阅读说明：本技术 片式电阻器 (Chip resistor ) 是由 筱浦高德 于 2020-02-27 设计创作，主要内容包括：本发明提供一种片式电阻器,其包括基片、一对上表面电极、电阻体、一对背面电极和一对侧面电极。基片具有上表面、背面和一对侧面。所述上表面和所述背面在所述基片的厚度方向上彼此朝向相反侧。所述一对侧面在与所述厚度方向正交的一个方向上彼此隔开间隔,且与所述上表面和所述背面相连。所述一对上表面电极在所述一方向上彼此隔开间隔,且与所述上表面接触。所述电阻体配置在所述上表面且与所述一对上表面电极相连。所述一对背面电极在所述一个方向上彼此隔开间隔且与所述背面接触。所述一对侧面电极与所述一对侧面接触,且与所述一对上表面电极和所述一对背面电极相连。所述一对背面电极各自具有第一层和第二层。所述第一层与所述背面接触。所述第二层覆盖所述第一层的至少一部分且由包含金属颗粒和合成树脂的材料形成。(A chip resistor includes a substrate, a pair of upper surface electrodes, a resistor body, a pair of rear surface electrodes, and a pair of side surface electrodes. The substrate has an upper surface, a back surface and a pair of side surfaces. The upper surface and the back surface face opposite sides to each other in a thickness direction of the substrate. The pair of side surfaces are spaced apart from each other in one direction orthogonal to the thickness direction, and are continuous with the upper surface and the back surface. The pair of upper surface electrodes are spaced apart from each other in the direction and are in contact with the upper surface. The resistor is disposed on the upper surface and connected to the pair of upper surface electrodes. The pair of back electrodes are spaced apart from each other in the one direction and are in contact with the back surface. The pair of side electrodes is in contact with the pair of side surfaces, and is connected to the pair of upper surface electrodes and the pair of back surface electrodes. The pair of back electrodes each have a first layer and a second layer. The first layer is in contact with the back surface. The second layer covers at least a part of the first layer and is formed of a material including metal particles and a synthetic resin.)

1. A chip resistor, comprising:

a substrate having an upper surface and a back surface facing opposite sides to each other in a thickness direction, and a pair of side surfaces spaced apart from each other in one direction orthogonal to the thickness direction and connected to the upper surface and the back surface;

a pair of upper surface electrodes spaced apart from each other in the one direction and contacting the upper surface;

a resistor disposed on the upper surface and connected to the pair of upper surface electrodes;

a pair of back electrodes spaced apart from each other in the one direction and contacting the back surface; and

a pair of side electrodes contacting the pair of side surfaces and connected to the pair of upper surface electrodes and the pair of back surface electrodes,

the pair of back electrodes each have a first layer in contact with the back surface and a second layer covering at least a part of the first layer,

the second layer is composed of a material containing metal particles and a synthetic resin.

2. The chip resistor according to claim 1, wherein:

the first layer has an insulating property and is formed of a material containing a synthetic resin,

the second layer covers the entirety of the first layer.

3. The chip resistor according to claim 2, wherein:

the first layer reaches a boundary between either one of the pair of side surfaces and the back surface.

4. The chip resistor according to claim 2, wherein:

the first layer is spaced apart from a boundary in the one direction, wherein the boundary is a boundary between either one of the pair of side surfaces and the back surface,

the second layer is in contact with an area of the back surface between the first layer and a boundary that is a boundary between either of the pair of side surfaces and the back surface.

5. The chip resistor according to claim 1, wherein:

the first layer is electrically conductive and formed of a material comprising glass,

the first layer is spaced apart from a boundary in the one direction, wherein the boundary is a boundary between either one of the pair of side surfaces and the back surface.

6. The chip resistor according to claim 5, wherein:

the first layer is formed of a material comprising silver particles.

7. The chip resistor according to claim 5 or 6, wherein:

the second layer is in contact with an area of the back surface between the first layer and a boundary that is a boundary between either of the pair of side surfaces and the back surface.

8. The chip resistor of claim 7, wherein:

the second layer covers a part of the first layer and bulges from the back surface in the thickness direction.

9. The chip resistor of claim 7, wherein:

the second layer covers the entirety of the first layer.

10. The chip resistor according to any one of claims 1 to 9, wherein:

the metal particles comprise silver.

11. The chip resistor according to any one of claims 1 to 10, wherein:

the pair of side electrodes is formed of a metal thin film.

12. The chip resistor of claim 11, wherein:

the metal thin film is formed of an alloy containing nickel and chromium.

13. The chip resistor according to any one of claims 1 to 10, wherein:

the pair of side electrodes is formed of a material containing silver particles and a synthetic resin.

14. The chip resistor according to any one of claims 1 to 13, wherein:

further having a pair of external electrodes covering the pair of upper surface electrodes, the pair of back surface electrodes, and the pair of side surface electrodes,

the pair of external electrodes is formed of a plating layer.

15. The chip resistor of claim 14 wherein:

the pair of external electrodes each have an intermediate portion and an outer portion covering the intermediate portion,

the intermediate portion covers any one of the pair of upper surface electrodes, any one of the pair of rear surface electrodes overlapping with the upper surface electrode when viewed in the thickness direction, and any one of the pair of side surface electrodes connected to the upper surface electrode and the rear surface electrode,

the intermediate portion comprises nickel.

16. The chip resistor of claim 15 wherein:

the outer portion comprises tin.

17. The chip resistor according to any one of claims 1 to 16, wherein:

the substrate is formed of a ceramic containing alumina.

