Thick Film Power Resistor Applications

Power resistors are used in a wide range of applications. They are primarily used as protection devices but are also found in power dissipation applications. The most common types of power resistor technology are wirewound and thick film. They are compared in detail elsewhere on this blog.

How To Choose The Right Resistor - 3 Things To Consider

When trying to choose the right resistor for a particular application it may appear only resistance value, tolerance and voltage is relevant. These parameters are important but if a resistor is to perform to specification over the long term there are three key issues to consider.

Performance trade offs

There is no such thing as a perfect resistor, which means there must be some level of compromise. Performance characteristics are often closely linked. Therefore, fixing one parameter can have a detrimental effect on another.

High Value Resistors Manufacturing And Application Issues

There are many resistors available with values in the mega-ohm range. Resistors in this resistance range are available in a wide range of package styles to suit a variety of applications. Making high value resistors for specialist applications in the Giga-ohm range is more complicated.

Surge Resistors In ESD Management Applications

In this post, we consider the use of Surge resistors to maintain operator safety in applications with the potential for high ESD.

The term Pulse generally refers to an overload condition withhigh power and long duration whereas surge generally means an overload of high voltage and with short duration (as in ESD).

The paper manufacturing industry noticed a potential problem with fast moving webs of material back in the mid 1800’s. Some printing, plastics, textiles and pharmaceutical (among others) industries manufacturing processes can generate high level static charges.

Thick Film Resistor Terminations - Eliminating Long Term Reliability Issues

Considerable effort may go into designing a thick film resistor product to survive demanding environmental conditions. However, failure to consider the resistor terminations to the system board can lead to reduced performance and/or premature device failure.

Custom Thick Film Resistors - Advantages and Disadvantages

When choosing resistors for use in demanding applications there are many issues to consider.

However, sometimes design compromises are not an option and custom thick film resistors are the only solution. In this post, we consider the advantages and disadvantages of choosing a bespoke resistor specifically designed for a particular application.

Choosing A Thick Film Power Resistor Substrate

Armed with the resistor performance specification and full details of the application a specialist thick film power resistor manufacturer will select the most appropriate substrate technology to deliver a reliable resistor solution at an appropriate cost.

There are four main substrate technologies used in thick film resistor manufacture, they are:

1. Alumina

2. Aluminium Nitride

3. Steel

4. Silicon

High Power Thick Film Resistors In High Temperature Applications

Resistors are used in a variety of demanding high power, high temperature applications. These applications include down hole, process applications and military systems. In this post, we discuss the impact of temperature on resistor performance, high power resistor technologies and design solutions to deliver long-term stable performance at temperature extremes.

Thick Film Resistors vs Bulk Metal Foil Resistors - A Comparison

The bulk metal foil resistor was first developed by Dr Felix Zandman (who went on to found Vishay) in the early 1960’s and is now a mainstream resistor technology. In this post, we compare the performance of bulk metal foil resistor technology with thick film.

Construction Comparison

The bulk metal foil manufacturing process involves attaching a bulk metal foil to a ceramic substrate using an adhesive. A photoetching process is then used to form the resistor pattern. The final step is to adjust the resistor value and tolerance using a laser.

Thick Film Custom Resistor Package Styles

Thick film resistor technology is the ideal choice for many applications. Other resistor technologies may outperform thick film in certain applications but are usually lower density and/or higher cost solutions. Thick film technology has excellent thermal properties and is low inductance. It also offers high resistance density (small size) and is comparatively cheap.