WO2020034979A1 - Polymer-based conductive composite material and overcurrent protection element - Google Patents

Polymer-based conductive composite material and overcurrent protection element Download PDF

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WO2020034979A1
WO2020034979A1 PCT/CN2019/100508 CN2019100508W WO2020034979A1 WO 2020034979 A1 WO2020034979 A1 WO 2020034979A1 CN 2019100508 W CN2019100508 W CN 2019100508W WO 2020034979 A1 WO2020034979 A1 WO 2020034979A1
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polymer
composite material
conductive composite
based conductive
carbide
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PCT/CN2019/100508
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French (fr)
Chinese (zh)
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方勇
刘利锋
夏坤
高道华
刘玉堂
张伟
吴国臣
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上海长园维安电子线路保护有限公司
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    • 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
    • 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

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  • the invention relates to a polymer-based conductive composite material and an overcurrent protection element, in particular to a polymer-based conductive composite material with low room temperature resistance, excellent environmental resistance and good processability, and a product prepared therefrom.
  • Overcurrent protection element in particular to a polymer-based conductive composite material with low room temperature resistance, excellent environmental resistance and good processability, and a product prepared therefrom.
  • An overcurrent protection element made of a polymer-based conductive composite material can maintain a low resistance value at room temperature or lower. Because the conductive composite material has a positive temperature coefficient effect, when an overcurrent or overtemperature phenomenon occurs in a circuit, Its resistance will instantly increase to a high resistance value, so that the circuit is in an open state to achieve the purpose of protecting circuit components. Therefore, the polymer-based conductive composite material can be connected to the circuit as the core material of an overcurrent or temperature sensing element. Such materials have been widely used in electronic circuit protection components.
  • the polymer-based conductive composite material is generally composed of a polymer and a conductive filler, and the conductive filler is uniformly distributed in the polymer substrate on a macroscopic basis.
  • the polymers are generally crystalline polyolefins and copolymers thereof, such as polyethylene or ethylene-propylene copolymers.
  • Carbon black, metal powder or conductive ceramic powder conductive fillers are generally used. Carbon black cannot meet the requirements of low resistance of electronic circuits because of its high specific resistance.
  • the conductive composite material prepared with metal powder as the conductive filler has extremely low resistance, but because the metal powder is susceptible to oxidation, the conductive composite material needs to be encapsulated to prevent the resistance of the metal powder from being increased in the air due to oxidation.
  • metal carbide, metal nitride, or metal boride ceramic powder (such as titanium carbide) is gradually used as the conductive filler of low-resistance polymer-based conductive composite materials in the industry. Materials have come a long way. However, due to the high hardness of metal carbides, metal nitrides or metal borides, a series of problems (such as severe wear of mechanical parts and high processing costs) have occurred during the production and processing process.
  • the area of the overcurrent protection element is further reduced (such as 1210, 1206, 0805, 0603 and other sizes), and it becomes more and more obvious.
  • the new ternary Mn + 1AXn phase filler is found late, the molding process is complicated, the industrialization level is low, and its price is relatively expensive. Using it as a conductive filler will greatly increase the manufacturing cost of the enterprise. Therefore, it is necessary to develop a conductive composite material with low resistance, excellent environmental reliability, good processability and relatively low cost.
  • An object of the present invention is to provide a polymer-based conductive composite material.
  • Yet another object of the present invention is to provide an overcurrent protection element prepared from the polymer-based conductive composite material.
  • the overcurrent protection element has low cost, low resistance, excellent environmental reliability, and good processing performance.
  • the present invention discloses a polymer-based conductive composite material, including:
  • a polymer substrate which accounts for 20% to 75% of the volume fraction of the polymer-based conductive composite material
  • the first conductive filler is a solid solution, which accounts for 10% to 80% of the volume fraction of the conductive composite material, has a particle size of 0.1 ⁇ m to 10 ⁇ m, and has a volume resistivity not greater than 200 ⁇ ⁇ cm.
  • the conductive filler is dispersed Among the polymers, the solid solution is a combination of one or two or more of a metal boride, a metal nitride, a metal carbide, or a metal silicide.
  • the second conductive filler is a conductive filler having a layered structure, and has a particle diameter of 0.1 ⁇ m to 20 ⁇ m, a particle size distribution range of 0.01 ⁇ m to 100 ⁇ m, and a volume resistivity of less than 1 ⁇ 10-3 ⁇ ⁇ cm, which accounts for the high 2% to 50% of the volume fraction of the molecular-based conductive composite material is dispersed in the polymer substrate.
  • the molecular formula of the conductive filler having a layered structure in ⁇ ⁇ cm is: Mn + 1AXn, where:
  • M element is one of transition metal elements Sc, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta;
  • Element A is one of Group IIIA, Group IVA, Group VA or Group VIA elements Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl, Pb;
  • Element X is a carbon or nitrogen element; 1 ⁇ n ⁇ 3 and is an integer.
