Disc varistor and method of manufacturing the same

A method of manufacturing a disc varistor, comprising:

• a first step of forming a disc-shaped first ceramic body having on a first surface thereof a first electrode and on a second surface thereof a second electrode, and a disc-shaped second ceramic body having, on a first surface thereof a third electrode and on a second surface thereof a fourth electrode;
• a second step of forming a U-shaped initial lead wire to be electrically connected to the first and second ceramic bodies, the initial lead wire being formed such that a first upper portion of the initial lead wire protrudes higher than a second upper portion of the initial lead wire;
• a third step of inserting the first ceramic body between the first and second upper portions of the initial lead wire, and locating the second ceramic body such that the third electrode of the second ceramic body and the second electrode of the first ceramic body are provided on opposite sides of the second upper portion of the initial lead wire, thus electrically connecting the first upper portion of the initial lead wire to the first electrode, and electrically connecting the second upper portion of the initial lead wire to the second electrode and the third electrode;
• a fourth step of primarily bending the upward protruding portion of the initial lead wire toward the second ceramic body, thus providing a first extension that extends to a position above outer circumference of the second ceramic body, secondarily bending an end portion of the first extension toward the fourth electrode of the second ceramic body, thus providing a second extension, and electrically connecting the second extension to the fourth electrode;
• and
• a fifth step of cutting a lower portion of the initial lead wire to be divided into a first lead wire and a second lead wire, and coating the first and second ceramic bodies and surrounding areas with an insulating material.

A method of manufacturing a disc varistor, comprising:

• a first step of forming a disc-shaped first ceramic body having, on a first surface thereof a first electrode and on a second surface thereof a second electrode, and a disc-shaped second ceramic body having, on a first surface thereof a third electrode and on a second surface thereof a fourth electrode;
• a second step of forming a U-shaped initial lead wire to be electrically connected to the first and second ceramic bodies, the initial lead wire being formed such that a first upper portion of the initial lead wire protrudes higher than a second upper portion of the initial lead wire;
• a third step of inserting the first ceramic body between the first and second upper portions of the initial lead wire, and locating the second ceramic body such that the third electrode of the second ceramic body and the second electrode of the first ceramic body are provided on opposite sides of the second upper portion of the initial lead wire;
• a fourth step of primarily bending the upward protruding portion of the initial lead wire toward the second ceramic body, thus providing a first extension that extends to a position above the outer circumference of the second ceramic body, and secondarily bending an end portion of the first extension toward the fourth electrode of the second ceramic body;
• a fifth step of electrically connecting the first upper portion of the initial lead wire to the first electrode, electrically connecting the second upper portion of the initial lead wire to the second electrode and the third electrode, electrically connecting the second extension to the fourth electrode, and cutting a lower portion of the initial lead wire to divide the initial lead wire into a first lead wire and a second lead wire;
• and
• a sixth step of coating the first and second ceramic bodies and surrounding areas with an insulating material.