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A common type of varistor is the chip varistor, which is essentially a zinc oxide varistor. The core material used in this device is zinc oxide, known for its unique electrical properties.
The non-linear resistor element is designed to act as a surge protection device, and the main component of the zinc oxide varistor is zinc oxide itself. It is created by incorporating small amounts of other trace elements into zinc oxide, followed by a ceramic manufacturing process that forms a mixture with conductive properties.
One of the key characteristics of a zinc oxide varistor is its nonlinear voltage-current relationship. This means that when the voltage across the varistor is below its rated threshold, the resistance is very high—often in the range of megaohms.
However, when the voltage exceeds the varistor's rated value, the resistance drops dramatically, sometimes reaching just a few milliohms. This makes it significantly different from regular resistors, which follow Ohm’s Law.
Chip varistors do not obey Ohm’s Law because their resistance changes depending on the applied voltage. If the voltage across the chip varistor is lower than its nominal rating, the resistance becomes extremely high, effectively blocking current flow.
But if the voltage rises above the rated level, the varistor quickly switches from a high-resistance state to a low-resistance state, allowing a large current to pass through. This helps protect the circuit from overvoltage damage.
Once the voltage returns to a safe level—below the nominal rating—the varistor reverts back to its high-impedance state, resuming normal operation.
The manufacturing process for chip varistors is relatively straightforward. It involves several steps such as lamination, cutting, debinding, sintering, chamfering, applying terminal electrodes, and electroplating. These processes result in a compact and efficient device suitable for a wide range of electronic applications.
In summary, chip varistors are essential components in modern electronics, providing reliable protection against voltage surges and ensuring the safety and longevity of sensitive circuits.