Current-Sense Resistor Structure With Conductive Heat-Dissipating Cover
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Solution Overview
Problem
Conventional resistors used for current detection generate excessive heat, leading to fluctuations in resistance due to inadequate heat dissipation properties.
Innovation Solution
A resistor design featuring a resistive body sandwiched between insulators with a conductive covering body on at least one insulator, incorporating a conductive layer with high thermal conductivity and a slit structure to enhance heat dissipation and reduce thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional resistor structure is used, then the device is simple and easy to manufacture, but heat dissipation property is insufficient leading to temperature rise and resistance fluctuation
Solution Approach 1:
The covering body is divided into multiple layers: a base covering body and an additional conductive layer. This segmentation allows the heat dissipation function to be enhanced by adding the conductive layer without completely redesigning the entire resistor structure, thus improving heat dissipation while controlling complexity increment
Solution Approach 2:
The resistor employs a composite structure combining the insulating covering body with a conductive layer having high thermal conductivity. This composite material approach allows the integration of materials with complementary properties - the insulating covering body provides electrical insulation while the conductive layer provides thermal conduction pathways for heat dissipation
2Power
If the resistive body operates at high current, then current detection capability is improved, but heat generation increases causing resistance value fluctuation
Solution Approach 1:
The conductive layer acts as an intermediary between the resistive body and the external environment. It provides a dedicated thermal conduction pathway that mediates heat transfer from the resistive body to the covering body and ultimately to the surroundings, preventing direct thermal coupling that would cause resistance fluctuation
3Temperature
If thermal conductivity is increased to improve heat dissipation, then temperature stability is improved, but material selection and manufacturing complexity increase
Solution Approach 1:
Instead of making the entire covering body highly conductive (which would complicate manufacturing), only a partial conductive layer is added on specific regions. This partial action approach provides sufficient thermal conduction pathways for heat dissipation while maintaining manufacturing simplicity and avoiding the need to redesign the entire covering body structure
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 dissipates heat generated by the resistive body, stabilizing resistance values and improving mechanical strength through enhanced thermal conductivity and stress relief.
Implementation Method 1
the first layer having electrical conductivity and being in contact with at least one of the first insulator and the second insulator
Data Source
AI summary
A resistor includes a first insulator, a resistive body, a second insulator, a pair of electrodes, and a covering body. The first insulator has a first obverse surface facing in a thickness direction thereof. The resistive body is provided on the first obverse surface. The second insulator covers the resistive body. The pair of electrodes are electrically connected to the resistive body at both sides in a first direction perpendicular to the thickness direction. The covering body is formed on at least one of the first insulator and the second insulator. The covering body has electrical conductivity. The first layer is in contact with at least one of the first insulator and the second insulator.