example, the peeled regions are made in a plurality of places is carried out simultaneously.
According to the present invention, cap terminals that have been press-fit into a wire-wound resistive element are prevented from coming off, and the resistance wire and the cap terminals reliably make contact so as to ensure stable conduction therebetween.
An embodiment according to the present invention is described in detail below with reference to accompanying drawings.
The noise-preventing resistor 10 illustrated in
The resistor 10 is a noise-preventing resistor mounted on an engine ignition device, for example, and functioning as a noise filter for effectively controlling radiation noise such as ignition noise generating at the time of engine ignition.
The resistance wire 7 is selected from metal wires such as, for example, a nickel-iron (Ni—Fe) wire, a nickel (Ni) wire, a chromium (Cr) wire, and a nickel-chromium (Ni—Cr) wire in accordance with the resistance value of the resistor. Wire diameter of the resistance wire 7 is approximately several tens of μm (30 to 60 μm), for example, and the wire is continuously wound around the core 5 at a narrow pitch. The metal wire is used as is for the resistance wire 7. However, a coated conducting wire having a resin coating applied on the metal wire surface may be used.
Core material resulting from bundling many fibers made of insulating material such as glass, ferrite, resin or alumina, for example, is used as the core 5. A glass fiber bundle is appropriate from the viewpoint of cost and high heat resistance. The glass fiber bundle is made up of multiple glass fibers, each fiber having a diameter of several to several tens of μm. Therefore, due to the shape of the core not being maintained but curving when transported in a long state before cutting, epoxy resin, silicon resin, etc. for example, is impregnated into the glass fiber core so as to heat cure and maintain the shape thereof.
Other than glass, material for the core may be fibers made of insulating material such as ferrite, resin or alumina, for example, bundled together and shaped using resin.
An insulative coating (resin coating) 6 made of resin is formed on the outer circumferential surface of the wire-wound resistive element 2. Here, epoxy resin, silicon resin, etc. is applied coating the outer circumferential surface of the core 5 around which the resistance wire 7 is wound. The insulative coating 6 has a role of preventing the resistance wire from springing back.
As illustrated in
That is, regions in which the insulative coating 6 remains and regions (peeled regions) in which the insulative coating 6 is removed so as to expose the resistance wire 7 exist in either end part of the outer circumferential surface of the wire-wound resistive element 2, thereby allowing the exposed resistance wire 7 to make contact with the cap terminals 3a and 3b, and ending up securing electrical connections.
The cap terminals 3a and 3b are made of a conductive metal such as iron, stainless steel, etc., and the surfaces thereof are plated with copper or nickel etc. Moreover, the cap terminals 3a and 3b have openings 4a and 4b, respectively, for attaching (fitting) at either end of the wire-wound resistive element 2, and are formed in bottomed cylindrical shapes. Here, a long metal pipe is cut to a predetermined length, or a metal plate is cut to a predetermined length and bent, for manufacturing the cap terminals 3a and 3b.
Formation of the cap terminals 3a and 3b in a cylindrical form ensures, for example, connection stability with the ignition coil main body, and easiness of processing such as manufacturing by cutting a long metal pipe to a predetermined length or cutting a metal plate to a predetermined length and bent.
Note that since the resin coating as an insulative coating has a role of securing the resistance wire 7 as described above, thickness of the coating is set just thick enough to conceal the resistance wire 7. Meanwhile, if the thickness of the resin coating is uneven, the insulative coating is assumed to also be cut by the openings 4a and 4b of the cap terminals at the time of press-fitting the cap terminals 3a and 3b. However, due to having the peeled regions, an effect that the unevenness in thickness of the insulative coating is within an allowable range can be expected.
Next, a manufacturing method of the noise-preventing resistor according to the embodiment is explained.
In Step S15, epoxy resin or silicon resin, for example, is coated on the outer circumferential surface of the core around which the resistance wire is wound as described above, dried and cured. Since the resin coating is for securing the resistance wire, thickness of the resin coating to be formed may be just thick enough to conceal the resistance wire, as described above. The applied resin coating is then cured.
In Step S17, a long resistive element that has the resistance wire wound around the outer circumferential surface and coated with resin is cut together with the resistance wire to a predetermined size using a cutter or the like. As a result, individual pieces of a wire-wound resistive element (resistor) are manufactured.
In Step S19, the peeled regions described above are formed. That is, part of the resin coating on the wire-wound resistive element surface is peeled off so as to expose the resistance wire. Here, the resin coating is peeled off using any one of the following methods.
(1) Cut the resin coating on the surface of the wire-wound resistive element and the upper part of the resistance wire using a cutter with a flat blade or round blade. At this time, cutting is performed from the axial inner side of the wire-wound resistive element outward (toward either end surface side). As a result, cut-off resin and residue of the resistance wire are not left on the surface of the wire-wound resistive element.
(2) Grind the resin coating on the surface of the wire-wound resistive element and the upper part of the resistance wire with a file.
(3) Scratch the resin coating on the surface of the wire-wound resistive element, and the upper part of the resistance wire using metal with a sharp point (may be a brush) so as to scrape them and expose the resistance wire.
In Step S21, a cap terminal is fit on either end of the wire-wound resistive element. For example, the cap terminals are mechanically pressed (press fitted) in the axial direction so as to fix them to the end parts of the wire-wound resistive element, with the openings of the cap terminals facing the axial end parts of the wire-wound resistive element. As a result, electric conduction between the resistance wire and the cap terminals may be ensured in the already-formed peeled regions.
