Printed chip resistor and manufacturing method thereof

Abstract

The invention discloses a printed chip resistor and a manufacturing method thereof. The printed chip resistor comprises a substrate, a resistance layer, a lower electrode and an upper electrode. Wherein the resistive layer is arranged on the top surface of the substrate, the lower electrode is arranged between the substrate and the resistive layer, and the resistive layer is arranged between the upper electrode and the lower electrode. The specific structure of the printed chip resistor is favorable for improving the conduction sectional area of the resistor and shortening the path length of the resistor, so that the application requirement of low resistance value can be met, and the heat dissipation effect of the printed chip resistor is improved.

Description

Technical Field

[0001] The present invention relates to a printed chip resistor, and in particular to a printed chip resistor having low resistance characteristics and good heat dissipation effect and a manufacturing method thereof. Background Art

[0002] With the development trend of miniaturization of electronic products, the active and passive components therein are also reduced in size. Among them, printed chip resistors are also common passive components in these electronic products. The resistance layer of printed chip resistors is generally formed by a resistor paste, and the resistor paste contains resistor functional powder, glass powder, ceramic powder, inorganic sintering aids and organic substances. Since glass powder, ceramic powder and inorganic sintering aids still have a relatively high resistance after sintering, in order to meet the application requirements of low resistance, the amount of resistor functional powder is generally increased or additional conductive precious metals (such as palladium or silver, etc.) are added. However, the increase in the amount of resistor functional powder or the addition of conductive precious metals will increase costs.

[0003] Secondly, the electrodes of a general printed chip resistor are set at both ends of the resistor layer, so the heat energy generated by the current flowing through the resistor layer can only be dissipated through the ceramic substrate with a low thermal conductivity (about 17W / mK). Therefore, when there is a current surge or high power is used, the resistor layer is prone to stress changes due to the accumulated heat energy, resulting in abnormal resistance.

[0004] In view of this, there is an urgent need to provide a printed chip resistor and a manufacturing method thereof to improve the shortcomings of the existing printed chip resistor and the manufacturing method thereof. Summary of the invention

[0005] One aspect of the present invention provides a printed chip resistor having a resistor body with a specific structure, which can increase the conductive cross-sectional area of ​​the resistor and shorten its path length, thereby meeting the application requirements of low resistance characteristics. In addition, this specific structure helps to improve the heat dissipation effect of the printed chip resistor, thereby avoiding the impact caused by thermal stress changes.

[0006] Another aspect of the present invention provides a method for manufacturing a printed chip resistor, which forms the printed chip resistor of the present invention through a specific preparation process to meet product requirements for low resistance characteristics and avoid abnormal resistance defects caused by thermal stress changes.

[0007] According to one aspect of the present invention, a printed chip resistor is provided. The printed chip resistor comprises a substrate, a resistor layer, a lower electrode and an upper electrode. The resistor layer is disposed on the top surface of the substrate, and along a direction perpendicular to the top surface, the lower electrode is disposed between the substrate and the resistor layer, and the resistor layer is disposed between the upper electrode and the lower electrode.

[0008] According to some embodiments of the present invention, at least a portion of the upper electrode overlaps at least a portion of the lower electrode.

[0009] According to some embodiments of the present invention, corresponding to the overlapping range of the upper electrode and the lower electrode, the resistance layer covers the overlapping range.

[0010] According to some embodiments of the present invention, the upper electrode and the lower electrode are respectively located at two ends of the substrate.

[0011] According to some embodiments of the present invention, the top surface is a square having a first side and a second side, and the first side is perpendicular to the second side. Where L1 represents the length of the first side. Along the extension direction of the second side, the length of the lower electrode is not greater than Wherein L2 represents the length of the second side.

[0012] According to some embodiments of the present invention, the first side is longer than the second side, and along the extension direction of the first side, the length of the lower electrode is not less than

[0013] According to some embodiments of the present invention, the aforementioned printed chip resistor further comprises a protective layer, two back electrodes and two terminal electrodes. The protective layer is disposed on the upper electrode, and the protective layer completely covers the resistor layer. The two back electrodes are respectively disposed at two ends on the bottom surface of the substrate. The two terminal electrodes are respectively disposed at two ends of the substrate, wherein one of the two terminal electrodes is electrically connected to one of the two back electrodes and the lower electrode, and the other of the two terminal electrodes is electrically connected to the other of the back electrodes and the upper electrode.

