WO2021175347A1 - Method of producing a resistor for power applications - Google Patents

Method of producing a resistor for power applications Download PDF

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Publication number
WO2021175347A1
WO2021175347A1 PCT/CZ2020/050055 CZ2020050055W WO2021175347A1 WO 2021175347 A1 WO2021175347 A1 WO 2021175347A1 CZ 2020050055 W CZ2020050055 W CZ 2020050055W WO 2021175347 A1 WO2021175347 A1 WO 2021175347A1
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WO
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Prior art keywords
resistor
conductive patterns
electrically conductive
printed
particles
Prior art date
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PCT/CZ2020/050055
Other languages
French (fr)
Inventor
Jan Řeboun
Aleš Hamáček
Radek Soukup
Jiří Hlína
Silvan Pretl
Robert Vik
Jiří Navrátil
Original Assignee
Západočeská Univerzita V Plzni
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Publication of WO2021175347A1 publication Critical patent/WO2021175347A1/en

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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/0213—Electrical arrangements not otherwise provided for
    • H05K1/0263—High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board
    • H05K1/0265—High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board characterized by the lay-out of or details of the printed conductors, e.g. reinforced conductors, redundant conductors, conductors having different cross-sections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
    • H01C17/06—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
    • H01C17/06—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base
    • H01C17/065—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base by thick film techniques, e.g. serigraphy
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
    • H01C17/06—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base
    • H01C17/065—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base by thick film techniques, e.g. serigraphy
    • H01C17/06506—Precursor compositions therefor, e.g. pastes, inks, glass frits
    • H01C17/06513—Precursor compositions therefor, e.g. pastes, inks, glass frits characterised by the resistive component
    • H01C17/06526—Precursor compositions therefor, e.g. pastes, inks, glass frits characterised by the resistive component composed of metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/003—Thick film resistors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/06—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material including means to minimise changes in resistance with changes in temperature
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/16—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
    • H05K1/167—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor incorporating printed resistors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/12—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
    • H01C17/22—Apparatus or processes specially adapted for manufacturing resistors adapted for trimming
    • H01C17/24—Apparatus or processes specially adapted for manufacturing resistors adapted for trimming by removing or adding resistive material
    • H01C17/242—Apparatus or processes specially adapted for manufacturing resistors adapted for trimming by removing or adding resistive material by laser
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/09—Use of materials for the conductive, e.g. metallic pattern
    • H05K1/092—Dispersed materials, e.g. conductive pastes or inks
    • H05K1/097—Inks comprising nanoparticles and specially adapted for being sintered at low temperature
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/03—Conductive materials
    • H05K2201/0332—Structure of the conductor
    • H05K2201/0335—Layered conductors or foils
    • H05K2201/0338—Layered conductor, e.g. layered metal substrate, layered finish layer, layered thin film adhesion layer
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/10—Using electric, magnetic and electromagnetic fields; Using laser light
    • H05K2203/107—Using laser light
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/11—Treatments characterised by their effect, e.g. heating, cooling, roughening
    • H05K2203/1126—Firing, i.e. heating a powder or paste above the melting temperature of at least one of its constituents
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/14—Related to the order of processing steps
    • H05K2203/1476—Same or similar kind of process performed in phases, e.g. coarse patterning followed by fine patterning
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/17—Post-manufacturing processes
    • H05K2203/171—Tuning, e.g. by trimming of printed components or high frequency circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/12—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
    • H05K3/1216—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns by screen printing or stencil printing
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/12—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
    • H05K3/1283—After-treatment of the printed patterns, e.g. sintering or curing methods
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/12—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
    • H05K3/1283—After-treatment of the printed patterns, e.g. sintering or curing methods
    • H05K3/1291—Firing or sintering at relative high temperatures for patterns on inorganic boards, e.g. co-firing of circuits on green ceramic sheets
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/14—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using spraying techniques to apply the conductive material, e.g. vapour evaporation

