TWI785260B - overcurrent protection device - Google Patents
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Abstract
一種過電流保護裝置包含一正溫度係數(PTC)聚合物元件、兩個電極及一無電源跳脫指示物。該正溫度係數聚合物元件具有兩個相反表面。該兩個電極分別連接於該兩個表面。該無電源跳脫指示物形成在至少一個該等電極上,以感測該過電流保護裝置的溫度。本發明的過電流保護裝置處於跳脫狀態時,可立刻被辨識出,且其整體生產成本及製程可被大幅減少。An overcurrent protection device includes a positive temperature coefficient (PTC) polymer element, two electrodes and a no power trip indicator. The positive temperature coefficient polymer element has two opposing surfaces. The two electrodes are respectively connected to the two surfaces. The no power trip indicator is formed on at least one of the electrodes to sense the temperature of the overcurrent protection device. When the overcurrent protection device of the present invention is in a tripped state, it can be identified immediately, and its overall production cost and manufacturing process can be greatly reduced.
Description
本發明是有關於一種過電流保護裝置,特別是指一種包含無電源跳脫指示物以感測其溫度的過電流保護裝置。The present invention relates to an over-current protection device, in particular to an over-current protection device including a no-power trip indicator for sensing its temperature.
正溫度係數(positive temperature coefficient, PTC)元件具有PTC效應,使其可用作為一電路保護裝置(例如保險絲)。A positive temperature coefficient (PTC) device has a PTC effect, making it useful as a circuit protection device (eg, a fuse).
參閱圖1,現有電路保護裝置包含PTC聚合物材料8及兩個分別連接於該PTC聚合物材料8之兩個相反表面81的電極9,該PTC聚合物材料8包含一含有一晶體區域及一非晶體區域的聚合物基材,及一顆粒狀導電填料,該顆粒狀導電填料分散於該聚合物基體之非晶體區域,並形成一用於電連接該等電極9之間的連續導電路徑。該PTC效應指的是一種現象,該現象是當該晶體區域的溫度被升高至其熔點時,該晶體區域中的結晶開始熔化,從而產生一新的非晶體區域。當該新的非晶體區域增加至一合併至該原非晶體區域的程度時,該顆粒狀導電填料的導電路徑會轉變為非連續且該PTC聚合物材料8的電阻會急劇增加,造成該等電極9之間電不導通。Referring to Fig. 1, the existing circuit protection device comprises a PTC polymer material 8 and two
中華民國專利TW 424929號記載一種電子保險絲,包含一殼體、一填充於該殼體中的填料、內含在該填料中的導電顆粒、兩個伸入該殼體的導電片及一跨接該等導電片的發光二極體(LED)。該填料可膨脹以反應溫度上升。該等導電片連接該填料,並以適當間距彼此間隔。該發光二極體與該填料並聯地連接。當電路發生短路時,該填料會因溫度上升而膨脹,且該等導電顆粒會彼此分隔。因此,電流不穿過該填料而經過該發光二極體,造成該發光二極體發光。The Republic of China Patent No. TW 424929 describes an electronic fuse, which includes a housing, a filler filled in the housing, conductive particles contained in the filler, two conductive sheets extending into the housing, and a jumper Light emitting diodes (LEDs) of the conductive sheets. The packing can expand to increase the reaction temperature. The conductive sheets are connected to the filler and spaced apart from each other at a proper distance. The light emitting diode is connected in parallel with the filler. When the circuit is short-circuited, the filler will expand due to temperature rise, and the conductive particles will be separated from each other. Therefore, current passes through the LED instead of the filler, causing the LED to emit light.
然而,上述電子保險絲的配置增加了複雜度及製造成本,因此,可輕易生產且符合工業需求的過電流保護裝置仍有待開發。However, the configuration of the above-mentioned electronic fuse increases the complexity and the manufacturing cost, therefore, an over-current protection device that can be easily produced and meets the needs of the industry remains to be developed.
