Printed resistors for flexible electronics—thermal variance mitigation and tolerance improvement via oxide-metal coatings

Abstract

Manufactured resistors in conventional electronics are classified into tolerance groups ranging from <1% for high stability film types (E192) to 20% (E6) which are often carbon-based and utilised in less critical resistance value contexts such as current limiting or pull-up/down applications [IEC 60063:2015, Preferred number series for resistors and capacitors. One of the major identified challenges in the printed electronics industry currently is the ability to match this manufacturing capability for printed resistors in terms of initial tolerance, stability over time and power capabilities. In this work, a variety of screen-printed carbon resistors were designed and produced. The effects of utilising additional screen-printed ZnO and Ag layers as thermal variance management for the carbon resistors are investigated with the aim of improving the resistors power rating and stability. The introduction of ZnO or ZnO/Ag layers to carbon resistors saw notable improvements in the peak power capability, stability when sustaining 500 mW power dissipation, and stability in varying environmental conditions. Utilizing ZnO and Ag layers also notably improved the initial tolerance groupings when compared to basic uncoated carbon resistors.