CN210200440U - PTC over-current protection device capable of effectively improving long-term environmental stability - Google Patents
PTC over-current protection device capable of effectively improving long-term environmental stability Download PDFInfo
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- CN210200440U CN210200440U CN201920973748.8U CN201920973748U CN210200440U CN 210200440 U CN210200440 U CN 210200440U CN 201920973748 U CN201920973748 U CN 201920973748U CN 210200440 U CN210200440 U CN 210200440U
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Abstract
The utility model relates to a polymer PTC over-current protection device which takes conductive polymer composite material as main material and has excellent long-term environmental stability. The utility model has the characteristics of it is following: 1. the main material of the element is a composite material of high molecular polymer and conductive particles; 2. the element is provided with a conductive hole, and the conductive hole is positioned inside the element; 3. the element can be composed of a layer of conductive polymer composite sheet material, and can also be formed by overlapping a plurality of layers of composite sheet materials; 4. the component may comprise both single-bond and double-bond surface mount types, and also comprises a chip component.
Description
Technical Field
The utility model relates to a can effectively improve long-term environmental stability's PTC overcurrent protection device, especially relate to a conductive hole is located inside the component, has good long-term environmental stability's polymer PTC overcurrent protection device.
Background
The conductive polymer composed of the high molecular polymer and the conductive particles dispersed in the high molecular polymer and the overcurrent protection device with Positive Temperature Coefficient (PTC) characteristics prepared by the conductive polymer can be used for overcurrent protection in a circuit. Generally, a polymer PTC over-current protection device has a low resistance value at room temperature or when a small current flows through the device, and when the temperature rises to a critical temperature or an excessive current is generated on the circuit, the resistance value can jump up thousands of times at once, thereby suppressing the excessive current from flowing through the device and achieving the purpose of protecting the circuit. When the temperature is reduced to room temperature or no overcurrent exists on the circuit, the polymer PTC overcurrent protection element can be restored to a low-resistance state, so that the circuit can operate normally again. The advantage of repeated use makes the macromolecule PTC over-current protection element widely used in electronic circuits.
In the prior art, the conductive holes of the surface mount component are located at two ends of the component, and have the functions of conducting electricity and conducting tin.
As in the patent numbers of the applicant: 201510080399.3 discloses a surface-mount circuit protection device with positive temperature coefficient of resistance effect, comprising: the conductive composite material base layer with resistance positive temperature coefficient effect and the upper electrode and the lower electrode which are attached to the upper surface and the lower surface of the base layer form a conductive composite layer together, wherein at least one high-resistance conductive composite layer and one low-resistance conductive composite layer are provided, and the resistance ratio of the high-resistance conductive composite layer to the low-resistance conductive composite layer is not less than 5: 1. compared with the conventional surface mounting type circuit protection element, the surface mounting type circuit protection element has the characteristics of triple protection of overcurrent, overvoltage and overtemperature.
When the device is applied, after long-term electrification or multiple protection, due to the effect of expansion with heat and contraction with cold, the arrangement of internal molecules is greatly changed when the PTC core material is in the cyclic expansion and contraction process, so that the resistance is continuously increased, and the use function is influenced. The sheet element is more of a single-layer sandwich chip nonporous structure, and is formed by welding pins on two surfaces of electrodes, so that the defects are more obvious.
Disclosure of Invention
The utility model discloses aim at: the PTC over-current protection device can effectively improve long-term environmental stability, and avoids the defect that the using function is influenced by continuous rise of resistance after long-term electrification or multiple protection in application.
The purpose of the utility model is realized through the following scheme: a macromolecule PTC over-current protection element capable of effectively improving long-term environment stability is a surface mounting type sheet element, at least comprises a composite material sheet with a resistance positive temperature coefficient effect, a conductive electrode, a conductive hole and a terminal electrode, wherein the conductive hole is positioned in the macromolecule PTC over-current protection element, and the surface mounting type sheet element comprises:
1) composite sheet material having at least one positive temperature coefficient of resistance effect, comprising:
(a) the high molecular conductive composite material base layer with the resistance positive temperature coefficient effect is less than 0.001 omega.m in volume resistivity, consists of at least one polymer and at least one conductive filler which is dispersed in the polymer, is less than 1 mu omega.m in volume resistivity and 0.1 mu m-50 mu m in particle size, and is provided with a first surface and a second surface which are opposite;
(b) a first conductive electrode on a first surface of the conductive composite base layer;
(c) a second conductive electrode on a second surface of the conductive composite substrate;
2) the first conductive hole is electrically connected with one conductive electrode in each composite material sheet, and is not electrically connected with the other corresponding conductive electrode;
a second conductive via which is not electrically connected to the conductive electrode in each composite material sheet which has been electrically connected to the first conductive via, and which is electrically connected to the conductive electrode in each composite material sheet which is not electrically connected to the first conductive via;
the first and second conductive holes are positioned in the element;
3) the first end electrode is positioned on one surface or two surfaces of the outermost layer of the whole surface mounting element, is connected with the first conductive hole, is used as a bonding pad, and is electrically connected with one electrode of an external circuit after being welded into the circuit;
the second end electrode is positioned on the same surface or two surfaces of the outermost layer of the whole surface mounting component as the first end electrode, is electrically isolated from the first end electrode, is connected with the second conductive hole, is used as a bonding pad, and is electrically connected with the other electrode of the external circuit after being welded into the circuit; alternatively, the first and second electrodes may be,
the first pin is positioned on one surface of the whole sheet element, is electrically connected with the first metal foil and the conductive hole electrically connected with the first metal foil, is electrically connected with one conductive electrode in each composite material sheet, and is not electrically connected with the other corresponding conductive electrode;
the second pin is positioned on the other side of the whole sheet element, is electrically connected with the second metal foil and the conductive hole electrically connected with the second metal foil, is not electrically connected with the conductive electrode which is electrically connected with the first pin in each composite material sheet, and is electrically connected with the conductive electrode which is not electrically connected with the first pin in each composite material sheet;
4) and the insulating layers are attached between the first conductive electrode and the second conductive electrode on the non-identical composite material sheet and between the conductive electrode on the outermost layer of the element and the metal foil and are used for electrical isolation.
