EP0533760B1 - Verfahren zur herstellung einer elektrischen vorrichtung - Google Patents

Verfahren zur herstellung einer elektrischen vorrichtung Download PDF

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Publication number
EP0533760B1
EP0533760B1 EP91910990A EP91910990A EP0533760B1 EP 0533760 B1 EP0533760 B1 EP 0533760B1 EP 91910990 A EP91910990 A EP 91910990A EP 91910990 A EP91910990 A EP 91910990A EP 0533760 B1 EP0533760 B1 EP 0533760B1
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EP
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Prior art keywords
mixture
polymer material
electrodes
electrically conductive
polymer
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Expired - Lifetime
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EP91910990A
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English (en)
French (fr)
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EP0533760A1 (de
Inventor
Tomas Hansson
Ulf Henriksson
Hakan Johansson
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ABB AB
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Asea Brown Boveri AB
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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01CRESISTORS
    • H01C7/00Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/02Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material having positive temperature coefficient
    • H01C7/027Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material having positive temperature coefficient consisting of conducting or semi-conducting material dispersed in a non-conductive organic material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20Conductive material dispersed in non-conductive organic material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20Conductive material dispersed in non-conductive organic material
    • H01B1/22Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20Conductive material dispersed in non-conductive organic material
    • H01B1/24Conductive material dispersed in non-conductive organic material the conductive material comprising carbon-silicon compounds, carbon or silicon

