Patent ID: 7038572
Filing Date: 2006-05-02
Classification: H01C,Y10S,Y10T

Abstract:
1. A power chip resistor comprising: a first and second film resistor each having (a) a substrate with a top surface, a bottom surface, a first end surface, an opposing end surface, a first side surface and an opposing side surface, (b) a film resistive element on the top surface of each substrate, (c) an end cap on the first end surface and electrically connected to the film resistive element, (d) a second end cap on the opposing end surface and electrically connected to the film resistive element, and (e) each end cap extending onto the top surface, the bottom surface, the first side surface and the second side surface; the second film resistor of approximately the same physical size as the first film resistor, the second film resistor of approximately the same orientation as the first film resistor; an inert encapsulant of glass frit between the top surface of the first film resistor and the bottom surface of the second film resistor; a first nickel barrier plating electrically connecting the end cap on the first end surface of the substrate of the first film resistor and the first end surface of the substrate of the second film resistor and mechanically bonding the film resistors without adhesive or solder; a second nickel barrier plating electrically connecting the second end cap on the second end surface of the substrate of the first film resistor and the second end cap on the second end surface of the substrate of the second film resistor and mechanically bonding the film resistors without adhesive or solder; whereby the first and second nickel barrier plating used to connect the end caps and the encapsulant provide long-term mechanical stability and resistance to resistive heating; wherein the power chip resistor is flow solderable due to the resistance to resistive heating provided by the first and second nickel barrier plating; wherein the power chip resistor is formed by separating the first film resistor from the second film resistor with the inert encapsulant, connecting the end cap on the first end surface of the first film resistor with the end cap on the first end surface of the second film resistor using the first nickel barrier plating, and connecting the end cap on the second end surface of the second film resistor with the end cap on the second end surface of the second film resistor using the second nickel barrier plating, the first and second nickel barrier plating mechanically bonding the film resistors without adhesive or solder.