因此,本發明之目的,即在提供一種過電流保護裝置,可以克服上述先前技術的至少一個缺點。Therefore, the object of the present invention is to provide an overcurrent protection device that can overcome at least one of the above-mentioned disadvantages of the prior art.
於是,本發明的過電流保護裝置包含一正溫度係數(PTC)聚合物元件、兩個電極及一無電源跳脫指示物。該正溫度係數聚合物元件具有兩個相反表面。該兩個電極分別連接於該兩個表面。該無電源跳脫指示物形成在至少一個該等電極上,以感測該過電流保護裝置的溫度。Therefore, the overcurrent protection device of the present invention includes a positive temperature coefficient (PTC) polymer element, two electrodes and a no power trip indicator. The positive temperature coefficient polymer element has two opposing surfaces. The two electrodes are respectively connected to the two surfaces. The no power trip indicator is formed on at least one of the electrodes to sense the temperature of the overcurrent protection device.
本發明之功效在於:當本發明過電流保護裝置處於跳脫狀態時,可立刻被辨識出,且本發明過電流保護裝置的整體生產成本及製程可被大幅減少。The effect of the present invention is that: when the overcurrent protection device of the present invention is in a tripped state, it can be recognized immediately, and the overall production cost and process of the overcurrent protection device of the present invention can be greatly reduced.
以下將就本發明內容進行詳細說明:The content of the present invention will be described in detail below:
在本發明的部分具體實施例中,該無電源跳脫指示物與該至少一個電極直接接觸。In some embodiments of the present invention, the dead power trip indicator is in direct contact with the at least one electrode.
較佳地,該無電源跳脫指示物包括一熱致變色的材料。更佳地,該過電流保護裝置具有一跳脫表面溫度,該跳脫表面溫度等於或高於該無電源跳脫指示物的變色溫度。又更佳地,該過電流保護裝置的跳脫表面溫度高於70℃。Preferably, the dead power trip indicator comprises a thermochromic material. More preferably, the overcurrent protection device has a trip surface temperature which is equal to or higher than the discoloration temperature of the no-power trip indicator. Still more preferably, the trip surface temperature of the overcurrent protection device is higher than 70°C.
較佳地,該無電源跳脫指示物的變色溫度高於60℃。更佳地,該無電源跳脫指示物的變色溫度高於60℃且不高於200℃。Preferably, the discoloration temperature of the no-power trip indicator is higher than 60°C. More preferably, the discoloration temperature of the no-power trip indicator is higher than 60°C and not higher than 200°C.
在本發明的部分具體實施例中,該過電流保護裝置還包含一設置在該無電源跳脫指示物與該至少一個電極之間的覆蓋層。較佳地,該無電源跳脫指示物透過該覆蓋層與該至少一個電極間接接觸。可選擇地,該覆蓋層包圍在該正溫度係數聚合物元件及該等電極外,且是由一導熱絕緣材料所製成。In some embodiments of the present invention, the overcurrent protection device further includes a covering layer disposed between the no-power trip indicator and the at least one electrode. Preferably, the dead power trip indicator is in indirect contact with the at least one electrode through the covering layer. Optionally, the covering layer surrounds the PTC polymer element and the electrodes, and is made of a thermally conductive insulating material.
較佳地,該正溫度係數聚合物元件包括一聚合物基材及一分散在該聚合物基材中的顆粒狀導電填料。更佳地,該顆粒狀導電填料是選自於碳黑粉末、金屬粉末、導電陶瓷粉末或其組合。又更佳地,該顆粒狀導電填料是碳黑粉末。Preferably, the positive temperature coefficient polymer element includes a polymer substrate and a granular conductive filler dispersed in the polymer substrate. More preferably, the granular conductive filler is selected from carbon black powder, metal powder, conductive ceramic powder or a combination thereof. Still more preferably, the granular conductive filler is carbon black powder.
在本發明被詳細描述之前,應當注意在以下的說明內容中,類似的元件是以相同的編號來表示。Before the present invention is described in detail, it should be noted that in the following description, similar elements are denoted by the same numerals.
