Coil resistor and method for manufacturing same

• US 10,446,303 B2
• Filed: 06/23/2017
• Issued: 10/15/2019
• Est. Priority Date: 08/10/2016
• Status: Active Grant

• Current Assignee: KOA Corporation
• Original Assignee: KOA Corporation
• Inventors: Mizouchi, Yasuo, Kumagai, Ringo, Nebashi, Kazunari
• Primary Examiner(s): Lee, Kyung S
• Application Number:
  US16/323,151
• Publication Number:
  US 20190172614A1
• Time in Patent Office: 844 Days
• CPC Class Codes: H01C 1/01 Mounting; Supporting
• CPC Class Codes: H01C 1/148 the terminals embracing or surrounding the resistive element H01C1/142 takes precedence
• CPC Class Codes: H01C 17/00 Apparatus or processes specially adapted for manufacturing resistors providing fillings for housings or enclosures H01C1/02; reducing insulation surrounding a resistor to powder H01C1/03; manufacture of thermally variable resistors H01C7/02, H01C7/04
• CPC Class Codes: H01C 17/006 adapted for manufacturing resistor chips
• CPC Class Codes: H01C 17/04 adapted for winding the resistive element
• CPC Class Codes: H01C 17/28 adapted for applying terminals
• CPC Class Codes: H01C 3/00 Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
• CPC Class Codes: H01C 3/14 the resistive element being formed in two or more coils or loops continuously wound as a spiral, helical or toroidal winding H01C3/02 - H01C3/12 take precedence
• CPC Class Codes: H01C 3/20 wound on cylindrical or prismatic base H01C3/16 takes precedence

Abstract

A single or multiple cutters are pressed against end surfaces of a resistive element so as to form a plurality of notches in rims of the end surfaces. At this time, notches are formed such that notch depth at the end surfaces of the resistive element toward the axis center is smaller than notch length from the end surfaces of the resistive element to the axis. This allows easy cutting and removal of the resistance wire at the resistive element ends of a coil resistor, etc., and prevention of fraying of a wound wire at the resistive element ends.

Claims

1. A coil resistor made by attaching a cap electrode on either end part of a resistive element formed by winding a resistance wire around the circumference of a core that is formed by twisting together fibrous insulating material, comprising a plurality of notches of a predetermined length formed along the axis of the resistive element on rims of either end surface of the resistive element.

2. The coil resistor according to claim 1, wherein the resistance wire is cut at the rims.

3. The coil resistor according to claim 1, wherein the plurality of notches is formed at substantially equal intervals along the circumference of the rims, and the intervals of the notches along the circumference are shorter than depth of the cap electrode toward the axis.

4. The coil resistor according to claim 1, wherein depth of the plurality of notches toward the axis center of the resistive element is deepest near the axial end part of a peripheral surface of the resistive element, and becomes shallower as the notches approach the central part along the axis of the peripheral surface from the end parts.

5. The coil resistor according to claim 1, wherein depth of the plurality of notches toward the axis center of the resistive element is the same depth at a notch starting point in the axial end part of a peripheral surface of the resistive element and at a notch ending point at a predetermined distance from the end part along the axis.

6. The coil resistor according to claim 1, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

12. The coil resistor according to claim 2, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

13. The coil resistor according to claim 3, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

14. The coil resistor according to claim 4, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

15. The coil resistor according to claim 5, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

7. A manufacturing method for a coil resistor comprising the steps of:

twisting together fibrous insulating material to form a long core;

winding a resistance wire around the circumference of the core;

cutting at a predetermined length the core around which the resistance wire is wound, so as to form a resistive element;

forming a plurality of notches of a predetermined length along the axis of the resistive element in rims of either end surface of the resistive element; and

attaching a cap electrode on either end part of the resistive element.

8. The manufacturing method for a coil resistor according to claim 7, wherein in the step of forming the plurality of notches, the resistance wire at the rims is cut.

9. The manufacturing method for a coil resistor according to claim 7, wherein in the step of forming the plurality of notches, the plurality of notches is formed in a plurality of places simultaneously in the rims of either end surface of the resistive element.

10. The manufacturing method for a coil resistor according to claim 7, wherein the plurality of notches is formed at substantially equal intervals along the circumference of the rims, and the intervals of the notches along the circumference are shorter than depth of the cap electrode toward the axis.

11. The manufacturing method for a coil resistor according to claim 7, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

16. The manufacturing method for a coil resistor according to claim 8, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

17. The manufacturing method for a coil resistor according to claim 9, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.

18. The manufacturing method for a coil resistor according to claim 10, wherein the plurality of notches is formed within a range of less than 10% of the region of the peripheral surface of the resistive element that is covered by the cap electrode.