JP2008066346A - Ptc element and battery protection system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a PTC element which can prevent a coating material for forming a protective film of the exposed surface of the PTC element from leaking to a part where the coating material must not be held. <P>SOLUTION: The PTC element comprises an element body 4 having a resistance increasing as a temperature rises in a predetermined temperature region, a pair of first electrode plate 10 and second electrode plate 12 bonded to front and back sides of the element body 4, and a protective film 3 covering the exposed portion of the element body 4 not covered with the first electrode plate 10 and second electrode plate 12. The first electrode plate 10 has an element bonding surface 100 where the first electrode plate and the element body come into direct contact, and an element nonbonding surface 101 where the first electrode plate 10 and the element body 4 are not bonded on the extension surface of the element bonding surface 100. The element nonbonding surfaces 101 are formed oppositely to each other while sandwiching the element body 4 and a surface 102 for receiving the protective film is formed on the element nonbonding surface 101. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a PTC element used for the purpose of protecting a battery or an electronic circuit from an overcurrent, and a battery protection system having the PTC element.

  A PTC (positive temperature coefficient) element has a characteristic that the resistance value of the element increases when the temperature of the element rises in a predetermined temperature region. In particular, when the temperature of the PTC element reaches the melting temperature of the polymer, the resistance of the PTC element increases rapidly. Such a property is called a PTC characteristic.

  The PTC element is incorporated in an electric circuit such as an electronic device. If an excessive current flows in the circuit for some reason during use of the electronic device, the temperature of the electronic device rises, and the temperature of the PTC element itself rises accordingly. When the temperature of the PTC element reaches the melting temperature of the polymer, the resistance value of the PTC element increases rapidly. As a result, the PTC element blocks excess current in the electric circuit. Therefore, it is possible to prevent the electrical device from being damaged due to excessive current.

  Thus, the PTC element is used as a safety protection device against overheating and excessive current. Specifically, the PTC element is incorporated in a circuit (protection circuit) for protecting a secondary battery that is a power source of a portable device such as a cellular phone from an overcurrent. When an excessive current flows during charging or discharging of the secondary battery, the PTC element cuts off the current and protects the secondary battery.

  An example of such a PTC element is a structure in which an element body (polymer positive temperature coefficient resistor) in which conductive particles are dispersed in a polymer material (crystalline polymer) is sandwiched between electrode plates (or metal foils). There is known a polymer PTC element having a thickness (see Patent Document 1).

  Conventionally, the polymer PTC element is manufactured by the following method. First, a polymer (such as high-density polyethylene) containing a conductive filler such as metal particles and carbon black is extruded to form an element body. Next, the polymer PTC element is completed by thermocompression bonding the electrode plate to the front and back surfaces of the element body.

  When the polymer PTC element is incorporated in a predetermined protection circuit, the electrode plate is joined to a terminal plate electrically connected to the protection circuit. This joining is conventionally performed by soldering, welding, or the like.

  The above-described incorporated polymer PTC element is gradually deteriorated by oxygen in the atmosphere. When the polymer PTC element deteriorates, there is a problem that the resistance value at room temperature (room temperature resistance value) increases.

  For such a problem, the influence of oxygen is reduced by forming a protective film on the surface exposed to the outside of the polymer PTC element. However, when this protective film is formed, the coating material for forming the protective film wraps around, and not only the externally exposed surface of the PTC element but also the electrode plate joined to the polymer PTC element, the battery, and the circuit In some cases, even the portion that joins the terminal is covered. In such a case, bonding between the electrode plate and terminals such as a battery or a circuit becomes insufficient, which may lead to a decrease in reliability.

Furthermore, if the thickness of the protective film increases and exceeds the designed dimensional tolerance as a PTC element, a dimensional defect as a polymer PTC element may occur, making it impossible to mount the protective circuit. there were.
International Publication No. 2004/023499 Pamphlet

  The present invention has been made in view of such a situation, and the object thereof is to make it effective that the coating material for forming the protective film on the externally exposed surface of the PTC element wraps around to the portion where the coating material should not be held. It is to provide a PTC element that can be prevented. Another object of the present invention is to provide a battery protection system having excellent reliability by incorporating the PTC element.

In order to achieve the above object, the PTC element according to the present invention includes:
An element body whose resistance value increases as the temperature rises in a predetermined temperature range;
A pair of first and second electrode plates joined to the front and back surfaces of the element body;
A PTC element having a protective film that covers an exposed portion of the element body that is not covered with the first and second electrode plates,
The first electrode plate is bonded to an element bonding surface in which the first electrode plate and the element main body are in direct contact, and the first electrode plate and the element main body are bonded on an extended surface of the element bonding surface. A non-junction element surface, and
The element non-bonding surfaces are formed to face each other with the element body interposed therebetween, and have a protective film receiving surface that receives the protective film.

  Preferably, the element body is a conductive polymer having a positive temperature coefficient.

