Laminated Variable Resistor Metal Phase Active Regions
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Solution Overview
Problem
Conventional laminated variable resistors have high breakdown voltage but can only handle low-intensity currents, are prone to burning out under high current or inrush conditions, and require expensive equipment and extensive training for manufacturing.
Innovation Solution
Reducing the mole percentage of oxides in active regions and replacing them with metals like gold, silver, palladium, platinum, or their alloys, allowing for a metal phase in the active regions, which enhances current intensity and simplifies the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional laminated variable resistor uses metal oxide material in active regions, then the breakdown voltage is high, but the current intensity is low and the device is prone to burning out under high current conditions
Solution Approach 1:
The patent changes the material composition parameter in the active regions by replacing metal oxide with metal phase materials (such as zinc, aluminum, or their alloys). This parameter change fundamentally alters the electrical characteristics, reducing breakdown voltage while significantly increasing current carrying capacity and intensity handling capability.
Solution Approach 2:
The patent employs composite material structure where metal phase materials are integrated into the active regions of the laminated variable resistor. This composite approach combines the beneficial properties of metal (high conductivity and current capacity) with the resistive characteristics needed for variable resistor function, achieving both high current intensity and controlled resistance.
2Reliability
If the conventional laminated variable resistor uses metal oxide material, then the breakdown voltage is high, but the equipment cost and training requirements are expensive
Solution Approach 1:
The patent adopts metal phase materials that can be processed using simpler, more cost-effective manufacturing techniques compared to metal oxide materials. These materials allow for easier fabrication with standard equipment, reducing both equipment investment and training requirements while maintaining functional reliability.
Solution Approach 2:
By changing the material phase from oxide to metal, the patent enables the use of more accessible manufacturing processes with lower equipment requirements. This parameter change simplifies production and reduces dependency on specialized equipment and highly trained personnel.
3Volume of moving object
If the conventional laminated variable resistor is made thin to reduce size, then the device is more compact, but it can only bear low intensity current
Solution Approach 1:
The patent changes the material phase parameter to metal phase, which has inherently higher electrical conductivity and current carrying capacity. This allows thin-dimensional devices to sustain high current intensity that would be impossible with conventional metal oxide materials of the same thickness.
Solution Approach 2:
By using metal phase composite materials in the thin laminated structure, the patent achieves a combination of compact dimensions and high current capacity that would be contradictory with traditional metal oxide materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces breakdown voltage, increases current intensity, and significantly lowers equipment and training costs, while maintaining the characteristics of a variable resistor.
Implementation Method 1
the active region has the metal phase, the breakdown voltage can be reduced, and the intensity is thus enhanced
Data Source
AI summary
A laminated variable resistor comprises a main body, internal electrodes extending along two side edges of the main body into the main body, terminal electrodes disposed on the two ends of the main body. The mole percentage of the oxide in overlapping active regions between opposite internal electrodes is reduced and the reduced portion is replaced by a metal selected from gold (Au), silver (Ag), palladium (Pd), platinum (Pt), rhodium (Rh), or the alloy of any two of such metals.