Definitions

  • the invention relates to a method of producing a copper-nickel alloy resistor for power applications compatible with copper conductive patterns.
  • Power electronics is nowadays a very intensively developing technical field, which is focused on the effective control of the flow of electrical power, which is used to supply a wide range of appliances.
  • the task of power applications falling into this technical field is the conversion, control and modification of electrical power by means of electrical equipment, the conversion being a change of at least one characteristic quantity of the power system by means of electronic switching components without significantly higher power loss.
  • An example of the technical solution of the module related to power electronics is, for example, the content of document CZ 32 915 U1.
  • Power electronics devices can be generally described by technical features, including a support substrate that provides support for electronic components and can also be used to conduct heat loss, as well as electronic components designed to meet the objective of power application, and last but not least, electrically conductive patterns that are formed on at least one of the surfaces of the substrate and serve as electrical power interconnections among electronic components.
  • a disadvantage of the background of the invention is the absence of printed resistors with a low-temperature coefficient of resistance, since the known printed thick film resistors are generally made of a material which is unsuitable for firing in a reducing or inert atmosphere, which is needed for firing copper conductive patterns. For these reasons, a problem arises with the demanding several-step production process, which is complicated by the mutual elimination of the firing of conductive patterns and passive electronic components in an oxidizing, or in an inert, firing atmosphere. Firing in one type of atmosphere damages those components of the power module that need firing in the other type of atmosphere.
  • the task of the invention is to provide a method of producing a resistor for power applications which would make it possible to produce resistors with electrically conductive copper patterns in a single firing that would allow to produce resistors with a low-temperature coefficient of resistance, that would allow to produce resistors with a pure elemental composition and that would be fast, suitable for use in mass production and that would be economically advantageous.
  • the task is solved by providing a method of producing a resistor for power applications according to the invention below.
  • electrically conductive patterns and at least one passive electronic component are made on the ceramic substrate of the power electronics module.
  • the core of the invention is based on the following process steps: a) semi-finished products of electrically conductive patterns are printed on the ceramic substrate with paste or ink based on dispersed copper particles, b) at least one resistive film is printed on the ceramic substrate with AerosolJet technology with ink based on dispersed copper and nickel particles, or from constantan, c) the semi-finished products are fired in an inert atmosphere at a temperature between 650 °C and 960 °C, wherein process steps a) and b) are arbitrarily interchangeable in order.
  • the greatest advantages of the invention include the simplification of the production process, in which it is possible to fire semi-finished products of copper electrically conductive patterns and resistive film simultaneously under the same temperature and firing atmosphere conditions. Not only is the production process faster, but energy and gas costs are also saved to create an inert atmosphere. In addition, allowing firing from 650 °C causes the particles in the resistive film to sinter, whereby the resulting products exhibit sufficient strength, adhesion and desired electrical conductivity without adding any binder, which is advantageous because the absence of binder does not affect the electrical properties of the products.
  • Another benefit of the invention is the arbitrary interchangeability of process steps a) and b), which makes it possible to design complicated patterns and designs of power applications that were previously out of the question, and in addition the arbitrariness of process steps a) and b) leads to a more efficient use in mass production, since one printing machine does not have to wait for the work of the other printing machine to be completed, but they can work simultaneously, with the work-in-progress products eventually being swapped.