  The PTC element according to the present invention includes an element bonding surface in which the first electrode plate and the element main body are in direct contact, and an element non-bonding in which the first electrode plate and the element main body are not bonded on an extended surface of the element bonding surface. The non-element bonding surface is formed to face each other with the element main body interposed therebetween, and has a protective film receiving surface that receives the protective film. By having such a protective film receiving surface, the phenomenon that the coating material forming the protective film wraps around the joint between the terminal of the battery, circuit, etc. and the electrode plate can be prevented. As a result, the reliability of the entire battery protection system can be maintained without deteriorating the adhesion between the other terminals and the electrode plate.

  Further, in the present invention, the formed protective film does not become too thick, does not exceed the design allowable dimension as a PTC element, and can prevent dimensional defects that cannot be mounted on the battery protection system. Furthermore, since the protective film is not extremely thin, deterioration of the element body due to oxygen can be suppressed.

  Preferably, the protective film receiving surface is formed on the entire outer periphery of the element bonding surface. Since the protective film receiving surface is formed on the entire outer periphery of the element bonding surface, the above effect can be further increased.

  Preferably, the element non-bonding surface of the first electrode plate further has a bonding portion with another terminal. Since the element non-joint surface has a joint with another terminal, heat generated during joining such as spot welding is difficult to be transmitted to the element body, so that thermal degradation of the element body can be effectively prevented. .

  Preferably, the first electrode plate is a clad plate in which two or more kinds of plate materials are laminated. Since the first electrode plate is made of the above clad plate, the first electrode plate can be directly joined to the electrode terminal for the battery, so that the manufacturing process is efficient and the overall system is thin and lightweight. Can be realized.

  Preferably, the element body is disposed on one end side in the longitudinal direction of the first electrode plate. With the configuration as described above, heat generated when the first electrode plate and the battery electrode terminal are joined can be further prevented from being transmitted to the element body.

  Preferably, unevenness is formed on the element bonding surface of the first electrode plate, and the unevenness is continuously formed from the element bonding surface to an outer peripheral portion of the element bonding surface. By forming irregularities on the element bonding surface, the adhesion between the element body and the first electrode plate can be further strengthened. Furthermore, irregularities are also formed on the outer peripheral portion of the element bonding surface, that is, the protective film receiving surface. Therefore, the adhesion between the protective film and the first electrode plate can be improved.

  In the present invention, a recess may be formed on the surface of the first electrode plate so as to hold the coating material for forming the protective film. Since the concave portion is formed on the surface of the first electrode plate, even if the coating material is supplied excessively, the wraparound of the coating material can be effectively prevented.

  In the present invention, a concave portion or a convex portion for positioning the element body may be formed on the surface of the first electrode plate. By forming the positioning concave portion or the convex portion, it is possible to prevent positional deviation at the time of joining the element body and the first electrode plate.

  Furthermore, in this invention, metal foil is laminated | stacked on the front and back of the said element main body, and the said 1st and 2nd electrode plate may be joined with respect to each metal foil.

The battery protection system according to the present invention includes:
A PTC element according to any of the above,
A battery electrically connected to the first electrode plate of the PTC element;
And a protection circuit electrically connected to the second electrode plate of the PTC element.

  In the battery protection system according to the present invention, a battery protection system having excellent reliability can be realized by incorporating the PTC element.

Hereinafter, the present invention will be described based on embodiments shown in the drawings.
FIG. 1 is a cross-sectional view of a principal part showing a usage state of a PTC element according to a first embodiment of the present invention.
2A is a plan view of the polymer PTC element shown in FIG. 1, and FIG. 2B is a cross-sectional view of the polymer PTC element shown in FIG.
FIG. 3A shows the unevenness (nodes) formed on the element bonding surface of the first electrode plate (cladding plate) bonded to the polymer PTC element according to the first embodiment of the present invention. An electron micrograph observed from vertically above the surface,
FIG. 3B shows unevenness (nodes) formed on the element bonding surface of the first electrode plate (cladding plate) bonded to the polymer PTC element according to the first embodiment of the present invention. An electron micrograph observed from the horizontal direction on the surface,
FIG. 4A is a cross-sectional view of a principal part showing a convex portion positioning portion in the first electrode plate (clad plate) of the polymer PTC element according to the second embodiment of the present invention.
FIG. 4B is a cross-sectional view of a main part showing a recessed portion positioning portion in the first electrode plate (clad plate) of the polymer PTC element according to the second embodiment of the present invention.
FIG. 5 is a cross-sectional view of an essential part showing a recess for holding a coating material for forming a protective film in the first electrode plate (clad plate) of the polymer PTC element according to the third embodiment of the present invention;
FIG. 6 is a cross-sectional view of an essential part of a polymer PTC element according to a fourth embodiment of the present invention.
FIG. 7 is a plan view of a polymer PTC element according to another embodiment of the present invention.

