Resistor Paste TCR Control via Manganese Oxide Glass Paste
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Solution Overview
Problem
As chip resistors are downsized, their temperature coefficient of resistance (TCR) increases, requiring various types of resistor pastes with different TCR drivers, making it challenging to achieve the necessary TCR within a narrow specification, such as ±100 ppm/°C.
Innovation Solution
A method of manufacturing a chip resistor paste by combining a basic resistor paste with a glass paste acting as a TCR driver, comprising manganese oxide, to adjust the TCR to a desired value, eliminating the need to stock multiple pastes based on resistor size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If chip resistors are downsized to reduce dimensions, then the size of the resistor is reduced, but the temperature coefficient of resistance (TCR) increases and becomes difficult to control within narrow specifications
Solution Approach 1:
The invention segments the TCR adjustment function into a separate glass paste component that can be independently added to the basic resistor paste. This allows the TCR to be adjusted by controlling the amount of glass paste added, rather than requiring different basic pastes for different TCR values. The segmentation enables independent optimization of paste composition and TCR control.
Solution Approach 2:
The invention changes the parameter control approach by using the composition ratio parameter (amount of glass paste added to basic resistor paste) to control TCR. Instead of changing the entire paste formulation, the method adjusts TCR by varying the proportion of glass paste containing manganese oxide, providing precise control over TCR values.
2Manufacturing precision
If various types of resistor pastes with different TCR drivers are stocked to meet different TCR specifications, then TCR control is achieved, but inventory complexity and manufacturing complexity increase
Solution Approach 1:
The invention creates a universal basic resistor paste that can serve multiple TCR specifications through the addition of a universal glass paste component. The glass paste acts as a multi-functional TCR driver that can adjust TCR to various target values depending on the amount added, eliminating the need for multiple specialized pastes.
Solution Approach 2:
The invention introduces dynamic adjustability to the paste system by allowing the TCR to be tuned continuously by varying the amount of glass paste added. This dynamic approach replaces the static inventory of discrete paste types with a flexible formulation system where TCR can be adjusted according to specific requirements.
3Manufacturing precision
If various types of resistor pastes with different TCR drivers are stocked to meet different TCR specifications, then TCR control is achieved, but the number of paste types to be managed increases
Solution Approach 1:
The invention extracts the TCR-driving function from the basic resistor paste and places it into a separate glass paste component. This extraction allows the basic paste to remain uniform while the TCR characteristics are controlled by the added glass paste, reducing the number of different paste types needed.
Solution Approach 2:
The glass paste serves as a universal TCR adjustment agent that can replace multiple specialized paste formulations. By using this single multi-functional component, the inventory of paste types is reduced while maintaining the ability to achieve various TCR specifications.
Data Source
AI summary
A method of manufacturing a resistor paste comprising steps of: (a) preparing a basic resistor paste comprising, (i) a conductive powder, (ii) a first glass frit, and (iii) a first organic medium; and (b) preparing a glass paste as a TCR driver comprising, (iv) a second glass frit comprising manganese oxide, and (v) a second organic medium, (c) adding the glass paste to the basic resistor paste to obtain a resistor paste with a desired TCR.