High-Voltage Resistor Structure With Insulator Element Shielding
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Solution Overview
Problem
High voltage resistor structures and voltage divider arrangements face challenges in manufacturing, reliability, and safety due to excessive electric stresses, which can lead to dielectric failures such as partial discharge or electrical breakdown.
Innovation Solution
The proposed solution involves a resistor structure comprising an electrically insulating substrate, conductive terminals, and a resistive path with an insulator element applied adjacent to the resistive path. The insulator element's thickness is at least 30% of the resistive trace's thickness when the trace is uncoated, or the total thickness of the insulator element and coating exceeds the coating thickness on the resistive trace by at least 30% when the trace is coated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resistive path is exposed without sufficient insulation, then the manufacturing process is simpler, but the reliability decreases due to dielectric failures under high electric field intensity
Solution Approach 1:
An insulator element is introduced as an intermediary component between the resistive path and the surrounding environment. This insulator element provides the necessary electrical insulation to prevent dielectric failures under high electric field intensity, thereby improving reliability without requiring fundamental changes to the manufacturing process
Solution Approach 2:
The insulator element is implemented as a thin film or coating applied directly to the substrate adjacent to the resistive path. This approach provides effective insulation while maintaining a compact structure and minimizing impact on manufacturing complexity
2Reliability
If the insulator element thickness is increased to protect against electric stresses, then the reliability improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a quantitative parameter for the insulator element thickness: at least 30% of the resistive trace thickness when uncoated, or the total thickness of insulator element and coating exceeds the coating thickness on the resistive trace by at least 30% when coated. This parameter-based approach provides clear manufacturing guidelines while ensuring sufficient insulation for reliability
Solution Approach 2:
The insulator element is applied during the manufacturing process before final assembly and testing. This preliminary application of insulation ensures that the protective function is built into the structure from the outset, allowing for quality control at the manufacturing stage rather than requiring post-manufacturing adjustments
Data Source
AI summary
A resistor structure includes at least an electrically insulating substrate, at least one electrically conductive terminal directly or indirectly provided on the substrate, at least one resistive path comprising at least one resistive trace directly or indirectly provided on the substrate and directly or indirectly joined to the terminal, wherein a thickness of the resistive trace is the thickness of the resistive trace in the thickness direction facing away from the substrate, characterized in that at least one insulator element is applied directly or indirectly and at least partially on the substrate, wherein a thickness of the insulator element is the thickness of the insulator element in the thickness direction facing away from the substrate.