CHIP RESISTOR AND METHOD FOR PRODUCING SAME
20200051716 ยท 2020-02-13
Inventors
Cpc classification
H01C7/00
ELECTRICITY
H01C1/02
ELECTRICITY
H01C1/14
ELECTRICITY
International classification
H01C1/14
ELECTRICITY
H01C7/00
ELECTRICITY
H01C17/00
ELECTRICITY
Abstract
An object of the present disclosure is to provide a chip resistor capable of suppressing degradation of long-term reliability, and a method for producing the chip resistor. The chip resistor of the present disclosure includes resistance member (11) formed of metal, and a pair of electrodes (12) respectively formed on both ends of first main surface (11a) of resistance member (11). The chip resistor further includes first protective film (13) formed on second main surface (11b) located on a rear side of first main surface (11a) of resistance member (11), second protective film (14) formed on first main surface (11a) of resistance member (11) and between the pair of electrodes (12), and a third protective film formed on a side surface parallel to a direction of a current flowing between the pair of electrodes (12) of resistance member (11). The side surface of resistance member (11) is provided with a protrusion that protrudes outward when viewed along the current flowing direction.
Claims
1. A chip resistor comprising: a resistance member; a pair of electrodes; a first protective film; a second protective film; and a third protective film, wherein the resistance member includes a first main surface, a second main surface located on a side opposite to the first main surface, and a protrusion that protrudes outward from a plane connecting an edge of the first main surface and an edge of the second main surface, the pair of electrodes are respectively disposed on both ends of the first main surface of the resistance member, and a direction connecting respective ones of the pair of electrodes is a direction along the edge of the first main surface and the edge of the second main surface, the first protective film is disposed on the second main surface of the resistance member, the second protective film is disposed on the first main surface of the resistance member and between the pair of electrodes, and the third protective film is disposed on the protrusion of the resistance member.
2. A chip resistor comprising: a resistance member; a pair of electrodes; a first protective film; a second protective film; and a third protective film, wherein the resistance member includes a first main surface, a second main surface located on a side opposite to the first main surface, and a recess that recesses inward from a plane connecting an edge of the first main surface and an edge of the second main surface, the pair of electrodes are respectively disposed on both ends of the first main surface of the resistance member, and a direction connecting respective ones of the pair of electrodes is a direction along the edge of the first main surface and the edge of the second main surface, the first protective film is disposed on the second main surface of the resistance member, the second protective film is disposed on the first main surface of the resistance member and between the pair of electrodes, and the third protective film is disposed on the recess of the resistance member.
3. The chip resistor according to claim 1, wherein the first protective film is disposed of a resin substrate.
4. A method for producing a chip resistor comprising: a step of forming a plurality of grooves on a main surface of a sheet-shaped resistance member and a rear surface located on a side opposite to the sheet-shaped resistance member when viewed from the main surface; a step of forming a protective member on the main surface of the sheet-shaped resistance member and inside the plurality of grooves in an integrated manner; a step of forming a plurality of electrodes between the grooves that are adjacent to each other at uniform intervals, by pasting a resist on the rear surface of the sheet-shaped resistance member, and performing plating on the rear surface of the sheet-shaped resistance member; and a step of cutting centers of the plurality of grooves and centers of the plurality of electrodes to divide the sheet-shaped resistance member into individual pieces.
5. The method for producing a chip resistor according to claim 4, wherein in the step of forming the plurality of electrodes, the plurality of grooves are formed in the sheet-shaped resistance member, by pasting a resist on the main surface and the rear surface of the sheet-shaped resistance member, performing etching on both the main surface and the rear surface of the sheet-shaped resistance member, and then removing the resist.
6. The chip resistor according to claim 2, wherein the first protective film is disposed of a resin substrate.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENT
[0040] An exemplary embodiment of a chip resistor and a method for producing the chip resistor according to the present disclosure will be described below with reference to the drawings.
(1) Chip Resistor
[0041]
[0042] The chip resistor according to the exemplary embodiment of the present disclosure includes resistance member 11, electrodes 12, first protective film 13, second protective film 14, plated layer 15, and third protective film 16, as illustrated in
[0043] First protective film 13 is formed on second main surface 11b of resistance member 11. Second protective film 14 is formed on first main surface 11a of resistance member 11 and between the pair of electrodes 12. Each plated layer 15 is formed from an upper surface of electrode 12 to corresponding end surface 11c of resistance member 11. Third protective films 16 respectively cover side surfaces 11d.
[0044] In
[0045] Upon operating, a current flows between the pair of electrodes 12 of resistance member 11. In other words, in
[0046] End surfaces 11c are parallel to a Y-Z plane, and side surfaces 11d are parallel to the X-axis.