  • the polymer substrate is: polyethylene, chlorinated polyethylene, oxidized polyethylene, polyvinyl chloride, butadiene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, polystyrene, Polycarbonate, polyamide, polyethylene terephthalate, polybutylene terephthalate, polyphenylene ether, polyphenylene sulfide, polyformaldehyde, phenolic resin, polytetrafluoroethylene, tetrafluoroethylene -Hexafluoropropylene copolymer, polytrifluoroethylene, polyvinyl fluoride, maleic anhydride grafted polyethylene, polypropylene, polyvinylidene fluoride, epoxy resin, ethylene-vinyl acetate copolymer, polymethyl methacrylate, One of ethylene-acrylic acid copolymers and mixtures thereof.
  • polyethylene includes: high density polyethylene, low density
  • the volume fraction of the polymer substrate in the conductive composite material is between 20% and 75%, preferably between 25% and 70%, and more preferably between 30% and 65%.
  • the conductive filler having a layered structure of Sc 2 InC, Ti 2 AlC, Ti 2 GaC, Ti 2 InC, Ti 2 TlC, V 2 AlC, V 2 GaC, Cr 2 GaC, Ti 2 AlN, Ti 2 GaN, Ti 2 InN, V 2 GaN, Cr 2 GaN, Ti 2 GeC, Ti 2 SnC, Ti 2 PbC, V 2 GeC, Cr 2 SiC, Cr 2 GeC, V 2 PC, V 2 AsC, Ti 2 SC, Zr 2 InC, Zr 2 TlC, Nb 2 AlC, Nb 2 GaC, Nb 2 InC, Mo 2 GaC, Zr 2 InN, Zr 2 TlN, Zr 2 SnC, Zr 2 PbC, Nb 2 SnC, Nb 2 PC, Nb 2 AsC, Zr 2 SC, Nb 2 SC, Hf 2 SC, Hf 2 InC, Hf 2 TlC, Ta 2 AlC, Ta 2 GaC, Hf 2 SnC, Hf 2 Pb
  • the average particle diameter of the conductive filler having a layered structure is 0.01 ⁇ m to 100 ⁇ m, preferably 0.05 ⁇ m to 50 ⁇ m, and more preferably 0.1 ⁇ m to 20 ⁇ m.
  • the volume resistivity of the conductive filler having a layered structure is less than 1 ⁇ 10 -3 ⁇ ⁇ cm, more preferably less than 5 ⁇ 10 -3 ⁇ ⁇ cm, and most preferably less than 1 ⁇ 10 -2 ⁇ ⁇ cm.
  • the volume fraction of the conductive filler having a layered structure in the polymer-based conductive composite material is between 2% and 50%, preferably between 4% and 45%, and more preferably between 6% and 40%. between.
  • the metal boride is tantalum boride, tantalum diboride, vanadium boride, vanadium diboride, zirconium diboride, titanium diboride, niobium boride, niobium diboride, dimolybdenum boride, pentaboron At least one of dimolybdenum disulfide, hafnium diboride, ditungsten boride, tungsten boride, dichromium boride, chromium boride, chromium diboride, or pentachrome triboride.
  • the metal nitride is at least one of tantalum nitride, vanadium nitride, zirconium nitride, titanium nitride, niobium nitride, or hafnium nitride.
  • the carbide is one of tantalum carbide, vanadium carbide, zirconium carbide, titanium carbide, niobium carbide, dimolybdenum carbide, hafnium carbide, tungsten carbide, ditungsten carbide, or trichromium dicarbonide.
  • the metal silicides are tantalum disilicide, pentatan trisilicide, trivanadium silicide, vanadium disilicide, zirconium disilicide, titanium disilicide, pentasilium trisiliconide, niobium disilicide, molybdenum disilicide, hafnium disilicide, disilicide At least one of tungsten, trichrome silicide or chromium disilicide.
  • the polymer-based conductive composite material may contain other additive components, such as an antioxidant, a radiation crosslinking agent (commonly referred to as a radiation accelerator, a crosslinking agent, or a crosslinking accelerator, such as triallyl isocyanurate Esters), coupling agents, dispersants, stabilizers, non-conductive fillers (such as magnesium hydroxide, calcium carbonate), flame retardants, arc inhibitors, or other components.
  • a radiation crosslinking agent commonly referred to as a radiation accelerator, a crosslinking agent, or a crosslinking accelerator, such as triallyl isocyanurate Esters
  • coupling agents such as dispersants, stabilizers, non-conductive fillers (such as magnesium hydroxide, calcium carbonate), flame retardants, arc inhibitors, or other components.
  • the overcurrent protection element prepared by using the above-mentioned polymer-based conductive composite material is covered with a metal electrode foil on each of the upper and lower sides of the core material of the conductive composite material, and the metal electrode foil is tightly combined with the polymer-based conductive composite material layer.