The polymer accounts for 20-75% of the volume fraction of the conductive composite material base layer, and is selected from one of polyethylene, chlorinated polyethylene, oxidized polyethylene, polyvinyl chloride, butadiene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyamide, polyethylene terephthalate, polybutylene terephthalate, polyphenylene oxide, polyphenylene sulfide, polyformaldehyde, phenolic resin, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, polytrifluoroethylene, polyvinyl fluoride, maleic anhydride grafted polyethylene, polypropylene, polyvinylidene fluoride, epoxy resin, ethylene-vinyl acetate copolymer, polymethyl methacrylate, ethylene-acrylic acid copolymer and a mixture thereof.
The conductive filler is selected from one or a mixture of metal powder and conductive ceramic powder, wherein the metal powder is selected from: one of copper, nickel, tungsten, tin, silver, gold or alloys thereof, and mixtures thereof; the conductive ceramic powder is selected from: one or more of metal nitride, metal carbide, metal boride and metal silicide.
The conductive holes are formed by a laser drilling or mechanical drilling process, one or more conductive holes at two poles are formed, and the conductive holes are through holes or blind holes, or one conductive hole is a through hole, and the other conductive hole is a blind hole; and a conductive metal layer is attached to the surface of the conductive hole.
The conductive metal layer is composed of one or a mixture of zinc, copper, nickel, cobalt, iron, tungsten, tin, lead, silver, gold, platinum or an alloy thereof, and is formed by chemical deposition, spraying, sputtering, electroplating or a combination of the processes.
The pins are conductive metal sheets, including copper sheets, nickel-plated copper sheets and the like.
The utility model discloses can specifically be as follows structure:
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is a polymer composite material base layer with the thickness of 0.3mm and is formed by high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the particle size of 0.1 mu m-50 mu m, and is provided with a first surface and a second surface which are opposite to each other and are compounded with copper foil to form a composite sheet;
(b) the first conductive electrode is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode copper foil is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive holes are through holes, are electrically connected with the second conductive electrodes and are not electrically connected with the corresponding first conductive electrodes;
the second conductive hole is a through hole, is not electrically connected with the second conductive electrode and is electrically connected with the first conductive electrode;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the first end electrode is positioned on the upper surface and the lower surface of the outermost layer of the whole surface mounting element, is connected with the first conductive hole, is used as a bonding pad, and is electrically connected with one electrode of an external circuit after being welded into the circuit;
and the second end electrode is positioned on the upper surface and the lower surface of the whole surface-mounted element as well as the first end electrode, is electrically isolated from the first end electrode, is connected with the second conductive hole, is used as a bonding pad, and is electrically connected with the other electrode of an external circuit after being welded into the circuit, so that the target surface-mounted polymer PTC over-current protection element with two welding surfaces and high environmental reliability is obtained.
Or, the utility model discloses can also specifically as follows the structure:
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is a polymer composite material base layer with the thickness of 0.3mm and is formed by high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the particle size of 0.1 mu m-50 mu m, and is provided with a first surface and a second surface which are opposite to each other and are compounded with copper foil to form a composite sheet;
(b) the first conductive electrode is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode copper foil is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching technology to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive holes are through holes, are electrically connected with the second conductive electrodes and are not electrically connected with the corresponding first conductive electrodes;
the second conductive holes are blind holes and are electrically connected with the first conductive electrodes and not electrically connected with the corresponding second conductive electrodes;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the second left metal foil is positioned below the outermost layer of the whole surface mounting element and is connected with the first conductive hole after the outer layer pattern of the second metal foil is etched and solder resist ink is printed, the first metal foil is a non-welding surface, the second left metal foil is used as a bonding pad, and the element is electrically connected with one electrode of an external circuit after being welded into the circuit;
and the second end electrode and the first end electrode are positioned on the second right metal foil below the whole surface mounting element, are electrically isolated from the first end electrode and connected with the second conductive hole to be used as a bonding pad, and are welded into the circuit to electrically connect the element with the other electrode of the external circuit, so that the target surface mounting type polymer PTC over-current protection element with a single welding surface and high environmental reliability is obtained.