(First embodiment)
Overall Configuration of Polymer PTC Element First, a polymer PTC element for protecting a secondary battery cell used as a power source of a portable device such as a mobile phone will be described as an embodiment of a PTC element according to the present invention.

A polymer PTC element 2 shown in FIG. 1 is incorporated between a secondary battery cell 32 which is a power source of a mobile phone and a protection circuit 30 for protecting the secondary battery cell 32 from overcurrent. The polymer PTC element 2 cuts off the current between the protection circuit 30 and the secondary battery cell 32 when an overcurrent that cannot be controlled by the protection circuit 30 flows during charging or discharging of the secondary battery cell 32. Thus, the secondary battery cell 32 is protected.
Below, the whole structure of a polymer PTC element is demonstrated first.

  A polymer PTC element 2 shown in FIG. 1 and FIG. 2 includes an element body 4 made of a conductive polymer having a positive resistance temperature characteristic (PTC characteristic). The element body 4 has front and back surfaces (a first surface 6 and a second surface 8 facing each other). A first electrode plate 10 and a second electrode plate 12 are joined to the first surface 6 and the second surface 8, respectively. As a result, the element body 4 is disposed so as to be sandwiched between the first electrode plate 10 and the second electrode plate 12.

  The exposed portion of the element body 4 that is not covered with the first electrode plate 10 and the second electrode plate 12 is covered with the protective film 3. By forming the protective film 3, it is possible to prevent the element body 4 from being oxidized by oxygen in the atmosphere and to prevent the element body 4 from being deteriorated. As a result, an increase in the room temperature resistance value of the polymer PTC element 2 can be prevented. Further, the mechanical strength of the element body 4 can be improved by the protective film 3.

  The type of the protective film 3 is not particularly limited as long as it has a function of shielding oxygen, and examples thereof include epoxy resin, EVOH (ethylene-vinyl alcohol copolymer), PVA (polyvinyl alcohol), and the like.

  In the present embodiment, the first electrode plate 10 is constituted by a clad plate in which two types of plate materials of a nickel layer 20 and an aluminum layer 22 are laminated. Although the thickness of a clad board is not specifically limited, Usually, it is about 100-300 micrometers. The length of the clad plate is not particularly limited and can be freely designed according to the application.

  As shown in FIG. 1, the first electrode plate 10 is bonded to the battery electrode terminal 34. Specifically, since the first electrode plate 10 is formed of a clad plate, the aluminum layer 22 and the electrode terminal 34 in the clad plate are joined by spot welding. The electrode terminal 34 of the secondary battery cell 32 is generally made of an aluminum material and is easily bonded to the aluminum layer 22 in the clad plate.

  When the first electrode plate 10 is not composed of a clad plate, for example, when the first electrode plate 10 is composed only of nickel or a nickel alloy, the thickness of the first electrode plate 10 is preferably It is 100-500 micrometers, More preferably, it is 150-300 micrometers.

  The first electrode plate 10 includes an element bonding surface 100 in which the nickel layer 20 and the first surface 6 of the element body 4 are in direct contact, and the nickel layer 20 and the element body 4 on the extended surface of the element bonding surface 100. The first surface 6 is not in direct contact with the element non-bonding surface 101. Therefore, the area of the first surface 6 of the element body 4 is at least smaller than the area of the nickel layer 20.

  The element non-joint surface 101 has a protective film receiving surface 102. As shown in FIG. 2A, the protective film receiving surface 102 includes a protective film receiving surface 102a and a protective film receiving surface that are formed to face each other with the element body 4 sandwiched in the short direction of the first electrode plate 10. The surface 102b has a protective film receiving surface 102c and a protective film receiving surface 102d that are formed to face each other with the element body 4 interposed therebetween in the longitudinal direction of the first electrode plate 10.

  The protective film receiving surfaces 102 a, 102 b, 102 c, and 102 d suffice as long as at least one pair (102 a, 102 b or 102 c, 102 d) formed so as to face each other is formed. It is preferable that a protective film receiving surface 102 is formed. By forming such a protective film receiving surface 102, the coating material for forming the protective film 3 is received by the protective film receiving surface 102, and the coating material can be prevented from wrapping around.

  Further, as shown in FIGS. 1 and 2, a terminal joint portion 103 is formed on the extended surface of the protective film receiving surface 102 d, and is joined to the secondary battery electrode terminal 34. Note that the terminal bonding portion 103 may be formed narrower than the protective film receiving surface 102d. Since the bonding between the terminal bonding portion 103 and the secondary battery electrode terminal 34 can be performed away from the element body 4, heat generated when the bonding is performed by spot welding or the like is not easily transmitted to the element body 4. Thermal deterioration of the element body 4 can be prevented.

  The widths of the protective film receiving surfaces 102a, 102b, 102c, and 102d may be different from each other. However, when the design dimension allowable width of the polymer PTC element 2 is the width W0 of the first electrode plate 10 The widths of the protective film receiving surfaces 102a and 102b are preferably larger than the widths of the protective film receiving surfaces 102c and 102d, and the widths of the protective film receiving surfaces 102a, 102b, 102c, and 102d are the same value (W1). Is particularly preferred. The width W1 of the protective film receiving surface 102 is preferably 20 to 500 μm, and more preferably 30 to 100 μm.

