Varistor Module With Metal Flat Spring And Limit Pins
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Solution Overview
Problem
Conventional surge protection elements with integrated temperature protection elements are prone to damage due to poor assembly and positioning, leading to unreliable protective functions and increased risk of overheating.
Innovation Solution
A varistor module design featuring a base, case, varistor body, and metal flat spring with limit structures and pins that securely position the varistor body, using ceramic or glass fiber materials for enhanced stability and heat resistance, and a low-melting-point solder connection for temperature-dependent disconnection to prevent further heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surge protection element is combined with a temperature protection element, then the protective function responds more quickly and uses less space, but the assembly is easily damaged due to poor fastening
Solution Approach 1:
The patent divides the surge protection element into multiple segments: the varistor body, limit pins, limit structures, and metal flat spring. Each component has a specific function, and together they form a robust assembly that maintains both reliability and strength.
Solution Approach 2:
The patent combines the surge protection element (varistor body) with the temperature protection element (metal flat spring with low-melting-point solder) into a single integrated module. This merging allows the temperature protection element to respond quickly to overheating while maintaining a compact structure.
2Stability of the object's composition
If limit structures and pins are added to secure the varistor body, then positioning stability improves, but device complexity increases
Solution Approach 1:
The limit pins serve multiple functions: they mechanically secure the varistor body in position, provide electrical connection paths, and work with the metal flat spring to enable temperature-dependent disconnection. This multi-functionality reduces the need for separate components.
Solution Approach 2:
The metal flat spring acts as an intermediary element between the limit pins and the varistor body. It provides a flexible connection that allows for thermal expansion and contraction while maintaining electrical contact, and its low-melting-point solder enables automatic disconnection when overheating occurs.
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 varistor module effectively stabilizes the varistor body's position, prevents damage, and ensures reliable protective functions by securely assembling and positioning the components, while the temperature-dependent disconnection mechanism prevents overheating and reduces the risk of ignition.
Implementation Method 1
the other end of the metal flat spring is connected to the splice segment through a low-melting-point solder, so that the adhesion force of the low-melting-point solder is lower than the restitution force of the metal flat spring at a predetermined temperature
Implementation Method 2
the adhesion force of the low-melting-point solder is lower than the restitution force of the metal flat spring at a predetermined temperature
Data Source
AI summary
A varistor module includes a base, a case, a varistor body and a metal flat spring. The base has two limit structures. The case is assembled with the base and to form a closed space. The limit structures are disposed in the closed space. The varistor body includes a ceramic chip and two limit pins. The ceramic chip has two electrode layers located on two opposite surfaces, respectively. The limit pins are disposed on the electrode layers, respectively. The limit pins extend outward from the corresponding electrode layers and pass through the limit structures. One of the limit pins forms a splice segment between the electrode layer and the limit structure. The metal flat spring is disposed on the base. One end of the metal flat spring passes out of the closed space, and the other end of the metal flat spring is connected to the splice segment.