Low-resistance, high-power resistor having a tight resistance tolerance despite variations in the circuit connections to the contacts

Claim 2

A low-resistance, high-power chip resistor having tight resistance tolerances despite variations in circuit connections to said resistor, said resistor comprising: (a) a ceramic resistor substrate, (b) metalizations provided on the upper surface of said substrate, there being two metalizations spaced apart from each other to provide a space therebetween, (c) a resistance film provided on said upper surface of said substrate in said space between said metalizations, and (d) first and second discrete spaced-apart low-resistivity, high-thermal-conductivity terminal plates, said terminal plates being respectively electrically connected to the upper surfaces of said metalizations and to said resistance film, each of said terminal plates extending across said substrate from one side region thereof to the opposite side region thereof.

Claim 3

The invention as claimed in claim 1, in which said resistor has an electrical resistance value in the range of one ohm and below.

Claim 4

The invention as claimed in claim 1, in which said resistor is mounted on and parallel to a heat-sinking circuit substrate in heat-sinking relationship thereto.

Claim 5

The invention as claimed in claim 3, in which said heat-sinking relationship to said circuit substrate comprises means to bond the lower surface of said ceramic resistor substrate to the upper surface of said heat-sinking circuit substrate.

Claim 6

The invention as claimed in claim 3, in which said heat-sinking relationship to said circuit substrate comprises means to bond the upper surfaces of said terminal plates to the upper surface of said heat-sinking circuit substrate such that said resistance film faces the upper surface of said heat-sinking circuit substrate.

Claim 7

The invention as claimed in claim 4, in which current leads are connected between said heat-sinking circuit substrate and said respective terminal plates, and in which sense leads are connected between said heat-sinking circuit substrate and said respective terminal plates.

Claim 8

The invention as claimed in claim 6, in which the resistance tolerances of said resistor are in the range about 0.1% to about 1% despite random variations in the locations at which said leads are connected to said terminal plates.

Claim 9

The invention as claimed in claim 1, in which a glass coating is provided over said resistance film.

Claim 10

The invention as claimed in claim 1, in which an environmental coating, of synthetic resin, is provided between said terminal plates above said resistance film.

Claim 11

The invention as claimed in claim 1, in which a glass coating is provided over said resistance film, and in which an environmental coating, of synthetic resin, is provided between said terminal plates over said glass coating.

Claim 12

The invention as claimed in claim 1, in which said resistance film is a single layer resistance film.

Claim 13

The invention as claimed in claim 11, in which said chip resistor includes only one said single layer resistance film.

Claim 14

The invention as claimed in claim 11, in which said single layer resistance film is a thick-film resistance material.

Claim 15

The invention as claimed in claim 1, in which the upper surfaces of each said terminal plates being flat from said one side region thereof to said opposite side region thereof and from one end region thereof to the opposite end region thereof, and in which the entire said top surfaces of each terminal plates being left exposed for subsequent attachment of wire leads.

Claim 16

The invention as claimed in claim 1, in which each said terminal plates being directly connected to each said metalizations by solder, and each said metalizations being directly connected to said resistance film.

Claim 17

The invention as claimed in claim 1, in which the end portions of said resistance film being directly connected to said upper surfaces of said metalizations.

Claim 18

The invention as claimed in claim 1, in which said terminal plates being preformed bulk metal plates.

Claim 19

The invention as claimed in claim 1, in which an entire bottom surface of said resistance film directly contacts said upper surface of said substrate, and an entire top surface of said resistance film directly contacts a glass layer.

Claim 20

A low resistance, high-power chip resistor having a small resistive-film area relative to resistor size, which comprises: (a) a generally rectangular resistor substrate formed of ceramic, (b) first and second preformed discrete terminal plates formed of highly-electrically-conductive high-thermal-conductivity metal, said terminal plates being large in comparison to the size of said resistor substrate, each of said terminal plates extending from near one side edge of said resistor substrate to near the opposite side edge thereof, said terminal plates being parallel to each other and being bonded to said resistor substrate in spaced-apart relationship from each other, thereby forming opposed walls of said terminal plates, the space between said opposed walls of said terminal plates being narrow in comparison to the dimensions of said terminal plates in a direction from said one side edge of said substrate to said opposite side edge thereof, thereby forming said spaced between said opposed walls of said terminal plates that has a width narrow in comparison to its length, and (c) a resistance film screen-printed on said resistor substrate forming a single layer of resistance film on the same side thereof as said terminal plates, said screen-printed resistance film filling said space between said opposed walls of said terminal plates, said resistance film being electrically connected to said terminal plates so that current flows through said film across said space.

