Lamination-Type Resistance Element Fine Adjustment
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Solution Overview
Problem
Existing lamination-type resistance elements face challenges in fine adjustment of resistance values due to limitations in the range of change and increased complexity and cost in manufacturing, with difficulties in reducing resistance values without risking short circuits or compromising design.
Innovation Solution
A lamination-type resistance element with internal electrodes arranged in groups, where the second group's gaps are aligned in the lamination direction, allowing for precise adjustment of resistance values by changing the size and number of gaps between internal electrodes, enabling fine tuning without affecting the resistance determined by the first group's configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of internal electrodes facing each other is increased or reduced to adjust resistance value, then the resistance value can be changed, but the range of change is wide and fine adjustment is difficult
Solution Approach 1:
The internal electrodes are divided into two groups: a first group where electrodes face each other through the thermistor layer (providing base resistance), and a second group where electrodes face each other on the same plane (providing fine adjustment capability). This segmentation allows independent optimization of each group's function.
Solution Approach 2:
The patent transitions from a single-dimension adjustment approach (only electrodes facing through the layer) to a two-dimension approach by adding electrodes that face each other on the same plane. This adds another degree of freedom for resistance adjustment.
2Manufacturing precision
If the gap between internal electrodes is reduced to decrease resistance value, then resistance decreases, but short circuit risk increases
Solution Approach 1:
By separating the electrode groups into different functional roles, the second group's electrodes on the same plane can be positioned to provide fine adjustment without creating the short circuit risks associated with reducing gaps in traditional configurations.
Solution Approach 2:
The thermistor layer acts as an intermediary that allows the first group of electrodes to establish base resistance while the second group's same-plane electrodes provide adjustment capability without directly compromising the electrical isolation that prevents short circuits.
3Manufacturing precision
If a no-connection-type internal electrode is added to adjust resistance, then resistance value can be modified, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the resistance-determining function and the fine-adjustment function into a unified laminated structure where both electrode groups are integrated during the same manufacturing process, avoiding the need for separate assembly steps.
Solution Approach 2:
The same lamination and sintering process that creates the thermistor layers also positions both groups of internal electrodes, making the manufacturing process universally capable of producing both the base structure and the adjustment features in one operation.
4Reliability
If multiple internal electrodes are arranged to face each other through the thermistor layer, then resistance can be determined, but fine adjustment capability is limited
Solution Approach 1:
The electrode system is segmented into two functional groups: the first group establishes stable base resistance through electrodes facing across the thermistor layer, while the second group enables fine adjustment through electrodes on the same plane.
Solution Approach 2:
The invention adds a new dimension to electrode arrangement by placing some electrodes on the same plane rather than only across the layer, providing an additional degree of freedom for fine resistance adjustment while maintaining the stability provided by the first group.
Data Source
AI summary
A lamination-type resistance element includes a laminated sinter having internal electrodes of a first group and internal electrodes of a second group, the first internal electrode group including a plurality of internal electrodes facing each other through a ceramic resistance layer and defining a resistance unit at the portion where the plurality of internal electrodes face each other. A first end of the resistance unit is connected to a first external electrode and the second end is connected to a second external electrode. The second internal electrode group includes a plurality of pairs of internal electrodes in which the inner ends face each other through a gap on the same plane inside the laminated sinter, and a plurality of pairs of gaps in the plurality of internal electrodes are arranged at the same location when seen from one end of the lamination direction of the laminated sinter. Thereby, fine adjustment of a resistance value can be performed.