Thermistor Resistance Adjustment via Post-Sintering Removal
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Solution Overview
Problem
Conventional thermistor elements exhibit significant variation in resistance values after baking, and there is no method to adjust the resistance value post-manufacturing, making it difficult to achieve accurate temperature detection across a wide temperature range.
Innovation Solution
A method involving removal processing of the thermistor portion to adjust the resistance value by changing the conduction path between electrode wires, allowing for precise adjustment of the resistance value without altering the B-constant, which includes measuring, calculating, and performing removal processing based on correlations between the range of removal and resistance value changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thermistor portion is formed into a predetermined shape and then baked into a sintered body, then the manufacturing process is simple and manufacturing cost is low, but there is great variation in the resistance values of individual thermistor elements
Solution Approach 1:
The patent applies preliminary action by forming the thermistor portion into a predetermined shape before baking, then performing removal processing after baking to adjust the resistance value. This two-stage approach allows the sintering process to complete first, establishing the base resistance, followed by precise trimming to achieve target resistance values, thereby resolving the contradiction between simple manufacturing and resistance consistency
Solution Approach 2:
The patent changes physical parameters by removing portions of the sintered thermistor body to alter the conduction path length and cross-sectional area. This parameter modification directly adjusts the resistance value while maintaining the sintered structure's integrity, enabling precise resistance control without complicating the overall manufacturing process
2Productivity
If the thermistor element is manufactured through baking, then the manufacturing process is complete, but there is no method for adjusting the resistance value after manufacturing
Solution Approach 1:
The patent introduces dynamics by making the resistance value adjustable after the initial manufacturing process. The removal processing step creates a dynamic adjustment capability, allowing the resistance value to be modified based on actual performance requirements, thus transforming a static manufactured product into an adaptable component
Solution Approach 2:
The patent applies self-service by enabling the thermistor element to achieve its target resistance value through controlled removal of excess material. The adjustment process uses the element's own sintered structure to fine-tune its electrical properties, eliminating the need for external modification or replacement
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 enables the thermistor element to achieve a desired resistance value with reduced variations, ensuring high accuracy in temperature detection across a wide range without affecting the B-constant, thus enhancing its performance and manufacturing efficiency.
Implementation Method 1
a thermistor portion (49) whose resistance value changes in response to temperature
Implementation Method 2
a thermistor portion (49) which is a sintered body formed from a thermistor material
Data Source
AI summary
In a manufacturing method for a thermistor element (3) including: a thermistor portion (49) which is a sintered body formed from a thermistor material; and a pair of electrode wires (25) which are embedded in the thermistor portion (49) and at least one end portion of each of the electrode wires projects at an outer side of the thermistor portion (49), the resistance value of the thermistor element (3) is adjusted by performing a removal processing of removing a part of the thermistor portion (49).