Inkjet Printed Resistor Element with Variable Dot Patterns
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Solution Overview
Problem
Existing methods for manufacturing resistor elements, such as screen printing, require multiple screen plates, are time-consuming, and unsuitable for small-volume production with varied resistances, as they necessitate preparing different resistive inks for different resistances and face challenges in precise positioning and filling gaps between printed electroconductive pastes.
Innovation Solution
The use of an ink jet method to apply fine particles of resistive inks with different compositions, forming overlapping dots to create resistor elements without the need for screen plates, allowing for varying resistance by adjusting the size, number, or shape of dots, and enabling easy adjustment of resistance post-manufacture by removing parts of the resistive portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screen printing is used to form resistor elements, then resistive portions can be formed with desired resistance, but screen plates must be replaced for every change in resistance, increasing cost and preparation time
Solution Approach 1:
The patent applies parameter changes by varying the dot size, dot interval, or dot pattern density in the resistive portion to achieve different resistance values. Instead of changing screen plates, the resistance is adjusted by modifying geometric parameters of the printed dots, allowing flexible resistance adjustment without additional preparation time.
Solution Approach 2:
The patent introduces dynamics by making the resistive portion configurable through variable dot arrangements. The dot size, spacing, and density can be dynamically adjusted according to the desired resistance value, enabling adaptive resistance control without fixed screen plate constraints.
2Adaptability or versatility
If multiple types of electroconductive pastes are printed by screen printing, then different resistance values can be achieved, but multiple printing steps and screen plate replacements are required, complicating the process
Solution Approach 1:
The patent applies universality by using a single screen plate for printing the resistive portion that can produce multiple resistance values. The same screen plate structure is used, but the resistance is varied through dot pattern modifications, making the screen plate multi-functional for different resistance requirements.
Solution Approach 2:
The patent applies segmentation by dividing the resistive portion into multiple discrete dots with variable sizes and spacing. This segmentation allows independent control of resistance characteristics through dot arrangement while using a single printing process, avoiding the need for multiple paste types.
3Ease of manufacture
If a single type of resistive ink is used to form resistors, then production can be simplified, but different resistances require different ink compositions, which is unsuitable for small-volume production with great varieties
Solution Approach 1:
The patent uses parameter changes by keeping the ink composition constant while varying the dot size, dot interval, and dot density to achieve different resistance values. This approach maintains production simplicity with a single ink type while providing versatility in resistance values through geometric parameter variation.
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
This approach eliminates the need for screen plates, reduces production costs and time, and allows for efficient production of resistor elements with a range of resistances, facilitating cost-effective and flexible manufacturing of electronic components.
Implementation Method 1
The first dots and the second dots are formed by ejecting fine particles of resistive inks having different compositions to apply the resistive inks onto a base material by, for example, an ink jet method.
Implementation Method 2
Alternatively, a laser printer may be used to apply fine particles of resistive toners having different compositions to the base material.
Data Source
AI summary
To provide an electronic component including a resistor element that can be efficiently produced with a range of resistances, and a method for manufacturing the electronic component, the electronic component includes a pair of terminals, and a resistor element disposed between the terminals. The resistor element includes at least two resistive portions (hereinafter referred to as a first resistive portion and a second resistive portion) that are continuously disposed. The first resistive portion includes a plurality of first dots overlapping one another. The second resistive portion includes a plurality of second dots having a different electric resistance from that of the first dots overlapping one another.