Nonlinear Resistive Element with Segmented Ceramic and Resin
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Solution Overview
Problem
The existing non-linear resistive elements, primarily composed of ceramic sintered compacts, face limitations in shape and size due to their design, making it difficult to visually confirm the application of surge voltage and degree of element deterioration, thereby restricting flexibility in mounting and design.
Innovation Solution
A non-linear resistive element with a ceramic sheet composed of decentralized ceramic pieces bound by insulating resin, featuring a convex surface shape and a conductive layer on its main faces, allowing for flexibility and adjustable shape and size, and incorporating a thermally responsive resin for visual indication of surge voltage application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic sintered compact is used as the non-linear resistive element, then the element exhibits stable non-linear voltage-current characteristic, but the shape and size are limited and flexibility is reduced
Solution Approach 1:
The ceramic sintered compact is divided into multiple small ceramic pieces (beads or granules) that are dispersed and embedded within a flexible resin matrix. This segmentation allows the individual ceramic pieces to maintain the non-linear resistive properties while the resin binder provides flexibility and adaptability to various shapes and sizes for mounting in different spaces.
Solution Approach 2:
The invention creates a composite material by combining ceramic pieces (providing non-linear electrical characteristics) with a resin binder (providing flexibility and mechanical strength). This composite structure integrates the advantages of both materials: the ceramic pieces ensure reliable voltage-dependent resistance while the resin matrix enables deformation to fit arbitrary shapes and mounting configurations.
2Volume of moving object
If the insulating resin layer is made thinner to reduce size, then the flexibility and deformability of the ceramic sheet improve, but the insulation and structural integrity may be compromised
Solution Approach 1:
The resin binder serves multiple local functions: it provides insulation between ceramic pieces, binds the ceramic pieces together to form a coherent sheet structure, and enables flexibility. By optimizing the resin's properties and distribution, the structure maintains integrity even with reduced thickness, as the resin creates a continuous matrix that holds the ceramic pieces in place while allowing deformation.
3Adaptability or versatility
If the ceramic pieces are arranged in a decentralized manner within the resin, then the flexibility and ease of deformation improve, but the manufacturing precision and uniformity of electrical properties may be affected
Solution Approach 1:
The invention controls the distribution and concentration of ceramic pieces within the resin matrix to achieve uniform electrical properties. By optimizing parameters such as ceramic piece size, shape, concentration, and spatial distribution, the composite material achieves both flexibility for deformation and consistency in non-linear voltage-current characteristics across the entire sheet.
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
This configuration enhances the flexibility and adjustability of the non-linear resistive element, enabling easy deformation to fit arbitrary shapes and sizes, ensuring reliable electrical contact and improved design freedom, while allowing visual confirmation of surge voltage exposure.
Implementation Method 1
a plurality of ceramic pieces 11 composed of ceramic sintered compact and having an approximately spherical shape are in a state decentrally arranged in an approximately planar shape, and are consolidated (formed, bound, gathered) in an approximately plate shape by an insulating resin 12
Implementation Method 2
incorporating a thermally responsive resin for visual indication of surge voltage application
Implementation Method 3
Non-linear resistive elements generally called a varistor show a characteristic of a resistance value thereof varying with a voltage applied thereto, i.e., have a non-linear voltage-current characteristic such that the element has a high resistance value showing an insulating characteristic when a normal voltage is applied thereto, while showing a low resistance value when an abnormal high voltage is applied thereto
Data Source
Figure 1~3
Figure 4A~4B
Figure 5A~5C
AI summary
Provided is a non-linear resistive element which improves the degree of freedom of design of its mounting space. A ceramic sheet 10 which constitutes the non-linear resistive element is configured by a plurality of ceramic pieces 11 being consolidated in a plate like form by an insulating resin 12. One or a plurality of ceramic pieces 11 configure each of a plurality of conductive paths which penetrate the ceramic sheet 10 in a thickness direction thereof, and the ceramic pieces 11 which configure both ends of the conductive paths partially projects from the insulating resin 12.