TW202027101A - Flexible resistor component and manufacturing method thereof - Google Patents

Abstract

A flexible resistor component include a resistor layer attached to a flexible substrate and a cover layer covering on surfaces of the flexible substrate and resistor layer but exposing electrodes on the resistor layer. Such a flexible resistor component performs good flexibility and bending so as to be assembled with a soft structure.

Description

Flexible resistance element and its manufacturing method

The present invention relates to the field of resistance elements, in particular to a flexible resistance element that can be assembled with a flexible circuit carrier.

Taiwan Patent No. I529753 discloses an over-current protection element, which includes a positive temperature coefficient (PTC) conductive composite material laminated between two metal foils, and its resistance is sensitive to temperature changes. Normal The overcurrent protection element maintains a low resistance under temperature. When the circuit or battery has an overcurrent or high temperature, the overcurrent protection element will instantly increase to a high resistance state to protect the battery or circuit element. Among them, the PTC conductive composite material is composed of one or more crystalline polymers and conductive additives.

Similar to the above-mentioned resistor elements that can achieve specific functions, usually a high-hardness substrate is used, which has limitations when it is assembled with other structures or elements and can be improved.

Provided herein is a flexible resistor element, which has a set resistance value, rated power and temperature coefficient of resistance characteristics, and is suitable for assembly with a flexible substrate. The flexible resistance element can include a flexible substrate and a flexible conductive material, and has the function of being flexible and flexible, and can be used as a resistance product that can withstand large-angle bending.

According to the above, a flexible resistance element includes: a flexible substrate; a resistance layer attached to a surface of the flexible substrate, wherein the resistance layer has a resistance pattern; a plurality of electrodes are separately attached to each other On the surface of the flexible substrate and part of the resistance layer; and a protective layer covering the other surface of the flexible substrate, on the resistance layer and part of the surface of the flexible substrate, wherein The protective layer exposes the electrodes, and the flexible electrical component has a bending degree greater than 90 degrees.

According to the above, a method for manufacturing a flexible resistance element includes: providing a flexible substrate; forming a resistance pattern on at least one surface of the flexible substrate; forming an electrode on the flexible substrate and part of the flexible substrate On the resistance pattern, wherein the electrode and the resistance pattern have conductive contact; and cover a protective layer on the flexible substrate, wherein the protective layer covers the resistance pattern and the surface of the flexible substrate beside the resistance pattern And the other surface of the flexible substrate exposes the electrode, and the flexible resistance element has a bending degree greater than 90 degrees.

The following detailed descriptions are provided with specific embodiments in conjunction with the accompanying drawings to make it easier to understand the purpose, technical content, characteristics and effects of the present invention.

Hereinafter, various embodiments of the present invention will be described in detail, with drawings as examples. In addition to these detailed descriptions, the present invention can also be widely implemented in other embodiments. Easy substitutions, modifications, and equivalent changes of any of the embodiments are included in the scope of the present invention, and the scope of the patent application is quasi. In the description of the specification, in order to enable the reader to have a more complete understanding of the present invention, many specific details are provided; however, the present invention may still be implemented under the premise that some or all of the specific details are omitted. In addition, well-known steps or elements are not described in details to avoid unnecessary limitation of the present invention. It should be noted that the drawings are for illustration purposes only, and do not represent the actual size or quantity of the components. Some details may not be completely drawn in order to keep the drawings simple.

Referring to FIGS. 1 and 2, a flexible resistance element 1 includes a flexible substrate 10 as a body, a resistance layer 12, a protection layer 14, and electrodes 16 and 18. In one example, the flexible resistance element 1 is a sheet resistance element with a uniform thickness and a sheet-like appearance, and exhibits a resistance value, a rated power, and a temperature coefficient of resistance. Secondly, the flexible substrate 10 can be provided by a plastic material, which has the characteristics of being light, thin and resistant to flexing, such as, but not limited to, polyimide (PI), polyethylene naphthalate (Polyethylene naphthalate, PEN), polyester (Polyester, PET), etc. The resistive layer 12 has a linear or curved resistive shape, and is attached or formed on at least one surface of the flexible substrate 10 by an appropriate method. The material is exemplified but not limited, such as a conductive alloy, a metal film, or a conductive material. Slurry. The electrodes 16, 18 are attached or formed on the resistive layer 12 by an appropriate method, and are electrically connected to the resistive layer 12, for example, partially overlap with the resistive pattern of the resistive layer 12 (not shown in the figure), and the protective layer 14 covers At least a part or all of the electrodes 16 and 18 are exposed on the resistive layer 12. In addition, the protective layer 14 also covers the other surface of the flexible substrate 10, and its material is exemplified but not limited, such as epoxy resin, polyester resin, polyimide or polypropylene.