Technical Field

The present invention relates to a chip resistor.

Background

A chip resistor surface-mounted on a wiring board of various electronic devices has been known. Patent document 1 discloses an example of a chip resistor. The chip resistor includes: an insulating substrate; a pair of upper surface electrodes and a pair of back surface electrodes respectively disposed at both ends of the insulating substrate; a resistor body electrically connected to the pair of upper surface electrodes; and a pair of end face electrodes for making the pair of upper face electrodes and the pair of back face electrodes electrically connected with each other.

The chip resistor is mounted on the wiring board via solder. When the chip resistor is used, heat is generated from the resistor body. Thereby, thermal stress due to a difference in thermal deformation between the pair of back electrodes and the solder acts on the solder. When the magnitude of the thermal stress is relatively large, when the thermal stress is repeatedly applied to the solder, cracks may be generated in the solder. When a crack is generated in the solder, there is a possibility that a current path between the wiring board and the chip resistor is blocked. Therefore, in the chip resistor, a countermeasure for suppressing generation of cracks in the solder due to thermal stress is required.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2008-53251.

Disclosure of Invention

Problems to be solved by the invention

In view of the above circumstances, an object of the present invention is to provide a chip resistor that can suppress generation of cracks in solder between a wiring board and a pair of back electrodes when the chip resistor is used.

Means for solving the problems

According to the present invention, there is provided a chip resistor comprising: a substrate having an upper surface and a back surface facing opposite sides to each other in a thickness direction, and a pair of side surfaces spaced apart from each other in one direction orthogonal to the thickness direction and connected to the upper surface and the back surface; a pair of upper surface electrodes spaced apart from each other in the one direction and contacting the upper surface; a resistor disposed on the upper surface and connected to the pair of upper surface electrodes; a pair of back electrodes spaced apart from each other in the one direction and contacting the back surface; and a pair of side electrodes in contact with the pair of side surfaces and connected to the pair of upper surface electrodes and the pair of back electrodes, the pair of back electrodes each having a first layer in contact with the back surface and a second layer covering at least a part of the first layer, the second layer being composed of a material containing metal particles and a synthetic resin.

Other features and advantages of the present invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying drawings.

Drawings

Fig. 1 is a plan view of a chip resistor according to a first embodiment of the present invention.

Fig. 2 is a plan view corresponding to fig. 1, which is a view through a pair of external electrodes and an upper layer of a protective layer.

Fig. 3 is a bottom view of the chip resistor shown in fig. 1.

Fig. 4 is a bottom view corresponding to fig. 3, through a pair of external electrodes.

Fig. 5 is a sectional view taken along line V-V of fig. 1.

Fig. 6 is a sectional view of a chip resistor according to a modification of the first embodiment of the present invention.

Fig. 7 is a bottom view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 8 is a bottom view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 9 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 10 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 11 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 12 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 13 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 14 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 15 is a sectional view taken along the line XV-XV of fig. 14.

Fig. 16 is a sectional view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 17 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 18 is a sectional view illustrating a manufacturing process of the chip resistor shown in fig. 1.

Fig. 19 is a sectional view of a chip resistor according to a second embodiment of the present invention.

Fig. 20 is a partially enlarged sectional view of fig. 19.

Fig. 21 is a sectional view of a chip resistor according to a third embodiment of the present invention.

Fig. 22 is a partially enlarged sectional view of fig. 21.

Fig. 23 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 21.

Fig. 24 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 21.

Fig. 25 is a sectional view of a chip resistor according to a fourth embodiment of the present invention.

Fig. 26 is a partially enlarged sectional view of fig. 25.

Fig. 27 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 25.

Fig. 28 is a plan view illustrating a manufacturing process of the chip resistor shown in fig. 25.

Detailed Description

A mode for carrying out the present invention will be described based on the drawings.

[ first embodiment ]

A chip resistor a10 according to a first embodiment of the present invention will be described with reference to fig. 1 to 5. The chip resistor a10 includes a substrate 10, a resistor body 20, a pair of electrodes 30, and a protective layer 40. In fig. 2, for the sake of easy understanding, the pair of external electrodes 34 (described in detail later) constituting a part of the pair of electrodes 30 and the upper layer 42 (described in detail later) of the protective layer 40 are penetrated. Fig. 4 is a view through the pair of external electrodes 34 for easy understanding.

In the description of the chip resistor a10 and the chip resistors a20 to a40 described later, the thickness direction of the substrate 10 is referred to as "thickness direction z" for convenience. One direction orthogonal to the thickness direction z is referred to as a "first direction x". A direction orthogonal to both the thickness direction z and the first direction x is referred to as a "second direction y".

The chip resistor a10 is surface-mounted on wiring boards of various electronic devices. The chip resistor a10 functions to limit the current flowing through the wiring board. The chip resistor a10 is a thick film (metal glaze) type resistor. As shown in fig. 1, the chip resistor a10 is rectangular in shape as viewed in the thickness direction z. In this case, the first direction x corresponds to the length direction of the chip resistor a 10. On the other hand, the chip resistor a10 may have a rectangular shape with the second direction y as the longitudinal direction when viewed in the thickness direction z.

As shown in fig. 1, 2, and 5, a resistor 20, a pair of electrodes 30, and a protective layer 40 are disposed on a substrate 10. The substrate 10 has insulation properties. The substrate 10 is rectangular in shape with a pair of peripheral edges along the first direction x as long sides, as viewed in the thickness direction. When the chip resistor a10 is used, the substrate 10 is required to have good heat dissipation properties because heat is generated from the resistor body 20. Therefore, the material of the substrate 10 is preferably relatively high in thermal conductivity. In the chip resistor A10, the substrate 10 is made of a material containing aluminum oxide (Al)₂O₃) The ceramic of (2).

