Ring varistor for use in DC micromotor

Abstract

The present invention provides a ring varistor for use in DC micromotor including a ring varistor substrate having nonlinear volt-ampere characteristics and at least three independent electrodes evenly sintered on an end face of the ring varistor substrate. The electrode gap between two adjacent electrodes consists of two straight parallel edges of the two adjacent electrodes, and an inner and an outer concentric arc on the substrate ring, the electrode gap is not orthogonal to the ring. Due to the asymmetry arrangement of the surface electrodes and the electrode gaps, the electrode materials and the substrate materials with different thermal conductivity have no contact cross distribution with each other at the radial electrode gap. During welding, the heat shock is transmitted asymmetrically through the asymmetric electrodes, to improve the uniformity of the heat conduction distribution of the varistor and reduce the defective rate of the substrate welding fracture.

Claims

1. A ring varistor for use in DC micromotor for improving welding fracture, comprising a ring varistor substrate with nonlinear volt-ampere characteristics and at least three electrodes sintered on an end surface of the substrate, wherein an electrode gap between any two adjacent electrodes is an electrode-free substrate enclosed by straight line parallel edges of the two electrodes and an inner and outer concentric arc on the substrate ring, a plane shape of the electrode gap between any two adjacent electrodes does not take any straight line passing through the circular center of the ring varistor in the gap plane as symmetrical axis.

2. The ring varistor according to claim 1, wherein the planar shape of the electrode gap between any two adjacent electrodes is not orthogonal to the substrate ring, and at least one straight line passing through the center of the circle can intersect at least part of one electrode.

3. The ring varistor according to claim 1, wherein cross angles to the substrate ring of the gap shape of the substrate between any two adjacent electrodes are consistent with each other, and distributed equally apart from each other.

4. The ring varistor according to claim 1, wherein the outer arc in the electrode gap between any two adjacent electrodes has a length of 1.20.8 mm.

5. The ring varistor according to claim 1, wherein the electrode is a single plane electrode sintered on one end face of the substrate, or a double plane electrodes sintered on upper and lower end faces of the substrate.

6. The ring varistor according to claim 1, wherein the electrode is one of the planar 3-pole, the planar 5-pole, the planar 6-pole and the planar 12-pole.

7. The ring varistor according to claim 1, wherein the ring varistor substrate with nonlinear volt-ampere characteristics is one of strontium titanate ring varistor substrate and zinc oxide ring varistor substrate.

8. The ring varistor according to claim 1, wherein the electrode is one of silver electrode, copper electrode and copper alloy electrode.

9. The ring varistor according to claim 1, wherein a size specification of the ring varistor substrate has a series of specifications from 9.5 mm to 23.0 mm in outer diameter matched with installation of a DC micromotor.

10. The ring varistor according to claim 1, wherein the ring varistor has a series of specifications with a varistor voltage E10 value of 1.5-100V.

11. The ring varistor according to claim 1, wherein the non-linear coefficient value of the ring varistor is 2.0-7.0.

12. The ring varistor according to claim 1, wherein a preparation method of the ring varistor comprises the steps of: solid synthesizing SrTiO.sub.3 or SrTiO.sub.3 composite system main material; adding semi-conductive agent, deionized water, additives and binder to obtain a slurry via ball milling; obtaining an embryo via spray granulation and dry pressing; discharging glue and reduce sintering the embryo to obtain a semi-conductive substrate; forming a strontium titanate ring varistor substrate with non-linear volt-ampere characteristics via oxidation heat treatment in air; and printing asymmetrical electrode bottom layer and surface layer, and obtaining a strontium titanate ring varistor after sintering.

13. The ring varistor according to claim 12, wherein each component of the slurry is mixed and has a median particle size of 1-4 m normal distribution.

14. A DC micromotor, comprising a stator and a rotor, wherein the DC micromotor is provided with a ring varistor for use in DC micromotor of claim 1 to improve welding fracture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order to better illustrate the technical solution of the present invention, the present invention will be described in detail in view of the examples and the attached drawings. All the specific parameters and descriptions of the examples of the present invention are used for better illustration only, not for limitation of the present invention. Any replacement, recombination, deletion or addition that does not exceed the expected effect of the technical solution will fall within the scope of protection of the present invention.

(2) FIG. 1 is a schematic diagram of a technical solution according to one embodiment of the present invention, showing a top view and side view of a ring varistor;

(3) FIG. 2 is a schematic diagram of a technical solution according to another embodiment of the present invention, showing a top view and side view of a ring varistor;

(4) FIG. 3 is a schematic diagram of a technical solution according to prior art, showing a top view and side view of a ring varistor;

(5) In FIGS. 1, 2 and 3, 1 is a ring varistor substrate for DC micromotor, the shadow part 2 is the electrode, and 3 is the electrode gap between any two adjacent electrodes. The electrode gap 3 is the substrate having no electrode covered, which is enclosed by two straight parallel edges of the two electrodes and an inner and an outer concentric arc on the substrate ring, D1 is the outer diameter of the ring varistor, D2 is the inner diameter of the ring varistor, T is the thickness of the ring varistor.

