Modular Chip Resistor Assembly for Flexible Power and Resistance
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Solution Overview
Problem
Existing resistor modules require manual mounting on circuit boards and have limited usability due to high rated power per resistor, making them inefficient for multiple resistor applications and requiring frequent design modifications for different specifications.
Innovation Solution
A chip resistor module comprising a wiring board with insulating substrate and electrical wire, bonded chip resistors, and terminal electrodes, allowing for modular assembly and easy adjustment of resistance values and power ratings by varying the number of resistors or wire patterns, with an insulating sealing member and optional thermally conductive sheet for enhanced protection and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single resistor with high rated power is used, then the power handling capability is improved, but the usability and flexibility for different specifications deteriorate
Solution Approach 1:
The resistor is divided into multiple chip resistors (first, second, third, and fourth chip resistors) connected in series. This segmentation allows the total resistance value to be adjusted by changing the number, arrangement, or resistance values of individual chip resistors, providing flexibility while maintaining high power handling capability through the series configuration.
2Manufacturing precision
If manual mounting is used, then the mounting precision is improved, but the productivity and ease of operation deteriorate
Solution Approach 1:
Multiple chip resistors and terminal plates are integrated into a single molded structure where the resin material encapsulates all components and forms integrated terminal structures. This merging allows the entire assembly to be mounted as one unit on a circuit board, improving both productivity and mounting precision while maintaining proper alignment through the mold's built-in positioning features.
3Manufacturing precision
If individual modifications to specifications are made, then the precision for specific applications is improved, but the device complexity and design time deteriorate
Solution Approach 1:
The resistor configuration is made dynamic and adjustable through the series connection of multiple chip resistors, where the total resistance can be modified by changing the number, arrangement, or individual values of chip resistors. This dynamic design allows flexible specification adjustments without requiring complete redesign of the entire resistor structure.
4Device complexity
If a single resistor structure is used, then the device complexity is reduced, but the adaptability for different resistance values and power ratings deteriorates
Solution Approach 1:
The molded structure serves multiple functions: it provides mechanical support, electrical insulation, environmental protection, and precise positioning for all chip resistors and terminal plates. This universal design allows the same basic structure to accommodate different configurations of chip resistors, enabling various resistance values and power ratings without requiring different structural designs.
Data Source
AI summary
A chip resistor module includes a wiring board, a plurality of chip resistors, and a pair of terminal electrodes. The wiring board includes an insulating substrate and an electrical wire provided on the insulating substrate. The plurality of chip resistors are bonded to the electrical wire. The pair of terminal electrodes is electrically connected to the electrical wire.