Fabrication method of surge protector device and the device fabricated by the method

A method for fabricating a surge protector device, said method comprising:

• a first step to prepare in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, metal bar holders supporting said metal bars from the side thereof, a mixture of oxidizing and refracting agents at a predetermined ratio, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and an outer wall adapted to be put in said case close to the inner wall thereof,
• a second step to mount said case on a holding table;
• a third step to lift the first metal bar by some means such as a vacuum gripper, set it on the bottom of said case and to take off said vacuum gripper;
• a fourth step to lift the second metal bar by some means such as a vacuum gripper and set on said first metal bar while said vacuum gripper keeps holding said second metal bar;
• a fifth step to put said oxidizing and refractory agents in said case, to give vibration to said holding table in order to stabilize said oxidizing and refractory agents while said vacuum gripper keeps holding said metal bar, to add said oxidizing and refractory agents if necessary and to give vibration again to said holding table, to repeat these steps until said oxidizing and refractory agents fill said case to a height such that all said metal bars except an uppermost metal bar and about three quarters in the direction of a diameter of said uppermost metal bar are buried in said oxidizing and refractory agents and to take off said vacuum gripper from said uppermost metal bar;
• a sixth step to lift said cap by some means such as a vacuum gripper and insert it into said case such that the bottom of said cap fixes said metal bar while said vacuum gripper keeps holding said cap;
• a seventh step to give force to said cap through said vacuum gripper such that said cap, said plural metal bars and said case are pressed by a predetermined force, to fix said cap and said case to each other by some means such as clasps and to take off said vacuum gripper from said cap;
• and
• an eighth step to hermetically seal an enclosure formed by said cap and said case.

A method for fabricating a surge protector device, said method comprising:

• a first step to prepare in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, metal bar holders supporting said metal bars from the side thereof, a mixture of oxidizing and refracting agents at a predetermined ratio, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and an outer wall adapted to be put in said case close to the inner wall thereof,
• a second step to mount said case on a holding table;
• a third step to lift the first metal bar by some means such as a vacuum gripper, set it on the bottom of said case and to take off said vacuum gripper;
• a fourth step to lift the second metal bar by some means such as a vacuum gripper and set on said first metal bar while said vacuum gripper keeps holding said second metal bar;
• a fifth step to put a cover having an aperture through which the vacuum gripper can be passed and an inlet port through which the oxidizing and refractory agents can be inserted on the case and to insert the oxidizing and refractory agents by blowing them with pressurized air while the cover is pressed in order not to be lifted until all said metal bars except an uppermost metal bar and about three quarters in the direction of a diameter of said uppermost metal bar are buried in said oxidizing and refractory agents and to take off said vacuum gripper from said uppermost metal bar;
• a sixth step to lift said cap by some means such as a vacuum gripper and insert it into said case such that the bottom of said cap fixes said metal bar while said vacuum gripper keeps holding said cap;
• a seventh step to give force to said cap through said vacuum gripper such that said cap, said plural metal bars and said case are pressed by a predetermined force, to fix said cap and said case to each other by some means such as clasps and to take off said vacuum gripper from said cap;
• and
• an eighth step to hermetically seal an enclosure formed by said cap and said case.

A method for fabricating a surge protector device, said method comprising:

• a first step to prepare in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, metal bar holders supporting said metal bars from the side thereof, a mixture of oxidizing and refracting agents at a predetermined ratio, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and an outer wall adapted to be put in said case close to the inner wall thereof,
• a second step to mount said case on a holding table;
• a third step to lift the first metal bar by some means such as a vacuum gripper, set it on the bottom of said case and to take off said vacuum gripper;
• a fourth step to lift the second metal bar by some means such as a vacuum gripper and set on said first metal bar while said vacuum gripper keeps holding said second metal bar;
• a fifth step to put said oxidizing and refractory agents in said case, to give vibration to said holding table in order to stabilize said oxidizing and refractory agents while said vacuum gripper keeps holding said metal bar, to add said oxidizing and refractory agents if necessary and to give vibration again to said holding table, to repeat these steps until said oxidizing and refractory agents fill said case to a height such that all said metal bars except an uppermost metal bar and about three quarters in the direction of a diameter of said uppermost metal bar are buried in said oxidizing and refractory agents;
• a sixth step to put an inner cap on said uppermost metal bar such that said inner cap fixes a part of said metal bar while said vacuum gripper holds said uppermost metal bar, to give a predetermined force to said inner cap, to fix said inner cap and said case and to take off said vacuum gripper from said uppermost metal bar;
• a seventh step to put an outer cap on said uppermost metal bar such that the conductive part of said outer cap contacts said uppermost metal bar and forms an electrode with it;
• an eighth step to give a predetermined force to said outer cap and to fix said outer cap and said case by some means such as clasps;
• and
• a ninth step to hermetically seal an enclosure formed by said outer cap and said case.

A surge protector device formed by a method said method comprising the steps of:

• preparing in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and to seal the case;
• mounting said case on a holding table;
• piling up said plurality of metal bars in order to form the inner surface of said bottom of said case;
• setting said cap on the surface of an uppermost metal bar piled in said case;
• giving a predetermined force to said cap such that said bottom of said cap, said plurality of metal bars and said bottom of said case are pressed by the predetermined force to fix said cap to said case;
• and
• sealing hermetically an enclosure formed by said cap and said case so that the inside of said enclosure is isolated from the outside.