As shown in fig. 5, the substrate 10 has an upper surface 11, a back surface 12, and a pair of side surfaces 13. The upper surface 11 and the back surface 12 face opposite sides to each other in the thickness direction z. The upper surface 11 faces upward in fig. 5. The back face 12 faces downward in fig. 5. When the chip resistor a10 is mounted on the wiring board, the back surface 12 faces the wiring board. A pair of side surfaces 13 are connected to the upper surface 11 and the back surface 12. As shown in fig. 2 and 4, the pair of side surfaces 13 are spaced apart from each other in the first direction x.

As shown in fig. 1, 2, and 5, the resistor 20 is disposed on the upper surface 11 of the substrate 10. The resistor 20 is a belt-like shape extending in the first direction x when viewed along the thickness direction z. In the chip resistor a10, the resistor body 20 is formed of a material containing metal particles and glass. The metal particles are, for example, ruthenium oxide (RuO)₂) Or a silver (Ag) -palladium (Pd) alloy.

As shown in fig. 2 and 5, the resistor 20 is formed with an adjustment groove 21 penetrating in the thickness direction z. The adjustment groove 21 is formed integrally with both the resistor 20 and a lower layer 41 (described later in detail) of the protective layer 40 covering the resistor 20. In the example shown in the chip resistor a10, the adjustment groove 21 has an L shape when viewed in the thickness direction z. One end of the resistor 20 in the second direction y is opened by the adjustment groove 21. The shape of the adjustment groove 21 as viewed in the thickness direction z is not limited to the example shown in the chip resistor a 10.

As shown in fig. 1 to 5, the pair of electrodes 30 are disposed on the substrate 10 at intervals in the first direction x. A pair of electrodes 30 is connected to the resistor 20 at both ends of the resistor 20 in the first direction x. When the chip resistor a10 is mounted on a wiring board, the pair of electrodes 30 is soldered to the wiring board. Thus, the pair of electrodes 30 constitute a conductive path between the resistor 20 and the wiring board. As shown in fig. 5, the pair of electrodes 30 each include an upper surface electrode 31, a rear surface electrode 32, a side surface electrode 33, and an external electrode 34.

The pair of upper surface electrodes 31 are spaced apart from each other in the first direction x and are in contact with the upper surface 11 of the substrate 10, as shown in fig. 2 and 5. The pair of upper surface electrodes 31 are connected to both ends of the resistor body 20 in the first direction x. Thereby, the pair of upper surface electrodes 31 and the resistor 20 are electrically connected. The pair of upper surface electrodes 31 are each in the shape of a strip extending in the second direction y. The pair of upper surface electrodes 31 is made of a material containing silver particles and glass.

The pair of back electrodes 32 are spaced apart from each other in the first direction x and are in contact with the back surface 12 of the substrate 10, as shown in fig. 4 and 5. The pair of back electrodes 32 are each in the shape of a strip extending in the second direction y. As shown in fig. 5, each of the pair of back electrodes 32 has a first layer 321 and a second layer 322.

As shown in fig. 5, the first layer 321 is in contact with the upper surface 11 of the substrate 10. In the chip resistor a10, the first layer 321 has insulation properties and is formed of a material containing synthetic resin. The synthetic resin is, for example, an epoxy resin. In the chip resistor a10, the first layer 321 reaches the boundary between either one of the pair of side faces 13 and the back face 12 of the substrate 10.

As shown in fig. 5, the second layer 322 covers at least a portion of the first layer 321. In the chip resistor a10, the second layer 322 covers the entirety of the first layer 321. The second layer 322 is formed of a material containing metal particles and a synthetic resin. Thus, the second layer 322 has conductivity. The metal particles comprise silver. The synthetic resin is, for example, an epoxy resin.

The pair of side electrodes 33 are in contact with the pair of side surfaces 13 of the substrate 10 as shown in fig. 2, 4 and 5. The pair of side electrodes 33 are connected to the pair of upper surface electrodes 31 and the pair of rear surface electrodes 32. Thereby, the pair of back electrodes 32 are electrically connected to the resistors 20 via the pair of side electrodes 33 and the pair of top electrodes 31. In the chip resistor a10, the pair of side electrodes 33 is formed of a metal thin film. The metal thin film is formed of an alloy containing nickel (Ni) and chromium (Cr).

As shown in fig. 5, each of the pair of side electrodes 33 has an upper surface portion 331, a rear surface portion 332, and a side surface portion 333. As shown in fig. 2 and 5, the upper surface portion 331 overlaps the upper surface 11 of the substrate 10 as viewed in the thickness direction z, and is in contact with any one of the pair of upper surface electrodes 31. As shown in fig. 4 and 5, the back surface portion 332 overlaps the back surface 12 of the substrate 10 as viewed in the thickness direction z, and is in contact with any one of the second layers 322 of the pair of back electrodes 32. As shown in fig. 5, the side surface portions 333 are in contact with either one of the pair of side surfaces 13 of the substrate 10 and the pair of upper surface electrodes 31. The side surface portions 333 are connected to the upper surface portion 331 and the rear surface portion 332 at both ends of the side surface portions 333 in the thickness direction z. In the chip resistor a10, the upper surface 331, the rear surface 332, and the side surface 333 are uniform in thickness.