參閱圖2,本發明過電流保護裝置之一第一實施例包含一正溫度係數(PTC)聚合物元件2、兩個電極3及一無電源跳脫指示物4。該正溫度係數聚合物元件2具有兩個相反表面21。該兩個電極3分別連接於該兩個表面21。該無電源跳脫指示物4形成在至少一個該等電極3上,以感測該過電流保護裝置的溫度。在該第一實施例中,該無電源跳脫指示物4與該至少一個電極3直接接觸。Referring to FIG. 2 , a first embodiment of the overcurrent protection device of the present invention includes a positive temperature coefficient (PTC)
該正溫度係數聚合物元件2包括一聚合物基材及一分散在該聚合物基材中的顆粒狀導電填料。在本發明的某些具體實施例中,該聚合物基材是由聚偏二氟乙烯(PVDF)所製成。在其他具體實施例中,該聚合物基材是由含有結晶聚烯烴的聚合物組成所製成,該結晶聚烯烴選自於非接枝的聚烯烴[例如:非接枝的高密度聚乙烯(HDPE)、非接枝的低密度聚乙烯(LDPE)、非接枝的超低密度聚乙烯(ULDPE)、非接枝的中密度聚乙烯(MDPE)、非接枝的聚丙烯(PP)]、經接枝的聚烯烴(例如:經羧酸酐接枝的聚乙烯)或其組合、或烯烴單體與酸酐的共聚物[例如:乙烯/馬來酸酐共聚物(PE/MA)、乙烯/丙烯酸丁酯/馬來酸酐三元共聚物(PE/BA/MA)]。The positive temperature
該顆粒狀導電填料是選自於碳黑粉末、金屬粉末、導電陶瓷粉末或其組合。在本發明的某些具體實施例中,該顆粒狀導電填料是碳黑粉末。The granular conductive filler is selected from carbon black powder, metal powder, conductive ceramic powder or a combination thereof. In some embodiments of the present invention, the particulate conductive filler is carbon black powder.
該無電源跳脫指示物4包括一熱致變色的(thermochromic)材料,其可為但不限於久榮碩豐生活科技有限公司(Chroma Life Technology Ltd.)或崇裕科技股份有限公司(New Prismatic Enterprise Co., Ltd.)的市售產品。The no
在本文中,術語“熱致變色的材料”是指藉由改變其吸收、穿透或反射光的能力以反應溫度變化的物質。因此,在本文中,術語“熱致變色的”及基於熱致變色的“顏色”改變是指該無電源跳脫指示物4任何可視覺化的改變。該可視覺化的改變包括嚴格定義的可見顏色改變、螢光改變、冷光(luminescence)改變、磷光改變,以及可指示出顏色或視覺現象發生、顏色或視覺現象消去、變成另一種顏色或其他視覺現象等類似現象改變。該改變是可視覺化的,換句話說,其是當肉眼觀看該無電源跳脫指示物4的任何表觀改變,無論是否透過濾光,也無論是否透過光刺激(例如:環境照明或特定波長的光曝照)。As used herein, the term "thermochromic material" refers to a substance that responds to changes in temperature by changing its ability to absorb, transmit or reflect light. Therefore, in this document, the term "thermochromic" and the "color" change based on thermochromism refer to any visual change of the
根據本發明,該熱致變色的材料可遍布分散於該無電源跳脫指示物4,或是集中在該無電源跳脫指示物4的一個區域或多個離散的區域。當該熱致變色的材料集中在該無電源跳脫指示物4的區域時,該區域可以是特定形狀,或是排列成預定的形狀、圖形或圖案。According to the present invention, the thermochromic material can be dispersed throughout the dead
在本發明的某些具體實施例中,該無電源跳脫指示物4具有一變色溫度(Tcc
)。該變色溫度可高於60℃。該變色溫度可不高於200℃。In some embodiments of the present invention, the no-
根據本發明,該過電流保護裝置具有一跳脫表面溫度(trip surface temperature),該跳脫表面溫度等於或高於該無電源跳脫指示物4的變色溫度。也就是說,該無電源跳脫指示物4的熱致變色的材料可改變顏色以反應一跳脫狀態(參閱圖3)。詳細來說,處於正常狀態時,該過電流保護裝置的表面溫度通常介於25~50℃之間,其低於該無電源跳脫指示物4的變色溫度。然而,當該過電流保護裝置跳脫時,該過電流保護裝置的表面溫度急劇增加至其跳脫表面溫度,其超過該無電源跳脫指示物4的變色溫度。因此,該無電源跳脫指示物4的熱致變色的材料的溫度改變可被觀察,並指示出跳脫狀態。According to the present invention, the overcurrent protection device has a trip surface temperature, which is equal to or higher than the discoloration temperature of the no-
在本發明的某些具體實施例中,該過電流保護裝置的跳脫表面溫度高於70℃。In some specific embodiments of the present invention, the trip surface temperature of the overcurrent protection device is higher than 70°C.