On the basis of the structure, the utility model discloses also can specifically be as follows the structure: and removing the metal foil on the non-welding surface, wherein the two conductive holes are only connected with the metal foil electrode on the welding surface except that the two conductive holes are electrically connected with a certain conductive electrode and the corresponding conductive electrodes are not electrically connected.
Alternatively, the present invention may be embodied as follows:
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is a polymer composite material base layer with the thickness of 0.3mm and is formed by high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the particle size of 0.1 mu m-50 mu m, and is provided with a first surface and a second surface which are opposite to each other and are compounded with copper foil to form a composite sheet;
(b) the first conductive electrode is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode copper foil is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive hole is a blind hole, is electrically connected with the first conductive electrode and the second metal foil, and is not electrically connected with the corresponding second conductive electrode;
the second conductive hole is a blind hole, is electrically connected with the second conductive electrode and the first metal foil, and is not electrically connected with the first conductive electrode;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the first pins are positioned on one surface of the whole chip component, are electrically connected with the first metal foil and the second conductive holes electrically connected with the first metal foil, and are not electrically connected with the corresponding first conductive electrodes;
and the second pins are positioned on the other surface of the whole sheet type element, are electrically connected with the second metal foil and the first conductive holes electrically connected with the second metal foil, and are not electrically connected with the corresponding second conductive electrodes, so that the target sheet type polymer PTC over-current protection element with high long-term environmental stability is obtained.
The utility model has the structural characteristics that: 1. the conductive hole for protecting the element to play the role of electrical connection is positioned in the element, so that the expansion and contraction amplitude of the PTC can be effectively inhibited; 2. the conductive vias may include both blind vias and through vias; 3. can contain two kinds of surface mounting types of single face of weld and two faces of weld and a slice formula type, wherein the characteristics of single face of weld surface mounting component have: the outermost layer of metal foil of the non-welding surface of the element can be paved with copper on the whole surface without designing an etching groove, so that the integral mechanical strength of the element can be improved; the copper layer can be removed on the non-welding surface, and the integral thickness of the product can be effectively reduced. The surface-mounted element with double welding surfaces is characterized in that: because the front and the back are not needed to be distinguished in the processing and using processes, the device has the advantages of convenient processing, detection and installation, and can save the production and installation cost. The chip element features that its two electrodes have blind holes and are positioned in the chip, and its two electrodes are welded to pins.
The utility model aims at providing a can effectively solve the PTC overcurrent protection component of above-mentioned problem, be about to electrically conductive hole design inside components and parts, except playing electrically conductive effect, can also effectively restrain PTC's expansion and contraction amplitude, subducted the displacement of the inside micromolecule of core to the long-term environmental stability of components and parts has been improved greatly.
The utility model discloses a realize that the technical scheme who takes of above-mentioned purpose does: the surface-mounted polymer PTC over-current protection device with excellent long-term environmental stability is obtained by forming a composite sheet by a polymer composite material base layer and a first conductive electrode and a second conductive electrode which are tightly attached to two sides of the polymer material base layer, etching an insulating groove on the composite sheet by an inner layer pattern transfer etching technology, then stacking two insulating layers on two surfaces of the etched composite sheet, respectively covering metal foils, carrying out high-temperature lamination, and then carrying out subsequent steps of drilling, copper deposition, copper plating, outer layer pattern etching, solder resist ink printing, solder resist ink curing and the like on a laminated substrate. The laminated substrate can be subjected to subsequent drilling, copper deposition and copper plating to form a chip of the chip element, and pins are welded on two electrodes of the chip, so that the chip type polymer PTC over-current protection device with excellent long-term environmental stability can be obtained.
The preparation method of the utility model can be described as follows: mixing a high molecular polymer and a conductive filler which are used as base components of a conductive high molecular composite material in a high-speed mixer, then mixing the mixture at the temperature of 100-200 ℃, and then preparing the mixture into a product with the area of 100-5000 cm by a mould pressing or extruding method2A composite material base layer with the thickness of 0.1-3.0 mm; then the metal foil is compounded on the first and second surfaces of the material base layer on the hot press by the hot pressing method to prepare a composite sheet material, and then the composite sheet material is processed by gamma ray (Co) ray60) Or electron beam irradiation crosslinking, and the dosage is 5-100 Mrad. And then adopting the processes of pressing, drilling, copper deposition and electroplating in the printed circuit board to make the initial structure of the element. The initial structure is subjected to the steps of etching an outer layer pattern, printing solder resist ink, curing solder resist ink and the like to obtain a surface mounting type polymer PTC over-current protection element; and the initial structure is subjected to reflow soldering, and the two-side electrodes are welded with pins, so that the sheet type polymer PTC over-current protection element can be obtained.