Definitions

  • the present invention relates to a method of manufacturing an electrical device, particularly an overcurrent protective device, comprising a body, provided with two parallel surfaces, of an electrically conductive polymer composition with a resistivity of at most 100 m ⁇ cm and two electrodes arranged in contact with the parallel surfaces, the polymer composition comprising a polymer material and an electrically conductive powdered material distributed in the polymer material.
  • PTC element Physical Temperature Coefficient
  • the resistance of a PTC element of the above kind is low, for example a few hundredths ⁇ , in the normal working range of the element which may extend to, for example, 80°C and increases slightly with the temperature. If the temperature of the element exceeds this value, for example because of overcurrent, the resistance increases more rapidly, and upon exceeding a certain critical temperature, the element suddenly changes from a low-resistance to a high-resistance state in which the resistance may amount to 10 k ⁇ and more.
  • thermal overload relay Another type of such an electrical device in the form of an overcurrent protective device is a thermal overload relay.
  • the used polymer material if it is a thermoplastic resin, for example polyethylene, is melted and mixed (compounded) with the conductive powdered material which normally consists of carbon in some form or of a metallic material or of a mixture of carbon and a metallic material.
  • the conductive powdered material which normally consists of carbon in some form or of a metallic material or of a mixture of carbon and a metallic material.
  • This technique involves a number of limitations.
  • the polymer material must have a relatively low viscosity and even if this is the case, it may be impossible to intermix the desired, sufficiently high contents of carbon.
  • the powerful processing during the compounding operation also entails a risk that the conductive material is crushed or otherwise influenced so as to undergo undesirable changes.
  • the produced mixture is subjected to a processing in connection with it being formed by extrusion, compression moulding, or in some other way, which entails a risk of an undesired anisotropy arising in the material in the formed product.
  • the processes described may lead to problems in achieving reproducible properties in the manufactured, finished body.
  • the body After the forming of the body of polymer composition, the body is provided with electrodes according to applied technique.
  • the electrodes usually consist of metal foils and are applied by being pressed onto the body while being heated.
  • the invention makes possible the use of polymer material with a considerably higher viscosity than what has previously been possible. It provides a considerably greater freedom of choice as regards types and contents of conductive materials.
  • the conductive material is not subjected to any processing with undesired consequences. No forming, entailing a risk of anisotropy, occurs.
  • the electrodes may be applied without having to carry out a separate operating step.
  • a particularly important advantage is that the method makes it possible to obtain devices with very low transition resistance between electrode and polymer composition.
  • the favourable results are obtained by mixing the polymer material in thermoplastic state and in powdered form with a grain size of below 100 ⁇ m, and of below 40 ⁇ m in at least 50% of the material, in solid, dry state with the electrically conductive powdered material in a grain size of below 100 ⁇ m into a mixture in which the polymer material constitutes at least 30 per cent and the electrically conductive powdered material at least 20 per cent of the total volume of these materials and by subjecting the mixture together with the electrodes to a pressing and a heating to a temperature at which the polymer material melts at least on the surface of the grains while forming a permanently coherent body of the mixture and while fixing the electrodes to the coherent body.
  • the grains of the polymer material then entirely lose their identity.
  • the mixture of polymer material and electrically conductive powdered material is subjected to a pressing operation at room temperature or other temperature which is considerably lower than the temperature at which the polymer material melts while forming a preformed body, before the mixture in the form of the preformed body together with the electrodes is subjected to the pressing and the heating for forming the permanently coherent body and for fixing the electrodes.
  • Electrodes there are preferably used prefabricated plates of a powdered metallic material, which have a porous structure on the side facing the mixture and are impermeable to the polymer material so that they prevent penetration of the polymer material to the side facing away from the mixture.
  • the electrodes are effectively secured to the conductive polymer composition without the polymer material providing any insulating or any possibly slightly conductive coating on the outside of the electrodes.
  • the polymer material penetrates, in its thermoplastic state, into the pores of the electrodes without penetrating the electrodes. Plates which are completely porous from the beginning may be made impermeable to the penetration of polymer material by being provided on the outside with a metallic coating, for example electrolytically.
  • the electrode material in powdered state may be applied in the form of layers on the surfaces of the conductive polymer composition, before it is subjected to pressing and heating for forming the permanently coherent body and for fixing the electrodes. Also in such a case, measures are preferably taken for ensuring that the electrodes are tight against the penetration of polymer material, for example by providing them with a tight coating of metallic material on that side facing away from the mixture.