  • the advantage of interchangeability stems from the AerosolJet technology, which allows the application of an aerosol with copper and nickel particles, or constantan, from a distance of up to 5 mm without the resistive film spreading, while well-covering unevenness caused by electrically conductive patterns or other electronic components.
  • Another advantage of the invention is the fact that printing with AerosolJet produces a resistor which has a small thickness and a large contact surface connected to the substrate, thus ensuring quality dissipation of heat loss, which is generated by the passage of current through the resistor thus prepared.
  • the resistor produced under the invention does not overheat during its operation.
  • the ink in process step b) contains copper and nickel particles in a ratio between 45 % and 55 % of nickel.
  • a suitably selected ratio of particle content leads to the formation of a constantan alloy during sintering in process step c), which has excellent operating characteristics in electronic applications due to the low temperature coefficient of resistance.
  • nanoparticles are used during process step b).
  • the nanoparticles sinter very well and, moreover, they adhere well when they hit the surface of the substrate or the semi-finished product of electrically conductive patterns and do not need additional binders. It is also unquestionable that due to the fineness of the nanoparticles, the formation of defects in the resistive film caused by the inhomogeneity of the impact surface is a very rare phenomenon.
  • the exact nominal value of resistance of the resistor after step c) is set by laser trimming.
  • AerosolJet technology allows the printing of a resistor with a relatively accurate thickness, it is possible to further refine the nominal value of resistance by means of laser trimming, especially for sensing resistors and so-called “shunt” resistors.
  • the advantages of the invention include cheap and fast production suitable for mass use, as well as the accuracy and stability of the products thus produced, the quality of electrical parameters, thanks to the absence of binders in the resistors.
  • Fig. 1 shows a method of producing a printed power resistor using a resistive ink containing Cu and Ni nanoparticles, which are printed on a substrate only after the printing of electrically conductive patterns
  • Fig. 2 shows a method of producing a printed power resistor using a resistive ink containing constantan nanoparticles with a ratio of 45:55 (Ni:Cu), which are printed on a substrate before the printing of electrically conductive patterns.
  • test modules for power electronics were produced as follows.
  • Semi-finished products of electrically conductive patterns were printed on the ceramic substrate 1 with paste 2 or ink 2 based on dispersed copper particles 4.
  • resistive films were printed on the ceramic substrate 1 with AerosolJet technology with ink 3 based on dispersed copper and nickel particles 4 and 5, or from constantan particles 8.
  • the order in which the semi finished products were printed was arbitrary.
  • the semi-finished products were fired in an inert atmosphere to form fired films 9, 10, 11 forming resistors and electrically conductive patterns from the semi-finished products.
  • the modules had ceramic substrates 1 with dimensions of 10 cm x 10 cm.
  • Electrically conductive patterns have been designed for test transmissions of different levels of electrical power, including the design of electrodes for connecting resistors produced by the method of the invention.
  • the electrically conductive patterns were made of copper and were printed using screen -printing technology.
  • Inks 3 were used for the production of resistors for use in AerosolJet technology with a known ratio of the content of particles 4 and 5 Ni and Cu and with a known size range of used particles.
  • the ink components consist of metal particles and a stabilizing liquid which prevents the metal particles from agglomerating and which evaporates after printing.
  • the thickness of the resistors was gradually chosen in the range from 500 nm to 10 ⁇ m.
  • the resistive films were printed on the substrate 1 of the sample before printing the electrically conductive patterns and further, the resistive films were printed on the substrate 1 of the sample after printing the electrically conductive patterns. Subsequently, all resistive films were fired together in an inert atmosphere of nitrogen, with the firing temperature set at 950 °C on a thermostat.
  • the constantan was ground to a mix of nanoparticles 8 with a size in the order of units and tens of nanometres.
  • the structural characterization of the resistor the structure has been verified as homogeneous and the measured temperature coefficient of resistance was 0.00005 K -1 .