In the process of manufacturing the circuit board, the conduction of a circuit is realized by adopting a copper deposition electroplating process after drilling, and the conductive hole is positioned in the component, so that the expansion and contraction amplitude of the PTC core material is effectively inhibited, and the aim of improving the long-term environmental stability of the component is fulfilled.
The utility model has the characteristics of it is following:
1. the main material of the element is a composite material of high molecular polymer and conductive particles;
2. the element is provided with a conductive hole, and the conductive hole is positioned inside the element;
3. the element can be composed of a layer of conductive polymer composite sheet material, and can also be formed by overlapping a plurality of layers of composite sheet materials;
4. the component may comprise both single-bond and double-bond surface mount types, and also comprises a chip component.
Drawings
FIG. 1: the utility model discloses a surface mounting element integral three-dimensional view;
FIG. 2: the utility model discloses embodiment 1 surface mounting structure single-layer sheet material cutting plane view;
FIG. 3: the utility model discloses embodiment 2 surface mounting structure single-layer sheet material cutting plane view;
FIG. 4: the utility model discloses embodiment 2 thin surface mounting structure single-layer sheet material cutting plane view;
FIG. 5: the utility model discloses embodiment 3 slice structure single layer sheet material cutting plane view;
FIG. 6: the utility model discloses embodiment 1 and comparative example high temperature and high humidity test, the relation chart of resistance along with the change of standing time;
reference numerals in the drawings indicate:
1-macromolecule conductive composite material base layer;
2-a first conductive electrode;
2 a-a second conductive electrode;
3. 3 a-upper and lower insulating layers;
4. 4 a-left and right first metal foils; 4b, 4 c-a first metal foil;
5. 5 a-left and right second metal foils; 5 b-a second metal foil;
6. 6 c-first conductive via;
6a, 6b, 6 d-second conductive via;
7. 7 a-insulation groove of the first and second conductive holes;
8-first pin;
8 a-second pin.
Detailed Description
Example 1
As shown in FIG. 1, a perspective view of the surface mounting device of the present invention and FIG. 2, a cross-sectional view of a single-layer sheet of the surface mounting structure of the present invention, which is an embodiment of the present invention, a polymer PTC over-current protection device is characterized in that,
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the high polymer conductive composite material base layer 1 with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is composed of high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the grain size of 0.1 mu m-50 mu m, is 0.3mm thick, and is provided with a first surface and a second surface which are opposite to each other and are compounded with copper foil to form a composite sheet;
(b) the first conductive electrode 2 is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode 2a is a copper foil and is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is etched with the insulation grooves 7 and 7a of the first conductive hole and the second conductive hole through pattern transfer;
2) the first conductive holes 6 are through holes, are electrically connected with the second conductive electrodes, and are not electrically connected with the corresponding first conductive electrodes;
the second conductive hole 6a is a through hole, is not electrically connected to the second conductive electrode, and is electrically connected to the first conductive electrode;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer 3 and the lower insulating layer 3a are attached to the outer surfaces of the first conductive electrode 2 and the second conductive electrode 2a on the composite material sheet, the upper insulating layer 3 is overlapped between the first conductive electrode 2 and the first metal foil, meanwhile, the lower insulating layer 3a is overlapped between the second conductive electrode 2a and the second metal foil for electrical isolation, and the first metal foil and the second metal foil are etched;
4) first end electrodes positioned on the upper surface and the lower surface of the outermost layer of the whole surface mounting component, wherein the left first metal foil 4 and the left second metal foil 5 form the upper first end electrode and the lower first end electrode, are connected with the first conductive hole 6 and are used as a bonding pad, and the component is electrically connected with one electrode of an external circuit after being welded into the circuit;
and the second end electrode and the first end electrode are positioned on the upper surface and the lower surface of the whole surface-mounted element, the right first metal foil 4a and the right second metal foil 5a form the upper end electrode and the lower end electrode, are electrically isolated from the first end electrode, are connected with the second conductive hole 6a, are used as a bonding pad, and are welded into a circuit to electrically connect the element with the other electrode of an external circuit, so that the target surface-mounted polymer PTC over-current protection element with two welding surfaces and high environmental reliability is obtained.