[0047] Resistance member 11 has a substantially columnar shape that is long in a direction along the flowing current (X-axis-direction). Further, a cross-sectional shape of resistance member 11 when viewed from the direction along the flowing current (viewed from X1 in
[0048] Protrusion 17 is a portion protruding outward from other portions on side surface 11d of resistance member 11, when viewed along the current flowing direction. In other words, protrusion 17 protrudes outward from a plane formed by connecting an edge of first main surface 11a and an edge of second main surface 11b (a plane parallel to the X-Z plane), along the direction orthogonal to the current flowing direction (Y-axis direction). In
[0049] Note that protrusion 17 may be sharply-pointed as illustrated in
[0050] Alternatively, protrusion 17 may have a hemispherical side-surface shape as in a modification illustrated in
[0051] A metal constituting resistance member 11 may be a single metal, but may preferably be a CuMnNi alloy or a CuMnSn alloy whose temperature coefficient of resistance (TCR) is nearly zero, and whose Peltier effect is minimized.
[0052] Here, a surface formed with the pair of electrodes 12 (plated layers 15) is mounted on a mounting substrate (hereinafter, not illustrated). Note that a direction toward to be mounted from the mounting substrate (toward the pair of electrodes 12) is defined as upward, for convenience.
[0053] Hereinafter, dimensions of a completed chip resistor will be described with reference to
[0054] Note that, those dimensions and materials are examples, and the chip resistor of the present disclosure is not necessarily limited to those dimensions and materials.
(2) Method for Producing Chip Resistor
[0055] Hereinafter, a method for producing the chip resistor according to the exemplary embodiment of the present disclosure will be described with reference to the drawings.
[0056] Note that, the method for producing the chip resistor is achieved by performing a resist application step, an etching step, a protective member forming step, plating step, polishing step, and an individualizing step in this order, as illustrated in a flowchart of
(Resist Application Step)
[0057] In the method for producing the chip resistor, a top view indicating the resist application step is illustrated in
[0058] First, as illustrated in
[0059] Note that, the upper surface of sheet-shaped resistance member 21 corresponds to first main surface 11a of resistance member 11. The lower surface of sheet-shaped resistance member 21 corresponds to second main surface 11b of resistance member 11. In other words, the upper surface and the lower surface of sheet-shaped resistance member 21 respectively correspond to a front surface and a rear surface of sheet-shaped resistance member 21.
(Etching Step)
[0060] In the method for producing the chip resistor, a top view indicating the etching step is illustrated in
[0061] Next, as illustrated in
[0062] At this time, the etching is performed from both the upper surface and the lower surface, and hence protrusion 17 is formed on the side surface (inner surface of groove 23) of resistance member 11, as illustrated
[0063] An upper portion and a lower portion of protrusion 17 are cutout portions upon etching. The etching is performed from both the upper surface and the lower surface, and hence, even in a case of thick resistance member 11, a shape of resistance member 11 can be processed with high accuracy. This improves the accuracy of a resistance value.
(Protective Member Forming Step)
[0064] In the method for producing the chip resistor, a top view indicating the protective member forming step is illustrated in
[0065] Note that
[0066] Next, protective member 24 is simultaneously formed on the lower surface of sheet-shaped resistance member 21 and inside grooves 23, as illustrated in
[0067] Note that, when sheet-shaped resistance member 21 is formed into individual pieces, protective member 24 at a portion on the lower surface of sheet-shaped resistance member 21 serves as first protective film 13 of the chip resistor, and protective member 24 at a portion filled inside groove 23 serves as third protective film 16 of the chip resistor. First protective film 13 and third protective film 16 are then integrally formed.
(Plating Step)
[0068] In the method for producing the chip resistor, a top view indicating the plating step is illustrated in
[0069] Next, as illustrated in
[0070] As a result, a plurality of electrodes 26 formed by the Cu plating are formed in the portions between adjacent grooves 23 with uniform intervals.
(Polishing Step)
[0071] In the method for producing the chip resistor, a top view indicating the polishing step is illustrated in
[0072] Next, as illustrated in
(Individualizing Step)
[0073] In the method for producing the chip resistor, a top view indicating an individualizing step is illustrated in
[0074] Next, as illustrated in
[0075] Finally, plated layer 15 is formed by performing Cu plating, Ni plating, and Sn plating from the upper surfaces of the pair of electrodes 12 of the chip resistor divided into the individual piece to end surfaces 11c of resistance member 11 to obtain the individualized chip resistor as illustrated in
[0076] Note that, in order to simplify the description,
[0077] In addition, a resistance value may be adjusted as appropriate. When adjusting the resistance value, first protective film 13 is cut together with resistance member 11 by a laser beam to form a trimming groove. This can suppress generation of burrs. Another protective film is then formed to cover at least the trimming groove.
