Current-Sense Resistor Contact Layout for Precise Resistance Tuning
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Solution Overview
Problem
Existing methods for manufacturing low-resistance current-measuring resistors face challenges such as difficulty in achieving low tolerance resistance values, distortion of current distribution leading to temperature increases, mechanical weak points, and space constraints due to incisions for resistance adjustment.
Innovation Solution
A manufacturing method that adjusts resistance by setting the distance between contact caps on the resistor element, eliminating the need for incisions, and utilizing a solder resist to define the current path precision, thereby achieving precise resistance values without mechanical weaknesses or temperature hotspots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If incisions are made in the resistor element for resistance adjustment, then resistance values can be adjusted, but measurement precision deteriorates due to current distribution distortion and temperature increases
Solution Approach 1:
The invention extracts the resistance adjustment function from the resistor element itself and relocates it to the support structure. By making incisions in the support element rather than the resistor element, the adjustment mechanism is separated from the current-carrying path, eliminating current distribution distortion while maintaining resistance adjustment capability
Solution Approach 2:
The support element acts as an intermediary between the power supply and the resistor element. The incisions in the support element control current distribution to the resistor element without directly interfering with the current flow through the resistor element itself, thus preventing temperature hotspots while enabling resistance adjustment
2Adaptability or versatility
If incisions are made in the resistor element for resistance adjustment, then resistance values can be adjusted, but reliability deteriorates due to mechanical weak points and cracking
Solution Approach 1:
The adjustment incisions are extracted from the resistor element and placed in the support element. This separation protects the resistor element from mechanical damage while maintaining the ability to adjust resistance through support element incisions
Solution Approach 2:
The support element is segmented through incisions to control current paths and adjust resistance. This segmentation occurs in the non-critical support structure rather than in the critical resistor element, maintaining overall component reliability
3Adaptability or versatility
If incisions are made in the resistor element for resistance adjustment, then resistance values can be adjusted, but device complexity increases due to additional space requirements
Solution Approach 1:
The adjustment mechanism is extracted from the resistor element and integrated into the support element. This consolidation eliminates the need for separate adjustment structures and reduces overall component size while maintaining resistance adjustment functionality
4Adaptability or versatility
If material is removed from the resistor element for resistance balancing, then resistance values can be adjusted, but manufacturing precision deteriorates due to fluctuations in internal thermal resistance
Solution Approach 1:
The resistance adjustment function is extracted from the resistor element material removal process and relocated to the support element incision process. This separation allows precise control of current paths without altering the resistor element's thermal properties or material consistency
Solution Approach 2:
Instead of changing the physical amount of resistor material (which affects thermal resistance), the invention changes the electrical path parameters through support element incisions. This allows resistance adjustment while maintaining consistent thermal resistance characteristics
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
Enables resistance values with tolerances less than 0.5% and prevents temperature hotspots, ensuring accurate measurement and improved mechanical resilience while minimizing component size.
Implementation Method 1
the distance between the two contact caps directly on the upper side of the resistor element and, thus, also the length of the current path through the resistor element and, therefore, also the resistance value
Data Source
AI summary
The invention relates to a manufacturing method for an electrical resistor (1), in particular for a low-resistance current measuring resistor, comprising the following steps:Provision of a flat support element (2) made of a conductor material,Provision of a flat resistor element (3) made of a resistor material,applying the flat resistor element (3) to the upper side of the support element (2) with an electrically insulating layer (4) between the resistor element (3) and the support element (2), andcontacting the resistor element (3) by means of two contact caps (8, 9) made of a conductive material, the two contact caps (8, 9) resting directly on the upper side of the resistor element (3) and enclosing a specific distance (d) between them directly on the upper side of the flat resistor element (3) along the direction of current flow in the resistor (1), andSpecification of a desired resistance value of the resistor (1).The manufacturing method according to the invention is characterised by the following step:Adjusting the resistance value of the resistor (1) by setting the distance (d) between the contact caps (8, 9) directly on the upper side of the resistor element (3), wherein the distance (d) is set as a function of the desired resistance value.