  • the volume resistivity of the overcurrent protection element is less than 0.02 ⁇ ⁇ cm at 25 ° C, and it has outstanding weather resistance and good processability.
  • the polymer-based conductive composite material of the present invention and the overcurrent protection element prepared from the polymer-based conductive composite material can be prepared as follows:
  • the polymer base material and the conductive filler are put into a mixing device at a mixing ratio, and melt-mixed at a temperature higher than the melting point of the polymer base material.
  • the mixing equipment may be an internal mixer, an open mill, a single-screw extruder, or a twin-screw extruder.
  • the melted and mixed polymer conductive composite material is processed into a sheet material through extrusion molding, compression molding or calendar molding.
  • the thickness of the conductive composite sheet is 0.01-3.0 mm, preferably 0.05-2.0 mm, and more preferably 0.1-1.0 mm for the convenience of processing.
  • the method for forming the core material composite sheet of the overcurrent protection element is to composite metal electrode foils on both sides of the polymer-based conductive composite sheet, and the method of composite metal electrode foils on both sides of the conductive composite sheet includes molding composite or conductive composite material from After the sheet extrusion die is extruded and in a molten state, the electrode foil is directly pressed together by a roller.
  • the composite sheet can be processed into surface-mount overcurrent protection components through a series of PCB processes such as etching, lamination, drilling, immersion copper, tin plating and dicing. It can also be cut into a single chip and connected with Other metal parts are machined into SMT or Strap-type overcurrent protection elements.
  • the method of dividing the core material composite sheet of the overcurrent protection element into a single chiplet includes any method of separating the single element from the composite product, such as die cutting, etching, scribing, and laser cutting.
  • the single chiplet has a planar shape, that is, there are two surfaces perpendicular to the current flowing direction, and the distance between the two surfaces is relatively small, that is, at most 3.0 mm, preferably at most 2.0 mm, and particularly preferably at most 1.0mm, for example 0.5mm.
  • the single chiplet may be of any shape, such as a rectangle, a triangle, a circle, a rectangle, a ring, a polygon, or other irregular shapes.
  • the metal electrode foil is tightly combined with the polymer-based conductive composite material layer.
  • the thickness of the metal electrode foil is generally at most 0.2 mm, preferably at most 0.1 mm, especially at most 0.08 mm, for example, 0.035 mm.
  • Suitable materials for metal electrode foils include nickel, copper, aluminum, zinc, and composites thereof, such as copper foil, nickel foil, single-sided nickel-plated copper foil, double-sided nickel-plated copper foil, and the like.
  • metal parts can be connected to the metal electrode foil by one or a combination of spot welding, laser welding, reflow soldering, electroplating, chemical deposition, spray coating, sputtering, or a conductive adhesive, thereby connecting overcurrent protection.
  • the term "metal part” includes any structural part that can communicate with the metal electrode foil, and it can be of any shape, for example, dot-shaped, linear, ribbon-shaped, lamellar, cylindrical, full-round through-hole, semi-circular through-hole, arc Through holes, blind holes, other irregular shapes, and combinations thereof.
  • the substrate of the "metal part” can be any metal and alloy capable of conducting electricity, such as nickel, copper, aluminum, zinc, tin, bismuth, indium, silver, gold, and alloys thereof.
  • the stability of the performance of the overcurrent protection element can be improved by means of crosslinking and / or heat treatment.
  • Cross-linking can be chemical cross-linking or radiation cross-linking, for example, it can be achieved using a cross-linking accelerator, electron beam irradiation or Co 60 irradiation.
  • the radiation dose required by the overcurrent protection element is generally less than 1000 kGy, preferably 1-500 kGy, and more preferably 1-200 kGy.
  • the heat treatment may be annealing, thermal cycling, and high and low temperature alternation, for example, + 85 ° C / -40 ° C high and low temperature alternation.
  • the temperature environment of the annealing may be any temperature below the decomposition temperature of the polymer substrate, such as a high temperature annealing above the melting temperature of the polymer substrate and a low temperature annealing below the melting temperature of the polymer substrate.
  • the resistance of the overcurrent protection element of the present invention at 25 ° C is less than 0.1 ⁇ ⁇ cm, preferably less than 0.05 ⁇ ⁇ cm, and most preferably less than 0.02 ⁇ ⁇ cm. Therefore, the resistance of the overcurrent protection element of the present invention at 25 ° C Very low, for example 1.0m ⁇ -20m ⁇ .
  • the polymer-based conductive composite material has low resistivity, excellent weather resistance, easy processing, and relatively low cost.
  • the overcurrent protection element prepared from the polymer-based conductive composite material has a low room temperature resistivity, excellent weather resistance, and low processing cost.
  • FIG. 1 is a schematic structural diagram of an overcurrent protection element according to the present invention.
