Chip Resistor Protrusion Design for Protective Film Adhesion
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Solution Overview
Problem
Conventional chip resistors experience degradation in long-term reliability due to the peeling off of third protective films from the resistance member, exposing the resistance member and affecting its reliability.
Innovation Solution
A chip resistor design featuring protrusions on the side surfaces of the resistance member, with a third protective film covering these protrusions, and a method involving etching to form grooves and integrate protective members within these grooves, increasing the contact area and preventing peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If third protective film is formed on flat side surface of resistance member, then formation process is simple, but adhesive property between protective film and resistance member degrades
Solution Approach 1:
The side surface of the resistance member is formed with a curved surface instead of a flat surface. This curved surface increases the contact area between the third protective film and the resistance member, thereby improving adhesive property and preventing peeling of the protective film during cutting and long-term use.
2Reliability
If third protective film is formed on exposed side surface before cutting, then protective coverage is achieved, but protective film peels off during cutting
Solution Approach 1:
The curved side surface provides increased surface area and better mechanical interlocking with the third protective film, preventing the film from peeling off during the cutting process and maintaining protective coverage throughout the product lifecycle.
3Productivity
If resistance member is cut after forming protective films, then individual chip resistors are produced, but resistance member becomes exposed from protective film
Solution Approach 1:
The curved side surface ensures that the third protective film maintains strong adhesion during the cutting process, preventing exposure of the resistance member and ensuring long-term reliability is not degraded by cutting operations.
Data Source
AI summary
An object of the present disclosure is to provide a chip resistor capable of suppressing degradation of long-term reliability, and a method for producing the chip resistor. The chip resistor of the present disclosure includes resistance member formed of metal, and a pair of electrodes respectively formed on both ends of first main surface of resistance member. The chip resistor further includes first protective film formed on second main surface located on a rear side of first main surface of resistance member, second protective film formed on first main surface of resistance member and between the pair of electrodes, and a third protective film formed on a side surface parallel to a direction of a current flowing between the pair of electrodes of resistance member. The side surface of resistance member is provided with a protrusion that protrudes outward when viewed along the current flowing direction.