Punched Part Integrating Resistor and IC Landing Area
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Solution Overview
Problem
Current current-measuring resistor production methods involve separate packaging of resistors and integrated circuits, leading to increased complexity and parasitic effects due to soldered connections, and existing integrated solutions are not suitable for precision resistors with different material requirements.
Innovation Solution
A punched part made of composite material with integrated current connecting parts, a resistor element, and a landing area for an integrated circuit, along with voltage measuring contacts and external contacts, allowing for the integration of the resistor and evaluation circuit in a single housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate packaging of resistors and integrated circuits is used, then individual components can be optimized independently, but packaging complexity and production cost increase
Solution Approach 1:
The patent combines the resistor and integrated circuit into a single punched part with a unified structure. The resistor element, connecting parts, and landing area for the integrated circuit are integrated in one component, eliminating the need for separate packaging and reducing overall system complexity while maintaining independent optimization capabilities.
Solution Approach 2:
The punched part serves multiple functions simultaneously: it acts as a resistor, provides connecting parts for current flow, and includes a landing area for mounting the integrated circuit. This multi-functional design eliminates the need for separate packaging of different components.
2Ease of manufacture
If separate packaging with soldered connections is used, then components can be independently manufactured, but parasitic effects increase
Solution Approach 1:
By integrating the resistor and integrated circuit mounting area into one punched part, the patent eliminates soldered connections between separate components. The direct integration removes intermediate connection paths that would otherwise introduce parasitic effects, while manufacturing remains straightforward through the punching process.
3Ease of manufacture
If uniform material is used for punched part, then manufacturing is simplified, but precision resistor requirements cannot be met
Solution Approach 1:
The punched part features different materials in different regions: the resistor element is made from a resistance material (e.g., CuMnNi alloy) while the connecting parts are made from conductor material (e.g., copper). This local differentiation allows each region to have optimized properties for its specific function while maintaining a unified manufacturing process.
Solution Approach 2:
The punched part is constructed as a composite material structure with multiple material types (resistance material and conductor material) combined in a single component. This composite approach enables precision resistor performance while maintaining manufacturing simplicity through integrated production.
4Measurement precision
If integrated circuit is mounted on printed circuit board, then voltage measurement is enabled, but connection complexity and parasitic effects increase
Solution Approach 1:
The patent integrates the integrated circuit mounting area directly into the punched part structure through the landing area. This eliminates the need for separate printed circuit board mounting and complex soldered connections, reducing connection complexity while maintaining voltage measurement capability.
Solution Approach 2:
The patent extracts the integrated circuit mounting function from the traditional printed circuit board approach and incorporates it directly into the punched part structure. The landing area provides direct mounting capability, eliminating intermediate connection layers and reducing overall system complexity.
Data Source
AI summary
The invention relates to a punched part for producing an electrical resistor, in particular a current measuring resistor, comprising a resistor element (9) consisting of a low-resistance resistive material (for example Manganin®) and two electrical connection parts (10, 11) consisting of a conductor material (for example copper), wherein the resistor element (9) is arranged between the two electrical connection parts (10, 11) in the direction of current flow in such a way that the electrical current flows through the resistor element (9). In accordance with the invention, the punched part additionally has a landing area (14) for providing an integrated circuit (16) on the landing area (14) of the punched part. Furthermore, the invention comprises a current sensor comprising such a punched part and a corresponding production method.