Abstract

The invented method of producing a resistor for power applications uses AerosolJet printing technology to produce a resistor on a ceramic substrate, thereby simplifying the production process by combining resistor firing and firing electrically conductive patterns on a ceramic substrate for a single firing at temperatures ranging from 650 °C to 960 °C in the same atmosphere.

Description

Method of producing a resistor for power applications
Field of the Invention
The invention relates to a method of producing a copper-nickel alloy resistor for power applications compatible with copper conductive patterns.
Background of the Invention
Power electronics is nowadays a very intensively developing technical field, which is focused on the effective control of the flow of electrical power, which is used to supply a wide range of appliances. The task of power applications falling into this technical field is the conversion, control and modification of electrical power by means of electrical equipment, the conversion being a change of at least one characteristic quantity of the power system by means of electronic switching components without significantly higher power loss. An example of the technical solution of the module related to power electronics is, for example, the content of document CZ 32 915 U1.
Power electronics devices can be generally described by technical features, including a support substrate that provides support for electronic components and can also be used to conduct heat loss, as well as electronic components designed to meet the objective of power application, and last but not least, electrically conductive patterns that are formed on at least one of the surfaces of the substrate and serve as electrical power interconnections among electronic components.
One of the approaches to making modules for power applications is by means of printing. Electrically conductive pattern or passive electronic components are printed by the InkJet method directly on the substrate surface. An example of such a solution is the invention of document WO 2006/076607 A1, which presents the production of electronics by printing.
A disadvantage of the background of the invention is the absence of printed resistors with a low-temperature coefficient of resistance, since the known printed thick film resistors are generally made of a material which is unsuitable for firing in a reducing or inert atmosphere, which is needed for firing copper conductive patterns. For these reasons, a problem arises with the demanding several-step production process, which is complicated by the mutual elimination of the firing of conductive patterns and passive electronic components in an oxidizing, or in an inert, firing atmosphere. Firing in one type of atmosphere damages those components of the power module that need firing in the other type of atmosphere.
The above problem is solved by the invention of document US 4 316 920 B, which presents a method of producing thick film resistors and firing them on copper conductive patterns. The disadvantages of the invention are that the production process is again long and process- intensive, that the materials used contain binder particles which influence the behaviour of the electronic component in the passage of electric current and in the action of waste heat.
The task of the invention is to provide a method of producing a resistor for power applications which would make it possible to produce resistors with electrically conductive copper patterns in a single firing that would allow to produce resistors with a low-temperature coefficient of resistance, that would allow to produce resistors with a pure elemental composition and that would be fast, suitable for use in mass production and that would be economically advantageous.
Summary of the Invention
The task is solved by providing a method of producing a resistor for power applications according to the invention below.
As part of the method of producing a resistor for power applications, electrically conductive patterns and at least one passive electronic component are made on the ceramic substrate of the power electronics module. The core of the invention is based on the following process steps: a) semi-finished products of electrically conductive patterns are printed on the ceramic substrate with paste or ink based on dispersed copper particles, b) at least one resistive film is printed on the ceramic substrate with AerosolJet technology with ink based on dispersed copper and nickel particles, or from constantan, c) the semi-finished products are fired in an inert atmosphere at a temperature between 650 °C and 960 °C, wherein process steps a) and b) are arbitrarily interchangeable in order.
The greatest advantages of the invention include the simplification of the production process, in which it is possible to fire semi-finished products of copper electrically conductive patterns and resistive film simultaneously under the same temperature and firing atmosphere conditions. Not only is the production process faster, but energy and gas costs are also saved to create an inert atmosphere. In addition, allowing firing from 650 °C causes the particles in the resistive film to sinter, whereby the resulting products exhibit sufficient strength, adhesion and desired electrical conductivity without adding any binder, which is advantageous because the absence of binder does not affect the electrical properties of the products.
Another benefit of the invention is the arbitrary interchangeability of process steps a) and b), which makes it possible to design complicated patterns and designs of power applications that were previously out of the question, and in addition the arbitrariness of process steps a) and b) leads to a more efficient use in mass production, since one printing machine does not have to wait for the work of the other printing machine to be completed, but they can work simultaneously, with the work-in-progress products eventually being swapped. The advantage of interchangeability stems from the AerosolJet technology, which allows the application of an aerosol with copper and nickel particles, or constantan, from a distance of up to 5 mm without the resistive film spreading, while well-covering unevenness caused by electrically conductive patterns or other electronic components. Another advantage of the invention is the fact that printing with AerosolJet produces a resistor which has a small thickness and a large contact surface connected to the substrate, thus ensuring quality dissipation of heat loss, which is generated by the passage of current through the resistor thus prepared. Thus, the resistor produced under the invention does not overheat during its operation.
