The manufacturing process of high-precision resistors is a complex and intricate process that involves multiple steps and key technologies. The following is a detailed introduction to its manufacturing process:
1、 Overview of Manufacturing Process
The manufacturing process of high-precision resistors usually includes multiple steps such as electrode preparation, resistor body formation, protective layer printing, resistance adjustment, packaging, and testing. Each stage requires strict control of process parameters to ensure the accuracy, stability, and reliability of the resistor.
2、 Specific manufacturing process steps
Electrode preparation
Printing electrodes on insulating substrates (such as alumina ceramics) for connecting resistors. Electrode materials are usually chosen from metals or alloys with good conductivity, such as silver, palladium, etc.
After electrode printing, it needs to be dried and sintered to form a strong electrode layer.
Formation of resistors
Using screen printing or vacuum coating technology to deposit resistive materials on electrodes to form resistors. The selection of resistive materials depends on the required resistance value and accuracy requirements.
After the formation of the resistor, it also needs to be dried and sintered to ensure the stability and accuracy of the resistor.
Protective layer printing
In order to protect the resistor from mechanical damage and environmental impact, a protective layer needs to be printed on the resistor. The protective layer material is usually selected from materials such as glass paste or resin that have good insulation properties and weather resistance.
The protective layer also needs to be dried and sintered after printing.
Resistance adjustment
In order to meet the accuracy requirements of resistors, it is necessary to adjust the resistance value of the resistor body. Common repair methods include laser repair and mechanical repair.
Laser trimming cuts a resistor by precisely controlling the intensity and position of the laser beam, thereby changing its resistance value. Mechanical trimming adjusts the shape or size of the resistor through mechanical means to achieve the desired resistance value.
Packaging and Testing
Encapsulation is the assembly of resistors with electrodes, leads, and other components to form a complete resistor device. The selection of packaging materials depends on the usage environment and performance requirements of the resistive device.
Testing is the performance testing of packaged resistive devices, including indicators such as resistance value, temperature coefficient, and accuracy. Testing equipment usually uses high-precision resistance testers or automatic testing systems.
3、 Key technologies
High precision printing technology
High precision printing technology is one of the key technologies for achieving high-precision resistor manufacturing. By precisely controlling the positioning accuracy and printing parameters of the printing machine, it is possible to ensure uniform deposition of resistive materials and precise control of the size and shape of the resistor body.
Laser trimming technology
Laser trimming technology is an important means to achieve precise adjustment of high-precision resistance values. By precisely controlling the intensity and position of the laser beam, small cutting and adjustment of the resistor can be achieved to achieve the desired resistance value.
Automated testing and screening technology
Automated testing and screening technology can greatly improve the production efficiency and product quality of high-precision resistors. By using high-precision testing equipment and automatic screening systems, rapid testing and precise screening of resistance devices can be achieved, ensuring product consistency and reliability.
4、 The development trend of manufacturing technology
With the continuous improvement of precision and automation requirements in the manufacturing industry, the manufacturing process of high-precision resistors is also constantly developing. In the future, the manufacturing process of high-precision resistors will pay more attention to intelligence, greenness, and efficiency. For example, by integrating more artificial intelligence technologies to achieve adaptive welding parameter optimization and intelligent scheduling of automated production lines; At the same time, the application of low-energy and environmentally friendly welding technology and materials will further enhance the market competitiveness of high-precision resistors.
In summary, the manufacturing process of high-precision resistors is a complex and intricate process that involves multiple steps and key technologies. By continuously optimizing manufacturing processes and introducing new technologies, the accuracy, stability, and reliability of high-precision resistors can be further improved, meeting the modern electronic industry's demand for high-performance resistor devices.
