Chip Resistor Electrode Dimension Control via Meandering Conductive Plates
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Solution Overview
Problem
Existing chip resistor manufacturing methods often result in errors in electrode dimensions during the cutting process, leading to incorrect resistance values and current measurements due to misalignment of cutting positions.
Innovation Solution
A method involving the formation of a resistor assembly with elongated conductive and resistance body plates, bonded by welding, and then divided into chip resistors using a punching process with precision molds to ensure accurate electrode dimensions and resistance values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a grid-type insulating layer is formed and a conductive member is formed in the remaining region to obtain a plate-shaped resistor assembly, then the four electrodes can be provided on one surface of the resistance body, but cutting position shifts generate errors in electrode dimensions and resistance values
Solution Approach 1:
The patent applies preliminary action by pre-forming the conductive member with a meandering shape that includes predetermined cutting lines before the actual cutting process. The conductive member is designed with extended portions that will become separate electrodes after cutting, ensuring that even if cutting positions shift, the electrodes maintain their functional dimensions and the resistance body maintains its designed resistance value.
2Productivity
If cutting positions are shifted from desired positions, then manufacturing efficiency is maintained, but errors are generated in electrode dimensions and resistance values
Solution Approach 1:
The patent applies parameter changes by modifying the shape and configuration of the conductive member to be meandering with extended portions that accommodate cutting position variations. The conductive member's geometry is specifically designed so that dimensional parameters of the electrodes remain within acceptable tolerances even when cutting positions deviate from ideal positions, ensuring accurate current measurement functionality.
3Ease of manufacture
If the dimension of the conductive member is defined by a relationship with the insulating layer, then the electrode structure can be formed, but trimming processes are required to correct dimensional errors
Solution Approach 1:
The patent eliminates the need for trimming by applying preliminary action - the conductive member is pre-formed with a meandering shape that includes built-in compensation for cutting position shifts. The extended portions of the conductive member are designed to become separate electrodes after cutting, ensuring correct dimensions are achieved directly during the forming process without requiring subsequent trimming operations.
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 reduces errors in electrode dimensions and resistance values, allowing for precise current detection and efficient manufacturing of chip resistors without the need for trimming, enhancing the accuracy and reliability of current measurements.
Implementation Method 1
bonded by welding
Data Source
AI summary
A method of manufacturing a chip resistor includes forming a resistor assembly in which a conductive member including portions separated from each other in a first direction is provided in a resistance body member; and dividing the resistor assembly into chip resistors, each including a chip-shaped resistance body formed by a part of the resistance body member, a pair of main electrodes formed by a part of the conductive member and separated from each other in the first direction, and a pair of sub-electrodes formed by a part of the conductive member, separated from each other in the first direction, and adjacent to the main electrodes in a second direction perpendicular to the first direction with concave portions recessed in the first direction interposed therebetween, by punching.