As shown in fig. 1, 3, and 5, the pair of external electrodes 34 cover the pair of upper surface electrodes 31, the pair of rear surface electrodes 32, and the pair of side surface electrodes 33. Thereby, the pair of external electrodes 34 are electrically connected to any of the pair of upper surface electrodes 31, the pair of back surface electrodes 32, and the pair of side surface electrodes 33. The pair of electrodes 30 is electrically connected to the resistor 20. The pair of external electrodes 34 is formed of a plating layer.

As shown in fig. 5, the pair of outer electrodes 34 each have an intermediate portion 341 and an outer portion 342. The intermediate portion 341 covers any one of the pair of upper surface electrodes 31, any one of the pair of rear surface electrodes 32 overlapping the upper surface electrodes 31 when viewed in the thickness direction, and any one of the pair of side surface electrodes connected to the upper surface electrodes 31 and the rear surface electrodes 32. Middle portion 341 comprises nickel. The outer portion 342 covers the middle portion 341. The outer portion 342 comprises tin (Sn).

As shown in fig. 1 and 5, the protective layer 40 covers the resistor 20. The protective layer 40 has a lower layer 41 and an upper layer 42.

As shown in fig. 2 and 5, lower layer 41 covers a part of resistor 20. Resistor 20 protrudes in first direction x from both ends of lower layer 41 in first direction x. The lower layer 41 is formed with the aforementioned adjustment groove 21. The lower layer 41 is formed of a material containing glass.

As shown in fig. 1 and 5, upper layer 42 covers a part of resistor 20 and lower layer 41. The upper layer 42 also covers a portion of the upper surface 11 of the substrate 10 and a portion of the pair of upper surface electrodes 31. The upper layer 42 is formed of a material containing black epoxy resin, for example.

[ modification of the first embodiment ]

Next, a chip resistor a11, which is a modification of the chip resistor a10, will be described with reference to fig. 6.

In the chip resistor a11, the structure of the pair of side electrodes 33 is different from that of the chip resistor a10 described above.

In the chip resistor a11, as shown in fig. 6, each of the upper surface portions 331 of the pair of side electrodes 33 protrudes in the thickness direction z from the surface of any one of the pair of upper surface electrodes 31. Each of the rear portions 332 of the pair of side electrodes 33 protrudes in the thickness direction z from the surface of any one of the second layers 322 of the pair of rear electrodes 32. The side surface portions 333 of the pair of side surface electrodes 33 each bulge out in the first direction x from either one of the pair of side surfaces 13 of the substrate 10. In the chip resistor a11, a pair of side electrodes 33 is formed of a material containing silver particles and a synthetic resin. The synthetic resin is, for example, an epoxy resin.

Next, an example of a method for manufacturing the chip resistor a10 will be described with reference to fig. 7 to 18. Here, the sectional position in each of fig. 16 and 18 is the same as that in fig. 15.

First, as shown in fig. 7, a plurality of upper surface electrodes 82 in contact with an upper surface 811 are formed on a sheet-like base material 81 having the upper surface 811 and a back surface 812 facing opposite sides to each other in a thickness direction z. The upper surface 811 is provided with a plurality of primary grooves 81A extending in the second direction y and a plurality of secondary grooves 81B extending in the first direction x. The plurality of primary grooves 81A and the plurality of secondary grooves 81B are each recessed from the upper surface 811 in the thickness direction z. A plurality of primary grooves 81A and a plurality of secondary grooves 81B are also disposed on the back surface 812. The respective formation positions of the plurality of primary grooves 81A and the plurality of secondary grooves 81B in the back surface 812 correspond to the respective formation positions of the plurality of primary grooves 81A and the plurality of secondary grooves 81B in the upper surface 811. In the upper surface 811 and the back surface 812, the plurality of areas 80 divided by the plurality of primary grooves 81A and the plurality of secondary grooves 81B each correspond to the substrate 10 of the chip resistor a 10.

As shown in fig. 7, the plurality of upper surface electrodes 82 are independently formed in a state of being spaced apart from each other in the first direction x in the plurality of regions 80 located on the upper surface 811 of the base material 81. The plurality of upper surface electrodes 82 are each formed in a respective manner across the plurality of primary grooves 81A. Thereby, a pair of upper surface electrodes 82 spanning the pair of primary grooves 81A that divide the plurality of regions 80 are formed. The pair of upper surface electrodes 82 corresponds to the pair of upper surface electrodes 31 of the chip resistor a 10. The plurality of upper surface electrodes 82 are formed by printing a paste containing silver particles and glass frit on the upper surface 811 and then firing the paste.

Next, as shown in fig. 8 and 9, a plurality of rear surface electrodes 83 are formed in contact with the rear surface 812 of the base 81. The plurality of back electrodes 83 are independently formed in a state of being spaced apart from each other in the first direction x in the plurality of regions 80 located on the back surface 812. Each of the plurality of back electrodes 83 is composed of a first layer 831 and a second layer 832. First, as shown in fig. 8, a plurality of first layers 831 are each formed in a respective manner across the plurality of primary grooves 81A. The plurality of first layers 831 are formed by printing a paste containing an epoxy resin as a main component on the back surface 812 and then thermally curing the paste.

Next, as shown in fig. 9, a plurality of second layers 832 independently covering the plurality of first layers 831 are formed. Each of the plurality of second layers 832 is formed to cover the entirety of each of the plurality of first layers 831. Thereby, a pair of first layers 831 and a pair of second layers 832 which span the respective pair of primary grooves 81A which divide the plurality of regions 80 are formed. The pair of first layers 831 and the pair of second layers 832 correspond to the pair of back electrodes 32 of the chip resistor a 10. The plurality of second layers 832 are formed by independently printing a paste containing an epoxy resin as a main agent and silver particles on the plurality of first layers 831 and then thermally curing the paste. With the above, the plurality of back electrodes 83 are formed.