It is advantageous in the context of the method of the invention to use screen printing during process step a). This printing technology can cover large areas in a short time, which is ideal for the purpose of the invention, since electrically conductive patterns take up much more area than the resistors in terms of surface area.
Furthermore, it may be advantageous in the context of the method of the invention if the ink in process step b) contains copper and nickel particles in a ratio between 45 % and 55 % of nickel. Thus, a suitably selected ratio of particle content leads to the formation of a constantan alloy during sintering in process step c), which has excellent operating characteristics in electronic applications due to the low temperature coefficient of resistance.
It may also be advantageous in the context of the method of the invention if nanoparticles are used during process step b). The nanoparticles sinter very well and, moreover, they adhere well when they hit the surface of the substrate or the semi-finished product of electrically conductive patterns and do not need additional binders. It is also unquestionable that due to the fineness of the nanoparticles, the formation of defects in the resistive film caused by the inhomogeneity of the impact surface is a very rare phenomenon.
Last but not least, it may be advantageous within the scope of the invention that the exact nominal value of resistance of the resistor after step c) is set by laser trimming. Although AerosolJet technology allows the printing of a resistor with a relatively accurate thickness, it is possible to further refine the nominal value of resistance by means of laser trimming, especially for sensing resistors and so-called “shunt” resistors. The advantages of the invention include cheap and fast production suitable for mass use, as well as the accuracy and stability of the products thus produced, the quality of electrical parameters, thanks to the absence of binders in the resistors. In addition, in the case of the use of nanoparticles in ink, the production is made cheaper due to the fact that it is not necessary to produce constantan nanoparticles directly for the ink preparation, which would be long-lasting, expensive and difficult to obtain by grinding, but that it is possible to chemically prepare nanoparticles from copper and nickel, which sinter together into the form of constantan when fired from 650 °C.
Explanation of drawings
The present invention will be explained in detail by means of the following figures where:
Fig. 1 shows a method of producing a printed power resistor using a resistive ink containing Cu and Ni nanoparticles, which are printed on a substrate only after the printing of electrically conductive patterns,
Fig. 2 shows a method of producing a printed power resistor using a resistive ink containing constantan nanoparticles with a ratio of 45:55 (Ni:Cu), which are printed on a substrate before the printing of electrically conductive patterns.
Example of the invention embodiments
It shall be understood that the specific cases of the invention embodiments described and depicted below are provided for illustration only and do not limit the invention to the examples provided here. Those skilled in the art will find or, based on routine experiment, will be able to provide a greater or lesser number of equivalents to the specific embodiments of the invention which are described here.
Using the invention, test modules for power electronics were produced as follows. Semi-finished products of electrically conductive patterns were printed on the ceramic substrate 1 with paste 2 or ink 2 based on dispersed copper particles 4. Furthermore, resistive films were printed on the ceramic substrate 1 with AerosolJet technology with ink 3 based on dispersed copper and nickel particles 4 and 5, or from constantan particles 8. The order in which the semi finished products were printed was arbitrary. Subsequently, the semi-finished products were fired in an inert atmosphere to form fired films 9, 10, 11 forming resistors and electrically conductive patterns from the semi-finished products.
The modules had ceramic substrates 1 with dimensions of 10 cm x 10 cm. Electrically conductive patterns have been designed for test transmissions of different levels of electrical power, including the design of electrodes for connecting resistors produced by the method of the invention. The electrically conductive patterns were made of copper and were printed using screen -printing technology.
Inks 3 were used for the production of resistors for use in AerosolJet technology with a known ratio of the content of particles 4 and 5 Ni and Cu and with a known size range of used particles. The ink components consist of metal particles and a stabilizing liquid which prevents the metal particles from agglomerating and which evaporates after printing. The thickness of the resistors was gradually chosen in the range from 500 nm to 10 μm. The resistive films were printed on the substrate 1 of the sample before printing the electrically conductive patterns and further, the resistive films were printed on the substrate 1 of the sample after printing the electrically conductive patterns. Subsequently, all resistive films were fired together in an inert atmosphere of nitrogen, with the firing temperature set at 950 °C on a thermostat.
During the inspection of the test resistors, the following was observed:
Figure imgf000008_0001
Furthermore, ink 7 with constantan nanoparticles 8, which was composed of Ni and Cu components with a ratio of 45:55 (Ni:Cu), was tested. For use in ink 7, the constantan was ground to a mix of nanoparticles 8 with a size in the order of units and tens of nanometres. During the structural characterization of the resistor, the structure has been verified as homogeneous and the measured temperature coefficient of resistance was 0.00005 K-1.
Furthermore, successful experiments were performed to adjust the resistance of the resistor by removing the material by laser trimming to form film 12, where the resistance value of the test resistor was changed from 652 mΩ to 680 mΩ.
Industrial applicability
The method of producing a resistor for power applications according to the invention will find its application in the mass production of electronic components and modules for power electronics. List of reference numerals
1 ceramic substrate
2 printed copper paste / ink
3 printed ink containing Cu and Ni nanoparticles
4 Cu nanoparticles
5 Ni nanoparticles
6 solvent (or dispersant)
7 printed constantan ink
8 constantan nanoparticles
9 fired Cu film
10 fired Cu/Ni film
11 fired constantan film
12 laser- trimmed resistive film

