Additive Electrical Resistor Formation with Target Length Control
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Solution Overview
Problem
The manufacturing of electrical resistors with precise electrical resistance values is challenging due to imprecisions in cross-section and length, leading to deviations from nominal values, and existing methods, such as subtractive technologies, are costly and time-consuming, while additive technologies lack sufficient precision for many applications.
Innovation Solution
A method involving additive manufacturing where an electrically resistive layer is formed on a substrate, with its resistance measured to determine a target length, allowing for precise positioning of conductive terminals to achieve the desired electrical resistance, eliminating the need for costly subtractive methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If subtractive technologies like laser ablation are used for fine adjustment of resistor dimensions, then manufacturing precision of electrical resistance is improved, but manufacturing cost and manufacturing time increase
Solution Approach 1:
The patent applies preliminary action by forming the electrically resistive element with precisely controlled dimensions through additive manufacturing before final assembly. The element is manufactured with target dimensions that pre-determine the electrical resistance value, eliminating the need for subsequent subtractive trimming operations. This preliminary precise formation resolves the contradiction by achieving high precision without the cost and time penalties of later adjustment.
Solution Approach 2:
The patent inverts the traditional manufacturing sequence by using additive manufacturing to directly create the resistive element with precise dimensions, rather than using subtractive methods to trim down from a larger piece. This inversion of the manufacturing approach (adding material with precision rather than removing material) achieves high electrical resistance precision while avoiding the cost and complexity of subtractive technologies.
2Manufacturing precision
If subtractive technologies like laser ablation are used for fine adjustment of resistor dimensions, then manufacturing precision of electrical resistance is improved, but manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by forming the electrically resistive element with precisely controlled dimensions through additive manufacturing before final assembly. The element is manufactured with target dimensions that pre-determine the electrical resistance value, eliminating the need for subsequent subtractive trimming operations. This preliminary precise formation resolves the contradiction by achieving high precision without the time penalties of later adjustment.
Solution Approach 2:
The patent extracts the trimming operation from the manufacturing process entirely by using additive manufacturing to directly create the resistive element with the correct dimensions. By removing the subtractive trimming step (taking it out of the process), the patent achieves high electrical resistance precision while significantly reducing total manufacturing time.
3Ease of manufacture
If additive manufacturing is used for forming electrical resistors, then manufacturing cost and productivity are improved, but manufacturing precision of electrical resistance deteriorates
Solution Approach 1:
The patent substitutes mechanical measurement and trimming systems with a digitally controlled additive manufacturing system. The additive process uses digital models to directly deposit material in precise geometries, replacing the mechanical subtractive trimming process. This substitution maintains low cost and high productivity while achieving improved precision through digital control and automated deposition.
Solution Approach 2:
The patent changes the critical parameters from post-manufacturing trimming operations to in-process deposition parameters. By controlling deposition rate, layer thickness, and path planning during additive manufacturing, the resistive element is formed with precise dimensions directly. This parameter change from post-processing to in-process control achieves high precision while maintaining the cost and productivity benefits of additive manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of electrical resistors with high accuracy (below 1% or 0.01%) while maintaining economic viability, ensuring reliable electrical resistance values without the need for expensive and time-consuming fine adjustments.
Implementation Method 1
a first deposition device (140) configured for depositing an electrically resistive material for forming an electrically resistive layer (14)
Data Source
Figure 1
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AI summary
Shown herein is a method of forming an electrical resistor (10) comprising the steps of: forming an electrically resistive layer (14) on a substrate (12); measuring an electrical resistance-related parameter of the electrically resistive layer (14) and determining a target length (L) of the electrically resistive layer (14) corresponding to a target electrical resistance; and forming first and second electrically conductive terminals (16a, 16b) contacting the electrically resistive layer (14), said first and second electrically conductive terminals (16a, 16b) being separated by a distance corresponding to the target length (L). In an alternative embodiment, an electrically isolating layer is formed on the electrically resistive layer having first and second ends, wherein the electrically isolating layer covers the electrically resistive layer in an overlap region extending between said and second ends, such that a length of the electrically resistive layer covered by the electrically isolating layer corresponds to the target length (L). First and second electrically conductive terminals are formed directly adjacent to the first and second ends of the electrically insulating layer, respectively. Corresponding arrangements for forming the electrical resistors are likewise disclosed.