The preparation method specifically comprises the following steps:
mixing high density polyethylene and metal boride in a certain proportion in a high speed mixer for 15 min. Then mixing the mixture components in an internal mixer at 180 deg.C, cooling, pulverizing, and pressing into 400cm area in a pressing mold under 5Mpa at 180 deg.C2A polymer conductive composite material base layer 1 with the thickness of 0.3 mm; flattening the copper foil with roughened surface, hot-pressing to two sides of the polymer composite material base layer under the conditions of 5Mpa pressure and 170 ℃ to obtain the polymer PTC composite sheet material composed of the first conductive electrode 2, the polymer conductive composite material base layer 1 and the second conductive electrode 2a, heat-treating in a vacuum oven at 85 ℃ for 48 hours, and then using gamma ray (Co) to make the sheet material undergo the processes of rolling, rolling and rolling60) Irradiating with a dose of 15 Mrad; then the composite sheet is subjected to a pattern transfer etching technology to enable the first conductive electrode 2 and the second conductive electrode 2a to be etched into insulating grooves 7 and 7a of a first conductive hole and a second conductive hole respectively, then the upper insulating layer 3 is overlapped between the first conductive electrode 2 and the first metal foil, meanwhile, the lower insulating layer 3a is overlapped between the second conductive electrode 2a and the second metal foil, etching is carried out to form a left first metal foil 4 and a right first metal foil 4 and a left second metal foil 5 and a right second metal foil 5a, then high-temperature pressing is carried out, and the pressed substrate is subjected to drilling, copper deposition and copper plating to form a first conductive hole 6 and a second conductive hole 6 a. The two conductive holes are through holes. Wherein the first conductive via 6 is electrically connected to the second conductive electrode 2a and not electrically connected to the first conductive electrode 2; the second conductive via 6a is electrically connected to the first conductive electrode 2 and is not electrically connected to the second conductive electrode 2 a. Two-way valveThe holes are electrically connected to the first and second metal foils attached to both sides. And then, forming upper and lower first end electrodes by the left first metal foil 4 and the left second metal foil 5, and forming upper and lower second end electrodes by the right first metal foil 4a and the right second metal foil 5a through subsequent steps of terminal electrode tinning, outer layer pattern etching, solder resist ink printing and the like. Thus, the surface-mounted polymer PTC over-current protection element with two welding surfaces and high environmental reliability is prepared. (refer to FIGS. 1 and 2)
The utility model discloses also parallelly connected by two-layer or multilayer composite sheet, adopt same conduction mode to realize to reach the purpose that reduces the product internal resistance. The same two-pole conductive hole is arranged in the device, and the expansion and contraction amplitude of the PTC can be effectively inhibited, so that the surface-mounted polymer PTC over-current protection element with two welding surfaces and high long-term environmental stability is prepared.
After the prepared overcurrent protection element is placed in a long-term environment, compared with the traditional conductive hole at two ends, the environment stability is obviously improved, and the reference is made to fig. 6.
Example 2
A PTC over-current protection device capable of effectively improving long-term environmental stability:
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the high polymer conductive composite material base layer 1 with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is composed of high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the grain size of 0.1 mu m-50 mu m, is 0.3mm thick, and is provided with a first surface and a second surface which are opposite to each other and are compounded with copper foil to form a composite sheet;
(b) the first conductive electrode 2 is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode 2a is a copper foil and is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching technology to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive holes 6 are through holes, are electrically connected with the second conductive electrodes 2a, and are not electrically connected with the corresponding first conductive electrodes 2;
the second conductive hole 6b is a blind hole, is electrically connected with the first conductive electrode 2, and is not electrically connected with the corresponding second conductive electrode 2 a;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the second left metal foil is positioned below the outermost layer of the whole surface mounting element and is connected with the first conductive hole after the outer layer pattern of the second metal foil is etched and solder resist ink is printed, the first metal foil is a non-welding surface, the second left metal foil is used as a bonding pad, and the element is electrically connected with one electrode of an external circuit after being welded into the circuit;
and the second end electrode and the first end electrode are positioned on the second right metal foil below the whole surface mounting element, are electrically isolated from the first end electrode and connected with the second conductive hole to be used as a bonding pad, and are welded into the circuit to electrically connect the element with the other electrode of the external circuit, so that the target surface mounting type polymer PTC over-current protection element with a single welding surface and high environmental reliability is obtained.