Next, as shown in fig. 10, a plurality of resistors 84 are formed in contact with the upper surface 811 of the base 81. The plurality of resistors 84 are independently formed in the plurality of regions 80 located on the upper surface 811. The resistor body 84 in each of the plurality of regions 80 corresponds to the resistor body 20 of the chip resistor a 10. In each of the plurality of regions 80, both ends of the resistor 84 in the first direction x are in contact with the pair of upper surface electrodes 82. The plurality of resistors 84 are formed by printing a paste containing metal particles and glass frit on the rear surface 812 and then firing the paste. The metal particles are ruthenium oxide or silver-palladium alloy.

Next, as shown in fig. 11, a plurality of lower layers 851 independently covering the plurality of resistors 84 are formed. The plurality of lower layers 851 each correspond to the lower layer 41 of the protective layer 40 of the chip resistor a 10. The lower layers 851 are formed by printing glass paste on the resistors 84 and then firing the glass paste.

Next, as shown in fig. 12, a plurality of adjustment grooves 841 penetrating in the thickness direction z are formed integrally with both the plurality of resistors 84 and the plurality of lower layers 851. Each of the plurality of adjustment grooves 841 corresponds to an adjustment groove 21 in the chip resistor a 10. The plurality of the adjustment grooves 841 are formed using a laser cutting device.

Each of the plurality of adjustment grooves 841 is formed by, first, bringing probes for measuring the resistance value into contact with both ends in the first direction x of the resistor body 84 to be formed of the adjustment grooves 841. Next, a groove penetrating through both the resistor 84 and the lower layer 851 in the thickness direction z is formed along the second direction y from one end of the resistor 84 in the second direction y. The grooves are formed until the resistance value of the resistor body 84 becomes close to a predetermined value (the resistance value of the chip resistor a 10), and then the grooves extending in the first direction x are formed from the ends of the grooves. When the resistance value of the resistor 84 becomes a predetermined value, the formation of the groove is completed. Through the above steps, the plurality of adjustment grooves 841 are formed.

Next, as shown in fig. 13, a plurality of upper layers 852 are formed to cover a plurality of resistors 84, a plurality of lower layers 851, and a portion of each of the plurality of upper surface electrodes 82. The upper layers 852 are formed in a band shape extending in the second direction y while being spaced apart from each other in the first direction x. The upper layers 852 span the secondary grooves 81B formed in the upper surface 811 of the substrate 81. A portion of the upper layer 852 located in the plurality of areas 80 of the upper surface 811 corresponds to the upper layer 42 of the protective layer 40 of the chip resistor a 10. The upper layers 852 are formed by printing a paste mainly composed of an epoxy resin which integrally covers the resistors 84 and the lower layers 851, and then thermally curing the paste.

Next, as shown in fig. 14, the base 81 is divided along the plurality of primary grooves 81A. Thereby, a plurality of base materials 81 extending in the second direction y in a belt shape are obtained. Through this step, as shown in fig. 15, a pair of side surfaces 813 appear at both ends of the plurality of base members 81 in the first direction x. The pair of side surfaces 813 face the first direction x.

Next, as shown in fig. 16, a pair of side electrodes 86 in contact with the pair of side surfaces 813 of the base 81 are formed. The pair of side electrodes 86 are formed in contact with both the pair of upper surface electrodes 82 and the second layer 832 of the pair of back surface electrodes 83. The pair of side electrodes 86 are formed by forming a nickel-chromium alloy film on a part of each of the pair of side surfaces 813, the pair of upper surface electrodes 82, and the pair of rear surface electrodes 83 by sputtering.

Next, as shown in fig. 17, the base 81 is divided along the secondary grooves 81B. Thereby, the base material 81 is obtained as a plurality of pieces. The base material 81 to be monolithic corresponds to the substrate 10 of the chip resistor a 10. A pair of upper surface electrodes 82, a pair of rear surface electrodes 83, a resistor 84, a lower layer 851, an upper layer 852, and a pair of side surface electrodes 86 are disposed on a base material 81 which is a single piece.

Finally, as shown in fig. 18, a pair of external electrodes 87 are formed so as to cover the pair of upper surface electrodes 82, the pair of rear surface electrodes 83, and the pair of side surface electrodes 86, respectively, which are disposed on the base 81 as a single piece. The pair of external electrodes 87 corresponds to the pair of external electrodes 34 of the chip resistor a 10. The pair of external electrodes 87 are each composed of an intermediate portion 871 and an outer portion 872. The intermediate portion 871 corresponds to the intermediate portion 341 of each of the pair of external electrodes 34 of the chip resistor a 10. The outer portions 872 correspond to the respective outer portions 342 of the pair of outer electrodes 34 of the chip resistor a 10.

The intermediate portion 871 and the outer portion 872 are each formed by electrolytic barrel plating. The intermediate portion 871 is formed by depositing nickel on each of the pair of upper surface electrodes 82, the pair of rear surface electrodes 83, and the pair of side surface electrodes 86 exposed from the base 81. The outer portion 872 is formed by depositing tin on the intermediate portion 871. Through the above steps, the chip resistor a10 can be manufactured.

Next, the operation and effect of the chip resistor a10 will be described.

