Zinc oxide varistor structure

Claim 2

A composite useful for forming a varistor device comprised of a multi-layer varistor matrix containing a plurality of continuous metallizations comprised of at least a first and second metallization, said varistor matrix being comprised of at least three layers with a portion of each matrix layer being directly bonded to another matrix layer, said matrix totally surrounding and being directly bonded to each metallization, said metallizations being separated from each other by at least substantially a layer of matrix, each said metallization being present at substantially a region between two layers of matrix, said first and second metallizations being offset from each other, at least one of said first and second metallizations being overlapping, said varistor matrix being comprised of zinc oxide grains isolated from each other by continuous amorphous glassy phase, said metallizations being comprised of element silver, said composite having a porosity of less than about 10%.

Claim 3

The composite according to claim 1 wherein each said metallization is substantially in the form of a sheet, wherein there are a plurality of first and second metallizations and wherein each first metallization overlaps with each second metallization.

Claim 4

A varistor device comprised of a varistor matrix containing a first and second metallization, said varistor matrix being comprised of at least three layers with a portion of each matrix layer being directly bonded to another matrix layer, said first and second metallizations being spaced from each other by at least substantially a layer of matrix, each said metallization being present at substantially the region between two layers of matrix and being in direct contact with said matrix, each said metallization having a proximal end portion and a distal end portion wherein the proximal end portion is closest to the edge of the matrix and opposite the distal end portion which is farthest away from the edge of the matrix, each said metallization having only its proximal end portion exposed, said first and second metallizations being overlapping and offset from each other, each said metallization being continuous and being comprised of an elemental silver, said varistor matrix being comprised of zinc oxide grains isolated from each other by continuous amorphous glassy phase, said varistor device having a porosity of less than about 10%.

Claim 5

A varistor device comprised of a varistor matrix containing a first and second metallization, said varistor matrix being comprised of at least three layers with a portion of each matrix layer being directly bonded to another matrix layer, said first and second metallizations being spaced from each other by at least substantially a layer of matrix, each said metallization being present at substantially the region between two layers of matrix and being in direct contact with said matrix, each said metallization having a proximal end portion and a distal end portion wherein the proximal end portion is closest to the edge of the matrix and opposite the distal end portion which is farthest away from the edge of the matrix, each said metallization having only its proximal end portion exposed, said first and second metallizations being overlapping and offset from each other, each said metallization being continuous and being comprised of an elemental silver, said varistor matrix being comprised of zinc oxide grains isolated from each other by continuous amorphous glassy phase, said varistor device having a porosity of less than about 10%.

Claim 6

The varistor device according to claim 3 wherein each said metallization is substantially in the form of a sheet.

Claim 7

A varistor device comprised of a varistor matrix containing a plurality of first and second metallizations, said varistor matrix being comprised of more than three layers with a portion of each matrix layer being directly bonded to another matrix layer, said metallizations being spaced from each other by at least substantially a layer of matrix and being in direct contact with said matrix, each said metallization being present at substantially the region between two layers of matrix, each said metallization having a proximal end portion and a distal end portion wherein the proximal end portion is closest to the edge of the matrix and opposite the distal end portion which is farthest away from the edge of the matrix, each said metallization being totally surrounded by said matrix except for its proximal end portion, each said first metallization having its proximal end portion electrically connected to form a first electrode, each said second metallization having its proximal end portion electrically connected to form a second electrode, said first and second metallizations being offset from each other, at least a pair of said spaced first and second metallizations being overlapping, each said metallization being continuous and being comprised of elemental silver, said varistor matrix being comprised of zinc oxide grains isolated from each other by continuous amorphous glassy phase, said varistor device having a porosity of less than about 10%.

Claim 8

A varistor device comprised of a varistor matrix containing a plurality of first and second metallizations, said varistor matrix being comprised of more than three layers with a portion of each matrix layer being directly bonded to another matrix layer, said metallizations being spaced from each other by at least substantially a layer of matrix and being in direct contact with said matrix, each said metallization being present at substantially the region between two layers of matrix, each said metallization having a proximal end portion and a distal end portion wherein the proximal end portion is closest to the edge of the matrix and opposite the distal end portion which is farthest away from the edge of the matrix, each said metallization being totally surrounded by said matrix except for its proximal end portion, each said first metallization having its proximal end portion electrically connected to form a first electrode, each said second metallization having its proximal end portion electrically connected to form a second electrode, said first and second metallizations being offset from each other, at least a pair of said spaced first and second metallizations being overlapping, each said metallization being continuous and being comprised of elemental silver, said varistor matrix being comprised of zinc oxide grains isolated from each other by continuous amorphous glassy phase, said varistor device having a porosity of less than about 10%.

Claim 9

The varistor device according to claim 5 wherein each said metallization is substantially in the form of a sheet and wherein each said first metallization overlaps with each said second metallization.

Claim 10

The varistor device according to claim 5 wherein each said first metallization is disposed at about a right angle to each said second metallization.

Claim 11

The varistor device according to claim 5 wherein each said first metallization is disposed at an angle of about 180° C. to each said second metallization.