[0014] According to another aspect of the present invention, a method for manufacturing a printed chip resistor is provided. The manufacturing method first forms a lower electrode on the top surface of a substrate, then forms a resistor layer on the lower electrode, and then forms an upper electrode on the resistor layer to form the resistor body of the printed chip resistor of the present invention. In this method, along a direction perpendicular to the top surface, at least a portion of the upper electrode overlaps at least a portion of the lower electrode.

[0015] According to some embodiments of the present invention, after forming the aforementioned resistor body, the manufacturing method further includes performing a resistance trimming operation on the upper electrode and / or the lower electrode.

[0016] According to some embodiments of the present invention, after forming the aforementioned resistor body, the manufacturing method may further form a protective layer on the upper electrode, wherein the protective layer completely covers the resistor layer. Then, two back electrodes are formed on the bottom surface of the substrate, wherein the two back electrodes are respectively located at the two ends of the bottom surface. Next, two terminal electrodes are respectively formed at the two ends of the substrate to form the printed chip resistor of the present invention. Among them, one of the two terminal electrodes is electrically connected to one of the back electrodes and the lower electrode, and the other is electrically connected to the other of the back electrodes and the upper electrode.

[0017] The printed chip resistor and its manufacturing method of the present invention can form a resistor body with a three-dimensional structure by setting a resistor layer between two electrodes, thereby increasing the conductive cross-sectional area of ​​the printed chip resistor and shortening its path length, so that the application requirements of low resistance value can be met without adjusting the material formula. Furthermore, the resistor layer set between the upper electrode and the lower electrode can have a better heat dissipation effect by dissipating the heat energy generated during application through the electrodes, thereby achieving the characteristic of effectively resisting current surges. In addition, the present invention can effectively adjust the resistance characteristics of the printed chip resistor and avoid thermal damage to the resistance layer by heat energy by performing a resistance repair operation on at least one of the upper electrode and the lower electrode. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to have a more complete understanding of the embodiments of the present invention and its advantages, please refer to the following description and the corresponding drawings. It must be emphasized that the various features are not depicted to scale and are only for illustration purposes. The contents of the relevant drawings are described as follows.

[0019] Figure 1 A schematic flow chart of a method for manufacturing a printed chip resistor according to some embodiments of the present invention is shown.

[0020] Figure 2A and Figure 2B A schematic cross-sectional view and a schematic top view of a resistor body of a printed chip resistor according to some embodiments of the present invention are respectively illustrated.

[0021] Figure 2C and Figure 2D Schematic top views of the resistor body of the printed chip resistor according to some embodiments of the present invention are respectively shown.

[0022] Figure 3A and Figure 3B A cross-sectional schematic diagram and a top schematic diagram of a printed chip resistor according to some embodiments of the present invention are respectively illustrated.

[0023] Figure 4A and Figure 4B A cross-sectional schematic diagram and a top schematic diagram of a printed chip resistor according to some embodiments of the present invention are respectively illustrated.

[0024] Figure 5 Schematic cross-sectional views of printed chip resistors according to some embodiments of the present invention are shown. DETAILED DESCRIPTION

[0025] In order to have a more complete understanding of the embodiments of the present invention and its advantages, please refer to the following description and the corresponding drawings. It must be emphasized that the various features are not depicted to scale and are only for illustration purposes. The contents of the relevant drawings are described as follows.

[0026] Please also refer to Figure 1 , Figure 2A and Figure 2B ,in Figure 1 A schematic diagram of a process for manufacturing a printed chip resistor according to some embodiments of the present invention is shown, and Figure 2A and Figure 2B A schematic cross-sectional view and a schematic top view of a resistor body 200 of a printed chip resistor according to some embodiments of the present invention are respectively shown. In method 100, a lower electrode 220 is first formed on the top surface of a substrate 210, as shown in operation 110. There is no particular limitation on the material of the substrate 210 of the present invention, which only needs to be able to support the electrodes, resistor layers and various structural layers of the printed chip resistor and not affect the properties of the chip resistor. In some specific examples, the material of the substrate 210 may include but is not limited to aluminum oxide (Al2O3), aluminum nitride (AlN), other appropriate materials, or any combination of the above materials.

