JPH10223401A - Resistor and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a small and inexpensive resistor having stabilized characteristics by a structure wherein a resistor made of a metal foil is sandwiched by first and second insulating plates made of a thermoplastic resin. SOLUTION: A resistor 12 comprising a metal foil is provided from a part of the lower surface of a first insulating member 11 made of a resin, e.g. thermoplastic polyamide resin, through the side and upper surfaces to a part of the opposite lower surface thereof and electrode corresponding parts 13, 14 are provided, respective, on the side surface and the lower surface of the first insulating member 11. The resistor 12 on the upper surface of the first insulating member 11 is provided with a cut 16 for enhancing adhesion of the first insulating member 11 to a second insulating member 11. The second insulating member 17 made of a resin, e.g. thermoplastic polyamide resin, is then provided to sandwich the resistor 12 on the upper surface of the first insulating member 11.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a low-resistance resistor used for detecting a current in a control circuit of a motor or a switching regulator, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, as a resistor used for detecting a current in a control circuit or the like, a chip-type resistor that can be surface-mounted has been required as electronic devices to be mounted become smaller.

A conventional resistor is disclosed in Japanese Unexamined Patent Publication No. 6-267.
The one disclosed in Japanese Patent No. 707 is known.

Hereinafter, a conventional resistor and a method of manufacturing the same will be described with reference to the drawings.

FIG. 3A is a top view of a conventional resistor, which is a perspective view of a resistor which is a main part of the conventional resistor, and FIG. 3B is a side view of the same.

In FIG. 1, reference numeral 1 denotes a first ceramic substrate. Reference numeral 2 denotes a metal resistor provided on the upper surface of the first ceramic substrate 1 and made of an alloy plate of various metals such as a copper-nickel plate, a manganin plate, a constantan plate, and a geranin plate. Reference numeral 3 denotes a pair of current terminals provided by bending the metal resistor 2 in a U-shape on opposite side surfaces of the first ceramic substrate 1. Reference numeral 4 denotes a pair of voltage terminals provided on one side of the first ceramic substrate 1 not having the current terminals 3 by bending the metal resistor 2 into a U-shape. Reference numeral 5 denotes a cutout provided in the metal resistor 2 by trimming to adjust the resistance value. Reference numeral 6 denotes a second ceramic substrate provided on the upper surface of the first ceramic substrate 1 with the metal resistor 2 interposed therebetween.

A method of manufacturing the conventional resistor having the above-described structure will be described below.

First, as a step of forming the metal resistor 2, a plurality of metal resistors 2 are formed by pressing a metal alloy foil such as a copper-nickel plate, a manganin plate, a constantan plate, and a geranin plate with a die. A series of continuous resistors is formed.

Next, as a trimming step, a current is passed between the current terminals 3 at both ends of the series of resistors obtained in the preceding step, and the voltage between the voltage terminals 4 of the metal resistors 2 is measured while measuring each metal. The resistance value of the resistor 2 is adjusted by any one of a method such as laser trimming, sand blasting, a diamond cutter, and a grinder to form the cutout 5.

Next, as a step of forming the metal resistor 2 on the upper surface of the ceramic substrate 1, a series of resistor groups obtained in the previous step are cut into respective resistors to obtain the metal resistor 2, which is obtained. The first ceramic substrate 1 is attached to the upper surface using an adhesive, and the second ceramic substrate 6 is attached so as to sandwich the metal resistor 2.

Next, a pair of current terminals 3 is formed by bending the metal resistor 2 in a U-shape on opposite side surfaces of the first ceramic substrate 1, and the current terminals 3 of the first ceramic substrate 1 are provided. The metal resistor 2 is bent into a U-shape on one side to form a pair of voltage terminals 4.

Next, insulation between the first ceramic substrate 1 and the second ceramic substrate 6 with the metal resistor 2 interposed therebetween is insulated and sealed by an insulating material such as a mold or resin dip.

Finally, portions corresponding to the current terminal 3 and the voltage terminal 4 are plated with nickel and solder to produce a conventional resistor.

[0014]

However, in the conventional resistor and the method of manufacturing the same, since the metal resistor 2 is sandwiched between the first and second ceramic substrates 1 and 6, the structure becomes complicated and the resistance is reduced. There was a problem that it would cause a large cost increase in the manufacture of the container.

An object of the present invention is to solve the above-mentioned conventional problems and to provide a small, inexpensive, characteristically stable resistor and a method of manufacturing the same.

[0016]

According to the present invention, in order to achieve the above-mentioned object, a resistor made of a metal foil is sandwiched between first and second insulating plates made of a thermoplastic resin.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The invention according to claim 1 of the present invention is directed to a first insulating member made of a thermoplastic resin, and a metal foil provided at least from a side surface of the first insulating member to a side surface facing the first insulating member. And a second insulating member made of a thermoplastic resin provided so as to sandwich the resistor on the upper surface of the first insulating member.

The invention described in claim 2 is the same as the invention described in claim 1.
The resistor on the upper surface of the first insulating member described in (1) has a notch.

According to a third aspect of the present invention, there is provided a process for forming a resistor group having a side electrode corresponding portion and a lower surface electrode corresponding portion at both ends via a resistor portion; A step of sandwiching the portion between the first and second insulating members and fixing / integrating the same, and bending the portion corresponding to the side electrode and the portion corresponding to the lower surface electrode along the outer periphery of the first insulating member and then separating the pieces. And a step of dividing into two.