According to the chip resistor a10, a pair of back electrodes 32 each have a first layer 321 and a second layer 322. The first layer 321 is in contact with the back side 12 of the substrate 10. The second layer 322 covers at least a portion of the first layer 321. The second layer 322 is formed of a material containing metal particles and a synthetic resin. When the chip resistor a10 is mounted on the wiring board, the second layer 322 is located closer to the solder than the first layer 321 in each of the pair of back electrodes 32. The young's modulus of the second layer 322 is small compared to the young's modulus of the pair of back electrodes 32 formed of the material containing glass and metal particles. This reduces thermal stress on the solder when the chip resistor a10 is used. Therefore, according to the chip resistor a10, it is possible to suppress generation of cracks in the solder between the wiring board and the pair of back electrodes 32 when the chip resistor a10 is used.

In the chip resistor a10, the first layer 321 of the pair of back electrodes 32 has insulation properties, and is formed of a material containing synthetic resin. Each of the second layers 322 of the pair of back electrodes 32 covers the entirety of the first layer 321. As described above, by forming each of the pair of back electrodes 32 in a two-layer structure including the first layer 321 and the second layer 322 of synthetic resin, it is possible to improve the bonding force between the pair of back electrodes 32 and the back surface 12 of the substrate 10 while securing the effect of reducing the thermal stress generated in the solder, and to avoid the reduction in the tensile strength of the pair of back electrodes 32.

In each of the pair of back electrodes 32 of the chip resistor a10, the first layer 321 has insulation properties, but the second layer 322 has conductivity. The second layer 322 covers the entirety of the first layer 321. Thus, in the step of forming the pair of external electrodes 87 shown in fig. 18, the pair of external electrodes 87 covering the entirety of the pair of back electrodes 83 can be formed.

In the chip resistor a10, the pair of side electrodes 33 is formed of a metal thin film. Accordingly, the thickness of each of the pair of side electrodes 33, for example, the thickness of each of the pair of side electrodes 33 formed of a material including silver particles and a synthetic resin, such as chip resistor a11, can be reduced.

The chip resistor a10 further has a pair of external electrodes 34 covering the pair of upper surface electrodes 31, the pair of back surface electrodes 32, and the pair of side surface electrodes 33. The pair of external electrodes 34 is formed of a plating layer. The pair of external electrodes 34 has an intermediate portion 341 containing nickel and an outer portion 342 covering the intermediate portion 341 and containing tin. Thus, when the chip resistor a10 is mounted on a wiring board, the solder and the exterior 342 form an integral alloy, and the chip resistor a10 has good mountability to the wiring board. Further, when the chip resistor a10 is mounted on the wiring board, since the intermediate portion 341 alleviates thermal shock due to solder or the like, the pair of upper surface electrodes 31, the pair of rear surface electrodes 32, and the pair of side surface electrodes 33 can be protected from the thermal shock.

[ second embodiment ]

A chip resistor a20 according to a second embodiment of the present invention will be described with reference to fig. 19 and 20. In these drawings, the same or similar elements as those of the chip resistor a10 are denoted by the same reference numerals, and redundant description thereof is omitted. Here, the cross-sectional position in fig. 19 is the same as that in fig. 5.

In the chip resistor a20, the structure of the pair of back electrodes 32 is different from that of the chip resistor a10 described above.

As shown in fig. 19 and 20, either one of the first layer 321 and the pair of side surfaces 13 of the substrate 10 is spaced apart from the boundary of the back surface 12 of the substrate 10 in the first direction x. Therefore, as shown in fig. 20, the back surface 12 has a region 121 between the boundary between any one of the pair of side surfaces 13 and the back surface 12 and the first layer 321. Each of the second layers 322 of the pair of back electrodes 32 is in contact with a region 121 of the back side 12 of the substrate 10.

Next, the operation and effect of the chip resistor a20 will be described.

According to the chip resistor a20, a pair of back electrodes 32 each have a first layer 321 and a second layer 322. The first layer 321 is in contact with the back side 12 of the substrate 10. The second layer 322 covers at least a portion of the first layer 321. The second layer 322 is formed of a material containing metal particles and a synthetic resin. Therefore, with the chip resistor a20, it is possible to suppress the generation of cracks in the solder between the wiring board and the pair of back electrodes 32 when the chip resistor a20 is used.

In the chip resistor a20, each of the first layers 321 of the pair of back electrodes 32, and either one of the pair of side faces 13 of the substrate 10 are spaced apart from the boundary of the back face 12 of the substrate 10 in the first direction x. Each of the second layers 322 of the pair of back electrodes 32 is in contact with the region 121 of the back surface 12 between the boundary of the back surface 12 and the first layer 321 at either one of the pair of side surfaces 13. It is known that thermal stress generated in solder at the time of use of the chip resistor a20 is concentrated particularly in the vicinity of the boundary between any one of the pair of side surfaces 13 of the substrate 10 and the back surface 12. This makes it possible to increase the thickness of the first layer 321 while ensuring a reduction effect of thermal stress generated in the solder without affecting the dividing step of the base material 81 shown in fig. 14 and 15.

[ third embodiment ]

A chip resistor a30 according to a third embodiment of the present invention will be described with reference to fig. 21 and 22. In these drawings, the same or similar elements as those of the chip resistor a10 are denoted by the same reference numerals, and redundant description thereof is omitted. Here, the cross-sectional position in fig. 21 is the same as that in fig. 5.

In the chip resistor a30, the structure of the pair of back electrodes 32 is different from that of the chip resistor a10 described above.