  On the other hand, the thickness T1 of the protective film 3 is required to be smaller than the width W1 of the protective film receiving surface 102, and is preferably about 50 to 200 μm. If the thickness T1 is too thin, the protective film 3 cannot sufficiently prevent the element body 4 from being oxidized.

  In the present embodiment, even if the thickness of the protective film 3 varies somewhat, the outer periphery of the protective film 3 does not protrude outward from the outer edge of the first electrode plate 10. Therefore, the allowable dimension width in design of the polymer PTC element 2 is not exceeded, and a dimensional defect of the polymer PTC element 2 can be prevented.

  In this embodiment, as shown in FIG. 1 and FIG. 2, irregularities are formed on the element bonding surface 100 of the first electrode plate 10, and the irregularities are formed from the element bonding surface 100 to the outer periphery of the element bonding surface 100. Part, that is, the protective film receiving surfaces 102a to 102d are continuously formed.

  The unevenness formed on the element bonding surface 100 is for strengthening thermocompression bonding with the element main body 4, and the unevenness formed on the protective film receiving surface 102 provides adhesion with the protective film 3. It is for strengthening. Although the formation method is not specifically limited, For example, roughening treatment by plating film formation is preferable. A large number of nodular protrusions are formed on the element bonding surface 100 and the protective film receiving surface 102 of the first electrode plate 10 by the roughening treatment by the plating film formation.

  When the element main body 4 and the element bonding surface 100 are thermocompression bonded, the unevenness 13 formed on the element bonding surface 100 bites into and engages the surface (second surface 8) of the element main body 4, and the both are bonded. Can be strengthened. Further, when the coating material for forming the protective film 3 is held on the protective film receiving surface 102, the coating material and the unevenness 13 formed on the protective film receiving surface 102 mesh with each other, thereby improving the adhesion. it can.

  As shown in FIGS. 3 (A) and 3 (B), the unevenness 13 is preferably a nodule having an unevenness difference of about 5 to 15 μm and a constricted middle or base with respect to the head.

  In addition, as a method for forming the unevenness formed on the element bonding surface 100 and the protective film receiving surface 102, in addition to the roughening treatment by plating film formation, the surface treatment with acid, etching treatment, blast treatment, cutting, etc. Examples thereof include a roughening process by processing and other processes. Further, after forming irregularities on the entire surface of one side of the first electrode plate 10, a part of one side of the first electrode plate 10 is flattened by pressing or the like, so that the terminal joint portion 103 in the first electrode plate 10 is formed. It may be formed. Alternatively, a portion other than the element bonding surface 100 may be masked to form irregularities only on the element bonding surface 100.

  Although the second electrode plate 12 is not particularly limited, in this embodiment, as shown in FIGS. 1 and 2, the area of the second electrode plate 12 and the area of the second surface 8 of the element body 4 are the same. . Therefore, the area of the element bonding surface 120 where the second electrode plate 12 and the second surface of the element body 4 are in direct contact is also the same as the area of the second electrode plate 12 and the second surface 8 of the element body 4. . Further, the element bonding surface 120 of the second electrode plate 12 is formed with unevenness, similar to the element bonding surface 100 of the first electrode plate 10. The method for forming irregularities on the element bonding surface 120 in the second electrode plate 12 is the same as the method for forming irregularities in the first electrode plate 10.

  In the present embodiment, the second electrode plate 12 is made of nickel or a nickel alloy and is spot-welded to the terminal plate 16 shown in FIG. The terminal plate 16 is also made of a nickel plate that can be easily joined to the second electrode plate 12 by spot welding, and the terminal plate 16 is electrically connected to the protection circuit 30. The thickness of the 2nd electrode board 12 is about 100-300 micrometers normally, and the thickness of the terminal board 16 is also about 100-300 micrometers normally. Note that a joint portion with the terminal plate 16 may be provided on the extended surface of the element joint surface 120 in the second electrode plate 12.

The shape of the element body 4 is not particularly limited, and examples thereof include a rectangular parallelepiped type and a cylindrical type. When the shape of the element body 4 is a rectangular parallelepiped, the dimensions of the element body 4 are about 3 to 5 mm in length, 2 to 5 mm in width, and about 0.5 to 1.0 mm in thickness.
Method for manufacturing polymer PTC element 2

Next, a manufacturing method of the polymer PTC element 2 will be described.
(Element body 4)
The element body 4 is generally composed of a resin composition (conductive polymer) including a polymer (polymer compound such as a thermosetting resin or a thermoplastic resin) as main components and conductive particles. The element body 4 may include both a thermosetting resin and a thermoplastic resin as a polymer.