Claim 21

A low resistance, high-power chip resistor having a small resistive-film area relative to resistor size, which comprises: (a) a generally rectangular resistor substrate formed of ceramic, (b) first and second preformed discrete terminal plates formed of highly-electrically-conductive high-thermal-conductivity metal, said terminal plates being large in comparison to the size of said resistor substrate, each of said terminal plates extending from near one side edge of said resistor substrate to near the opposite side edge thereof, said terminal plates being parallel to each other and being bonded to said resistor substrate in spaced-apart relationship from each other, thereby forming opposed walls of said terminal plates, the space between said opposed walls of said terminal plates being narrow in comparison to the dimensions of said terminal plates in a direction from said one side edge of said substrate to said opposite side edge thereof, thereby forming said spaced between said opposed walls of said terminal plates that has a width narrow in comparison to its length, and (c) a resistance film screen-printed on said resistor substrate forming a single layer of resistance film on the same side thereof as said terminal plates, said screen-printed resistance film filling said space between said opposed walls of said terminal plates, said resistance film being electrically connected to said terminal plates so that current flows through said film across said space.

Claim 22

The invention as claimed in claim 19, in which the electrical resistance of said resistance film is less than about one ohm.

Claim 23

The invention as claimed in claim 19, in which said resistor is mounted on and parallel to a heat-sinking circuit substrate in heat-sinking relationship thereto.

Claim 24

The invention as claimed in claim 21, in which said heat-sinking relationship to said circuit substrate comprises means to bond the lower surface of said ceramic resistor substrate to the upper surface of said heat-sinking circuit substrate.

Claim 25

The invention as claimed in claim 21, in which said resistor is inverted, and said heat-sinking relationship to said circuit substrate comprises means to bond the lower surfaces of said terminal plates to the upper surface of said heat-sinking circuit substrate.

Claim 26

The invention as claimed in claim 22, in which current leads can be randomly positioned on exposed surfaces of said terminal plates opposite said resistor substrate and are connected between said heat-sinking circuit substrate and said respective terminal plates, and in which sense leads can be randomly positioned on said exposed surfaces of said terminal plates opposite said resistor substrate and are connected between said heat-sinking circuit substrate and said respective terminal plates.

Claim 27

The invention as claimed in claim 24, in which the resistance tolerances of said resistor are in the range about 0.1% to about 1% despite random variations in the locations at which said leads are connected to said terminal plates.

Claim 28

The invention as claimed in claim 19, in which a glass coating is provided over said resistance film.

Claim 29

The invention as claimed in claim 19, in which an environmental coating, of synthetic resin, is provided between said terminal plates above said resistance film.

Claim 30

The invention as claimed in claim 19, in which a glass coating is provided over said resistance film, and in which an environmental coating is provided between said terminal plates over said glass coating.

Claim 31

The invention as claimed in claim 19, in which said chip resistor is mounted on a heat-sinking circuit substrate with the bottom of said resistor substrate bonded by solder, in high heat-transfer relationship, to the upper surface of said heat-sinking circuit substrate.

Claim 32

The invention as claimed in claim 29, in which a metalization layer is interposed between the bottom surface of said resistor substrate and said solder that bonds to said heat-sinking circuit substrate.

Claim 33

The invention as claimed in claim 19, in which said resistor has an electric resistance in the range of one ohm and lower, and has a resistance tolerance in the range plus or minus 1% down to plus or minus 0.1%.

Claim 34

The invention as claimed in claim 19, in which said screen-printed resistance film occupies less than fifty percent of the top surface area of said resistor substrate.

Claim 35

The invention as claimed in claim 19, in which a metalization is provided between the bottom surface of each of said terminal plates and said ceramic resistor substrate.

Claim 36

The invention as claimed claim 21, in which said resistor is inverted, and solder layers are provided in bonded relationships to the sides of said terminal plates remote from said resistor substrate, and to said heat-sinking circuit substrate.

Claim 37

The invention as claimed in claim 19, in which said screen-printed resistance film covers most of said space between said opposed walls of said terminal plates.