參閱圖4,本發明過電流保護裝置之一第二實施例與該第一實施例相似,差異之處在於該第二實施例,還包含一設置在該無電源跳脫指示物4與該至少一個電極3之間的覆蓋層5。在該第二實施例中,該無電源跳脫指示物4透過該覆蓋層5與該至少一個電極3間接接觸。此外,該覆蓋層5包圍在該正溫度係數聚合物元件2及該等電極3外。Referring to Fig. 4, a second embodiment of the overcurrent protection device of the present invention is similar to the first embodiment, the difference is that the second embodiment also includes a power-off
該覆蓋層5可由一導熱絕緣材料所製成。導熱絕緣材料的例子可包括但不限於阻焊(solder mask)、膠帶(tape)、環氧樹脂或聚矽氧樹脂。該覆蓋層5可保護該正溫度係數聚合物元件2及該等電極3遭受外力或環境因素損壞。The covering
本發明將就以下實施例來作進一步說明,但應瞭解的是,該等實施例僅為例示說明之用,而不應被解釋為本發明實施之限制。The present invention will be further described with reference to the following examples, but it should be understood that these examples are for illustrative purposes only, and should not be construed as limitations on the implementation of the present invention.
實施例Example
製備聚合物摻合組成(polymer blend composition)Preparation of polymer blend compositions
製備三種聚合物摻合組成(即配方1、配方2、配方3)的碳黑粉末(購自Columbian Chemicals公司,產品型號:Raven 430UB,DBP/D為0.95,體密度為0.53 g/cm3
)及聚合物基材如下所述。在配方1中,該聚合物基材為乙烯/丙烯酸丁酯/馬來酸酐三元共聚物(PE/BA/MA) (購自Arkema公司,產品型號:Lotader® 3410,BA含量18.0 wt%,MA含量3.1 wt%,熔點91℃)。在配方2中,該聚合物基材包括HDPE(購自台灣塑膠工業股份有限公司,產品型號:HDPE9002,熔點130℃)作為非接枝的聚烯烴,及經馬來酸酐接枝的HDPE (MA-g-HDPE,購自杜邦,產品型號:MB100D,熔點134℃)作為經不飽和羧酸酐接枝的聚烯烴。在配方3中,該聚合物基材為聚偏二氟乙烯(PVDF) (購自Arkema公司,產品型號:Kynar® 761,熔點170℃)。上述三種聚合物摻合組成的聚合物基材及碳黑粉末的配比分別如表1所示。Preparation of carbon black powder (purchased from Columbian Chemicals, product model: Raven 430UB, DBP/D is 0.95, bulk density is 0.53 g/cm ) of three kinds of polymer blending compositions (being formula 1,
將上述三種聚合物基材分別與碳黑粉末在一混煉機(廠牌:Brabender)中混合配料,以溫度為200℃、攪拌轉速為30 rpm的條件混合配料10 min,以分別得到三種聚合物摻合組成(即配方1、配方2、配方3)。The above three polymer substrates were mixed with carbon black powder in a mixer (brand: Brabender), and the temperature was 200 °C, and the stirring speed was 30 rpm for 10 minutes to obtain three polymers. Composition of blends (i.e. formula 1,
製備小片(chip)Preparation of small pieces (chip)
將上述三種聚合物摻合組成各自置於模具中,以熱壓溫度為200℃及熱壓壓力為80 kg/cm2
的條件進行熱壓4 min,以分別形成三種厚度為0.33 mm的薄片。將三種薄片從模具中取出,分別將每一種薄片置於兩片鍍鎳銅箔(作為電極)中,並在200℃及80 kg/cm2
下進行熱壓4 min,以分別形成厚度為0.4 mm的層板。再將該等層板切成多個8 mm × 8 mm的小片後,用Co-60 γ射線以總輻射劑量150 kGy照射每一小片。在25℃中以微歐姆計測量每一小片的初始電阻,三種小片各自的初始電阻平均值(n=100)及計算而得的體積電阻率平均值分別如表1所示。