  • FIG. 2 is a schematic structural diagram of an overcurrent protection component with pins prepared in Embodiment 1 of the present invention.
  • the composition of the conductive composite material for preparing the overcurrent protection element is shown in Table 1.
  • the polymer is high-density polyethylene with a melting temperature of 131 ° C, a density of 0.954g / cm 3 , and an added content of 50%;
  • the first conductive filler is solid solution titanium carbide TiC, with an average particle diameter of 2.5um, and the added amount is 44%;
  • the second conductive filler is Ti3AlC2 with a layered structure, the average particle diameter is 2.0 ⁇ m, and the added amount is 6%.
  • the preparation process of the overcurrent protection element is as follows: set the temperature of the mixer to 180 ° C and the rotation speed to 30 rpm, add the polymer for 3 minutes, and then add the conductive filler to continue the mixer for 15 minutes to obtain the polymer.
  • Based conductive composites The melt-mixed polymer-based conductive composite material is rolled through an open mill to obtain a polymer-based conductive composite material 11 having a thickness of 0.20-0.25 mm.
  • FIG. 1 is a schematic structural diagram of an overcurrent protection element according to the present invention.
  • a layer of polymer-based conductive composite material 11 is placed between two metal electrode foils 12 symmetrical to each other.
  • the metal electrode foil 12 and the polymer-based conductive composite material layer 11 are tight. Combined.
  • the polymer-based conductive composite material 11 and the metal electrode foil 12 are tightly bonded together by a thermocompression bonding method.
  • the temperature of thermocompression is 180 ° C. Preheat for 5 minutes, then press for 3 minutes at a pressure of 5 MPa, then press for 10 minutes at a pressure of 12 MPa, and then cold press for 8 minutes on a cold press.
  • Die-cut into a single component of 3 * 4mm, and finally, two metal pins 13 are connected to the surfaces of two metal electrode foils 12 by reflow soldering to form an overcurrent protection component.
  • the steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as those in Example 1, but the volume fraction of the first conductive filler solid solution TiC was changed from 44% to 38%, and the volume fraction of the second conductive filler Ti3AlC2 was changed from 6 % Becomes 12%.
  • the formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1.
  • the steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as in Example 1, but the volume fraction of the first conductive filler solid solution TiC is changed from 44% to 32%, and the volume fraction of the second conductive filler Ti3AlC2 is changed from 6 % Becomes 18%.
  • the formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1.
  • the steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as those in Example 1, but the volume fraction of the first conductive filler solid solution TiC was changed from 44% to 26%, and the volume fraction of the second conductive filler Ti3AlC2 was changed from 6 % Becomes 24%.
  • the formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1.
  • the steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as in Example 1, but the volume fraction of the first conductive filler solid solution TiC is changed from 44% to 20%, and the volume fraction of the second conductive filler Ti3AlC2 is changed from 6 % Becomes 30%.
  • the formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1. Comparative Example
  • the steps of the polymer-based conductive composite material and the overcurrent protection element prepared in the comparative example are the same as in Example 1, but the volume fraction of the first conductive filler solid solution TiC is changed from 44% to 50%, and the volume of the second conductive filler Ti3AlC2 is changed. The score changed from 6% to 0%, that is, the addition of the second conductive filler was eliminated.
  • the formula of the polymer-based conductive composite material of this comparative example and the electrical characteristics of the overcurrent protection element are shown in Table 1.
  • Table 1 shows the comparison between the torque and the host current when the rotor speed is fixed during the processing of the hybrid device by the polymer-based conductive composite of the present invention, and the temperature at 25 ° C after the overcurrent protection element is triggered under the condition of 6V / 50A. Resistance value after 1 hour in the environment.
  • R represents the resistance of the overcurrent protection element chip, that is, the surface of the conductive composite material covered with the metal electrode foil 12;
  • R0 represents the resistance after the two electrode pins 12 are welded on the surface of the two electrode foils 12 of the overcurrent protection element ;
  • R1 represents the resistance value measured after the overcurrent protection element is continuously energized (6V / 50A) for 6 seconds and placed in a 25 ° C temperature environment for 1 hour;
  • R100 represents the overcurrent protection element is continuously energized (6V / 50A) 6 After 60 seconds, power off for 60 seconds, and then cycle 100 times, and then measure the resistance value after standing for 1 hour at 25 ° C.
  • High temperature and high humidity (High temperature and humidity) R1000h indicates the resistance value measured after the overcurrent protection element is placed in an environment of 85 ° C and 85% RH for 1000 hours, and then placed in a temperature environment of 25 ° C for 1 hour.
  • Heat shock (Rock Shock) R100 means that the overcurrent protection element is stored for 1hr in + 85 ° C environment, and converted to -40 ° C environment for 1hr in 5min. This cycle is repeated 100 times, and then placed in 25 ° C temperature environment for 1 hour The measured resistance value.
