Static Electricity Countermeasure Component with Composite Resin Layers
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Solution Overview
Problem
Conventional static electricity countermeasure components fail to prevent insulation deterioration caused by high-voltage static electric pulses due to inferior hardness and weather resistance of silicone-based resin, leading to potential carbonization and insulation breakdown.
Innovation Solution
A static electricity countermeasure component comprising a ceramic substrate with extractor electrodes, an over-voltage protective material layer containing metal powder and silicone-based resin, an intermediate layer with insulating powder and silicone-based resin, and a protective resin layer, which effectively bypasses discharge currents to ground and prevents insulation deterioration by minimizing discharge sparks reaching the outermost protective resin layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicone-based resin is used in the over-voltage protective material layer, then voltage tolerance and heat resistance are improved, but hardness and weather resistance deteriorate
Solution Approach 1:
The patent uses a composite structure with multiple resin layers: the over-voltage protective material layer uses silicone-based resin for voltage tolerance and heat resistance, while the outermost protective resin layer uses epoxy resin or phenol resin for hardness and weather resistance. This composite material approach allows each layer to发挥 its strengths without compromising the other properties.
2Strength
If epoxy resin or phenol resin is used in the outermost protective resin layer, then hardness and weather resistance are improved, but voltage tolerance and heat resistance deteriorate
Solution Approach 1:
The patent employs a multi-layer composite structure where the outermost protective resin layer uses epoxy resin or phenol resin to provide hardness and weather resistance, while the underlying over-voltage protective material layer uses silicone-based resin to provide voltage tolerance and heat resistance. This layered composite material solution allows the system to simultaneously achieve conflicting properties that cannot be obtained with a single material.
3Reliability
If discharge current flows between conductive particles in over-voltage protective material, then static electricity countermeasure function is achieved, but insulation deterioration occurs due to sparks jumping beyond the material
Solution Approach 1:
The patent introduces an intermediate protective resin layer between the over-voltage protective material layer and the outermost protective resin layer. This intermediate layer acts as a mediator that prevents sparks generated by discharge current between conductive particles from reaching and damaging the outermost protective resin layer, thereby maintaining insulation properties while preserving the static electricity protection function.
4Reliability
If static electricity countermeasure component is placed between signal line and ground, then static electricity protection is achieved, but stray capacitance increases deteriorating signal quality at high speeds
Solution Approach 1:
The patent uses a thin-film structure for the over-voltage protective material layer with controlled thickness (1 μm to 100 μm) and low dielectric constant materials to minimize stray capacitance. This thin-film approach allows the component to provide static electricity protection while maintaining low capacitance that does not deteriorate high-speed signal quality above several hundred Mbps.
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 component significantly enhances insulation durability and prevents insulation deterioration by using a silicone-based resin with polysiloxane and insulating powders, ensuring high tolerance to static electric pulses and maintaining signal quality at high speeds.
Implementation Method 1
a discharge current flows between conductive particles or semi-conducting particles dispersed in the over-voltage protective material that is an insulating material between the opposing gap electrodes when over-voltage by static electricity is applied between the opposing gap electrodes
Implementation Method 2
an intermediate layer disposed over the over-voltage protective material layer, containing an insulating powder and a silicone-based resin
Data Source
AI summary
A static electricity countermeasure component comprising; a ceramic substrate; at least two extractor electrodes opposingly disposed and mutually separated on the ceramic substrate; an over-voltage protective material layer disposed to cover a portion of each extractor electrode and a gap between the extractor electrodes, containing a metal powder and a silicone-based resin; an intermediate layer disposed over the over-voltage protective material layer, containing an insulating powder and a silicone-based resin; and a protective resin layer disposed over the intermediate layer.