Chip Resistor Meandering Trimming Grooves

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Solution Overview

Problem

Existing chip resistors face challenges in achieving precise resistance value adjustment and improved anti-surge characteristics due to variations in initial resistance values and maladjustment during the trimming process, particularly when forming trimming grooves in meandering resistive elements.

Innovation Solution

A chip resistor design featuring a resistive element with a meandering shape, including a rectangular adjustment part with angled second trimming grooves that extend alongside the shortest current path, allowing for precise resistance value adjustment and improved anti-surge characteristics by separating the regions for rough and fine adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If trimming grooves are formed in meandering resistive elements to adjust resistance values, then resistance value adjustment capability is improved, but maladjustment occurs and yield declines

Engineering Contradiction:

Improveresistance value adjustment precisionVSAvoidyield

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The adjustment part is divided into a first region for rough adjustment and a second region for fine adjustment. Multiple trimming grooves are formed in the first region to achieve rough resistance value adjustment, while a single trimming groove is formed in the second region for precise fine adjustment. This segmentation allows systematic control of the resistance value adjustment process, reducing maladjustment and improving yield.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the current path is elongated to improve anti-surge characteristics, then anti-surge capability is improved, but the resistance value becomes harder to control within target range

Engineering Contradiction:

Improveanti-surge characteristicsVSAvoidresistance value control precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The adjustment part is segmented into a first region containing multiple trimming grooves for rough adjustment and a second region containing a single trimming groove for fine adjustment. This segmentation enables precise control of resistance value even when the current path is elongated for anti-surge characteristics, as the fine adjustment region can compensate for variations introduced by the meandering shape.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If multiple trimming grooves are formed for rough adjustment, then resistance value range coverage is improved, but adjustment complexity increases

Engineering Contradiction:

Improveresistance value range coverageVSAvoidadjustment process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjustment part is divided into functional regions: the first region contains multiple trimming grooves for rough adjustment to cover a wide resistance value range, while the second region contains a single trimming groove for fine adjustment. This segmentation organizes the complexity systematically, making the adjustment process more manageable and predictable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multiple trimming grooves in the first region perform preliminary rough adjustment to bring the resistance value close to the target range. This preliminary action reduces the burden on the final fine adjustment step, simplifying the overall adjustment process and improving predictability.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If trimming grooves are formed in areas with high current distribution, then resistance value adjustment effectiveness is improved, but anti-surge characteristics deteriorate

Engineering Contradiction:

Improveresistance value adjustment effectivenessVSAvoidanti-surge characteristics

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Different regions of the adjustment part are assigned different functions based on local current distribution characteristics. The first region is designed for rough adjustment with multiple trimming grooves, while the second region is specifically designed for fine adjustment with a single trimming groove positioned to balance adjustment effectiveness with anti-surge performance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11646136B2Chip resistor and method of manufacturing chip resistor

Publication Date: 2023.05.09 KOA CORP

AI summary

A chip resistor includes an insulated substrate having a rectangular parallelepiped shape, a first front electrode and a second front electrode created on both longitudinal ends of the insulated substrate, and a resistive element making a connection between the first and second front electrodes. The resistive element is formed in a meandering shape with a first region and a second region continuing in series via a jointing section between a pair of connecting portions. Moreover, in the first region, a first trimming groove for rough adjustment is formed to elongate a current path of the resistive element. In the second region, a second trimming groove is formed for fine adjustment extending in a direction angled with respect to a straight line along a direction in which the first trimming groove extends.