Aluminum Case Resistor is a type of resistor that uses aluminum material as the casing, combining the good thermal conductivity and lightweight characteristics of aluminum with the basic functions of the resistor. This type of resistor is commonly used in applications that require good heat dissipation performance and high power capacity, such as power supplies, inverters, motor drives, charging stations, and other industrial electrical equipment.

Structure and Materials

The main components of aluminum shell resistors include:

Resistor: usually composed of alloy wire (such as nickel chromium alloy) or resistance film, these materials have stable resistance characteristics and good heat resistance.

Insulation base: usually made of ceramic or other high-temperature insulation materials, used to support resistance wires and provide certain insulation performance.

Aluminum shell: As a heat sink, the aluminum shell directly contacts the resistor and quickly transfers heat to the external environment through the good thermal conductivity of aluminum.

End cover: usually made of aluminum, used to seal both ends of the aluminum shell and provide wiring terminals for connecting resistors.

Lead or terminal: Used to connect the conductive part of a resistor, usually made of copper or tin plated copper, for easy soldering and connection into a circuit.

characteristic

High power endurance: Aluminum shell resistors can withstand high power, typically ranging from a few watts to several thousand watts, making them suitable for high-power applications.

Good heat dissipation performance: As a heat sink, the aluminum shell provides an excellent heat dissipation path, allowing the resistor to maintain stability under long-term high load operation.

High mechanical strength: The aluminum shell endows the resistor with high mechanical strength, which can resist vibration and impact, and is suitable for harsh environments.

Lightweight: Compared to traditional cast iron or cement resistors, aluminum shell resistors are lighter and easier to install and transport.

Small size: Aluminum shell resistors are usually smaller in size than other types of resistors at the same power, saving space.

application

Aluminum shell resistors are widely used in the following fields:

Power supply equipment: used for power filtering, current limiting, and voltage distribution.

Industrial control system: used for motor drive, heater control, and frequency converter.

Automotive Electronics: Used for automotive ignition systems and electronic control units.

New energy equipment: used for solar inverters, wind turbine control, and electric vehicle charging stations.

Testing and measuring equipment: used for precision measurement and calibration of circuits.

Selection considerations

When selecting aluminum shell resistors, the following factors need to be considered:

Rated power: Select the appropriate aluminum shell resistor according to the power requirements of the circuit.

Resistance value: Select the appropriate resistance value according to the circuit design requirements.

Error level: Select an appropriate error level based on the accuracy requirements of the circuit.

The specific packaging type of aluminum shell resistors mainly depends on their application scenarios and usage requirements. The following are some common packaging types:

TO-220 packaging: This is a common type of packaging commonly used for power resistors. Its dimensions are 22.0mm x 14.0mm x 9.0mm (length x width x height), with a large heat dissipation area, suitable for high-power applications. The resistor of this packaging type usually has three pins, two of which are the current outlet and the other is the ground terminal.

TO-247 packaging: This is a larger packaging type that is also used for high-power resistors. Its dimensions are 24.7mm x 13.8mm x 8.6mm (length x width x height), with a larger heat dissipation area and higher power capacity. The resistor of this packaging type usually has three pins, two of which are the current outlet and the other is the ground terminal.

TO-3 packaging: This is a relatively small packaging type commonly used for low-power resistors. Its dimensions are 10.2mm x 7.3mm x 4.3mm (length x width x height), suitable for space limited applications. The resistor of this packaging type usually has two pins, which are the current lead end and the ground end.

TO-202 packaging: This is a small packaging type commonly used for low-power resistors. Its dimensions are 20.2mm x 10.2mm x 4.3mm (length x width x height), suitable for space limited applications. The resistor of this packaging type usually has two pins, which are the current lead end and the ground end.

The selection of these packaging types depends on the power requirements, size limitations, and heat dissipation requirements of the resistors. When selecting aluminum shell resistors, the appropriate packaging type should be determined based on specific application scenarios and requirements.

Aluminum shell resistors play an important role in specific applications due to their unique performance, especially in situations that require high power and good heat dissipation. With the advancement of electronic technology and the continuous development of industrial demand, the design and manufacturing technology of aluminum shell resistors are also constantly improving to meet more stringent application requirements.