Rectangular Chip Resistor Trimming Slot Orientation
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Solution Overview
Problem
Existing chip resistors face issues with current constriction and microcrack formation due to trimming slots, leading to resistance changes and poor tolerance to overload currents, especially when forming L-shaped cuts or linear slots perpendicular to current flow.
Innovation Solution
A rectangular chip resistor design featuring top electrodes with cutout and protruding parts, allowing trimming slots to be formed along the longitudinal direction of the substrate, reducing current constriction by orienting slots with the current flow and using laser trimming to minimize microcrack formation and overlap trimming slots for precise resistance adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If trimming slots are formed linearly or in L-shape perpendicular to current flow for resistance adjustment, then resistance can be adjusted, but current constriction and microcrack formation occur causing resistance changes and poor overload tolerance
Solution Approach 1:
Instead of forming trimming slots perpendicular to the current flow direction (conventional approach), the patent inverts the approach by forming trimming slots in the longitudinal direction parallel to the current flow. This inversion eliminates current constriction at slot tips and bends, preventing microcrack formation and improving overload tolerance while maintaining resistance adjustability through laser trimming
2Manufacturing precision
If trimming slots are formed to adjust resistance, then resistance setting is achieved, but current turbulence causes local heat generation and resistance instability
Solution Approach 1:
The patent inverts the conventional trimming slot orientation from perpendicular to parallel with the current flow direction. This eliminates turbulent current flow at slot tips and bends, preventing local heat generation and resistance instability, while laser trimming maintains precise resistance setting capability
3Ease of manufacture
If trimming slots are formed perpendicular to current flow, then resistance adjustment is possible, but current constriction leads to microcrack development and resistance change
Solution Approach 1:
The patent inverts the trimming slot orientation from perpendicular to parallel with the current flow. This eliminates current constriction and microcrack formation that cause resistance drift, while laser trimming provides precise resistance adjustment. The longitudinal slot configuration ensures stable resistance characteristics under various operating conditions
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 design effectively suppresses current constriction and microcrack-related issues, enabling precise resistance setting and improved tolerance to overload currents, even at higher power ratings, by maintaining a stable current flow and reducing resistance changes during overload.
Implementation Method 1
forming a trimming slot in the resistive element for adjusting resistance
Data Source
AI summary
The chip resistor includes insulating substrate 10, first and second top electrodes (11x, 11b) on the top surface of the insulating substrate each on either longitudinal end thereof, and resistive element 12 electrically in contact with the top electrodes, wherein each of the top electrodes has, on its inner side facing to the other, cutout part 11a and protruding part 11b, with the cutout part in the first top electrode extending from at least one longitudinal side of the insulating substrate, transversely inwards thereof, and with the cutout part in the second top electrode arranged substantially point-symmetrically to the cutout part in the first top electrode with respect to the center of the insulating substrate, wherein the resistive element has contacting regions 12b, and non-contacting regions 12c, and trimming slot (53a, 53b) including a linear part.