The first layer 321 of the pair of back electrodes 32 has conductivity. The first layer 321 is formed of a material containing silver particles and glass. As shown in fig. 21 and 22, either one of the first layer 321 and the pair of side surfaces 13 of the substrate 10 is spaced apart from the boundary of the back surface 12 of the substrate 10 in the first direction x. Therefore, as shown in fig. 22, the back surface 12 has a region 121 between the boundary between any one of the pair of side surfaces 13 and the back surface 12 and the first layer 321.

As shown in fig. 22, each of the second layers 322 of the pair of back electrodes 32 is in contact with a region 121 of the back surface 12 of the substrate 10. In the chip resistor a20, the second layer 322 covers a portion of the first layer 321. In the chip resistor a30, the second layer 322 bulges in the thickness direction z from the back surface 12.

Next, an example of a method for manufacturing the chip resistor a30 will be described with reference to fig. 23 and 24.

In an example of the method of manufacturing the chip resistor a30, the step of forming the plurality of back electrodes 83 is different from that in the example of the method of manufacturing the chip resistor a 10. Therefore, in the description of an example of the method for manufacturing the chip resistor a30, only the step of forming the plurality of back electrodes 83 will be described.

First, as shown in fig. 23, each of the plurality of first layers 831 is formed to be spaced apart from the plurality of primary grooves 81A of the base 81 in the first direction x. Thereby, in each of the plurality of regions 80 located on the back surface 812 of the base 81, a pair of first layers 321 spaced apart from each other in the first direction x is formed. Between the 2 first layers 831 adjacent to each other with the plurality of primary grooves 81A interposed therebetween, a gap 812A, which is a part of the back surface 812, appears. The plurality of first layers 831 are formed by printing a paste containing silver particles and glass frit on the rear surface 812 and then firing the paste.

Next, as shown in fig. 24, a plurality of second layers 832 in contact with the plurality of first layers 831 are formed. Each of the second layers 832 covers a part of each of the 2 first layers 831 adjacent to each other with the primary grooves 81A interposed therebetween, and is formed to fill the gap 812A. At this time, in each of the plurality of second layers 832, a portion overlapping the gap 812A is recessed toward the back surface 812 as viewed in the thickness direction z. Each of the plurality of second layers 832 is formed by printing a paste containing an epoxy resin as a main component and silver particles on the gap 812A and the 2 first layers 831 located adjacent to the gap 812A, and then thermally curing the paste. The plurality of back electrodes 83 are formed by the above steps.

Next, the operation and effect of the chip resistor a30 will be described.

According to the chip resistor a30, a pair of back electrodes 32 each have a first layer 321 and a second layer 322. The first layer 321 is in contact with the back side 12 of the substrate 10. The second layer 322 covers at least a portion of the first layer 321. The second layer 322 is formed of a material containing metal particles and a synthetic resin. Therefore, with the chip resistor a30, it is possible to suppress the generation of cracks in the solder between the wiring board and the pair of back electrodes 32 when the chip resistor a30 is used.

In the chip resistor a30, the first layer 321 of the pair of back electrodes 32 has conductivity and is formed of a material containing glass. Either one of the first layer 321 and the pair of side surfaces 13 of the substrate 10 is spaced apart from the boundary of the back surface 12 of the substrate 10 in the first direction x. Each of the second layers 322 of the pair of back electrodes 32 is in contact with the region 121 of the back surface 12 between the boundary of the back surface 12 and the first layer 321 at either one of the pair of side surfaces 13. In the chip resistor a30, it was confirmed by the inventors of the present invention that the bonding force of the first layer 321 and the second layer 322 is relatively small. Therefore, the first layer 321 and the second layer 322 are configured to be in contact with the back surface 12 of the substrate 10, respectively, so that the pair of back surface electrodes 32 can be prevented from being peeled off from the substrate 10.

Each of the second layers 322 of the pair of back electrodes 32 covers a part of the first layer 321, and bulges in the thickness direction z from the back surface 12 of the substrate 10. Thereby, when the chip resistor a30 is mounted on the wiring board, bubbles contained in the solder are easily pushed out by the second layer 322. This can improve the mounting strength of the chip resistor a30 to the wiring board.

[ fourth embodiment ]

A chip resistor a40 according to a fourth embodiment of the present invention will be described with reference to fig. 25 and 26. In these drawings, the same or similar elements as those of the chip resistor a10 are denoted by the same reference numerals, and redundant description thereof is omitted. Here, the cross-sectional position in fig. 25 is the same as that in fig. 5.

In the chip resistor a40, the structure of the pair of back electrodes 32 is different from that of the chip resistor a10 described above.

The first layer 321 of the pair of back electrodes 32 has conductivity. The first layer 321 is formed of a material containing silver particles and glass. As shown in fig. 25 and 26, either one of the first layer 321 and the pair of side surfaces 13 of the substrate 10 is spaced apart from the boundary of the back surface 12 of the substrate 10 in the first direction x. Therefore, as shown in fig. 26, the back surface 12 has a region 121 located at a position between the boundary between any one of the pair of side surfaces 13 and the back surface 12 and the first layer 321.

As shown in fig. 26, each of the second layers 322 of the pair of back electrodes 32 is in contact with a region 121 of the back surface 12 of the substrate 10. In the chip resistor a40, the second layer 322 covers the entirety of the first layer 321.

Next, an example of a method for manufacturing the chip resistor a40 will be described with reference to fig. 27 and 28.

In an example of the method of manufacturing the chip resistor a40, the step of forming the plurality of back electrodes 83 is different from that in the example of the method of manufacturing the chip resistor a 10. Therefore, only the step of forming the plurality of back electrodes 83 will be described here.

