Compact Resistor Electrode Structure for Low-Resistance Sensing
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Solution Overview
Problem
Existing resistors face challenges in achieving both smaller size and lower resistance, particularly for on-board applications in automobiles, as the resistance value is dependent on the dimension of the resistor, making it difficult to further reduce resistance beyond expected limits.
Innovation Solution
A resistor design with a resistance body and electrodes where the end surfaces of the resistance body are abutted and bonded to the electrodes, featuring leg portions that protrude from the main body portions, allowing for a length dimension of 3.2 mm or less, and adjustable resistance values through proportional adjustments without changing the overall dimension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the dimension of the resistance body is reduced to achieve smaller size, then the resistance value increases, but lower resistance is required for on-board applications
Solution Approach 1:
The patent extends the electrode structure beyond the resistance body in the longitudinal direction, creating leg portions that protrude from the main body. This dimensional extension allows the overall resistor length to exceed the resistance body length, enabling lower resistance values without increasing the resistance body volume. The leg portions provide additional conductive path length outside the resistance body, effectively reducing total resistance while maintaining compact resistance body dimensions.
Solution Approach 2:
The electrode is divided into distinct segments: a main body portion bonded to the resistance body and leg portions protruding therefrom. This segmentation allows independent optimization of each portion - the main body portion maintains compact dimensions for small size, while the leg portions extend to provide additional conductive length for lower resistance, resolving the contradiction between size and resistance value.
2Length of moving object
If the length dimension is reduced to 3.2 mm or less for miniaturization, then the resistance value becomes too high, but lower resistance is needed for current sensing applications
Solution Approach 1:
The patent utilizes the longitudinal dimension by extending leg portions of the electrode beyond the resistance body boundaries. While the resistance body maintains a compact length of 3.2 mm or less, the overall resistor length exceeds this due to the protruding leg portions. This dimensional strategy provides sufficient conductive path length for low resistance while keeping the resistance body miniaturized for compact installation.
Solution Approach 2:
Different portions of the electrode have different functional qualities: the main body portion is optimized for compact bonding to the resistance body, while the leg portions are optimized for providing extended conductive length. This local differentiation allows the resistor to achieve both small size (through compact main body) and low resistance (through extended leg portions).
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 achieves resistors with lower resistance values, improved stability, and reduced electromigration, while maintaining a compact size, enhancing heat radiation and design flexibility, and ensuring consistent sensing accuracy.
Implementation Method 1
end surfaces of the resistance body are respectively abutted to and bonded to end surfaces of the electrodes
Data Source
AI summary
A resistor contains a resistance body and a pair of electrodes (a first electrode body and a second electrode body), wherein end surfaces of the resistance body are respectively abutted to and bonded to end surfaces of the electrodes (a first electrode body and a second electrode body), the electrodes (a first electrode body and a second electrode body) each includes a main body portion and a leg portion, the leg portion protruding from the main body portion in the mounting surface of the resister, and a length dimension of the resistor is equal to or shorter than 3.2 mm.