  • the resistance of the overcurrent protection element in Examples 1-5 is less than 20 milliohms. After 100 times of current shock, high temperature, high humidity, and temperature shock environment experiments, the resistance change of the overcurrent protection element is relatively Small, lower than conventional non-second conductive filler formulation systems.
  • the polymer-based conductive composite material used in the overcurrent protection element of the present invention contains a second conductive filler with a low resistivity and a layered structure, and the self-lubricating property of the second conductive filler.
  • Both the torque and the host current are lower than the conductive composite material of a single conductive filler system, which shows that the new system has excellent processing performance, at the same time has lower room temperature resistivity, excellent weather resistance, and does not need to be encapsulated to protect the polymer
  • over-current protection elements with a thickness of 0.2mm-2.0mm and a current carrying area of 1210, 1206, 0805, 0603, etc. can be prepared.

Abstract

A polymer-based conductive composite material and an overcurrent protection element prepared therefrom. The polymer-based conductive composite material comprises an insulating polymer substrate and two conductive fillers dispersed in the polymer substrate. The polymer substrate accounts for 20% - 75% of the volume fraction of the polymer-based conductive composite material. The two conductive fillers account for 25% - 85% of the volume fraction of polymer-based conductive composite material. The two conductive fillers both have outstanding weather resistance and excellent conductivity. One of conductive fillers has self-lubricating properties and is easy to process and produce. The overcurrent protection element prepared by using said conductive composite material has a "sandwich" structure, a composite material being used as the core material, the upper and lower sides of the core material being covered with metal electrode foils, the conductive composite core material and the metal electrode foil being tightly bonded. Such kind of overcurrent protection element has low electrical resistance, excellent environmental resistance and reliability and good processability.

Description

高分子基导电复合材料及过流保护元件Polymer-based conductive composite material and overcurrent protection element 技术领域Technical field
本发明涉及一种高分子基导电复合材料及过流保护元件,具体指一种具有较低的室温电阻、优异耐环境可靠性和良好可加工性能的高分子基导电复合材料及由其制备的过流保护元件。The invention relates to a polymer-based conductive composite material and an overcurrent protection element, in particular to a polymer-based conductive composite material with low room temperature resistance, excellent environmental resistance and good processability, and a product prepared therefrom. Overcurrent protection element.
背景技术Background technique
高分子基导电复合材料制备的过电流保护元件在室温或更低温度条件下可维持较低的电阻值,因导电复合材料具有正温度系数效应,当电路中发生过电流或过高温现象时,其电阻会瞬间增加到一高阻值,使电路处于断路状态,以达到保护电路元件的目的。因此可把高分子基导电复合材料连接到电路中,作为过电流或温度传感元件的核心材料。此类材料已被广泛应用于电子线路保护元器件上。An overcurrent protection element made of a polymer-based conductive composite material can maintain a low resistance value at room temperature or lower. Because the conductive composite material has a positive temperature coefficient effect, when an overcurrent or overtemperature phenomenon occurs in a circuit, Its resistance will instantly increase to a high resistance value, so that the circuit is in an open state to achieve the purpose of protecting circuit components. Therefore, the polymer-based conductive composite material can be connected to the circuit as the core material of an overcurrent or temperature sensing element. Such materials have been widely used in electronic circuit protection components.
高分子基导电复合材料一般由高分子和导电填料复合而成,导电填料宏观上均匀分布于所述高分子基材中。高分子一般为结晶性的聚烯烃及其共聚物,例如:聚乙烯或乙烯-丙烯共聚物等,一般选用碳黑、金属粉或导电陶瓷粉导电填料。碳黑因自身电阻率较高,无法满足电子线路的低电阻化的要求。以金属粉为导电填料制备的导电复合材料,具有极低的电阻,但因金属粉容易氧化,需对导电复合材料进行包封,以防止金属粉在空气中氧化而造成的电阻升高,一方面,包封的过流保护元件尺寸不能有效降低,难以满足电子元器件小型化的要求,另一方面,对包封材料和包封工艺均提出较高的要求。为实现低电阻,高环境可靠性,行业内逐渐趋向以金属碳化物、金属氮化物或金属硼化物陶瓷粉(如碳化钛)作为低电阻的高分子基导电复合材料的导电填料,且此类材料已经有了长足的发展。但由于金属碳化物、金属氮化物或金属硼化物的高硬度特点,在生产加工过程中产生了一系列问题(如机械部件磨损严重、加工成本高),这种情况在长期的生产过程中及过流保护元件面积进一步缩小(如1210,1206,0805,0603等尺寸)时表现的越来越明显。而新型的三元Mn+1AXn相填料因其发现较晚,成型加工工艺复杂,工业化水平较低,其价格较为昂贵,以其作为导电填料,则会大幅提高企业的制造成本。因此必须开发具有低电阻、优良的环境可靠性、良好加工性能且成本较为低廉的导电复合材料。