First, as shown in fig. 27, each of the plurality of first layers 831 is formed to be spaced apart from the plurality of primary grooves 81A of the base 81 in the first direction x. Thereby, in each of the plurality of regions 80 located on the back surface 812 of the base 81, a pair of first layers 321 spaced apart from each other in the first direction x is formed. Between the 2 first layers 831 adjacent to each other with the plurality of primary grooves 81A interposed therebetween, a gap 812A, which is a part of the back surface 812, appears. The plurality of first layers 831 are formed by printing a paste containing silver particles and glass frit on the rear surface 812 and then firing the paste.

Next, as shown in fig. 28, a plurality of second layers 832 in contact with the plurality of first layers 831 are formed. Each of the second layers 832 covers the entire of each of the 2 first layers 831 adjacent to each other with the primary grooves 81A interposed therebetween, and is formed so as to fill the gap 812A. Each of the plurality of second layers 832 is formed by printing a paste containing an epoxy resin as a main component and silver particles on the gap 812A and the 2 first layers 831 located adjacent to the gap 812A, and then thermally curing the paste. Through the above steps, the plurality of back electrodes 83 are formed.

Next, the operation and effect of the chip resistor a40 will be described.

According to the chip resistor a40, a pair of back electrodes 32 each have a first layer 321 and a second layer 322. The first layer 321 is in contact with the back side 12 of the substrate 10. The second layer 322 covers at least a portion of the first layer 321. The second layer 322 is formed of a material containing metal particles and a synthetic resin. Therefore, according to the chip resistor a40, it is possible to suppress generation of cracks in the solder between the wiring board and the pair of back electrodes 32 when the chip resistor a40 is used.

The present invention is not limited to the above-described embodiments. The specific structure of each part of the present invention can be variously modified in design.

Various embodiments of the present invention are defined by the following notations.

Note 1. a chip resistor, comprising:

a substrate having an upper surface and a back surface facing opposite sides to each other in a thickness direction, and a pair of side surfaces spaced apart from each other in one direction orthogonal to the thickness direction and connected to the upper surface and the back surface;

a pair of upper surface electrodes spaced apart from each other in the one direction and contacting the upper surface;

a resistor disposed on the upper surface and connected to the pair of upper surface electrodes;

a pair of back electrodes spaced apart from each other in the one direction and contacting the back surface; and

a pair of side electrodes contacting the pair of side surfaces and connected to the pair of upper surface electrodes and the pair of back surface electrodes,

the pair of back electrodes each have a first layer in contact with the back surface and a second layer covering at least a part of the first layer,

the second layer is composed of a material containing metal particles and a synthetic resin.

Supplementary note 2. the chip resistor according to supplementary note 1, wherein,

the first layer has an insulating property and is formed of a material containing a synthetic resin,

the second layer covers the entirety of the first layer.

Note 3 that the chip resistor according to note 2, wherein,

the first layer reaches a boundary between either one of the pair of side surfaces and the back surface.

Note 4. the chip resistor according to note 2, wherein,

the first layer is spaced apart from a boundary in the one direction, wherein the boundary is a boundary between either one of the pair of side surfaces and the back surface,

the second layer is in contact with an area of the back surface between the first layer and a boundary that is a boundary between either of the pair of side surfaces and the back surface.

Note 5 that the chip resistor according to note 1, wherein,

the first layer is electrically conductive and formed of a material comprising glass,

the first layer is spaced apart from a boundary in the one direction, wherein the boundary is a boundary between either one of the pair of side surfaces and the back surface.

Supplementary note 6. the chip resistor according to supplementary note 5, wherein,

the first layer is formed of a material comprising silver particles.

Note 7 that the chip resistor according to note 5 or 6, wherein,

the second layer is in contact with an area of the back surface between the first layer and a boundary that is a boundary between either of the pair of side surfaces and the back surface.

Note 8 that the chip resistor according to note 7, wherein,

the second layer covers a part of the first layer and bulges from the back surface in the thickness direction.

Reference numeral 9 shows a chip resistor according to reference numeral 7, wherein,

the second layer covers the entirety of the first layer.

10 the chip resistor according to any one of supplementary notes 1 to 9, wherein,

the metal particles comprise silver.

The chip resistor according to any one of supplementary notes 1 to 10, wherein,

the pair of side electrodes is formed of a metal thin film.

Reference numeral 12, a chip resistor according to reference numeral 11, wherein,

the metal thin film is formed of an alloy containing nickel and chromium.

Reference numeral 13 denotes a chip resistor according to any one of claims 1 to 10,

the pair of side electrodes is formed of a material containing silver particles and a synthetic resin.

Reference numeral 14 denotes a chip resistor according to any one of claims 1 to 13,

further having a pair of external electrodes covering the pair of upper surface electrodes, the pair of back surface electrodes, and the pair of side surface electrodes,

the pair of external electrodes is formed of a plating layer.

Supplementary note 15, the chip resistor as described in supplementary note 14, wherein,

the pair of external electrodes each have an intermediate portion and an outer portion covering the intermediate portion,

the intermediate portion covers any one of the pair of upper surface electrodes, any one of the pair of rear surface electrodes overlapping with the upper surface electrode when viewed in the thickness direction, and any one of the pair of side surface electrodes connected to the upper surface electrode and the rear surface electrode,

the intermediate portion comprises nickel.

Supplementary note 16, the chip resistor as described in supplementary note 15, wherein,

the outer portion comprises tin.

Reference numeral 17, the chip resistor according to any one of claims 1 to 16,

the substrate is formed of a ceramic containing alumina.