  First, a polymer compound (thermosetting resin, thermoplastic resin, etc.), conductive particles (metal powder, carbon black, etc.), a low molecular organic compound, a reaction initiator for cross-linking the polymer compounds, etc. Weigh and knead to adjust the PTC composition. The kneading method is not particularly limited, and examples thereof include a kneader, an extruder, and a mill. Further, as the conductive particles to be contained in the PTC composition, only conductive particles having a predetermined particle diameter are classified using a sieve or the like. Next, this PTC composition is shape | molded and the element main body 4 (FIG. 1) is obtained.

  Although it does not specifically limit as a thermosetting resin, An epoxy resin, a polyimide resin, unsaturated polyester resin, a silicon resin, a polyurethane resin, a phenol resin, etc. are mentioned. Preferably, an epoxy resin is used as the thermosetting resin. By using an epoxy resin, the polymer PTC element can have a sufficient resistance change amount and heat resistance. As for the molecular weight of the thermosetting resin, the weight average molecular weight Mw is usually about 300 to 10,000. Said thermosetting resin may be used independently and multiple types of resin may be used. Moreover, you may use the compound which has a structure where different kinds of thermosetting resins were bridge | crosslinked.

  Although it does not specifically limit as a thermoplastic resin, Preferably, a crystalline polymer is used. The melting point of the thermoplastic resin is not particularly limited, but is preferably about 70 to 200 ° C. By using a resin having a melting point within this range, it is possible to prevent the thermoplastic resin from melting, flowing, and deformation of the element body during the operation of the polymer PTC element.

  Specific thermoplastic resins include polyolefins such as polyethylene, copolymers such as ethylene-vinyl acetate copolymer, vinyl halides such as polyvinyl chloride, polyvinyl fluoride, and polyvinylidene fluoride, and vinylidene polymers, 12-nylon, and the like. Polyamide, polystyrene, polyacrylonitrile, thermoplastic elastomer, polyethylene oxide, polyacetal, thermoplastic modified cellulose, polysulfones, polymethyl (meth) acrylate, and the like.

  Although the weight average molecular weight Mw of a thermoplastic resin is not specifically limited, Preferably, it is 10000-5 million. These thermoplastic resins may be used alone or a plurality of types of resins may be used. Moreover, you may use the compound which has a structure where different types of thermoplastic resins were bridge | crosslinked.

  Although it does not specifically limit as electroconductive particle contained in the element main body 4, Metal powder, carbon black, etc. are illustrated. Preferably, metal powder is used as the conductive particles. As the metal powder, a powder mainly composed of nickel is preferably used. The average particle diameter of the metal powder is preferably 0.1 μm or more, and more preferably about 0.5 to 4.0 μm.

  In the element body 4, the content of the conductive particles in the resin composition is preferably 20 to 80% by mass with respect to the entire resin composition. By setting the content of the conductive particles within this range, the room temperature resistance value during non-operation can be sufficiently lowered, and a large resistance change amount can be obtained. Furthermore, variation in element resistance can be sufficiently reduced.

  The resin composition constituting the element body 4 further includes, for example, a low-molecular organic compound such as wax, oil, fatty acid, and higher alcohol in addition to the above-described thermosetting resin, thermoplastic resin, and conductive particles. But you can. As a result, it is possible to increase the resistance change amount accompanying the temperature rise of the element body 4.

  The element body 4 may include a base material that has a gap inside and can fill the gap with the resin composition. Such a substrate is not particularly limited as long as it can play the above role, and examples thereof include woven fabrics, nonwoven fabrics, and continuous porous bodies.

The element body 4 is irradiated with an electron beam as necessary. By this electron beam irradiation, the reaction initiator functions and the cross-linking reaction between the polymers is promoted. The energy source for the crosslinking reaction is not limited to electron beams, and gamma rays, ultraviolet rays, heat, and the like are also used. What is necessary is just to adjust suitably the acceleration voltage and electron beam irradiation amount of the electron beam to irradiate according to the kind of high molecular compound contained in the element main body 4, or the dimension of an element main body. The electron beam irradiation may be performed after the electrode plates 10 and 12 are joined.
(Formation and thermocompression bonding of the first electrode plate 10 and the second electrode plate 12)

  The method for manufacturing the clad plate constituting the first electrode plate 10 is not particularly limited, and is formed by rolling a nickel metal plate or nickel alloy plate having a predetermined thickness and an aluminum metal plate or aluminum alloy plate having a predetermined thickness. Is done. The second electrode plate 12 is formed by punching and molding a nickel metal plate or nickel alloy plate having a predetermined thickness. The element bonding surface 100 and the protective film receiving surface 102 of the nickel layer 20 in the first electrode plate 10 and the element bonding surface 120 in the second electrode plate 12 are bonded to the element body 4 or the protective film 3 by the method described above. Concavities and convexities are formed for strengthening.