The polymer-based conductive composite material is generally composed of a polymer and a conductive filler, and the conductive filler is uniformly distributed in the polymer substrate on a macroscopic basis. The polymers are generally crystalline polyolefins and copolymers thereof, such as polyethylene or ethylene-propylene copolymers. Carbon black, metal powder or conductive ceramic powder conductive fillers are generally used. Carbon black cannot meet the requirements of low resistance of electronic circuits because of its high specific resistance. The conductive composite material prepared with metal powder as the conductive filler has extremely low resistance, but because the metal powder is susceptible to oxidation, the conductive composite material needs to be encapsulated to prevent the resistance of the metal powder from being increased in the air due to oxidation. On the one hand, the size of the encapsulated overcurrent protection element cannot be effectively reduced, and it is difficult to meet the requirements for miniaturization of electronic components. On the other hand, higher requirements are placed on the encapsulation material and the encapsulation process. In order to achieve low resistance and high environmental reliability, metal carbide, metal nitride, or metal boride ceramic powder (such as titanium carbide) is gradually used as the conductive filler of low-resistance polymer-based conductive composite materials in the industry. Materials have come a long way. However, due to the high hardness of metal carbides, metal nitrides or metal borides, a series of problems (such as severe wear of mechanical parts and high processing costs) have occurred during the production and processing process. The area of the overcurrent protection element is further reduced (such as 1210, 1206, 0805, 0603 and other sizes), and it becomes more and more obvious. The new ternary Mn + 1AXn phase filler is found late, the molding process is complicated, the industrialization level is low, and its price is relatively expensive. Using it as a conductive filler will greatly increase the manufacturing cost of the enterprise. Therefore, it is necessary to develop a conductive composite material with low resistance, excellent environmental reliability, good processability and relatively low cost.
发明内容Summary of the Invention
本发明的目的在于提供一种高分子基导电复合材料。An object of the present invention is to provide a polymer-based conductive composite material.
本发明的再一目的在于提供一种由上述高分子基导电复合材料制备的过流保护元件,该过电流保护原件具有低成本、低电阻、优良的环境可靠性、良好加工性能。Yet another object of the present invention is to provide an overcurrent protection element prepared from the polymer-based conductive composite material. The overcurrent protection element has low cost, low resistance, excellent environmental reliability, and good processing performance.
为达到上述目的,本发明揭示一种高分子基导电复合材料,其包含:To achieve the above object, the present invention discloses a polymer-based conductive composite material, including:
高分子基材,占所述高分子基导电复合材料的体积分数的20%~75%;A polymer substrate, which accounts for 20% to 75% of the volume fraction of the polymer-based conductive composite material;
第一导电填料,为一种固溶体,占所述导电复合材料的体积分数的10%~80%,其粒径为0.1μm~10μm,且体积电阻率不大于200μΩ·cm,所述导电填料分散于所述的高分子之中;所述的固溶体为金属硼化物、金属氮化物、金属碳化物或金属硅化物中的一种或两种以上的组合物。The first conductive filler is a solid solution, which accounts for 10% to 80% of the volume fraction of the conductive composite material, has a particle size of 0.1 μm to 10 μm, and has a volume resistivity not greater than 200 μΩ · cm. The conductive filler is dispersed Among the polymers, the solid solution is a combination of one or two or more of a metal boride, a metal nitride, a metal carbide, or a metal silicide.
第二导电填料,为具有层状结构的导电填料,其粒径为0.1μm~20μm,且粒径分布范围为0.01 μm~100μm,体积电阻率小于1×10-3Ω·cm,占所述高分子基导电复合材料的体积分数的2%~50%,分散于所述高分子基材中。Ω·cm所述具有层状结构的导电填料分子式为:Mn+1AXn,其中,The second conductive filler is a conductive filler having a layered structure, and has a particle diameter of 0.1 μm to 20 μm, a particle size distribution range of 0.01 μm to 100 μm, and a volume resistivity of less than 1 × 10-3 Ω · cm, which accounts for the high 2% to 50% of the volume fraction of the molecular-based conductive composite material is dispersed in the polymer substrate. The molecular formula of the conductive filler having a layered structure in Ω · cm is: Mn + 1AXn, where:
M元素为过渡金属元素Sc、Ti、V、Cr、Zr、Nb、Mo、Hf、Ta之中的一种;M element is one of transition metal elements Sc, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta;
A元素为IIIA族、IVA族、VA族或VIA族元素Al、Si、P、S、Ga、Ge、As、Cd、In、Sn、Tl、Pb之中的一种;Element A is one of Group IIIA, Group IVA, Group VA or Group VIA elements Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl, Pb;
X元素为碳或氮元素;1≤n≤3且为整数。Element X is a carbon or nitrogen element; 1 ≦ n ≦ 3 and is an integer.