  • the metallic material in the electrodes may advantageously consist of nickel or copper but also other metallic materials in the form of pure metal or metal alloy with sufficient electric conductivity may be used.
  • a suitable grain size of the metallic material is 0.5 ⁇ m - 20 ⁇ m and a suitable thickness of an electrode 100-1000 ⁇ m.
  • the coating may advantageously consist of copper which provides a well scattered electrical conduction in the lateral direction within the electrode in question, irrespective of the material on which the electrode is otherwise based.
  • the tight surface layer on an otherwise porous electrode may advantageously have a thickness which amounts to 3-30% of the thickness of the entire electrode.
  • a crosslinkable linear polymer is used as polymer material in the manufacture of the device. If the crosslinking ability of the polymer material is utilized, the crosslinking is carried out after the mixture of the polymer material and the conductive material together with the electrodes has been subjected to the pressing and the heating for forming the permanently coherent body and for fixing the electrodes.
  • crosslinking polymer material By crosslinking polymer material, a greater mechanical and thermal stability of the manufactured device may be achieved.
  • the polymer material preferably consists of a polyolefin, such as polyethylene, polypropylene, polybutene, or a copolymer of ethylene and propylene.
  • a polyolefin such as polyethylene, polypropylene, polybutene, or a copolymer of ethylene and propylene.
  • Specially preferred is HD polyethylene.
  • liner polymers which may be made sufficiently fine-grained and be mixed in dry state with the conductive material and be transferred into thermoplastic state when the mixture is subjected to pressing and heating for forming a permanently coherent body of the polymer composition and for fixing the electrodes.
  • Examples of such other linear polymers are polyamide, polethylene terephthalate, polybutene terephthalate and polyoxymethylene.
  • the polymer material preferably has a crystallinity of at least 5%.
  • the grain size of the polymer material is preferably 5-100 ⁇ m, of which at least 50% of the material has a grain size smaller than 40 ⁇ m.
  • suitable electrically conductive materials in the polymer composition may be mentioned carbon in the form of conductive carbon powders such as carbon black, metallic materials such as, for example, nickel, tungsten, molybdenum, cobalt, copper, silver, aluminium and brass, borides such as, for example, ZrB 2 and TiB 2 , nitrides such as, for example, ZrN and TiN, oxides such as, for example, V 2 O 3 and TiO, carbides such as, for example, TaC, WC and ZrC, as well as mixtures of two or more of the exemplified materials such as, for example, a mixture of soot and nickel.
  • metallic materials such as, for example, nickel, tungsten, molybdenum, cobalt, copper, silver, aluminium and brass
  • borides such as, for example, ZrB 2 and TiB 2
  • nitrides such as, for example, ZrN and TiN
  • oxides such as, for example, V 2 O 3 and Ti
  • the grain size of the conductive carbon powders such as carbon black is usually 0.01-0.10 ⁇ m, the grain size of metallic material preferably 0.5-100 ⁇ m and the grain size of borides, nitrides, oxides, and carbides preferably 0.01-100 ⁇ m.
  • at least part of the electrically conductive powdered material has a grain size which is smaller than the cross section of the pores of the electrode, so that at least that part of the powdered material can accompany the polymer material when it penetrates into the pores of the electrode.
  • the polymer material suitably constitutes 30-80 per cent and the electrically conductive powdered material 20-70 per cent of the total volume of these materials in the polymer composition built up of the mixture.
  • the electrically conductive material consists of a mixture of carbon and metallic material, there are preferred a content of polymer material of 65-80 per cent and a content of electrically conductive powdered material of 20-35 per cent of the total volume of these materials in devices with a pronounced PTC effect.
  • the carbon preferably constitutes 5-75 per cent by volume and the metallic material 25-95 per cent by volume.
  • HD polyethylene 75 parts by volume HD polyethylene (NB 6081 from PLAST-LABOR S.A., Bulle, Switzerland) with a melting index (MI 190/2) of 40 g/10 min, a density of 0.960 g/cm 3 and a grain size of 5-90 ⁇ m, thereof a grain size of 24-36 ⁇ m in more than 50% of the material, is mixed with 13 parts by volume nickel powder with a grain size of less than 7 ⁇ m and with 12 parts by volume carbon black of type N550 (ASTM) with a grain size of 0.040-0.048 ⁇ m into a mixture in the form of a polymer composition.
  • the mixture is pressed at room temperature and a pressure of 70 MPa in a forming tool with a cylindrical cavity and one or two movable cylindrical dies into a preformed round plate with a diameter of 25 mm and a height of 1.5 mm.
  • each plate is electrolytically provided on one side with a 20 ⁇ m thick layer of copper which, for one thing, eliminates the presence of through-going pores by the layer being tight, and, for another, provides a radially scattered surface layer of high conductivity.
  • the plate of the polymer composition with one of the nickel electrode plates on each flat side is again placed in the forming tool with the copper layers facing outwards, whereupon the stack of the three plates is first pressed at room temperature and a pressure of 70 MPa and then at 150°C without changing the pressure.
  • the polymer composition then forms a permanently coherent body, to which the electrodes are mechanically secured in an effective manner with a low transition resistance between electrode and polymer composition by the polymer composition having penetrated into the pores of the electrodes or at least the polymer material and the part of the electrically conductive powdered material having a grain size which is smaller than the pores of the electrode.
