Resistor, in particular low-resistance current measuring resistor

• US 10,161,966 B2
• Filed: 07/22/2015
• Issued: 12/25/2018
• Est. Priority Date: 08/01/2014
• Status: Active Grant

• Current Assignee: Isabellenhuette Heusler GmbH & Co. KG
• Original Assignee: Isabellenhuette Heusler GmbH & Co. KG
• Inventors: Hetzler, Ullrich
• Primary Examiner(s): Mayo, III, William H
• Assistant Examiner(s): Robinson, Krystal
• Application Number:
  US15/329,084
• Publication Number:
  US 20170212148A1
• Time in Patent Office: 1,252 Days
• Field of Search: 324126
• CPC Class Codes: G01R 1/203 Resistors used for electric measuring, e.g. decade resistors standards, resistors for comparators, series resistors, shunts resistors in general H01C; microwave or radiowave terminations H01P1/26; coupling devices H01R
• CPC Class Codes: H01C 1/14 Terminals or tapping points or electrodes specially adapted for resistors in general H01R; Arrangements of terminals or tapping points or electrodes on resistors
• CPC Class Codes: H02G 5/02 Open installations
• CPC Class Codes: H05K 1/0306 Inorganic insulating substrates, e.g. ceramic, glass
• CPC Class Codes: H05K 1/111 Pads for surface mounting, e.g. lay-out
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 2201/10022 Non-printed resistor
• CPC Class Codes: H05K 2201/10151 Sensor

Abstract

The invention relates to a U-shaped resistor (1), in particular a low-resistance current-measuring resistor (1), comprising a first connection part (2) made of a conductive material having a first current contact surface for conducting an electrical current (I) into the resistor (1), and comprising a second connection part (3) made of a conductive material having a second current contact surface for conducting the current (I) out of the resistor (1), as well as comprising a resistor element (4) made of a resistor material, wherein the resistor element (4) is arranged in the direction of current flow between the first connection part (2) and the second connection part (3), such that the electrical current (I) flows through the electrical resistor (1). The current (I) perpendicularly enters or leaves the connections parts (2, 3) via their outer surfaces. In addition, the voltage taps are attached to the inner side of the U-shaped resistor (1), and contact the connection parts (2, 3) close to the transition to the resistor element (4).

Claims

1. A resistor comprising

a) a first connection part comprising a conductive material for conducting an electric current into the resistor,

b) a second connection part comprising a conductive material for conducting the electric current out of the resistor, wherein the first connection part and the second connection part are collectively referred to hereinafter as connection parts,

c) a resistor element comprising a resistive material, the resistor element being arranged in a direction of current flow between the first connection part and the second connection part so that the electric current flows through the resistor element, and

d) several voltage taps which electrically contact the connection parts and measure a voltage drop across the resistor element,

e) wherein the connection parts have a really extensive current contact surfaces to conduct the current in and out, and

f) at least one part of the resistor is essentially U-shaped in cross-section, and

g) the voltage taps are attached on an inner side of the connection parts, and

h) the current contact surfaces are attached on an outer side of the connection parts, and

i) the connection parts enclose an inner space, and

j) at least one part of a measurement device is arranged in the inner space, the measurement device being installed to measure the voltage drop across the resistor element.

2. The resistor according to claim 1, wherein the U-shaped part of the resistor has limbs that are formed by the connection parts and a base that is formed by the resistor element.

3. The resistor according to claim 2, wherein the current contact surfaces of the connection parts are essentially arranged as two contact surfaces parallel and spaced apart from each other.

4. The resistor according to claim 1, wherein the connection parts are each contacted by a plurality of pairs of voltage taps, which are arranged adjacently in the direction of current flow and distributed across a width of the connection parts.

5. The resistor according to claim 4, wherein the voltage taps are connected via balancing resistors to a signal output, the balancing resistors compensating asymmetries in a current density in the resistor element through appropriately adjusted resistance values.

6. The resistor according to claim 1, wherein

a) the measurement device comprises a printed circuit board which has soldering support surfaces to mechanically stabilize the resistor, and

b) the printed circuit board has connection pads which as voltage taps electrically contact the connection parts to measure the voltage drop across the resistor element, and

c) the printed circuit board is multilayered, the connection pads and the soldering support surfaces being arranged on outer layers of the printed circuit board, and

d) the connection pads of the printed circuit board for the voltage taps on the outer layers of the printed circuit board are connected by through-holes to striplines on an inner layer of the printed circuit board, and

e) the striplines run over each other on opposite-lying sides of the inner layer under cover, and

f) the printed circuit board is connected to the connection parts by one of the following connection types:

f1) a soldered connection,

f2) a sintered connection,

f3) a crimped connection, or

f4) an adhesive connection with an electrically conductive adhesive.

7. The resistor according to claim 6, wherein the printed circuit board is rigid.

8. The resistor according to claim 6, wherein the printed circuit board is flexible.

9. The resistor according to claim 6, wherein the printed circuit board is resistant to high temperatures up to a temperature of at least +150°

C.

10. The resistor according to claim 6, wherein the printed circuit board comprises multilayer ceramics.

11. The resistor according to claim 6, wherein the printed circuit board supports a measuring circuit for measuring the voltage drop across the resistor element.

12. The resistor according to claim 6, wherein the printed circuit board supports an optocoupler for galvanically isolated output of data or of an analog signal.