所述的高分子基材为:聚乙烯、氯化聚乙烯、氧化聚乙烯、聚氯乙烯、丁二烯-丙烯腈共聚物、丙烯腈-丁二烯-苯乙烯共聚物、聚苯乙烯、聚碳酸酯、聚酰胺、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚苯醚、聚苯硫醚、聚甲醛、酚醛树脂、聚四氟乙烯、四氟乙烯-六氟丙烯共聚物、聚三氟乙烯、聚氟乙烯、马来酸酐接枝聚乙烯、聚丙烯、聚偏氟乙烯、环氧树脂、乙烯-醋酸乙烯共聚物、聚甲基丙烯酸甲酯、乙烯-丙烯酸共聚物中的一种及其混合物。其中聚乙烯包括:高密度聚乙烯、低密度聚乙烯、超低密度聚乙烯、线性低密度聚乙烯、超高分子量聚乙烯等。The polymer substrate is: polyethylene, chlorinated polyethylene, oxidized polyethylene, polyvinyl chloride, butadiene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene copolymer, polystyrene, Polycarbonate, polyamide, polyethylene terephthalate, polybutylene terephthalate, polyphenylene ether, polyphenylene sulfide, polyformaldehyde, phenolic resin, polytetrafluoroethylene, tetrafluoroethylene -Hexafluoropropylene copolymer, polytrifluoroethylene, polyvinyl fluoride, maleic anhydride grafted polyethylene, polypropylene, polyvinylidene fluoride, epoxy resin, ethylene-vinyl acetate copolymer, polymethyl methacrylate, One of ethylene-acrylic acid copolymers and mixtures thereof. Among them, polyethylene includes: high density polyethylene, low density polyethylene, ultra low density polyethylene, linear low density polyethylene, ultra high molecular weight polyethylene, and the like.
所述高分子基材占所述导电复合材料的体积分数介于20%-75%之间,优选为25%-70%之间,更优为30%-65%之间。The volume fraction of the polymer substrate in the conductive composite material is between 20% and 75%, preferably between 25% and 70%, and more preferably between 30% and 65%.
所述具有层状结构的导电填料为Sc 2InC、Ti 2AlC、Ti 2GaC、Ti 2InC、Ti 2TlC、V 2AlC、V 2GaC、Cr 2GaC、Ti 2AlN、Ti 2GaN、Ti 2InN、V 2GaN、Cr 2GaN、Ti 2GeC、Ti 2SnC、Ti 2PbC、V 2GeC、Cr 2SiC、Cr 2GeC、V 2PC、V 2AsC、Ti 2SC、Zr 2InC、Zr 2TlC、Nb 2AlC、Nb 2GaC、Nb 2InC、Mo 2GaC、Zr 2InN、Zr 2TlN、Zr 2SnC、Zr 2PbC、Nb 2SnC、Nb 2PC、Nb 2AsC、Zr 2SC、Nb 2SC、Hf 2SC、Hf 2InC、Hf 2TlC、Ta 2AlC、Ta 2GaC、Hf 2SnC、Hf 2PbC、Hf 2SnN、Ti 3AlC 2、V 3AlC 2、Ta 3AlC 2、Ti 3SiC 2、Ti 3GeC 2、Ti 3SnC 2、Ti 4AlN 3、V 4AlC 3、Ti 4GaC 3、Nb 4AlN 3、Ta 4AlC 3、Ti 4SiC 3、Ti 4GeC 3之中的一种或两种以上的混合物。 The conductive filler having a layered structure of Sc 2 InC, Ti 2 AlC, Ti 2 GaC, Ti 2 InC, Ti 2 TlC, V 2 AlC, V 2 GaC, Cr 2 GaC, Ti 2 AlN, Ti 2 GaN, Ti 2 InN, V 2 GaN, Cr 2 GaN, Ti 2 GeC, Ti 2 SnC, Ti 2 PbC, V 2 GeC, Cr 2 SiC, Cr 2 GeC, V 2 PC, V 2 AsC, Ti 2 SC, Zr 2 InC, Zr 2 TlC, Nb 2 AlC, Nb 2 GaC, Nb 2 InC, Mo 2 GaC, Zr 2 InN, Zr 2 TlN, Zr 2 SnC, Zr 2 PbC, Nb 2 SnC, Nb 2 PC, Nb 2 AsC, Zr 2 SC, Nb 2 SC, Hf 2 SC, Hf 2 InC, Hf 2 TlC, Ta 2 AlC, Ta 2 GaC, Hf 2 SnC, Hf 2 PbC, Hf 2 SnN, Ti 3 AlC 2 , V 3 AlC 2 , Ta 3 AlC 2 , Ti 3 SiC 2 , Ti 3 GeC 2 , Ti 3 SnC 2 , Ti 4 AlN 3 , V 4 AlC 3 , Ti 4 GaC 3 , Nb 4 AlN 3 , Ta 4 AlC 3 , Ti 4 SiC 3 , One or a mixture of two or more of Ti 4 GeC 3 .