The preparation method specifically comprises the following steps:
mixing high density polyethylene and metal boride in a certain proportion in a high speed mixer for 15 min. Then mixing the mixture components in an internal mixer at 180 deg.C, cooling, pulverizing, and pressing into 400cm area in a pressing mold under 5Mpa at 180 deg.C2And a polymer composite substrate (reference numeral 1) having a thickness of 0.3 mm. Flattening the copper foil with roughened surface, hot pressing to two sides of the polymer composite material base layer under 5Mpa and 170 deg.C to obtain polymer PTC composite sheet (combination of labels 1, 2 and 2 a), and vacuum dryingAfter heat treatment at 85 ℃ for 48 hours in a chamber, gamma rays (Co)60) Irradiation, dose 15 Mrad. Then, the composite sheet is subjected to a pattern transfer etching technology to enable a first conductive electrode (reference numeral 2) and a second conductive electrode (reference numeral 2 a) to be etched to form insulating grooves (reference numerals 7 and 7 a) respectively, then an insulating layer (reference numeral 3) is overlapped between the first conductive electrode (reference numeral 2) and a first metal foil (reference numeral 4 b), meanwhile, another insulating layer (reference numeral 3a) is overlapped between the second conductive electrode (reference numeral 2 a) and a second metal foil (reference numerals 5 and 5a combination), then high-temperature pressing is carried out, and the pressed substrate is subjected to drilling, copper deposition and copper plating to form two conductive holes, namely a first conductive hole (reference numeral 6) and a second conductive hole (reference numeral 6 b). The first conductive hole is a through hole, and the second conductive hole is a blind hole. Wherein the first conductive hole (reference numeral 6) is electrically connected with the second conductive electrode (reference numeral 2 a), is not electrically connected with the first conductive electrode (reference numeral 2), and is electrically connected with the first and second metal foils (reference numerals 4b and 5, 5a combined) pasted on the two sides; the second conductive hole (reference numeral 6 b) is electrically connected to the first conductive electrode (reference numeral 2), is not electrically connected to the second conductive electrode (reference numeral 2 a), is electrically connected to the second metal foil (reference numeral 5a), and is not electrically connected to the first metal foil (reference numeral 4 b). Then, the second metal foil (5, 5a combination) is subjected to tin plating, outer layer pattern etching, solder resist ink printing, and the like to form a first terminal electrode (5) and a second terminal electrode (5 a), and the first metal foil (4 b) is a non-soldered surface. Thus preparing the surface-mounted polymer PTC over-current protection element with a single welding surface, good mechanical strength and high long-term environmental stability. (refer to FIG. 3)
The utility model discloses also parallelly connected by two-layer or multilayer composite sheet, adopt same conduction mode to realize to reach the purpose that reduces the product internal resistance. Except for the metal foil of the non-welding surface, the insulating groove is not required to be etched, and the insulating groove is required to be etched in all the other layers of conductive electrodes and the metal foil of the welding surface. The second conductive via hole is drilled to at least the electrode layer near the metal foil of the non-welding surface, but not electrically connected with the metal foil of the non-welding surface. Therefore, the expansion and contraction amplitude of the PTC can be effectively inhibited, and the surface-mounted polymer PTC over-current protection element with a single welding surface, good mechanical strength and high long-term environmental stability is prepared.
Example 3
Referring to fig. 4, the other structure is the same as that of embodiment 2 except that the first metal foil 4b of the non-bonding surface is removed, and the two-electrode conductive via is electrically connected to one conductive electrode and the corresponding conductive electrode is not electrically connected, wherein the first conductive via 6 is electrically connected to the second conductive electrode 2a, and the second conductive via 6b is electrically connected to the first conductive electrode 2 and is connected to the metal foil electrode of the bonding surface. The whole thickness of the product can be effectively thinned. Thus preparing the surface-mounted polymer PTC over-current protection element with a single welding surface, thin product thickness and high long-term environmental stability.
Example 4
Mixing high density polyethylene and metal boride in a certain proportion in a high speed mixer for 15 min. Then mixing the mixture components in an internal mixer at 180 deg.C, cooling, pulverizing, and pressing into 400cm area in a pressing mold under 5Mpa at 180 deg.C2And a polymer composite substrate (reference numeral 1) having a thickness of 0.3 mm. Flattening the copper foil with roughened surface, hot pressing to two sides of the polymer composite material base layer under 5Mpa and 170 deg.C to obtain polymer PTC composite sheet (combination of labels 1, 2 and 2 a), heat treating at 85 deg.C for 48 hr in vacuum oven, and treating with gamma ray (Co)60) Irradiation, dose 15 Mrad. Then, the composite sheet is subjected to a pattern transfer etching technology to enable a first conductive electrode (reference numeral 2) and a second conductive electrode (reference numeral 2 a) to be etched to form insulating grooves (reference numerals 7 and 7 a) respectively, then an insulating layer (reference numeral 3) is overlapped between the first conductive electrode (reference numeral 2) and a first metal foil (reference numeral 4 c), meanwhile, another insulating layer (reference numeral 3a) is overlapped between the second conductive electrode (reference numeral 2 a) and a second metal foil (reference numeral 5 b), then high-temperature pressing is carried out, and the pressed substrate is subjected to drilling, copper deposition and copper plating to form two conductive holes, namely a first conductive hole (reference numeral 6 c) and a second conductive hole (reference numeral 6 d). Both the two conductive holes are blind holes. Wherein the first conductive hole (label)No. 6 c) is electrically connected to the first conductive electrode (No. 2) and the second metal foil (No. 5 b), and is not electrically connected to the second conductive electrode (No. 2 a) and the first metal foil (No. 4 c); the second conductive hole (reference numeral 6 d) is electrically connected to the second conductive electrode (reference numeral 2 a) and the first metal foil (reference numeral 4 c), and is not electrically connected to the first conductive electrode (reference numeral 2) and the second metal foil (reference numeral 5 b). Then, a first lead (8) is welded on the first metal foil (4 c) and a second lead (8 a) is welded on the second metal foil (5 b), respectively, thereby preparing a sheet type polymer PTC overcurrent protection element with high long-term environmental stability. (refer to FIG. 5)
The utility model discloses also parallelly connected by two-layer or multilayer composite sheet, adopt same conduction mode to realize to reach the purpose that reduces the product internal resistance. The two-pole conductive holes are drilled at least to the position close to the electrode not electrically connected with the metal foil. Therefore, the expansion and contraction amplitude of the PTC can be effectively inhibited, and the chip type polymer PTC over-current protection element with high long-term environmental stability is prepared.