[0027] The lower electrode 220 can be formed on one end of the substrate 210 by printing a conductive electrode paste and sintering it. In some specific examples, the conductive electrode paste can be, for example, a composition of silver and glass paste, and the sintering temperature can be, for example, 600° C. to 850° C. In some embodiments, the thickness of the lower electrode 220 can be 10 μm to 30 μm. The method for forming the lower electrode 220 is well known to those skilled in the art, so it is not further described here.

[0028] The shape of the substrate 210 is not particularly limited, and only needs to meet the requirements of the back-end application. In some embodiments, the substrate 210 may be, for example, square and have a side 211 and a side 213 perpendicular to each other, wherein the side 211 and the side 213 have a length L1 and a length L2 respectively. Along the extension direction of the side 211, the length L'1 of the lower electrode 220 is not greater than and preferably greater than or equal to and less than or equal to If the length L'1 is greater than Although the resistor layer 230 formed later can be electrically insulated from the upper electrode 240, the resistor body 200 formed is still prone to short circuit defects and is difficult to meet application requirements. and less than or equal to When the lower electrode 220 has a more appropriate size, the conductive cross-sectional area of ​​the resistor can be effectively increased and the path length can be shortened, thereby better meeting the application requirements of low resistance values. It is understandable that, as the lower electrode 220 , the lower limit of the length L′2 is not particularly limited, and only needs to be greater than 0.

[0029] After performing operation 110, a resistor layer 230 is formed on the lower electrode 220, as shown in operation 120. The resistor layer 230 can be formed by printing a resistor paste and sintering it. In some specific examples, the material of the resistor paste may include, but is not limited to, ruthenium oxide (RuO2), nickel oxide (NiO), manganese oxide (Mn3O-), zinc oxide (ZnO), iron oxide (Fe3O4), cobalt oxide (Co3O4), copper manganese tin alloy (Zeranin), manganese copper alloy (Manganin), copper nickel alloy (CuNi44), nickel chromium aluminum silicon alloy, nickel chromium alloy (NiCr), other suitable resistor materials, or any mixture of the above materials, and the sintering temperature may be, for example, 600°C to 850°C. In some embodiments, the thickness of the resistor layer 230 may be 10μm to 30μm. The method for forming the resistor layer 230 is well known to those skilled in the art, so it is not further described here.

[0030] There is no particular restriction on the location of the resistor layer 230. It is preferably located at the middle of the substrate 210 and completely covers a portion of the lower electrode 220 so that the lower electrode 220 and the subsequently formed upper electrode 240 do not form a short circuit. There is no particular restriction on the shape and size of the resistor layer 230, which only needs to meet the requirements of the back-end application. In some examples, the length of the resistor layer 230 along the extension direction of the side edge 211 is not greater than When the length of the resistance layer 230 is not greater than In addition to providing a better insulation effect for the lower electrode 220 and the upper electrode 240 , the resistance layer 230 can also effectively reduce the manufacturing cost of the printed chip resistor.

[0031] After performing operation 120, the upper electrode 240 is formed on the resistor layer 230 to form the resistor body 200 of the printed chip resistor of the present invention, as shown in operations 130 and 140. The upper electrode 240 can be formed using the same formation method and material as the lower electrode 220, and the upper electrode 240 can have the same or different size specifications as the lower electrode 220.

[0032] In the resistor body 200, the upper electrode 240 and the lower electrode 220 are respectively located at opposite ends of the substrate 210, and the resistor layer 230 is disposed between the lower electrode 220 and the upper electrode 240 along a direction perpendicular to the top surface of the substrate 210. In some embodiments, at least a portion of the upper electrode 240 overlaps at least a portion of the lower electrode 220. In these embodiments, corresponding to the overlapping range of the lower electrode 220 and the upper electrode 240, the resistor layer 230 covers the overlapping range, wherein the area of ​​the resistor layer 230 is not less than the area of ​​the overlapping range. Preferably, the area of ​​the resistor layer 230 is greater than the area of ​​the overlapping range.

[0033] Although Figure 2B The lower electrode 220 and the upper electrode 240 are shown as T-shaped, but the present invention is not limited thereto. In other embodiments, the lower electrode 220 and the upper electrode 240 may have other appropriate shapes according to the requirements of the back-end application. Figure 2C As shown, the lower electrode 221 of the resistor body 200a may have comb-shaped portions connected in parallel, and along a direction perpendicular to the top surface of the substrate 210, a portion of these comb-shaped portions overlaps the upper electrode 240; Figure 2D As shown, the upper electrode 241 of the resistor body 200b has comb-shaped portions connected in parallel, and the lower electrode 223 has an extension portion 223a and a comb-shaped portion protruding from the extension portion 223a, wherein along a direction perpendicular to the top surface of the substrate 210, the comb-shaped portion of the upper electrode 241 and the comb-shaped portion of the lower electrode 223 have an overlapping portion.