【表1】
製備過電流保護裝置Preparation of overcurrent protection device
<實施例1 (E1)<Example 1 (E1) >>
將兩個金屬導體引腳分別連接上述配方1聚合物摻合組成製得的每一小片的兩片鍍鎳銅箔,隨後將小片包覆上由環氧樹脂製得的覆蓋層。將一熱致變色的材料[購自久榮碩豐生活科技有限公司,產品型號:H810Kb70P40,變色溫度(Tcc )為70℃,溫度低於Tcc 時呈現白色,溫度高於Tcc 時呈現藍色]網版印刷在該覆蓋層上,乾燥約2 min,以製得E1的形成有一跳脫指示物的過電流保護裝置。Two metal conductor pins were respectively connected to two nickel-plated copper foils of each small piece prepared by the polymer blending composition of the above formula 1, and then the small piece was covered with a covering layer made of epoxy resin. A thermochromic material [purchased from Jiurong Shuofeng Life Technology Co., Ltd., product model: H810Kb70P40, the discoloration temperature (T cc ) is 70°C, white when the temperature is lower than T cc , and blue when the temperature is higher than T cc color] screen-printed on the covering layer, and dried for about 2 minutes to obtain the E1 overcurrent protection device with a tripping indicator formed.
<實施例2<Example 2 及3 (E2and 3 (E2 及E3)and E3) >>
E2及E3的過電流保護裝置的製程條件與實施例1相似,差異之處在於將該聚合物摻合組成及該熱致變色的材料分別改變如表2所示。The process conditions of the overcurrent protection devices of E2 and E3 are similar to those of Example 1, except that the blending composition of the polymer and the thermochromic material are changed as shown in Table 2.
<實施例4<Example 4 至6 (E4-E6)to 6 (E4-E6) >>
E4-E6的過電流保護裝置的製程條件分別與實施例1至3相似,差異之處在於將該熱致變色的材料分別改變如表2所示。The process conditions of the overcurrent protection devices of E4-E6 are similar to those of Examples 1 to 3, except that the thermochromic materials are changed as shown in Table 2.
<比較例1<Comparative example 1 至3 (CE1-CE3)to 3 (CE1-CE3) >>
CE1-CE3的過電流保護裝置的製程條件分別與實施例1至3相似,差異之處在於CE1-CE3的跳脫指示物是由一非熱致變色的(non-thermochromic,即不隨著溫度改變顏色的)黑色標記油墨所形成(如表2所示)。
【表2】
性能測試Performance Testing
[[ 室溫顏色觀察Room temperature color observation (Color observation at room temperatur)](Color observation at room temperature)]
分別觀察E1-E6及CE1-CE3的過電流保護裝置在25℃中(非跳脫狀態)的跳脫指示物的初始顏色,其結果分別如表3所示。Observe the initial colors of the trip indicators of the overcurrent protection devices of E1-E6 and CE1-CE3 at 25°C (non-trip state), and the results are shown in Table 3 respectively.
