Chip Component Fuse Network for Resistance and Capacitance Tuning

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Solution Overview

Problem

Conventional chip resistors and capacitors face challenges in accommodating a wide range of resistance and capacitance values due to limitations in geometric precision and micromachining, leading to issues with transfer errors during substrate mounting and requiring labor-intensive design processes for multiple capacitance values.

Innovation Solution

A chip component design featuring a substrate with an element circuit network, external connection electrodes, and fuses that allow for easy mounting and adjustment of resistance and capacitance values without the need for solder printing, enabling high-density mounting and precise geometric precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If laser trimming is used to adjust resistance value to target value, then resistance precision is improved, but manufacturing complexity increases and productivity decreases

Engineering Contradiction:
Improveresistance value precisionVSAvoidmanufacturing efficiency
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-forming the resistive film with precise thickness and material composition during the manufacturing process, so that the resistance value is already close to the target value before laser trimming. This preliminary preparation reduces the amount of trimming needed and improves manufacturing efficiency while maintaining precision.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent changes material parameters by using specific resistive materials with controlled resistivity and thickness, and by adjusting the film formation conditions. This allows the resistance value to be precisely controlled through material properties rather than relying solely on post-manufacturing laser trimming, thereby improving both precision and productivity.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If geometric precision is improved to reduce transfer errors during substrate mounting, then mounting reliability is improved, but manufacturing complexity increases

Engineering Contradiction:
Improvemounting reliabilityVSAvoidgeometric precision requirements
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by providing the insulating substrate with specific surface properties in the electrode regions, such as controlled roughness or coating layers, while maintaining different properties in other areas. This localized optimization improves mounting reliability at critical interfaces without requiring high geometric precision across the entire substrate, thereby reducing manufacturing complexity.

Inventive Principle:
Principle #3Local quality

3Measurement precision

If multiple types of capacitors with different capacitance values are designed individually, then capacitance precision is improved, but design time and labor increase

Engineering Contradiction:
Improvecapacitance value precisionVSAvoiddesign time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent applies universality by designing a common basic capacitor structure that can accommodate multiple capacitance values through standardized electrode patterns and dielectric layer configurations. This universal design framework allows different capacitance values to be achieved by varying only specific parameters such as electrode area or dielectric thickness, rather than creating entirely separate designs for each capacitance value, thereby reducing design time and labor while maintaining precision.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Area of moving object

If chip resistors are downsized to increase installation density, then area utilization is improved, but resistance value range and precision deteriorate

Engineering Contradiction:
Improvechip sizeVSAvoidresistance value range
Core Design Contradiction:
Area of moving objectVSAdaptability or versatility

Solution Approach 1:

The patent applies another dimension by transitioning from planar resistive films to three-dimensional resistive structures, such as vertically stacked resistive layers or columnar resistive elements. This dimensional change allows the resistance value to be controlled by the height or thickness of the resistive structure rather than its planar area, enabling a wide range of resistance values to be achieved in miniaturized chip formats without sacrificing precision or versatility.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10763016B2Method of manufacturing a chip component
Publication Date: 2020.09.01 ROHM CO LTD
  • US10763016B2 patent drawing
  • US10763016B2 patent drawing
  • US10763016B2 patent drawing

AI summary

A method for manufacturing a chip component includes forming an element, which includes a plurality of element parts, on a substrate. A plurality of fuses are formed, for disconnectably connecting each of the plurality of element parts to an external connection electrode. The external connection electrode, which is arranged to provide external connection for the element, is formed by electroless plating on the substrate.