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A common type of varistor is the chip varistor, which is essentially a zinc oxide varistor. The core component of this device is made from zinc oxide, a material known for its unique electrical properties.
The nonlinear resistor element is designed to function as a surge protection device. The main material used in a zinc oxide varistor is zinc oxide, which is processed through a ceramic manufacturing method.
In addition to zinc, small amounts of other elements are added to enhance performance. This mixture is then processed into a ceramic form, creating the conductive components that make up the varistor.
One of the fundamental characteristics of a zinc oxide varistor is its nonlinear voltage-current relationship. Under normal conditions, when the voltage across the varistor is lower than its rated voltage, the resistance is very high—often in the range of several megaohms.
However, if the voltage increases beyond the varistor's threshold, the resistance drops rapidly. It can decrease to just a few milliohms, allowing a large current to flow through the device. This behavior is what makes it different from standard 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 below its nominal rating, the resistance becomes extremely high, almost like an open circuit.
But once the voltage exceeds the rated value, the varistor quickly transitions from a high-resistance state to a low-resistance state, allowing a surge of current to pass through. This helps protect sensitive electronic components from damage caused by voltage spikes.
Once the voltage returns to a safe level, the varistor reverts back to its high-impedance state, resuming its protective role.
The manufacturing process of a chip varistor involves several steps, including lamination, cutting, debinding, sintering, chamfering, applying terminal electrodes, and electroplating. These steps ensure that the final product is both durable and effective in its function.
Through these processes, a reliable and efficient chip varistor can be produced, making it a crucial component in many modern electronic circuits.