[[ 跳脫測試escape test (Trip test)](Trip test)]
對於E1-E6及CE1-CE3的過電流保護裝置以定電壓16 Vdc及定電流10 A通電60 s進行跳脫測試,以一熱電偶測量過電流保護裝置跳脫瞬間的跳脫表面溫度,並觀察當過電流保護裝置處於跳脫狀態時的跳脫指示物的顏色,其結果分別如表3所示。
【表3】
表3結果顯示,E1-E6的過電流保護裝置處於跳脫狀態時(跳脫表面溫度高於其熱致變色的材料的Tcc )的跳脫指示物的顏色不同於其初始顏色,而CE1-CE3的過電流保護裝置處於跳脫狀態時的跳脫指示物並未改變其初始顏色,表示使用者可以立刻以肉眼(即無需任何偵測儀器)辨識出E1-E6的過電流保護裝置是否處於跳脫狀態。The results in Table 3 show that when the overcurrent protection devices of E1-E6 are in the tripped state (the trip surface temperature is higher than the T cc of the thermochromic material), the color of the trip indicator is different from its initial color, while CE1 - When the overcurrent protection device of CE3 is in the trip state, the trip indicator does not change its initial color, which means that the user can immediately identify whether the overcurrent protection device of E1-E6 is with the naked eye (that is, without any detection equipment) in a state of escape.
綜上所述,藉由包含該可反應溫度的跳脫指示物,當本發明過電流保護裝置處於跳脫狀態時,可經由該跳脫指示物的顏色改變立刻被辨識出,且本發明過電流保護裝置的整體生產成本及製程可被大幅減少,故確實能達成本發明之目的。In summary, by including the temperature-reactive tripping indicator, when the overcurrent protection device of the present invention is in the tripped state, it can be recognized immediately through the color change of the tripping indicator, and the present invention has passed The overall production cost and manufacturing process of the current protection device can be greatly reduced, so the purpose of the present invention can indeed be achieved.
惟以上所述者,僅為本發明之實施例而已,當不能以此限定本發明實施之範圍,凡是依本發明申請專利範圍及專利說明書內容所作之簡單的等效變化與修飾,皆仍屬本發明專利涵蓋之範圍內。But what is described above is only an embodiment of the present invention, and should not limit the scope of the present invention. All simple equivalent changes and modifications made according to the patent scope of the present invention and the content of the patent specification are still within the scope of the present invention. Within the scope covered by the patent of the present invention.
2:正溫度係數聚合物元件 21:表面 3:電極 4:無電源跳脫指示物 5:覆蓋層 8:正溫度係數材料 81:表面 9:電極2: Positive temperature coefficient polymer element 21: surface 3: electrode 4: No power trip indicator 5: Overlay 8: Positive temperature coefficient material 81: surface 9: Electrode
本發明之其他的特徵及功效,將於參照圖式的實施方式中清楚地呈現,其中: [圖1]是一現有過電流保護裝置的示意圖; [圖2]是本發明過電流保護裝置的第一具體實施例處於一正常(非跳脫)狀態的示意圖; [圖3]是該第一具體實施例處於一跳脫狀態的示意圖;及 [圖4]是本發明過電流保護裝置的第二具體實施例的示意圖。Other features and effects of the present invention will be clearly presented in the implementation manner with reference to the drawings, wherein: [Figure 1] is a schematic diagram of an existing overcurrent protection device; [Fig. 2] is a schematic diagram of the first embodiment of the overcurrent protection device of the present invention in a normal (non-tripping) state; [Fig. 3] is a schematic diagram of the first embodiment in a tripping state; and [ Fig. 4 ] is a schematic diagram of a second specific embodiment of the overcurrent protection device of the present invention.
2:正溫度係數聚合物元件 2: Positive temperature coefficient polymer element
21:表面 21: surface
3:電極 3: electrode
4:無電源跳脫指示物 4: No power trip indicator
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