Claims

1. A method of producing a resistor for power applications, in which electrically conductive patterns and at least one passive electronic component are made on a ceramic substrate of a power electronics module characterized in that it consists of the following process steps: a) semi-finished products of electrically conductive patterns are printed on the ceramic substrate with paste or ink based on dispersed copper particles, b) at least one resistive film is printed on the ceramic substrate with AerosolJet technology with ink based on dispersed copper and nickel particles, or constantan particles, c) the semi-finished products are fired in an inert atmosphere at a temperature between 650 °C and 960 °C, wherein process steps a) and b) are arbitrarily interchangeable in order.
2. Method according to claim 1 characterized in that screen printing is used in process step a).
3. Method according to claim 1 or 2 characterized in that in process step b) the ink contains copper and nickel particles in a ratio from 45 % to 55 % of nickel.
4. Method according to any of claims 1 to 3 characterized in that nanoparticles are used in process step b).
5. Method according to any of claims 1 to 4 characterized in that the exact nominal value of resistance of the resistor is set by laser trimming after process step c).
PCT/CZ2020/050055 2020-03-03 2020-08-20 Method of producing a resistor for power applications WO2021175347A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4316920A (en) * 1980-07-03 1982-02-23 Bell Telephone Laboratories, Incorporated Thick film resistor circuits
US20030175411A1 (en) * 2001-10-05 2003-09-18 Kodas Toivo T. Precursor compositions and methods for the deposition of passive electrical components on a substrate
US20060159838A1 (en) * 2005-01-14 2006-07-20 Cabot Corporation Controlling ink migration during the formation of printable electronic features
US20150197063A1 (en) * 2014-01-12 2015-07-16 Zohar SHINAR Device, method, and system of three-dimensional printing

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US8120232B2 (en) * 2009-01-20 2012-02-21 Palo Alto Research Center Incorporated Sensors and actuators using piezo polymer layers
DE102013113485A1 (en) * 2013-12-04 2015-06-11 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. A method of forming an electrically conductive structure on a plastic substrate
FR3052698B1 (en) * 2016-06-15 2019-08-09 Centre National De La Recherche Scientifique METHOD AND APPARATUS FOR MANUFACTURING A MECATRONIC SYSTEM BY THREE-DIMENSIONAL PRINTING
CN115767794A (en) * 2017-12-01 2023-03-07 捷普有限公司 Flexible heater

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Publication number Priority date Publication date Assignee Title
US4316920A (en) * 1980-07-03 1982-02-23 Bell Telephone Laboratories, Incorporated Thick film resistor circuits
US20030175411A1 (en) * 2001-10-05 2003-09-18 Kodas Toivo T. Precursor compositions and methods for the deposition of passive electrical components on a substrate
US20060159838A1 (en) * 2005-01-14 2006-07-20 Cabot Corporation Controlling ink migration during the formation of printable electronic features
US20150197063A1 (en) * 2014-01-12 2015-07-16 Zohar SHINAR Device, method, and system of three-dimensional printing

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