FIG. 3 is a schematic diagram of the manufacturing process of the flexible resistance element 1 of the present invention. Please refer to FIG. 3, providing a flexible substrate (step 20), and secondly, forming a resistance pattern on at least one surface of the flexible substrate (step 22). The method for forming the resistance pattern of the resistance layer is an example but Unlimited, including die cutting, printing, laser or etching. Taking etching as an example, the removal method is to cover a photosensitive film on the conductive film, and through a yellow light process, such as exposure, development, etching, etc., to shape the conductive film to form a resistive layer with a resistive pattern. Taking printing as an example, a resistive pattern is formed through a printing process, and a design screen pattern is used according to resistance value requirements to provide a screen with a resistive pattern. Afterwards, the screen is used for printing, and the conductive paste can be printed on the surface of the flexible substrate to form the resistance pattern. The resistance pattern can be in the shape of a straight bar or a zigzag line. Afterwards, an electrode is formed on part of the flexible substrate and part of the resistor pattern (step 24). This formation method is to cover the exposed flexible substrate beside the resistor pattern and the resistor pattern with another photosensitive film. After exposing part of the resistive pattern through the yellow light process, a conductive material is formed on the exposed resistive pattern through electroplating and other appropriate methods to form electrodes, wherein the electrode and the resistive pattern have conductive contact. After that, the protective layer is covered on the surface of the resistance pattern, the surface of the flexible substrate beside the resistance pattern, and the other surface of the flexible substrate (step 26). It should be noted that in practice, the above process can be used to make multiple flexible resistive elements at a time. Therefore, after the above steps, an appropriate division method, such as punching, can be added to form a plurality of separated sheets. Flexible resistive element (step 28).

Therefore, according to the above-mentioned flexible resistance element, through the material matching of the flexible substrate and the resistance layer, plus the design of geometric dimensions (including area and thickness), the formed sheet-shaped flexible resistance element It has a bend degree greater than 90 degrees, a low temperature coefficient of resistance (TCR) (please provide if the value range is available), power resistance, and can be suitable for high and low temperature storage environments (if the value range is available, please provide).

The above-mentioned embodiments are only to illustrate the technical ideas and features of the present invention, and their purpose is to enable those who are familiar with the art to understand the content of the present invention and implement them accordingly. When they cannot be used to limit the patent scope of the present invention, That is, all equal changes or modifications made in accordance with the spirit of the present invention should still be covered by the patent scope of the present invention.

1: Flexible resistance element 10: Flexible substrate 12: Resistance layer 14: protective layer 16: electrode 18: Electrode 20, 22, 24, 26, 28: steps

Figure 1 is a three-dimensional bending schematic diagram of a partial structure of a single flexible resistance element of the present application.

Fig. 2 is a schematic cross-sectional view of a single flexible resistor element of the present application.

Fig. 3 is a schematic diagram of the manufacturing process of the flexible resistance element of the present invention.

1: Flexible resistance element

10: Flexible substrate

12: Resistance layer

14: protective layer

16: electrode

18: Electrode

Claims (8)

A flexible resistance element, including: A flexible substrate; A resistance layer is attached to a surface of the flexible substrate, wherein the resistance layer has a resistance pattern; A plurality of electrodes are separately attached to the surface of the flexible substrate and part of the resistance layer; and A protective layer covers the other surface of the flexible substrate, the resistance layer and part of the surface of the flexible substrate, wherein the protective layer exposes the electrodes and the flexible electrical component Has a degree of bend greater than 90 degrees. The flexible resistance element according to claim 1, wherein the material of the flexible substrate includes polyimide (PI), polyethylene naphthalate (PEN) or polyester (PET). The flexible resistance element according to claim 1, wherein the material of the resistance layer includes a conductive alloy, a metal film or a conductive paste. The flexible resistance element according to claim 1, wherein the material of the protective layer includes epoxy resin, polyester resin, polyimide or polypropylene. A manufacturing method of a flexible resistance element, including: Provide a flexible substrate; Forming a resistance pattern on at least one surface of the flexible substrate; Forming an electrode on the flexible substrate and part of the resistance pattern, wherein the electrode and the resistance pattern have conductive contact; and Covering a protective layer on the flexible substrate, wherein the protective layer covers the resistance pattern, the surface of the flexible substrate beside the resistance pattern, and the other surface of the flexible substrate, and exposes the electrode , And the flexible resistance element has a bending degree greater than 90 degrees. The method for manufacturing a flexible resistor element according to claim 5, wherein the step of forming the resistor pattern includes: Attach a conductive film to the surface of the flexible substrate by laminating, sputtering or printing; Cover a photosensitive film on the conductive film; Performing a yellowing process to remove part of the conductive film; and Remove the photosensitive film. The method for manufacturing a flexible resistor element according to claim 5, wherein the step of forming the resistor pattern includes: Provide a screen with a resistive pattern; Applying the screen on the surface of the flexible substrate and printing a conductive paste on the surface of the flexible substrate to form the resistance pattern; and Remove the screen on the surface of the flexible substrate. The method for manufacturing a flexible resistive element according to claim 5, wherein the step of forming the electrode includes exposing a part of the resistive pattern through a yellowing process, and plating a conductive material on the exposed part of the resistive pattern .

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