A surge protector device formed by a method, said method comprising:

• a first step to prepare in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, metal bar holders supporting said metal bars from the side thereof, a mixture of oxidizing and refracting agents at a predetermined ratio, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and an outer wall adapted to be put in said case close to the inner wall thereof,
• a second step to mount said case on a holding table;
• a third step to lift the first metal bar by some means such as a vacuum gripper, set it on the bottom of said case and to take off said vacuum gripper;
• a fourth step to lift the second metal bar by some means such as a vacuum gripper and set on said first metal bar while said vacuum gripper keeps holding said second metal bar;
• a fifth step to put said oxidizing and refractory agents in said case, to give vibration to said holding table in order to stabilize said oxidizing and refractory agents while said vacuum gripper keeps holding said metal bars, to add said oxidizing and refractory agents if necessary and to give vibration again to said holding table, to repeat these steps until said oxidizing and refractory agents fill said case to a height such that all said metal bars except an uppermost metal bar and about three quarters in the direction of a diameter of said uppermost metal bar are buried in said oxidizing and refractory agents and to take off said vacuum gripper from said uppermost metal bar;
• a sixth step to lift said cap by some means such as a vacuum gripper and insert it into said case such the bottom of said cap fixes said metal bar while said vacuum gripper keeps holding said cap;
• a seventh step to give force to said cap through said vacuum gripper such that said cap, said plural metal bars and said case are pressed by a predetermined force, to fix said cap and said case to each other by some means such as clasps and to take off said vacuum gripper from said cap;
• and
• an eighth step to hermetically seal an enclosure formed by said cap and said case.

A surge protector device formed by a method, said method comprising:

• a first step to prepare in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, metal bar holders supporting said metal bars from the side thereof, a mixture of oxidizing and refracting agents at a predetermined ratio, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and an outer wall adapted to be put in said case close to the inner wall thereof,
• a second step to mount said case on a holding table;
• a third step to lift the first metal bar by some means such as a vacuum gripper, set it on the bottom of said case and to take off said vacuum gripper;
• a fourth step to lift the second metal bar by some means such as a vacuum gripper and set on said first metal bar while said vacuum gripper keeps holding said second metal bar;
• a fifth step to put a cover having an aperture through which the vacuum gripper can be passed and an inlet port through which the oxidizing and refractory agents can be inserted into the case and to insert the oxidizing and refractory agents by blowing them with pressurized air while the cover is pressed in order not to be lifted until all said metal bars except an uppermost metal bar and about three quarters in the direction of a diameter of said uppermost metal bar are buried in said oxidizing and refractory agents and to take off said vacuum gripper from said uppermost metal bar;
• a sixth step to lift said cap by some means such as a vacuum gripper and insert it into said case such that the bottom of said cap fixes said metal bar while said vacuum gripper keeps holding said cap;
• a seventh step to give force to said cap through said vacuum gripper such that said cap, said plural metal bars and said case are pressed by a predetermined force, to fix said cap and said case to each other by some means such as clasps and to take off said vacuum gripper from said cap;
• and
• an eighth step to hermetically seal an enclosure formed by said cap and said case.

A surge protector device formed by a method, said method comprising:

• a first step to prepare in advance a plurality of metal bars each coated with a resistive film, a case whose bottom is at least partially conductive which can house said metal bars and has a shape adapted to fix said metal bars, metal bar holders supporting said metal bars from the side thereof, a mixture of oxidizing and refracting agents at a predetermined ratio, and a cap whose bottom is at least partially conductive which has a shape adapted to fix said metal bars and an outer wall adapted to be put in said case close to the inner wall thereof,
• a second step to mount said case on a holding table;
• a third step to lift the first metal bar by some means such as a vacuum gripper, set it on the bottom of said case and to take off said vacuum gripper;
• a fourth step to lift the second metal bar by some means such as a vacuum gripper and set on said first metal bar while said vacuum gripper keeps holding said second metal bar;
• a fifth step to put said oxidizing and refractory agents in said case, to give vibration to said holding table in order to stabilize said oxidizing and refractory agents while said vacuum gripper keeps holding said metal bars, to add said oxidizing and refractory agents if necessary and to give vibration again to said holding table, to repeat these steps until said oxidizing and refractory agents fill said case to a height such that all said metal bars except an uppermost metal bar and about three quarters in the direction of a diameter of said uppermost metal bar are buried in said oxidizing and refractory agents;
• a sixth step to put an inner cap on said uppermost metal bar such that said inner cap fixes a part of said metal bar while said vacuum gripper holds said uppermost metal bar, to give a predetermined force to said inner cap, to fix said inner cap and said case and to take off said vacuum gripper from said uppermost metal bar;
• a seventh step to put an outer cap on said uppermost metal bar such that the conductive part of said outer cap contacts said uppermost metal bar and forms an electrode with it;
• an eighth step to give a predetermined force to said outer cap and to fix said outer cap and said case by some means such as clasps;
• and
• a ninth step to hermetically seal an enclosure formed by said outer cap and said case.