Next, the first electrode plate 10 and the second electrode plate 12 are thermocompression bonded to the front and back surfaces (the first surface 6 and the second surface 8) of the element body 4 by a hot press machine or the like. Although the heating temperature at the time of thermocompression bonding depends on the material of the element body 4, it is preferably about 130 to 180 ° C. The pressure during thermocompression bonding is preferably about 1 × 10 ^{6 to} 3 × 10 ⁶ Pa.

At the time of thermocompression bonding, the element main body 4 is slightly crushed in the thickness direction due to pressure and may protrude slightly to the side of the electrode plates 10 and 12, but unnecessary portions can be easily removed.
(Formation of protective film 3)

Next, the protective film 3 is formed on the exposed side surface of the element body 4 that is not surrounded by the electrode plates 10 and 12. A method for forming the protective film 3 is not particularly limited, and examples thereof include a method in which the above-described epoxy resin or the like is applied and dried. When the protective film 3 is formed, excess coating material is held on the protective film receiving surface 102 of the first electrode plate 10. Therefore, it can be prevented that the first electrode plate 10 wraps around the joint surface with the other terminals (the surface on which the coating material should not be held), and no joint failure occurs. Furthermore, even if the thickness of the protective film 3 varies somewhat, the outer periphery of the protective film 3 does not protrude outward from the outer edge of the first electrode plate 10. Therefore, the allowable dimension width in design of the polymer PTC element 2 is not exceeded, and a dimensional defect of the polymer PTC element 2 can be prevented.
In this way, as shown in FIG. 2, the polymer PTC element 2 according to this embodiment is completed.
Assembly method of polymer PTC element 2

  As shown in FIG. 1, the polymer PTC element 2 is incorporated between the secondary battery cell 32 and the protection circuit 30. In order to connect the polymer PTC element 2 as shown in FIG. 1, for example, first, the aluminum layer 22 side of the terminal joint surface 103 of the first electrode plate 10 (clad plate) in the element 2 is connected to the secondary battery cell 32. Spot welding is performed in contact with the electrode terminal 34. When a gap is formed between the PTC element 2 and the secondary battery cell 32, a spacer 36 or the like is disposed between the PTC element 2 and the secondary battery cell 32.

  Next, or before and after that, the terminal plate 16 connected to the protection circuit 30 is joined to the second electrode plate 12 by spot welding.

  In the polymer PTC element 2 according to the present embodiment, since the first electrode plate 10 has the terminal joint surface 103, heat at the time of spot welding the terminal joint surface 103 and the electrode terminal 34 of the secondary battery cell 32. Is difficult to be transmitted to the element body 4 and can prevent thermal deterioration of the element body 4.

  Since heat degradation of the element body 4 can be prevented, the polymer PTC element 2 according to the present embodiment can reduce power consumption during normal use, and can supply current if necessary. The original function of blocking and protecting the secondary battery cell 32 can be effectively exhibited.

  The present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention.

(Second Embodiment)
For example, as shown in FIGS. 4 (A) and 4 (B), the present invention may have a positioning portion for fixing the joining position of the element body 4 on the first electrode plate 10 (cladding plate). Good. Below, the difference between 2nd Embodiment and 1st Embodiment is described, and the description regarding both common items is abbreviate | omitted.

  In the polymer PTC element 2 shown in FIG. 4A, a set of convex positioning portions 41a is formed on the nickel layer 20 side of the first electrode plate 10 (cladding plate). The upper surface is a protective film receiving surface 102. The element body 4 is installed and joined inside the set of convex positioning portions 41a. That is, the inner surface partitioned by the positioning portion 41 a is the element bonding surface 100. By doing in this way, by installing the element main body 4, it is possible to prevent the positional deviation at the time of joining the element main body 4 and the first electrode plate 10 (cladding plate).

  Concavities and convexities 13 are formed on the element bonding surface 100 and the positioning portion 41a defined by the positioning portion 41a. As a result, the bonding strength between the element body 4 and the first electrode plate 10 (cladding plate) can be improved during thermocompression bonding between the element body 4 and the first electrode plate 10 (cladding plate), and further protection The adhesion between the film 3 and the protective film receiving surface 102 can also be improved.

  In the polymer PTC element 2 shown in FIG. 4B, a concave positioning part 41b is formed on the nickel layer 20 side of the first electrode plate 10 (cladding plate). The element body 4 is installed and joined inside the positioning portion 41b. That is, the surface on which the positioning portion 41 b is formed is the element bonding surface 100. By doing in this way, the position shift at the time of joining with the element main body 4 and the 1st electrode board 10 (cladding board) can be prevented.

  Moreover, the unevenness | corrugation 13 is formed in the positioning part 41b and its outer peripheral part. As a result, the bonding strength between the element body 4 and the first electrode plate 10 (cladding plate) can be improved during thermocompression bonding between the element body 4 and the first electrode plate 10 (cladding plate), and further protection The adhesion between the film 3 and the protective film receiving surface 102 can also be improved.

