Ceramic Circuit Substrate Resistor Layout for Lower Resistance
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Solution Overview
Problem
Existing circuit substrates for lighting devices face challenges in reducing the electrical resistance of resistors used to adjust current flowing through light emitting elements, such as LEDs, while maintaining superior insulating and thermal conductivity properties.
Innovation Solution
A ceramic substrate with a resistor having a meandering resistive element that interconnects comb-tooth shaped electrodes, allowing for reduced electrical resistance through optimized geometry and material composition, enabling precise resistance adjustment via laser trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional resistor structure is used on the ceramic substrate, then the insulating and thermal conductivity properties of the substrate are maintained, but the electrical resistance of the resistor cannot be sufficiently reduced
Solution Approach 1:
The electrode is divided into multiple comb-tooth portions that extend in a direction intersecting the body portion extension direction. This segmentation increases the electrode surface area in contact with the resistive element, thereby reducing electrical resistance while maintaining the ceramic substrate's insulating and thermal conductivity properties.
Solution Approach 2:
The electrode structure transitions from a simple linear configuration to a three-dimensional comb-tooth configuration. By extending comb-tooth portions in an direction intersecting the body portion extension direction, the electrode utilizes additional spatial dimensions to increase surface area and improve electrical contact with the resistive element, reducing electrical resistance without compromising substrate properties.
2Loss of energy
If the resistor electrical resistance is reduced by increasing electrode surface area, then energy loss is reduced, but the device complexity increases
Solution Approach 1:
The comb-tooth shaped first electrode and comb-tooth shaped second electrode are merged with the resistive element in a single integrated structure. The resistive element is positioned to contact both electrodes simultaneously, combining multiple functional elements into one compact assembly that reduces electrical resistance without proportionally increasing device complexity.
Solution Approach 2:
The comb-tooth electrode structure serves multiple functions: it provides electrical connection, increases surface area for reduced resistance, and maintains a compact form factor. This multi-functional design achieves resistance reduction without requiring additional separate components, thereby limiting the increase in device complexity.
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
The solution effectively reduces the electrical resistance of the resistor, improves manufacturing efficiency, and enhances the reliability and cost-effectiveness of the circuit substrate by allowing for precise resistance tuning and reduced heat generation.
Implementation Method 1
enabling precise resistance adjustment via laser trimming
Data Source
AI summary
A circuit substrate includes a substrate body made of a ceramic, wiring located on the substrate body, and a resistor interposed in the wiring and having an electrical resistance higher than that of the wiring. The wiring includes a first electrode and a second electrode. The first electrode includes a first body portion and a plurality of first comb-tooth portions each extending from the first body portion in a direction intersecting a direction in which the first body portion extends. The second electrode includes a second body portion and a plurality of second comb-tooth portions, each extending from the second body portion in a direction intersecting a direction in which the second body portion extends, and has a comb-tooth shape located to mesh with a comb-tooth shape of the first electrode with an interval. The resistor includes a resistive element located in contact with both the first body portion of the first electrode and the second body portion of the second electrode.