14. The resistor according to claim 1, further comprising at least one of the following features:

a) the connection parts are each plate-shaped,

b) the resistor element is plate-shaped,

c) the conductive material of the connection parts is copper or a copper alloy or aluminum,

d) the resistive material is a copper-manganese alloy,

e) the resistive material of the resistor element has a greater specific electrical resistance than the conductive material of the connection parts,

f) the resistive material of the resistor element has a specific electrical resistance, which is

f1) less than 50·

10<sup>−

7</sup> Ω

m, and

f2) greater than 1·

10<sup>−

8</sup> Ω

m,

g) the resistor has a resistance value, which is

g1) at least 0.1 μ

Ω

m, and

g2) a maximum of 1000 μ

Ω

,

h) the resistor has a continuous current-carrying capacity of at least 100A,

i) the current contact surfaces each have a size that is at least 30% of a total outer surface of the resistor,

j) the current contact surfaces each have a size that is at least 5 cm²,

k) the direction of current flow in the first connection part is opposite to the direction of current flow in the second connection part,

l) the resistor has a thickness that is at least 1 mm and a maximum of 20 mm,

m) the resistor has a resistance value with a temperature coefficient of less than 500 ppm/K,

n) the resistor has an inductance of less than 10 nH,

o) a thermal resistance between the current contact surfaces is less than 10 K/W,

p) the connection parts and the resistor element made from a composite material strip are detached and bent perpendicularly to a longitudinal direction of the composite material strip,

q) the connection parts are constructed in a plate shape, lying over each other sandwich-like and separately connected to each other by a method selected from the group consisting of soldering, welding, gluing and sintering,

r) the current flow surfaces are aligned with their contacting sides opposite each other,

s) the resistor has a length in the direction of current flow that is greater than 20 mm and less than 100 mm,

t) the resistor has a width perpendicular to the direction of current flow that is greater than 20 mm and less than 200 mm, and

u) the resistor has a thickness perpendicular to the direction of current flow that is greater than 2 mm and less than 50 mm.

15. A busbar arrangement comprising:

a) a first busbar to supply an electric current,

b) a second busbar to discharge the electric current, wherein the first busbar and the second busbar are collectively referred to hereinafter as two busbars, and

c) an electrical resistor that is arranged in a current flow direction between the two busbars so that the electric current flows through the electrical resistor,

d) wherein the electrical resistor is a resistor according to claim 1.

16. The busbar arrangement according to claim 15, wherein

a) the two busbars each have two limbs angled towards each other,

b) a first limb pair of limbs of the two busbars lies in a common plane,

c) a second limb pair of limbs of the two busbars lies in parallel planes spaced apart from each other, and

d) the second limb pair encloses the electrical resistor within it and electrically contacts the electrical resistor.

17. The busbar arrangement according to claim 15, wherein

a) one of the two busbars has two limbs angled towards each other,

b) the other of the two busbars is plate-shaped and flat,

c) one limb of the angled busbar is arranged parallel to the plate-shaped busbar,

d) the plate-shaped busbar and the limb parallel to it of the angled busbar encloses the electrical resistor therein and electrically contacts the electrical resistor.

18. The busbar arrangement according to claim 15, wherein

a) the two busbars are each plate-shaped and flat at least in a region of contacting with the resistor, and

b) the two busbars are arranged parallel and spaced apart from each other at least in the region of contacting with the resistor, and

c) the two busbars enclose the resistor therein and electrically contact the resistor in the region of contacting with the resistor.

19. The busbar arrangement according to claim 18, wherein the two busbars are spaced apart from the resistor in opposite directions so that the current flow direction is identical in the two busbars.

20. The busbar arrangement according to claim 18, wherein the two busbars are spaced apart from the resistor in the same direction so that the current flow direction in the two busbars is opposite.

21. The busbar arrangement according to claim 15, further comprising a spring clamp for crimping the two busbars, the spring clamp being electrically isolating on at least one side.

22. The busbar arrangement according to claim 15, further comprising a soldered connection between, on the one hand, the two busbars and, on the other hand, the resistor.

23. The busbar arrangement according to claim 15, further comprising an adhesive connection between, on the one hand, the two busbars and, on the other hand, the resistor.

24. The busbar arrangement according to claim 15, further comprising a sintered connection between, on the one hand, the two busbars and, on the other hand, the resistor.

13. A resistor comprising:

a) a first connection part comprising a conductive material for conducting an electric current into the resistor,

b) a second connection part comprising a conductive material for conducting the electric current out of the resistor, wherein the first connection part and the second connection part are collectively referred to hereinafter as connection parts,

c) a resistor element comprising a resistive material, the resistor element being arranged in a direction of current flow between the first connection part and the second connection part so that the electric current flows through the resistor element, and

d) several voltage taps which electrically contact the connection parts and measure a voltage drop across the resistor element,

e) wherein the connection parts have a really extensive current contact surfaces to conduct the current in and out, and

f) at least one part of the resistor is essentially U-shaped in cross-section, and

g) the voltage taps are attached on an inner side of the connection parts, and

h) the current contact surfaces are attached on an outer side of the connection parts, and

i) the resistor element has a cross-sectional shape in a cross-section at right angles to the direction of current flow, said shape deviating from a pure rectangular shape, and

j) the resistor element is multiply bent or angled perpendicularly to the direction of current flow so that it surrounds an inner space and at least partially encloses it, and

k) the resistor element has at least one limb, which extends in the direction of current flow and projects internally into the inner space, and

l) at least one voltage tap is attached to each of the connection parts in a proximity of one of the limbs.