  • the polymer composition has a resistivity of less than 50 m ⁇ cm. The manufactured device is excellently suited for use as PTC element.
  • a device is manufactured in the manner stated in Example 1 with the difference that the copper layers on the outside of the electrodes are not applied until the stack of the plates of the polymer composition and of the nickel electrodes has been pressed at room temperature into a coherent body. After application of the copper layers on the outside of the electrodes, the coherent body is subjected to a pressing at a pressure of 70 MPa and a temperature of 150°C.
  • a device is manufactured in the manner described in Example 1 with the difference that the electrode plates pressed at room temperature, instead of being provided with tight copper layers on the outside, are subjected to a sintering in hydrogen gas atmosphere at about 400°C for four hours followed by a grinding of the side facing away from the polymer composition using 320 mesh wet grinding paper.
  • the grinding entails a deformation of the surface layer so that this becomes tight.
  • This resuls in electrode plates with a porous surface structure on the side facing the polymer composition but without through-going pores. They will therefore become impermeable to polymer material during the hot pressing.
  • a device is manufactured in the manner described in Example 1 with the difference that the porous electrodes, instead of being provided on the outside with a copper layer, are made tight there by melting down the surface layer to a depth of about 50 ⁇ m and causing it to solidify by the use of laser.
  • the device is excellently suited for use as PTC element.
  • a device is manufactured in any of the ways described in Examples 1-4. After the last pressing with heat treatment, the polymer composition is subjected to a crosslinking by electron-irradiating the device in its entirety until the crosslinking degree of the polymer material amounts to 80%.
  • the polymer composition has a resistivity of less than 50 m ⁇ cm. The device is excellently suited for use as PTC element.
  • Electrodes are manufacturd in a manner described in Example 1, Example 3 or Example 4.
  • the electrodes are placed together with the polymer composition described in Example 1 in the form of a powder, that is, without preforming, in the cavity of a forming tool of the kind described in Example 1 with the electrodes on either side of the polymer composition and with the tight layers (Examples 1 and 4) facing outwards.
  • the polymer composition and the electrodes are subjected to a pressing with a pressure of 70 MPa at a temperature of 150°C.
  • the polymer composition has a resistivity of less than 50 m ⁇ cm.
  • the device is excellently suited for use as PTC element.
  • a device is manufactured in any of the ways described in Examples 1-6 but with the difference that, instead of polyethylene mentioned there, there is used an LD polyethylene (HX 1681 from PLAST-LABOR S.A.) with a melting index of 70 g/10 min, a density of 0.916 g/cm 3 and a grain size of 5-35 ⁇ m, thereof a grain size of 10-14 ⁇ m in more than 50% of the material.
  • the polymer composition has a resistivity of less than 50 m ⁇ cm.
  • the produced device is excellently suited for use as a PTC element.
  • a device is manufactured in any of the ways described in Example 1, 2, 3, 4 or 6, with the difference that instead of polyethylene mentioned there, there is used polypropylene (PB 0580 from PLAST-LABOR S.A.) with a melting index (MI 230/5) of 100 g/10 min, a density of 0.905 g/cm 3 , and a grain size of 5-90 ⁇ m, thereof a grain size of 24-36 ⁇ m in more than 50% of the material and the difference that the hot pressing is carried out at 170°C.
  • PB 0580 from PLAST-LABOR S.A.
  • a device is manufactured in any of the ways described in Examples 1-8, with the difference that instead of the electrically conductive powdered materials in the form of 13 parts by volume nickel powder and 12 parts by volume carbon black mentioned there, there are used 50 parts by volume ZrN with a grain size of less than 45 ⁇ m.
  • the polymer composition has a resistivity of less than 50 m ⁇ cm.
  • a device is manufactured in the manner described in Example 9, with the difference that instead of ZrN there is used TiN with a grain size of less than 6-10 ⁇ m.
  • the polymer composition has a resistivity of less than 35 m ⁇ cm.
  • a device is manufactured in any of the ways described in Examples 1-8, with the difference that instead of the electrically conductive powdered materials in the form of 13 parts by volume nickel powder and 12 parts by volume carbon black mentioned there, there are used 13 parts by volume of the same carbon black and 52 parts by volume TiN with a grain size of 6-10 ⁇ m.
  • the polymer composition has a resistivity of less than 35m ⁇ cm.
  • a device is manufactured in the manner described in Example 10, with the difference that instead of TiN there is used ZrB 2 with a grain size of less than 45 ⁇ m.
  • the polymer composition has a resistivity of less than 30 m ⁇ cm.
  • a device is manufactured in the manner described in Example 9, with the difference that instead of ZrN there is used TiB 2 with a grain size of less than 45 ⁇ m.
  • a device is manufactured in any of the ways described in Examples 1-8, but with the difference that instead of the electrically conductive powdered materials mentioned there in the form of 13 parts by volume nickel powder and 12 parts by volume carbon black, there is used 120 parts by volume soot of the same kind as in Example 1.
  • a device is manufactured in any of the ways described in Examples 1-8, with the difference that instead of the electrically conductive powdered materials mentioned there in the form of 13 parts by volume nickel powder and 12 parts by volume carbon black, there is used 60 parts by volume nickel powder of the same kind as in Example 1.