Claim 12

A process for producing a sintered multi-layer composite having a porosity of less than about 10% by volume of the composite, said composite being comprised of at least a three-layer varistor matrix of zinc oxide grains isolated from each other by continuous amorphous glassy phase wherein said matrix totally surrounds each of at least a first and second silver metallization, each said metallization having a proximal end portion and a distal end portion wherein the proximal end portion is closest to the edge of the matrix and opposite the distal end portion which is farthest away from the edge of the matrix, said metallizations being continuous, spaced from each other and having a configuration enabling said composite to be useful for forming a varistor device, which comprises: (a) providing a varistor-forming powder comprised of a mixture of zinc oxide and glassy phase-forming additive; (b) admixing said varistor-forming powder with an organic binding material; (c) forming the resulting mixture into tape; (d) providing a silver metallization-forming material; (e) forming a layered structure of at least three of said tapes containing said metallization-forming material therewithin between said layers, said metallization-forming material being present in a configuration and amount sufficient to produce said metallizations; (f) laminating the layered structure producing a laminated layered structure wherein none of said metallization-forming material is exposed; (g) firing said laminated structure to thermally decompose its organic component at an elevated temperature below about 600° C. leaving no significant deleterious residue in the resulting fired structure, said firing being carried out in an atmosphere or vacuum which has no significant deleterious effect on said composite; (h) sintering the resulting fired structure at a temperature ranging from about 1000° C. to about 1400° C. in an oxygen-containing atmosphere to produce a sintered product having the composition of said composite, said fired structure having a sufficient open volume available to accommodate said silver during sintering; and (i) cooling said sintered product to produce said composite, said sintering and cooling being carried out in an atmosphere which has no significant deleterious effect on said composite.

Claim 13

A process for producing a sintered multi-layer composite having a porosity of less than about 10% by volume of the composite, said composite being comprised of at least a three-layer varistor matrix of zinc oxide grains isolated from each other by continuous amorphous glassy phase wherein said matrix totally surrounds each of at least a first and second silver metallization, each said metallization having a proximal end portion and a distal end portion wherein the proximal end portion is closest to the edge of the matrix and opposite the distal end portion which is farthest away from the edge of the matrix, said metallizations being continuous, spaced from each other and having a configuration enabling said composite to be useful for forming a varistor device, which comprises: (a) providing a varistor-forming powder comprised of a mixture of zinc oxide and glassy phase-forming additive; (b) admixing said varistor-forming powder with an organic binding material; (c) forming the resulting mixture into tape; (d) providing a silver metallization-forming material; (e) forming a layered structure of at least three of said tapes containing said metallization-forming material therewithin between said layers, said metallization-forming material being present in a configuration and amount sufficient to produce said metallizations; (f) laminating the layered structure producing a laminated layered structure wherein none of said metallization-forming material is exposed; (g) firing said laminated structure to thermally decompose its organic component at an elevated temperature below about 600° C. leaving no significant deleterious residue in the resulting fired structure, said firing being carried out in an atmosphere or vacuum which has no significant deleterious effect on said composite; (h) sintering the resulting fired structure at a temperature ranging from about 1000° C. to about 1400° C. in an oxygen-containing atmosphere to produce a sintered product having the composition of said composite, said fired structure having a sufficient open volume available to accommodate said silver during sintering; and (i) cooling said sintered product to produce said composite, said sintering and cooling being carried out in an atmosphere which has no significant deleterious effect on said composite.

Claim 14

The process according to claim 9 wherein said sintering temperature ranges from about 1100° C. to about 1300° C.

Claim 15

The process according to claim 9 which is carried out in air.

Claim 16

The process according to claim 9 wherein said metallization-forming material is comprised of particulates of silver.

Claim 17

The process according to claim 9 wherein said metallization-forming material is comprised of a solid body of elemental silver.

Claim 18

The process according to claim 9 wherein each said metallization-forming material in said layered structure is substantially in the shape of a sheet.

Claim 19

The process according to claim 9 wherein said sintered composite contains a plurality of first and second metallizations, wherein each said metallization is substantially in the shape of a sheet, and wherein each said first metallization overlaps each said second metallization and is offset therefrom.

Claim 20

The process according to claim 9 wherein said metallizations in said sintered composite are comprised of a first and second metallization and wherein part of said matrix is removed to expose the proximal end portion of said first and second metallizations thereby producing a varistor device.

Claim 21

The process according to claim 9 wherein said metallizations in said sintered composite are comprised of a plurality of first and second metallizations, wherein part of said matrix is removed to expose the proximal end portion of each of said first and second metallizations, wherein said exposed proximal end portions of said first metallizations are electrically connected thereby producing a first electrode and wherein said exposed proximal end portions of said second metallizations are electrically connected thereby producing a second electrode.

Claim 22

The process according to claim 9 wherein said metallizations in said sintered composite are comprised of a plurality of first metallizations and a single second metallization, wherein part of said matrix is removed to expose the proximal end portion of each of said metallizations and wherein said exposed proximal end portions of said first metallizations are electrically connected thereby producing a varistor device.