(Embodiment 1) A resistor and a method of manufacturing the same according to an embodiment of the present invention will be described below with reference to the drawings.

FIG. 1A is a perspective view of a part of a second insulating member which is a main part of a resistor according to an embodiment of the present invention, and FIG. FIG.

In the figure, reference numeral 11 denotes a first insulating member made of a resin such as a thermoplastic polyimide resin (Legras, manufactured by Mitsui Toatsu Co., Ltd.), a polyetherimide resin, or the like. 12
Is a copper-nickel foil provided on a part of the lower surface opposing the upper surface from a part of the lower surface of the first insulating member 11,
The first insulating member 11 is a resistor made of metal foil such as manganin foil, constantan foil, geranin foil, and nichrome foil.
The portion provided on the side surface is a side electrode equivalent portion 13, and the portion provided on the lower surface is a lower surface electrode equivalent portion 14. Reference numeral 15 denotes a trimming groove for correcting the resistance value of the resistor 12. 16
Is a cutout provided on the resistor 12 on the upper surface of the first insulating member 11 to improve the adhesiveness of the resin between the first insulating member 11 and a second insulating member 17 described later. Reference numeral 17 denotes a second insulating member made of a resin such as a thermoplastic polyimide resin (manufactured by Mitsui Toatsu Co., Ltd .: Reglass) or a polyetherimide resin provided so as to sandwich the resistor 12 on the upper surface of the first insulating member 11. It is. Reference numeral 18 denotes a plating layer provided on the side electrode corresponding portion 13 and the lower surface electrode corresponding portion 14 of the resistor 12.

With respect to the resistor configured as described above,
Hereinafter, the manufacturing method will be described with reference to the drawings.

FIG. 2 is a process chart showing a method of manufacturing a resistor according to an embodiment of the present invention. First, as shown in FIG. 2A, a metal foil is processed to have a predetermined resistance value, and a series of resistor portions 21 are formed. The formed side electrode equivalent portion 22 and lower surface electrode equivalent portion 23 are continuously formed to form the resistor group 20. At this time, the resistor group 20 is held so as to be continuous at both ends or one end. This holding may be performed simultaneously so that the same metal foil can be continuously held when the metal foil is processed into the resistor group 20.
It may be performed by taping after processing into individual pieces.

Next, as shown in FIG. 2 (b), a trimming groove 24 is cut into the resistor portion 21 by a laser, a grinder, or the like so that the resistor 21 has a predetermined resistance value with high accuracy.
Is provided to trim the resistance value.

Next, as shown in FIG. 2C, the first and second insulating members 26 and 27 made of a film-like or sheet-like thermoplastic resin are connected to the resistance of the resistor processed in the previous step. Cut into strips according to the top dimensions of the body part 21,
The first and second insulating members 26,
27, it is laminated in a sandwich shape, and fixedly integrated from both sides of the first and second insulating members 26 and 27 by thermocompression bonding or ultrasonic welding.

Next, as shown in FIG. 2 (d), the metal foil connecting the resistor group 20 is cut or the tape is removed to connect to the resistor portion 21 and form two pairs of side-electrode-corresponding portions 22.
Is bent substantially along the side end of the first insulating member 26, and the lower surface electrode equivalent portion 23 is replaced with the first insulating member 26.
Bend substantially along the lower surface of the.

Finally, as shown in FIG. 2E, the substrate is divided into individual pieces, and nickel plating and solder plating are applied to the side electrode corresponding portions 22 and the lower surface electrode corresponding portions 23 to form a plating layer 25. It is used to manufacture resistors.

In the present embodiment, the shape of the notch is round, but it may be rectangular or slit.

[0030]

According to the present invention, a resistor is sandwiched between first and second insulating members made of a thermoplastic resin, and a method of thermocompression bonding or ultrasonic welding from both sides of the first and second insulating members is provided. Thus, it is possible to provide an inexpensive and characteristically stable resistor and a method of manufacturing the same.

[Brief description of the drawings]

FIG. 1 (a) is a perspective view in which a part of a second insulating member which is a main part of a resistor according to an embodiment of the present invention is cut away, and FIG.

FIG. 2 is a view showing the same manufacturing method.

FIG. 3A is a top view in which a resistor as a main part of a conventional resistor is seen through; FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 1st insulating member 12 Resistor 16 Notch 17 2nd insulating member

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI H01C 17/242 H01C 17/24 L (72) Inventor Koichi Ikemoto 1006 Ojidoma, Kadoma City, Osaka Prefecture Matsushita Electric Industrial Co., Ltd.

Claims (3)

[Claims] 1. A first insulating member made of a thermoplastic resin, a resistor made of a metal foil provided at least from a side surface of the first insulating member to a side surface facing the first insulating member, and an upper surface of the first insulating member. And a second insulating member made of a thermoplastic resin provided so as to sandwich the resistor. 2. The resistor according to claim 1, wherein the resistor on the upper surface of the first insulating member has a notch. 3. A step of forming a resistor group having a side electrode corresponding portion and a lower surface electrode corresponding portion at both ends via a resistor portion, and the first and second insulating portions of the resistor portion of the resistor group are formed. A resistor comprising: a step of sandwiching and fixing and integrating with a member; and a step of folding the portion corresponding to the side surface electrode and the portion corresponding to the lower surface electrode along the outer periphery of the first insulating member and then dividing the same into individual pieces. Manufacturing method.