Negative-Temperature-Coefficient Thermistor Partial Coating Overlap
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Solution Overview
Problem
The existing method of manufacturing electronic components using a glass film coating results in excessive glass slurry deposition on the barrel, necessitating frequent cleaning and hindering manufacturing efficiency and simplification.
Innovation Solution
The method involves applying a first and second coating layer partially covering the component body, with overlapping regions to reduce material adherence to holders and enhance component strength, while minimizing undried coating areas for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass slurry is sprayed from a nozzle onto the entire surface of the component body, then the glass film can be deposited onto the entire surface, but a large amount of glass slurry is deposited onto the inner surface of the barrel
Solution Approach 1:
The coating process is divided into multiple spraying passes with different nozzle positions and component rotation angles. The first coating layer is applied to specific regions, then the component is rotated to different angles for applying the second coating layer, ensuring complete coverage while controlling slurry deposition patterns.
Solution Approach 2:
The component body is pre-positioned at specific rotation angles (0° and 180°) before each coating application. The holder is designed with holding portions that engage with the component at predetermined positions, ensuring that the component is properly oriented before slurry application to minimize waste deposition.
2Manufacturing precision
If glass slurry is sprayed onto the entire surface of the component body, then complete coverage is achieved, but the barrel needs to be regularly cleaned
Solution Approach 1:
The coating is applied in segmented passes rather than attempting to cover the entire surface in one pass. The component is rotated to different angles between passes, allowing the slurry to be deposited more efficiently and reducing the amount that splatters onto the barrel interior.
Solution Approach 2:
The first and second coating layers are applied to partially overlap, ensuring complete coverage of the component surface while the holding portions prevent excessive material from reaching the barrel. The overlapping regions provide redundancy to ensure full coverage without requiring excessive slurry application.
3Manufacturing precision
If the component body is held during coating application, then stable coating can be achieved, but the holder material adheres to the undried coating layer
Solution Approach 1:
The holding portions are designed to engage with specific regions of the component body that are not coated with glass slurry. By extracting the holding function to specific geometric features (such as recesses or protrusions) on the component, the holder material does not contact the undried coating layer, eliminating adhesion problems.
Solution Approach 2:
The holding portions act as intermediaries between the holder and the component body. They are positioned and designed such that they contact only the uncoated regions or regions that will be coated last, serving as a mediator that prevents direct contact between the holder material and the undried coating layer.
4Strength
If multiple coating layers are applied with overlapping regions, then component strength is improved, but manufacturing process complexity increases
Solution Approach 1:
The application of multiple coating layers is merged into a single continuous manufacturing process. The component is held in the same holder and rotated to different angles within the same coating chamber, allowing the first and second coating layers to be applied in sequence without removing the component. This combines multiple operations into one integrated process.
Solution Approach 2:
The component is dynamically rotated to different angles (0° and 180°) during the coating process to enable application of multiple coating layers. The rotation mechanism allows the same component to be presented at different orientations for each coating pass, creating overlapping regions that strengthen the component without requiring separate manufacturing steps.
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 approach reduces cleaning and replacement time for holders, improves manufacturing efficiency, and enhances the strength of electronic components by forming overlapping regions with increased thickness in the coating layers.
Implementation Method 1
a first coating application step of applying a first coating to a portion of the surface of the component body and drying the first coating
Implementation Method 2
a curing step of curing the first coating so as to form the first coating layer and curing the second coating so as to form the second coating layer
Data Source
AI summary
A negative-temperature-coefficient thermistor component includes a core. Surfaces of the core are partially covered with a first insulating layer. Surfaces of the core are partially covered with a second insulating layer. The first insulating layer and the second insulating layer overlap each other on a first side surface and a second side surface, each of which is one of the surfaces of the core.