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Claims (16)

  1. Verfahren zur Herstellung einer elektrischen Vorrichtung, insbesondere einer Überstromschutzvorrichtung, mit einem zwei parallele Oberflächen aufweisenden Körper aus einer elektrisch leitenden Polymerverbindung mit einem spezifischen Widerstand von höchstens 100 mOhm·cm und zwei Elektroden, die in Kontakt mit den parallelen Oberflächen angeordnet sind, wobei die Polymerverbindung ein Polymermaterial und ein in diesem verteiltes elektrisch leitendes Pulvermaterial enthält,
    dadurch gekennzeichnet, daß
    das Polymermaterial im thermoplastischen Zustand und in Pulverform mit einer Korngröße von weniger als 100 µm, und weniger als 40 µm in mindestens 50 Prozent des Materials,
    im festen und trockenen Zustand mit dem elektrisch leitenden Pulvermaterial, welches eine Korngröße von weniger als 100 µm hat, zu einem Gemisch vermischt wird,
    in welcher das Polymermaterial mindestens 30 Prozent und das elektrisch leitende Pulvermaterial mindestens 20 Prozent des Gesamtvolumens dieser Materialien ausmacht,
    und daß das Gemisch zusammen mit den Elektroden einer Pressung und einer Erhitzung auf eine Temperatur ausgedetzt wird, bei der das Polymermaterial zumindest an der Oberfläche der Körner derart schmilzt, daß aus dem Gemisch, in der die Körner des Polymermaterials ihre Identität vollständig verloren haben, ein permanent zusammenhängender Körper gebildet wird und die Elektroden an den zusammenhängenden Körper fixiert werden.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das Gemisch einer Pressung bei Raumtemperatur oder einer anderen Temperatur, die bedeutend unter der Temperatur liegt, bei welcher das Polymermaterial schmilzt, unterworfen wird, wobei ein vorgeformter Körper gebildet wird, bevor das Gemisch in Gestalt des vorgeformten Körpers zusammen mit den Elektroden der Pressung und Erhitzung zur Bildung des permanent zusammenhängenden Körpers und zur Fixierung der Elektroden unterworfen wird.
  3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß als Elektroden vorgefertigte Platten aus einem pulverförmigen metallischen Material verwendet werden, welche Platten eine poröse Struktur an derjenigen Seite haben, die dem Gemisch zugewandt ist, und die dicht gegenüber dem Durchdringen von Polymermaterial zu der Seite sind, welche von dem Gemisch wegweist.
  4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, daß die Platten an der von dem Gemisch wegweisenden Seite dadurch dicht sind, daß sie auf der genannten Seite mit einem dichten Überzug aus einem metallischen Material versehen sind.
  5. Verfahren nach Anspruch 3, dadurch gekennzeichnet, daß die Platten an der von dem Gemisch wegweisenden Seite dadurch dicht sind, daß die genannte Seite mit einer geschmolzenen und fest gewordenen Oberflächenschicht aus dem pulverförmigen metallischen Material der Platten versehen ist.
  6. Verfahren nach Anspruch 3, dadurch gekennzeichnet, daß die Platten gegen ein Durchdringen von Polymermaterial undurchlässig sind infolge der Beseitigung von durchgehenden Poren durch Sintern der Platten und anschließender mechanischer Bearbeitung derjenigen Seite, die von dem Gemisch wegweist.
  7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß als Polymermaterial ein vernetzbares lineares Polymer verwendet wird und daß das Polymermaterial vernetzt wird, nachdem das Gemisch zusammen mit den Elektroden der Pressung und Erhitzung zur Bildung eines permanent zusammenhängenden Körpers und zur Fixierung der Elektroden ausgesetzt worden ist.
  8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß als Polymermaterial ein Polyolefin verwendet wird.
  9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, daß als Polymermaterial ein Polyethylen verwendet wird.
  10. Verfahren nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, daß das Polymermaterial 30 bis 80 Prozent und das elektrisch leitende Pulvermaterial 20 bis 70 Prozent des Gesamtvolumens dieser Materialien des Gemisches ausmacht.
  11. Verfahren nach einem der Ansprüche 1 bis 10, dadurch gekennzeichnet, daß das Polymermaterial 65 bis 80 Prozent und das elektrisch leitende Pulvermaterial 20 bis 35 Prozent des Gesamtvolumens dieser Materialien des Gemisches ausmacht.
  12. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, daß als elektrisch leitendes Pulvermaterial Kohlenstoff in Form von Ruß verwendet wird.
  13. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, daß als elektrisch leitendes Pulvermaterial in dem Gemisch ein metallisches Material verwendet wird.
  14. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, daß als elektrisch leitendes Pulvermaterial in dem Gemisch eine Mischung aus Kohlenstoff in Form von Ruß und einem metallischen Material verwendet wird.
  15. Verfahren nach einem der Ansprüche 13 oder 14, dadurch gekennzeichnet, daß das metallische Material aus Nickel besteht.
  16. Verfahren nach Anspruch 14, dadurch gekennzeichnet, daß der Kohlenstoff 5 bis 75 Prozent und das metallische Material 25 bis 95 Prozent des Gesamtvolumens dieser Materialien in der Mischung beträgt.
EP91910990A 1990-06-05 1991-05-28 Verfahren zur herstellung einer elektrischen vorrichtung Expired - Lifetime EP0533760B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
SE9001990A SE468026B (sv) 1990-06-05 1990-06-05 Saett att framstaella en elektrisk anordning
SE9001990 1990-06-05
PCT/SE1991/000375 WO1991019297A1 (en) 1990-06-05 1991-05-28 Method of manufacturing an electrical device

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EP0533760A1 EP0533760A1 (de) 1993-03-31
EP0533760B1 true EP0533760B1 (de) 1999-11-17

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EP (1) EP0533760B1 (de)
JP (1) JP2836959B2 (de)
AT (1) ATE186793T1 (de)
DE (1) DE69131787T2 (de)
SE (1) SE468026B (de)
WO (1) WO1991019297A1 (de)

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SE9001990D0 (sv) 1990-06-05
EP0533760A1 (de) 1993-03-31
DE69131787T2 (de) 2000-06-21
SE9001990L (sv) 1991-12-06
WO1991019297A1 (en) 1991-12-12
JP2836959B2 (ja) 1998-12-14
ATE186793T1 (de) 1999-12-15
JPH05508055A (ja) 1993-11-11
DE69131787D1 (de) 1999-12-23
SE468026B (sv) 1992-10-19

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