(Third embodiment)
For example, as shown in FIG. 5, the present invention may have a recess for holding the coating material for forming the protective film 3. That is, the concave portion may have a function as a protective film receiving surface. Moreover, you may combine this embodiment with formation of the recessed part or convex part for positioning in 2nd Embodiment. Below, the difference between 3rd Embodiment and 1st Embodiment is described, and the description regarding both common items is abbreviate | omitted.

  In the polymer PTC element 2 shown in FIG. 5, a recess 51 is formed on the nickel layer 20 side of the first electrode plate 10 (cladding plate). The size of the recess 51 is larger than the size of the element body 4 (second surface 8). Therefore, even when the element body 4 is installed inside the recess 51 and the coating material for forming the protective film 3 is applied, the coating material can be held inside the recess 51. As a result, it is possible to prevent the coating material from reaching the area (spot welded portion or the like) where the protective film 3 should not be formed on the surface of the first electrode plate 10 (cladding plate).

  Further, unevenness 13 is formed on the bottom surface of the recess 51. As a result, the bonding strength between the element body 4 and the first electrode plate 10 (clad plate) can be improved during thermocompression bonding between the element body 4 and the first electrode plate 10 (cladding plate). Furthermore, the effect of preventing the coating material from wrapping around can be further increased.

(Fourth embodiment)
For example, as shown in FIG. 6, not only the protective film receiving surface 102 is formed on the first electrode plate 10 (cladding plate), but also the second surface 8 of the element body 4 and the second electrode plate 12. There may be provided an element body protruding portion 63 protruding outward from the element bonding surface 61 in direct contact with the element bonding surface 61. By doing in this way, in addition to the effect in embodiment mentioned above, the surroundings of the coating material to the 2nd electrode plate 12 can be prevented. Below, the difference between 4th Embodiment and 1st Embodiment is described, and the description regarding a common matter of both is abbreviate | omitted.

  Since the element body 4 has the element body protrusion 63 shown in FIG. 6, when the coating material is applied to the element body 4, the step between the surface of the second electrode plate 12 and the surface of the element body protrusion 63. Can not get over. As a result, the coating material does not go around on the surface of the second electrode plate 12 but is held only on the surface of the element body protrusion 63. That is, it is possible to prevent the coating material from entering the surface of the second electrode plate 12 (the side to which the terminal plate 16 is joined). As a result, the second electrode plate 12 and the terminal plate 16 can be adhered and bonded satisfactorily without being interposed in the protective film 3.

  Moreover, since the protective film 3 is prevented from being formed on the surface of the second electrode plate 12 (the side to which the terminal plate 16 is joined) by the element body protrusion 63, the second electrode plate 12 and the terminal plate 16 are prevented. It is possible to improve the dimensional accuracy of the joint position (position of the terminal joint portion). Furthermore, it is possible to prevent a dimensional defect in the width and thickness of the entire polymer PTC element 2.

  Furthermore, as in the above-described embodiment, the coating material that should originally be held only on the exposed surface of the element body 4 is a surface that is bonded to the other terminal in the first electrode plate 10 (originally the coating material is held). Can be prevented. Moreover, since the coating thickness of the protective film 3 on the exposed surface of the element body 4 can be made sufficient, oxidation of the element body 4 can be effectively prevented.

  Note that the element body protrusion 63 causes the element body 4 to be slightly crushed in the thickness direction by pressure when the first electrode plate 10 (cladding plate) or the second electrode plate 12 is thermocompression bonded to the element body 4. It is formed by protruding slightly to the side of the electrode plate 10 or the second electrode plate 12. That is, in the above-described embodiment, a portion to be removed as an unnecessary portion in the element body functions as the element body protrusion 63 without being removed in the present embodiment. That is, in this embodiment, the process of removing unnecessary portions from the element body is omitted. As a result, the manufacturing man-hour and manufacturing cost of the polymer PTC element 2 can be reduced.

(Other embodiments)
Moreover, the shape shown in FIG. 7 can be employ | adopted as the 1st electrode plate 10 and the 2nd electrode plate 12 by making the element body 4 cylindrical. In this case, the protective film receiving surface 102 preferably has a donut shape with a width of R1. Even if it is a case where it is such a structure, the structure described in the above-mentioned embodiment, or the structure which combined them is applicable.

  Furthermore, as another embodiment, metal foils such as nickel are laminated on the front and back surfaces of the element body 4, and the first metal plate 10 and the second electrode plate 12 are solder layers for each metal foil. It may be joined via. The metal foil is made of a metal such as nickel or an alloy, and is hot-pressed on both surfaces of the sheet-like element body 4 and then punched into a predetermined dimension to be integrated with the element body 4. be able to. The thickness of metal foil is thinner than the thickness of the electrode plates 10 and 12, and is generally 25-30 micrometers. Also in this embodiment, the same effect as the above-described embodiment can be obtained.

