Resistive Element Dot Pattern Adjustment for Resistance Control
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Solution Overview
Problem
Existing methods for producing resistive elements, such as screen printing and inkjetting, face challenges in efficiently producing resistors with varying resistances, including high production costs, complex process requirements, and difficulties in high-mix, low-volume production, due to the need for multiple screen replacements and precise alignment of conductive pastes.
Innovation Solution
The method involves prototyping an electronic component with a resistive element arranged in a reference pattern using inkjetting, measuring the resistance, and adjusting the pattern by removing or modifying specific portions to achieve the desired resistance, allowing for efficient production of components with various resistances without the need for trimming or material changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screen printing is used to form resistive portions with different resistances, then resistance values can be achieved, but screen production cost increases and production time extends due to screen replacement for each resistance
Solution Approach 1:
A single screen is designed to form multiple different resistive portions with different resistance values on the same substrate. The screen contains multiple patterns that can print different resistor configurations simultaneously, eliminating the need for screen replacement when producing resistors with different resistance values, thus reducing production time while maintaining resistance precision
Solution Approach 2:
The screen is divided into multiple independent printing regions or patterns, each capable of forming resistive portions with different resistance values. This segmentation allows a single screen to perform multiple functions by printing different resistor patterns in different areas of the substrate without requiring screen changes
2Manufacturing precision
If multiple types of conductive pastes are applied by screen printing, then different resistance values can be achieved, but process complexity increases due to drying steps and screen replacement
Solution Approach 1:
Instead of using different conductive pastes with different compositions to achieve different resistance values, the invention uses a single conductive paste and varies the geometric parameters of the printed pattern (such as line width, spacing, or pattern density) to control resistance. This eliminates the complexity of managing multiple paste types, drying steps, and screen replacements while maintaining precise resistance control
3Ease of manufacture
If a single type of resistive ink is used for inkjetting, then production is simplified, but high-mix, low-volume production becomes difficult as different compositions must be prepared in advance for different resistances
Solution Approach 1:
The inkjet printing system uses a single resistive ink that can be dynamically programmed to deposit material with varying patterns, dot sizes, spacing, or layer counts based on real-time control parameters. This allows the system to adapt to different resistance requirements without changing the ink composition, enabling high-mix, low-volume production while maintaining ease of manufacture through digital control rather than material changes
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 enables efficient production of electronic components with precise resistance values by eliminating the need for laser trimming and reducing production time and material costs, while improving accuracy and flexibility in producing resistors with different resistances.
Implementation Method 1
arranging dots of a resistive ink containing a constituent that is to be the resistive element in an entire reference arrangement pattern by inkjetting
Data Source
AI summary
An electronic component and a method for producing the electronic component achieve efficient production of resistive elements with various resistances. The electronic component includes a pair of terminals opposite each other and a resistive element disposed between the pair of terminals. The resistive element includes a plurality of dots arranged so as to overlap each other in a reference arrangement pattern excluding a portion of the arrangement pattern. To produce the electronic component, an electronic component is prototyped in advance and includes a resistive element in which the dots are arranged in the entire reference arrangement pattern between the pair of terminals. The prototyped resistive element is then partially removed so as to attain a desired resistance. An electronic component is then produced in which the dots are arranged in the reference arrangement pattern with a portion of the arrangement pattern excluded on the basis of the shape of the partially removed resistive element.