[0034] Please also refer to Figure 1 , Figure 2B , Figure 2C and Figure 2D After performing operation 140, the method 100 may selectively perform a resistance trimming operation on the upper electrode 240 and / or the lower electrode 220 of the resistor body 200 to further adjust the resistance performance of the resistor body 200 to meet the application requirements. For example, the resistance trimming operation may be performed by laser processing to remove at least a portion of the upper electrode 240 and / or the lower electrode 220 to more finely adjust the electrical performance of the manufactured printed chip resistor. It is understandable that, if Figure 2C In the structure shown, when the resistance trimming operation is performed on the lower electrode 220, the laser is directly applied to the lower electrode 220, or applied to the resistance layer 230 covering the lower electrode 220, corresponding to the position of the lower electrode 220; when the resistance trimming operation is performed on the upper electrode 240, the laser applied to the upper electrode 240 is not limited to removing only a portion of the upper electrode 240, and it can also remove part or all of the resistance layer 230 at the corresponding position. Further, by applying the laser only to the upper electrode 240 or the lower electrode 220 (i.e., not applying the laser to the resistance layer 230), the thermal damage of the laser heat energy to the resistance layer 230 can be effectively avoided.

[0035] After the aforementioned operation 140 is performed, a protection layer, a back electrode and a terminal electrode may be further formed on the resistor body 200 to form the printed chip resistor of the present invention.

[0036] In some embodiments, the protective layer may be, for example, a single layer or a composite layer formed by multiple sub-layers. Figure 3A and Figure 3B ,as well as Figure 4A and Figure 4B As shown, the glass protective layer 250 and the epoxy resin protective layer 260 are sequentially formed on the upper electrode 240, wherein the glass protective layer 250 completely covers the resistor layer 230, and covers a portion of the upper electrode 240 and a portion of the lower electrode 220, and the epoxy resin protective layer 260 completely covers the glass protective layer 250. It can be understood that after the protective layer is formed, the lower electrode 220 and the upper electrode 240 are partially uncovered, and can be used as electrical connection points for the printed chip resistor formed subsequently. The glass protective layer 250 and the epoxy resin protective layer 260 are both formed using methods and materials well known to those skilled in the art, so they are not further described here.

[0037] like Figure 4A As shown. Two back electrodes 270 are formed on the bottom surface of the substrate 210, and correspond to the upper electrode 240 and the lower electrode 220, and these back electrodes 270 are respectively located at both ends of the substrate 210. In some specific examples, the back electrode 270 can be formed by printing a low-temperature silver paste (such as containing metallic silver and epoxy resin) or sputtering, and the material of the back electrode 270 can include but is not limited to nickel-chromium alloy (NiCr), copper-nickel alloy (CuNi), other copper alloys, other appropriate alloy materials, or any mixture of the above materials. The formation of the back electrode 270 is well known to those skilled in the art, so it is not further described here.

[0038] like Figure 5As shown, two terminal electrodes 280 are respectively formed at both ends of the substrate 210 to form the printed chip resistor of the present invention. Among them, one of the terminal electrodes 280 is electrically connected to the lower electrode 220 and the corresponding back electrode 270, and the other terminal electrode 280 is electrically connected to the upper electrode 240 and the corresponding back electrode 270. It can be understood that the terminal electrode 280 can be a single electrode layer formed by a single material or a composite electrode layer composed of multiple sublayers formed by multiple materials. In some examples, the terminal electrode 280 can be formed by sputtering, electroplating, or other appropriate methods, and the material of the terminal electrode 280 can include but is not limited to NiCr, copper, tin, nickel, other appropriate electrode materials, or any combination of the above materials. For example, the terminal electrode 280 can be a composite electrode layer, and it is first sputtered to form a NiCr sublayer, and then the nickel sublayer and the tin sublayer are electroplated in sequence. The formation of the terminal electrode 280 is well known to those skilled in the art, so it is not further described here.