  The polymer PTC element 2 according to the present invention is used not only as an overcurrent protection element for the secondary battery cell 32 but also as a self-control heating element, a temperature sensor, a current limiting element, an overcurrent protection element, and the like. It is possible.

  In the present invention, the method for producing the polymer PTC element 2 is not particularly limited. For example, as in the above-described embodiment, the polymer PTC element 2 may be manufactured as follows without joining the element body 4, the first electrode plate, and the second electrode plate in a single state. . That is, after the sheet-like element body constituting the element body 4 after cutting and the pair of sheet-like electrodes that respectively constitute the first electrode plate and the second electrode plate after cutting, the unnecessary portions are removed. Individual polymer PTC elements 2 may be formed by punching with a press. In that case, the efficiency of the manufacturing process of the polymer PTC element 2 can be improved by joining the assembly of parts constituting the polymer PTC element 2 at a time.

FIG. 1 is a cross-sectional view of a principal part showing a usage state of the polymer PTC element according to the first embodiment of the present invention. 2A is a plan view of the polymer PTC element shown in FIG. 1, and FIG. 2B is a cross-sectional view of the polymer PTC element shown in FIG. FIG. 3A shows the unevenness (nodes) formed on the element bonding surface of the first electrode plate (cladding plate) bonded to the polymer PTC element according to the first embodiment of the present invention. An electron micrograph observed from vertically above the surface, FIG. 3B, is formed on the element bonding surface of the first electrode plate (clad plate) bonded to the polymer PTC element according to the first embodiment of the present invention. It is the electron micrograph which observed the unevenness | corrugation (nodule) made from the horizontal direction with respect to the 1st electrode plate surface. FIG. 4A is a cross-sectional view of a main part showing a convex portion positioning portion in the first electrode plate (clad plate) of the polymer PTC element according to the second embodiment of the present invention, and FIG. It is principal part sectional drawing which shows the recessed part positioning part in the 1st electrode plate (clad board) of the polymer PTC element which concerns on 2nd Embodiment. FIG. 5 is an essential part cross-sectional view showing a recess for holding a coating material for forming a protective film in the first electrode plate (clad plate) of the polymer PTC element according to the third embodiment of the present invention. FIG. 6 is a cross-sectional view of a main part of a polymer PTC element according to the fourth embodiment of the present invention. FIG. 7 is a plan view of a polymer PTC element according to another embodiment of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 2 ... Polymer PTC element 3 ... Protective film 4 ... Element main body 6 ... 1st surface 8 ... 2nd surface 10 ... 1st electrode plate 100 ... Element bonding surface 101 ... Element non-bonding surface 102 ... Protective film receiving surface 103 ... Terminal bonding Part 12 ... Second electrode plate 120 ... Element bonding surface 13 ... Concavity and convexity 16 ... Terminal plate 20 ... Nickel layer 22 ... Aluminum layer 30 ... Protection circuit 32 ... Secondary battery cell 34 ... Electrode terminal

Claims (11)

An element body whose resistance value increases as the temperature rises in a predetermined temperature range;
A pair of first and second electrode plates joined to the front and back surfaces of the element body;
A PTC element having a protective film that covers an exposed portion of the element body that is not covered with the first and second electrode plates,
The first electrode plate is bonded to an element bonding surface in which the first electrode plate and the element main body are in direct contact, and the first electrode plate and the element main body are bonded on an extended surface of the element bonding surface. A non-junction element surface, and
The PTC element, wherein the element non-joint surfaces are formed to face each other with the element body interposed therebetween and have a protective film receiving surface for receiving the protective film.   The PTC element according to claim 1, wherein the element body is a conductive polymer having a positive temperature coefficient.   The PTC element according to claim 1, wherein the protective film receiving surface is formed on the entire outer periphery of the element bonding surface.   The PTC element according to any one of claims 1 to 3, wherein the element non-joint surface of the first electrode plate further has a joint with another terminal.   The PTC element according to any one of claims 1 to 4, wherein the first electrode plate is formed of a clad plate in which two or more kinds of plate materials are laminated.   The PTC element according to claim 1, wherein the element body is disposed on one end side in the longitudinal direction of the first electrode plate.   The unevenness is formed on the element bonding surface of the first electrode plate, and the unevenness is continuously formed from the element bonding surface to an outer peripheral portion of the element bonding surface. The PTC element according to any one of the above.   The PTC element according to claim 1, wherein a concave portion is formed on the surface of the first electrode plate so as to hold the coating material for forming the protective film.   The PTC element according to claim 1, wherein a concave portion or a convex portion for positioning the element body is formed on the surface of the first electrode plate.   The PTC element according to any one of claims 1 to 9, wherein metal foils are laminated on the front and back surfaces of the element body, and the first and second electrode plates are bonded to each metal foil. . The PTC element according to any one of claims 1 to 10,
A battery electrically connected to the first electrode plate of the PTC element;
A battery protection system comprising a protection circuit electrically connected to the second electrode plate of the PTC element.

Images