Claims (10)
1. The utility model provides a PTC over-current protection device that can effectively improve long-term environmental stability, is surface mounting type chip component, includes at least that composite material sheet, conductive electrode, electrically conductive hole and the end electrode that has a resistance positive temperature coefficient effect, its characterized in that: the conductive hole is positioned in the macromolecule PTC over-current protection element, wherein:
1) composite sheet material having at least one positive temperature coefficient of resistance effect, comprising:
(a) the high molecular conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of not more than 0.001 omega.m, consists of at least one polymer and at least one conductive filler which is dispersed in the polymer, has the volume resistivity of less than 1 mu omega.m and the grain size of 0.1 mu m-50 mu m, and is provided with a first surface and a second surface which are opposite;
(b) a first conductive electrode on a first surface of the conductive composite base layer;
(c) a second conductive electrode on a second surface of the conductive composite substrate;
2) the first conductive hole is electrically connected with one conductive electrode in each composite material sheet, and is not electrically connected with the other corresponding conductive electrode;
a second conductive via which is not electrically connected to the conductive electrode in each composite material sheet which has been electrically connected to the first conductive via, and which is electrically connected to the conductive electrode in each composite material sheet which is not electrically connected to the first conductive via;
the first and second conductive holes are positioned in the element;
3) the first end electrode is positioned on one surface or two surfaces of the outermost layer of the whole surface mounting element, is connected with the first conductive hole, is used as a bonding pad, and is electrically connected with one electrode of an external circuit after being welded into the circuit;
the second end electrode is positioned on the same surface or two surfaces of the outermost layer of the whole surface mounting component as the first end electrode, is electrically isolated from the first end electrode, is connected with the second conductive hole, is used as a bonding pad, and is electrically connected with the other electrode of the external circuit after being welded into the circuit; alternatively, the first and second electrodes may be,
the first pin is positioned on one surface of the whole sheet element, is electrically connected with the first metal foil and the conductive hole electrically connected with the first metal foil, is electrically connected with one conductive electrode in each composite material sheet, and is not electrically connected with the other corresponding conductive electrode;
the second pin is positioned on the other side of the whole sheet element, is electrically connected with the second metal foil and the conductive hole electrically connected with the second metal foil, is not electrically connected with the conductive electrode which is electrically connected with the first pin in each composite material sheet, and is electrically connected with the conductive electrode which is not electrically connected with the first pin in each composite material sheet;
4) and the insulating layers are attached between the first conductive electrode and the second conductive electrode on the non-identical composite material sheet and between the conductive electrode on the outermost layer of the element and the metal foil and are used for electrical isolation.
2. A PTC over-current protection device according to claim 1, wherein the polymer comprises 20-75% volume fraction of the conductive composite substrate, and is selected from polyethylene, chlorinated polyethylene, oxidized polyethylene, polyvinyl chloride, butadiene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyamide, polyethylene terephthalate, and polyethylene terephthalate
One of butanediol formate, polyphenyl ether, polyphenylene sulfide, polyformaldehyde, phenolic resin, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, polytrifluoroethylene, polyvinyl fluoride, maleic anhydride grafted polyethylene, polypropylene, polyvinylidene fluoride, epoxy resin, ethylene-vinyl acetate copolymer, polymethyl methacrylate, ethylene-acrylic acid copolymer and a mixture thereof.
3. A PTC overcurrent protection device according to claim 1, wherein the conductive filler is selected from one of metal powders, conductive ceramic powders, or a mixture thereof, wherein the metal powders are selected from: one of copper, nickel, tungsten, tin, silver, gold or alloys thereof, and mixtures thereof; the conductive ceramic powder is selected from: one or more of metal nitride, metal carbide, metal boride and metal silicide.
4. A PTC overcurrent protection device according to claim 1, wherein the conductive holes are formed by laser drilling or mechanical drilling, one or more conductive holes at two poles are through holes, blind holes, or a through hole at one end and a blind hole at the other end; and a conductive metal layer is attached to the surface of the conductive hole.
5. A PTC over-current protection device according to claim 4, wherein the conductive metal layer is made of one or a mixture of Zn, Cu, Ni, Co, Fe, W, Sn, Pb, Ag, Au, Pt or their alloys by chemical deposition, spraying, sputtering, electroplating or a combination thereof.