[0039] According to the above description, the printed chip resistor prepared by the present invention can form a resistor body with a three-dimensional structure by setting the resistor layer between the upper electrode and the lower electrode, thereby changing its resistance path to be conducted from the upper electrode located at the top to the lower electrode located at the bottom (or vice versa), thereby effectively shortening the path length, and through the laminated structure of the resistor layer and the two electrode layers, the conductive cross-sectional area of ​​the resistor is also increased. Accordingly, the printed chip resistor of the present invention can meet the application requirements of low resistance values ​​without adjusting the material formula of the resistor layer. Secondly, this three-dimensional laminated structure helps to dissipate the heat energy generated by the resistor layer, and has a better heat dissipation effect, thereby effectively resisting current surges. In addition, the present invention can directly perform resistance repair operations on the upper electrode and the lower electrode of this laminated structure to adjust the resistance characteristics, and can effectively avoid thermal damage to the resistor layer caused by the resistance repair heat energy.

[0040] Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention. Those skilled in the art may make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

[0041]

Explanation of symbols

[0042] 100: Method

[0043] 110,120,130,140: Operation

[0044] 200,200a,200b: Resistor body

[0045] 210:Substrate

[0046] 211,213: Side

[0047] 220,221,223: Lower electrode

[0048] 223a: Extension

[0049] 230: Resistance layer

[0050] 240,241: Upper electrode

[0051] 250: Glass protective layer

[0052] 260: Epoxy resin protective layer

[0053] 270: Back electrode

[0054] 280: terminal electrode

[0055] L1,L2,L'1,L'2: length.

Claims

1. A printed chip resistor, characterized in that: The printed chip resistor contains: substrate; a resistor layer disposed on the top surface of the substrate; a lower electrode; and The upper electrode is disposed between the substrate and the resistance layer along a direction perpendicular to the top surface, and the resistance layer is disposed between the upper electrode and the lower electrode.

2. The printed chip resistor according to claim 1, characterized in that: At least a portion of the upper electrode overlaps at least a portion of the lower electrode.

3. The printed chip resistor according to claim 2, characterized in that: Corresponding to the overlapping range of the upper electrode and the lower electrode, the resistance layer covers the overlapping range.

4. The printed chip resistor according to claim 1 or 2, characterized in that: The upper electrode and the lower electrode are respectively located at two ends of the substrate.

5. The printed chip resistor according to claim 4, characterized in that: The top surface is a square having a first side and a second side, the first side is perpendicular to the second side, and Along the extension direction of the first side, the length of the lower electrode is not greater than L1, wherein L1 represents the length of the first side; Along the extension direction of the second side, the length of the lower electrode is not greater than L2, wherein L2 represents the length of the second side.

6. The printed chip resistor according to claim 5, characterized in that: The first side is longer than the second side, and Along the extension direction of the first side, the length of the lower electrode is not less than L1.

7. The printed chip resistor according to claim 1, characterized in that: The printed chip resistor also includes: A protective layer is disposed on the upper electrode, and the protective layer completely covers the resistance layer; Two back electrodes are respectively disposed at two ends of the bottom surface of the substrate; as well as Two terminal electrodes are respectively arranged at two ends of the substrate, wherein one of the two terminal electrodes is electrically connected to one of the two back electrodes and the lower electrode, and the other of the two terminal electrodes is electrically connected to the other of the two back electrodes and the upper electrode.

8. A method for manufacturing a printed chip resistor, characterized in that: The preparation method comprises: forming a lower electrode on the top surface of the substrate; forming a resistance layer on the lower electrode; and An upper electrode is formed on the resistor layer to form a resistor body of the printed chip resistor, wherein at least a portion of the upper electrode overlaps at least a portion of the lower electrode along a direction perpendicular to the top surface.

9. The method for manufacturing a printed chip resistor according to claim 8, characterized in that: After forming the resistor body, the manufacturing method further comprises: A resistance repair operation is performed on the upper electrode and / or the lower electrode.

10. The method for manufacturing a printed chip resistor according to claim 8, characterized in that: After forming the resistor body, the manufacturing method further comprises: forming a protective layer on the upper electrode, wherein the protective layer completely covers the resistance layer; forming two back electrodes on the bottom surface of the substrate, wherein the two back electrodes are respectively located at two ends of the bottom surface; as well as Two terminal electrodes are respectively formed at both ends of the substrate to form the printed chip resistor, wherein one of the two terminal electrodes is electrically connected to one of the two back electrodes and the lower electrode, and the other of the two terminal electrodes is electrically connected to the other of the two back electrodes and the upper electrode.

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