(3) Effects
[0078] In the chip resistor according to the exemplary embodiment of the present disclosure, side surface 11d of resistance member 11 is provided with protrusion 17 that protrudes outward when viewed along the current flowing direction. This configuration increases a contact area between third protective film 16 covering this protrusion 17 and side surface 11d of resistance member 11. This makes it difficult for third protective film 16 to be peeled off, thereby preventing resistance member 11 from being exposed from third protective film 16. In addition, an effect of maintaining long-term reliability can be achieved.
[0079] In other words, protrusion 17 increases an area of side surface 11d of resistance member 11, and also allows resistance member 11 to be resistant to stress in a vertical direction.
[0080] Furthermore, protective member 24 to be third protective film 16 is filled inside grooves 23 in sheet-shaped resistance member 21. This allows third protective film 16 to be reliably filled inside grooves 23. This makes it difficult for third protective film 16 to be peeled off.
[0081] In other words, third protective film 16 invades grooves 23 (side surface 11d of resistance member 11). Thus, third protective film 16 is easily covered completely.
[0082] Third protective film 16 and first protective film 13 are integrally formed at the same time, making it difficult for third protective film 16 to be peeled off from resistance member 11, upon cutting.
[0083] Protrusion 17 is formed on side surface 11d of resistance member 11, and third protective film 16 is formed on side surface 11d of resistance member 11. Then, the pair of electrodes 12 (26) are formed. This can prevent plating from growing around side surface 11d of resistance member 11 upon forming the pair of electrodes 12, thereby stabilizing a resistance value.
[0084] Third protective film 16 is filled inside groove 23, thereby reducing a level difference between an upper surface of third protective film 16 formed in groove 23 and an upper surface of resistance member 11. This can reduce a step height at a portion where second protective film 14 is formed to prevent exposure of resistance member 11.
(4) First Modification of Chip Resistor
[0085] In the exemplary embodiment described above, protrusion 17 is formed on side surface 11d of resistance member 11. However, when viewed along a current flowing direction (X-axis direction; lateral direction), recess 18 that is recessed from other portions in side surface 11d of resistance member 11 may be formed, as illustrated in
[0086] Similar to protrusion 17, recess 18 thus formed increases a contact area between third protective film 16 covering this recess 18 and side surface 11d of resistance member 11. This makes it difficult for third protective film 16 to be peeled off. Therefore, resistance member 11 can be prevented from being exposed from third protective film 16, and long-term reliability can thus be maintained.
[0087] Upon etching upper and lower surfaces of sheet-shaped resistance member 21 illustrated in
[0088] Dimensions and materials of the chip resistor according to this first modification are the same as those of the chip resistor illustrated in
[0089] Note that the chip resistor is not necessarily limited to those dimensions and materials.
[0090] Note that, recess 18 may have a hemispherical side-surface shape as in a modification illustrated in
[0091] Recess 18 may have a columnar side-surface shape in place of the hemispherical side-surface shape described above. A shape of each of the plurality of recesses serving as recess 18 may be a pyramid such as a quadrangular pyramid, a cone, a prism, or a column. Intervals between the plurality of recesses can be selected as appropriate. When a plurality of recesses 18 are provided, their shapes or sizes are not necessarily uniform, and may be arbitrary. Note that each of
(5) Second Modification of Chip Resistor
[0092] In the exemplary embodiment described above, first protective film 13 is formed on second main surface 11b of resistance member 11, but resin substrate 19 in place of first protective film 13 may be pasted on second main surface 11b of resistance member 11, as illustrated in
[0093] This resin substrate 19 is thicker than first protective film 13, and is formed of glass epoxy that is the same material as a material used for the mounting substrate. When resin substrate 19 is directly formed on resistance member 11, resin substrate 19 and resistance member 11 are bonded by thermocompression bonding.
[0094] Resin substrate 19 improves resistance to bending stress of the chip resistor, and hence facilitates conveyance of the chip resistor within production processes. Further, solder crack caused by a difference in coefficient of thermal expansion between a mounted chip resistor and a mounting substrate can be prevented. Note that, first protective film 13 may further be formed on an upper surface of resin substrate 19.
INDUSTRIAL APPLICABILITY
[0095] A chip resistor and a method for producing the chip resistor according to the present disclosure have an effect of suppressing degradation of long-term reliability. The present disclosure is useful when applied to chip resistor or other components, which is used in various electronic devices and which uses a metal plate as resistance member.
REFERENCE MARKS IN THE DRAWINGS
[0096] 11: resistance member
[0097] 11a: first main surface
[0098] 11b: second main surface
[0099] 11c: end surface
[0100] 11d: side surface
[0101] 12, 26: electrode
[0102] 13: first protective film
[0103] 14: second protective film
[0104] 15: plated layer
[0105] 16: third protective film
[0106] 17: protrusion
[0107] 18: recess
[0108] 19: resin substrate