6. A PTC overcurrent protection device according to claim 1, wherein the leads are conductive metal sheets, including copper sheets, nickel-plated copper sheets, etc.
7. A PTC over-current protection device according to any of claims 1 to 4, which is effective in improving long-term environmental stability,
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the high polymer conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is composed of high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the grain diameter of 0.1 mu m-50 mu m, has a relative first surface and a relative second surface, and is compounded with copper foil to form a composite sheet;
(b) the first conductive electrode is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode copper foil is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive holes are through holes, are electrically connected with the second conductive electrodes and are not electrically connected with the corresponding first conductive electrodes;
the second conductive hole is a through hole, is not electrically connected with the second conductive electrode and is electrically connected with the first conductive electrode;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the first end electrode is positioned on the upper surface and the lower surface of the outermost layer of the whole surface mounting element, is connected with the first conductive hole, is used as a bonding pad, and is electrically connected with one electrode of an external circuit after being welded into the circuit;
and the second end electrode is positioned on the upper surface and the lower surface of the whole surface-mounted element as well as the first end electrode, is electrically isolated from the first end electrode, is connected with the second conductive hole, is used as a bonding pad, and is electrically connected with the other electrode of an external circuit after being welded into the circuit, so that the target surface-mounted polymer PTC over-current protection element with two welding surfaces and high environmental reliability is obtained.
8. A PTC over-current protection device according to any of claims 1 to 4, which is effective in improving long-term environmental stability,
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the high polymer conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is composed of high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the grain diameter of 0.1 mu m-50 mu m, has a relative first surface and a relative second surface, and is compounded with copper foil to form a composite sheet;
(b) the first conductive electrode is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode copper foil is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching technology to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive holes are through holes, are electrically connected with the second conductive electrodes and are not electrically connected with the corresponding first conductive electrodes;
the second conductive holes are blind holes and are electrically connected with the first conductive electrodes and not electrically connected with the corresponding second conductive electrodes;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the second left metal foil is positioned below the outermost layer of the whole surface mounting element and is connected with the first conductive hole after the outer layer pattern of the second metal foil is etched and solder resist ink is printed, the first metal foil is a non-welding surface, the second left metal foil is used as a bonding pad, and the element is electrically connected with one electrode of an external circuit after being welded into the circuit;
and the second end electrode and the first end electrode are positioned on the second right metal foil below the whole surface mounting element, are electrically isolated from the first end electrode and connected with the second conductive hole to be used as a bonding pad, and are welded into the circuit to electrically connect the element with the other electrode of the external circuit, so that the target surface mounting type polymer PTC over-current protection element with a single welding surface and high environmental reliability is obtained.
9. A PTC over-current protection device according to claim 8, wherein the metal foil on the non-soldering surface is removed, and the conductive holes on both electrodes are connected to the metal foil on the soldering surface except for one conductive electrode and the corresponding conductive electrode.
10. A PTC over-current protection device according to any of claims 1 to 4, which is effective in improving long-term environmental stability,
1) a composite sheet material having a positive temperature coefficient of resistance effect, comprising:
(a) the high polymer conductive composite material base layer with the resistance positive temperature coefficient effect has the volume resistivity of less than 0.001 omega.m, is composed of high-density polyethylene and metal boride with the volume resistivity of less than 1 mu omega.m and the grain diameter of 0.1 mu m-50 mu m, has a relative first surface and a relative second surface, and is compounded with copper foil to form a composite sheet;
(b) the first conductive electrode is a copper foil and is positioned on the first surface of the conductive composite material base layer;
(c) the second conductive electrode copper foil is positioned on the second surface of the conductive composite material base layer, and the formed composite sheet is subjected to pattern transfer etching to enable the first conductive electrode and the second conductive electrode to be etched to form an insulating groove respectively;
2) the first conductive hole is a blind hole, is electrically connected with the first conductive electrode and the second metal foil, and is not electrically connected with the corresponding second conductive electrode;
the second conductive hole is a blind hole, is electrically connected with the second conductive electrode and the first metal foil, and is not electrically connected with the first conductive electrode;
the first and second conductive holes are located on two sides of the element;
3) the upper insulating layer is overlaid between the first conductive electrode and the first metal foil, and the lower insulating layer is overlaid between the second conductive electrode and the second metal foil for electrical isolation;
4) the first pins are positioned on one surface of the whole chip component, are electrically connected with the first metal foil and the second conductive holes electrically connected with the first metal foil, and are not electrically connected with the corresponding first conductive electrodes;
and the second pins are positioned on the other surface of the whole sheet type element, are electrically connected with the second metal foil and the first conductive holes electrically connected with the second metal foil, and are not electrically connected with the corresponding second conductive electrodes, so that the target sheet type polymer PTC over-current protection element with high long-term environmental stability is obtained.
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