In Step S23, examinations, such as appearance image inspection and resistance value measurement of the resistor manufactured in the steps described above, are performed. Note that the resin curing method of Step S15 described above may be any one of curing at room temperature, heat curing (at 100 to 200° C., for example), or curing through ultraviolet light radiation.
A machining device 30 illustrated in
The cutters 39a to 39d and 39e to 39h are arranged radially along the outer circumference of the axis 41 on a plane perpendicular to the axis 41. The machining device 30 is structured such that only the cutters are replaceable when abrasion and/or damage occurs to these cutters.
In Step S31 of
In Step S35, the holder (support) 33 with the chucks 37a to 37d in an open state and the holder (support) 35 with the chucks 37e to 37h in an open state are moved in the directions indicated by arrows in
The predetermined positions where the wire-wound resistive element 2 is clamped from either end in this manner are starting points (ends) of the peeled regions for exposing the resistance wire. At the same time, the distance between electrodes is determined roughly by these predetermined positions.
Resistance value of the noise-preventing resistor according to the embodiment is determined according to positions (more specifically, mostly inward portions of the peeled regions in the axial direction) where the resistance wire conducts with the cap terminals. That is, while the conventional method of conducting and breaking the insulative coating has problems of varied conduction positions and unstable resistance values, resistance values of the resistor may be stabilized by determining the conduction positions ahead of time using non-coated regions (peeled regions) as in the embodiment.
In Step S37, the holders (supports) 33 and 35 are moved in directions indicated by arrows in
Note that while the machining device 30 illustrated in
Moreover, the peeled regions are preferably formed equidistant in multiple places on the circumferential surface of the wire-wound resistive element 2, and formed at positions such that they are not facing each other when viewed from the axial direction.
In this manner, cutting part of the insulative coating and part of the resistance wire including the upper part so as to make them flat reliably makes the cap terminals and the resistance wire in that region have surface contact, thereby securing mutual electrical conduction. Moreover, as described later, the cutter is positioned such that the upper part of the resistance wire is cut, thereby allowing formation of a peeled region by reliably cutting the insulative coating, even if there is fluctuation in thickness of the insulative coating and core diameter.
The peeled region 15 is formed linearly outward from the axial direction inner side of the wire-wound resistive element 2 as illustrated in
It is assumed that even if the position of an end part C of the peeled region 15 is near the opening 4 of the cap terminal 3, arc discharge etc. generates between the resistance wire and the cap terminal. Therefore, distance between the end part C of the peeled region 15 and the opening 4 of the cap terminal 3, namely difference distance: L2−L1, where L2 denotes depth of the cap terminal and L1 denotes cut length as shown in
It is confirmed that even if up to approximately 50% of the resistance wire including the upper part is cut radially within the peeled region of the noise-preventing resistor according to the embodiment, resistance property is not influenced. As a result, the case of cutting 50% of the resistance wire 7 using the cutter 39 is considered. If wire diameter ((Dr−Dg)/2) of the resistance wire 7 of
Note that while a round blade fitted with a curve of the resistor diameter Dr that changes according to the wire diameter of the resistance wire 7 may be used as the cutter 39, a flat blade unaffected by the wire diameter may be used from the viewpoint of cost.
As described above, the noise-preventing resistor according to the embodiment has a structure including: a cap terminal, which is attached to either end part of a wire-wound resistive element made by winding a resistance wire around the outer circumferential surface of a core, and peeled regions, which are provided by cutting a part of an insulative coating (resin coating) covering the resistance wire and a part of the resistance wire underneath the coating, so as to expose the resistance wire.
Since such peeled regions are provided, the cap terminals may be smoothly press-fit in the wire-wound resistive element, preventing the cap terminals from coming off without deformation even after fitting. Moreover, the core is not damaged when press-fitting the cap terminals, nor is strength against compression load applied axially on the wire-wound resistive element lost. As a result, the resistance wire and the cap terminals will make contact reliably in the peeled regions, ensuring stable electric conduction between the resistance wire and the cap terminals.
Furthermore, since the regions that are covered by the cap terminals on the outer circumferential surface of the wire-wound resistive element are used as peeled regions, contact portions of the cap terminals with the resistance wire will be identified uniquely and easily, making it possible to stabilize the resistance value of the noise-preventing resistor.
Yet further, the peeled regions formed through cutting until reaching either edge of the wire-wound resistive element will prevent the resin coating from being pushed into the openings of the cap terminals when press-fitting the cap terminals, and will also stabilize electrical conduction between the resistance wire and the cap terminals even if the slightest difference in level generates between insulative coated regions and non-coated regions, that is, the peeled regions.
In addition, since the peeled regions have a specific form and size that fit inside the attached cap terminals, the exposed resistance wire in the peeled regions exists inside of the cap terminals, thereby preventing exposure at the openings, resulting in preventing deterioration of the noise-preventing resistor due to rust etc. during use.
The present invention is not limited to the embodiment described above, and various modifications are possible. According to the embodiment described above, the peeled regions are provided extending linearly in the axial direction of the wire-wound resistive element. However, they are not limited thereto. For example,
Note that the peeled region 65d may have a form circling the end part surface of the wire-wound resistive element 2, or may have an orbiting form with intermittent breaks. Alternatively, while it is omitted from the drawings, the peeled region may have a form extending in a spiral form along the circumference of the wire-wound resistive element.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-208471 | Nov 2018 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/041554 | 10/23/2019 | WO | 00 |