(6) In FIG. 1, the shape of the substrate of electrode gap 3 of any two adjacent electrodes is not orthogonal to the ring, and the electrode gap 3 does not take OA, OB, OC in the plane as the symmetric axis; W is the width of the bare substrate of the electrode gaps between any two adjacent electrodes, the outer arc length of the three electrode gaps 3 is equal to 0.7 mm, and the electrodes have asymmetrical structure, at least one straight line passing through the center of the circle in the electrode gap intersects a portion of one electrode.

(7) In FIG. 2, the shape of the bare substrate of electrode gap 3 of any two adjacent electrodes is not orthogonal to the ring, and the electrode gap 3 does not take OA, OB, OC in the plane as the symmetric axis; the outer arc length of the three electrode gap 3 is 0.5 mm. The electrode has an asymmetrical structure. At least one straight line passing through the center of the circle in the electrode gap 3 intersects parts of the two electrodes at the same time. OA, OB, OC in FIG. 2 intersect parts of the two adjacent electrodes at the same time.

(8) In FIG. 3, the shape of the bare substrate of electrode gap 3 of any two adjacent electrodes is orthogonal to the ring, take OA, OB, OC in the plane as the symmetric axis, the outer arc length is 1.2 mm, and the electrode has symmetrical structure.

(9) FIG. 4 is a surface electron micrograph of a substrate after semi-conducting and before heat treatment according to embodiment 5 of the present invention;

(10) FIG. 5 is a surface electron micrograph of a substrate after semi-conducting and heat treatment according to embodiment 5 of the present invention;

(11) FIG. 6 is an electron micrograph of an electrode surface according to embodiment 5 of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(12) Referring to FIG. 1, a ring varistor for use in DC micromotor for improving welding fracture according to embodiments 1-6 of the present invention includes a strontium titanate ring varistor substrate 1 with nonlinear voltage-ampere characteristics and silver electrodes 2 sintered on the surface of the substrate, wherein the electrode has three electrodes in a single plane. The electrode gap 3 without electrode formed thereon is enclosed by an inner and outer concentric arc of the substrate 1 and two straight parallel edges of the two adjacent electrodes, any electrode gap 3 is not orthogonal to the ring, the shape of the electrode gap 3 does not take any straight line in the electrode gap passing through the center of the ring varistor as symmetrical axis. The shape of the three electrode gaps 3 is consistent with the cross angle to the ring in the plane, and is distributed equally on the ring. The outer arc length of the electrode gap is 0.7 mm, and the electrode itself has an asymmetric shape.

(13) Referring to FIG. 1, a ring varistor for use in DC micromotor according to comparative embodiments 1-6 of the prior art is shown. The comparative embodiments 1-6 of the prior art differs from the embodiments 1-6 of the present invention in that: the electrode gaps 3 are orthogonal to the ring, and the three electrode gaps take OA, OB and OC as the symmetrical axes. The outer arc length of the three electrode gaps 3 is 1.2 mm, and the electrodes themselves are symmetrical on the rings.

(14) The ring varistors according to comparative embodiments 1-6/embodiments 1-6 of the present invention are prepared by the following process:

(15) Step 1, solid phase synthesizing SrTiO.sub.3 composite material;

(16) ##STR00001##

(17) Step 2, successively adding semi-conductive agent, deionized water, additive and binder to obtain a slurry via ball milling, each component of the slurry being mixed uniformly and having a median particle size of 1-4 m normal distribution; and obtaining an embryo after spray granulation and dry pressing, in which, (0.05-0.0.1)La.sub.2O.sub.3, (0.1-0.3)Nb.sub.2O.sub.5, (0.2-0.4)ZrO.sub.2, (0.1-1.5%)(SiO.sub.2+MnCO.sub.3+Al(NO.sub.3).sub.3.Math.9H.sub.2O+Na.sub.2CO.sub.3) and appropriate amount of PVA are added successively;

(18) Step 3, preparing semi-conductive substrate by removing glue and reducing sintering, and the sintering atmosphere is N.sub.2 and N.sub.2 mixed gas, and the sintering process is carried out at 1320-1370 C.

(19) Step 4, carrying out oxidizing heat treatment in air to form a strontium titanate ring varistor substrate with non-linear volt-ampere characteristics; obtaining the voltage-sensitive voltage with different threshold values for DC micromotor via adjusting the heat treatment temperature and time;

(20) Step 5, printing the bottom layer and the surface layer of the electrode with asymmetric shape as shown in FIG. 1, sintering, and preparing the strontium titanate ring varistor of embodiment 1-6 of the present invention. The bottom layer and surface layer of electrode with symmetrical structure as shown in FIG. 3 are printed and sintered to obtain a strontium titanate varistor of comparative embodiments 1-6;

(21) The above steps include unspecified technical details well known in the art, which will not be detailed further in the present invention.

(22) Selecting 100 pieces from 100,000 pieces in embodiments 1-6 and comparative embodiments 1-6 and welding, after size inspection and appearance selection, recording the defective rate of substrate welding fracture in Table 1 and the specific dimensions of the varistors in Table 2.

(23) TABLE-US-00001 TABLE 1 Welding defects record Defect rate after welding (%) Comparative Serial number Outer Embodiments Embodiments of embodiments diameter Lot number having having and comparative of the of the Sintering Welding asymmetrical symmetrical embodiments varistor varistor Powder furnace temperature structure structure 1 120D SG253020b0 G127 328#/5# 400 C. 8 14 2 120D SG221335b0 G417 157#/2# 400 C. 4 18 3 107A SS240840y0 082powder 248#/2# 400 C. 1 2 4 107A SG260549b0 144 328#/3# 400 C. 0 3 powder 5 107A SG260749y0 167 248#/2# 400 C. 3 9 powder 6 107A SC262240b0 144 328#/3# 400 C. 0 0 powder Notes: The powder is granular material with different formula.

(24) Lot number of the varistor is used to record different formulation of the granular materials, molding date, and shift.

(25) TABLE-US-00002 TABLE 2 Sizes of the ring varistors according to embodiments and comparative embodiments Outer diameter Inner diameter Thickness Abbreviation D1 (mm) D2(mm) T(mm) 120D 12.00 0.30 6.95 0.30 1.10 107A 10.70 0.20 6.70 0.20 1.05
Analysis 1

(26) Lot number of the varistor, powder, sintering furnace, size of the varistor, welding temperature are kept consistent, the welding defect rate of the varistors having asymmetrical structures of embodiments 1-6 is obviously lower than those of the varistors having symmetrical structures in the prior art, and the decreasing trend does not change with the change of lot number of the varistor, powder and sintering furnace.

(27) Referring to embodiment 6 and comparative embodiment 6, under proper conditions of lot number of the varistor, powder, outer diameter of the varistor, welding temperature and sintering furnace, the prior art and the technical solution of the present invention have desirable welding effect. However, when the ring varistor has an outer diameter no less than 12 mm or when the formula is fine-tuned, compared with comparative embodiments 1 to 5, embodiments 1-5 show a significant improvement in welding defects relative to comparative embodiments 1-5.

(28) Electrical performance tests were performed on 20 chips in embodiments 5, 6 and 20 chips in comparative embodiments 5, 6, and the results were recorded in Table 3.

(29) TABLE-US-00003 TABLE 3 Results of electrical performance Electric Bending E1 E10 capacity strength (V) (V) a (nF) (N) Embodiment 5 MAX 8.26 13.51 4.75 56.80 60.30 lot number of varistor: MIN 6.74 11.07 4.48 44.20 41.10 SG260749y0107A X 7.56 12.40 4.65 50.57 49.28 Comparative embodiment 5 MAX 9.03 14.65 4.81 43.10 59.30 lot number of varistor: MIN 7.62 12.49 4.64 35.80 44.30 SG260749y0107A X 8.35 13.58 4.74 38.31 50.92 Embodiment 6 MAX 1.49 2.90 3.61 276.10 51.90 lot number of varistor: MIN 0.74 1.79 2.54 147.30 30.50 C262240b0107A X 1.05 2.24 3.02 209.07 39.29 Comparative ebodiment 6 lot MAX 1.40 2.78 3.39 177.10 56.00 number of varistor: MIN 0.72 1.82 2.48 123.30 32.40 SC262240b0107A X 1.04 2.24 2.96 149.23 42.05 Notes: Max refers to the maximum, Min refers to the minimum, and X refers to the average.
Analysis 2

(30) The embodiments 5 and 6 of the present invention and comparative embodiments 5 and 6 meet the requirements of the nonlinear volt-ampere characteristics of the varistor. The bending strength and a value of the varistor are slightly inferior, but can still meet the requirements of the use of the motors. However, due to the increase of the capacitance, the effect of electromagnetic interference suppression can be improved.

(31) The embodiment 5 of the present invention was selected to record the surface electron micrograph: the surface electron micrograph of the substrate after semi-conducting and before heat treatment, the surface electron micrograph of the substrate after semi-conducting and heat treatment, the electron micrograph of the electrode surface.

(32) Analysis 3

(33) In the preparation process of the present invention, the components are uniformly mixed via ball milling, and the median particle size is normal distribution of 1-4 m. From the electron micrograph shown in FIGS. 4 and 5, it can be seen that, after sintering, the grain distribution is uniform and no obvious holes are found, which can reduce the welding fracture caused by uneven heat conduction due to the holes. As can be seen in FIG. 6, the electrode surface has formed a compact conductive compound, and the thermal shock caused by welding can be conducted and diverged via the electrode faster than those of the structures in FIGS. 4 and 5. The asymmetrical structure of the electrodes can effectively improve the uniformity of the overall heat conduction of the varistor.

(34) The above described embodiments are only preferred embodiments of the present invention, and are not intended to limit the scope of the present invention. Any modification, equivalent replacement and improvement within the spirit and principle of the present invention should be included in the protection scope of the present invention.