所述具有层状结构的导电填料的平均粒径为0.01μm~100μm,优选为0.05μm~50μm,更优为0.1μm~20μm。The average particle diameter of the conductive filler having a layered structure is 0.01 μm to 100 μm, preferably 0.05 μm to 50 μm, and more preferably 0.1 μm to 20 μm.
所述具有层状结构的导电填料的体积电阻率小于1×10 -3Ω·cm,更优为小于5×10 -3Ω·cm,最优为小于1×10 -2Ω·cm。 The volume resistivity of the conductive filler having a layered structure is less than 1 × 10 -3 Ω · cm, more preferably less than 5 × 10 -3 Ω · cm, and most preferably less than 1 × 10 -2 Ω · cm.
所述具有层状结构的导电填料占所述高分子基导电复合材料的体积分数介于2%-50%之间,优选为4%-45%之间,更优为6%-40%之间。The volume fraction of the conductive filler having a layered structure in the polymer-based conductive composite material is between 2% and 50%, preferably between 4% and 45%, and more preferably between 6% and 40%. between.
所述金属硼化物为硼化钽、二硼化钽、硼化钒、二硼化钒、二硼化锆、二硼化钛、硼化铌、二硼化铌、硼化二钼、五硼化二钼、二硼化铪、硼化二钨、硼化钨、硼化二铬、硼化铬、二硼化铬或三硼化五铬之中的至少一种。The metal boride is tantalum boride, tantalum diboride, vanadium boride, vanadium diboride, zirconium diboride, titanium diboride, niobium boride, niobium diboride, dimolybdenum boride, pentaboron At least one of dimolybdenum disulfide, hafnium diboride, ditungsten boride, tungsten boride, dichromium boride, chromium boride, chromium diboride, or pentachrome triboride.
所述金属氮化物为氮化钽、氮化钒、氮化锆、氮化钛、氮化铌或氮化铪中的至少一种。The metal nitride is at least one of tantalum nitride, vanadium nitride, zirconium nitride, titanium nitride, niobium nitride, or hafnium nitride.
所述碳化物为碳化钽、碳化钒、碳化锆、碳化钛、碳化铌、碳化二钼、碳化铪、碳化钨、碳化二钨或二碳化三铬之中的一种。The carbide is one of tantalum carbide, vanadium carbide, zirconium carbide, titanium carbide, niobium carbide, dimolybdenum carbide, hafnium carbide, tungsten carbide, ditungsten carbide, or trichromium dicarbonide.
所述金属硅化物为二硅化钽、三硅化五钽、硅化三钒、二硅化钒、二硅化锆、二硅化钛、三硅化五钛、二硅化铌、二硅化钼、二硅化铪、二硅化钨、硅化三铬或二硅化铬之中的至少一种。The metal silicides are tantalum disilicide, pentatan trisilicide, trivanadium silicide, vanadium disilicide, zirconium disilicide, titanium disilicide, pentasilium trisiliconide, niobium disilicide, molybdenum disilicide, hafnium disilicide, disilicide At least one of tungsten, trichrome silicide or chromium disilicide.
所述高分子基导电复合材料可含有其他添加剂成分,如抗氧剂、辐射交联剂(常称为辐照促进剂、交联剂或交联促进剂,例如三烯丙基异氰脲酸酯)、偶联剂、分散剂、稳定剂、非导电性填料(如氢氧化镁,碳酸钙)、阻燃剂、弧光抑制剂或其他组分。这些组分通常至多占高分子基导电复合材料总体积的15%,例如10%体积百分比。The polymer-based conductive composite material may contain other additive components, such as an antioxidant, a radiation crosslinking agent (commonly referred to as a radiation accelerator, a crosslinking agent, or a crosslinking accelerator, such as triallyl isocyanurate Esters), coupling agents, dispersants, stabilizers, non-conductive fillers (such as magnesium hydroxide, calcium carbonate), flame retardants, arc inhibitors, or other components. These components usually account for at most 15%, such as 10% by volume, of the total volume of the polymer-based conductive composite material.
利用上述高分子基导电复合材料制备的过流保护元件,其导电复合材料芯材上下两面各覆有一层金属电极箔,金属电极箔与所述高分子基导电复合材料层紧密结合。The overcurrent protection element prepared by using the above-mentioned polymer-based conductive composite material is covered with a metal electrode foil on each of the upper and lower sides of the core material of the conductive composite material, and the metal electrode foil is tightly combined with the polymer-based conductive composite material layer.
在25℃时过流保护元件的体积电阻率小于0.02Ω·cm,且具有突出的耐候性能、良好可加工性能。The volume resistivity of the overcurrent protection element is less than 0.02Ω · cm at 25 ° C, and it has outstanding weather resistance and good processability.
本发明的高分子基导电复合材料以及由该高分子基导电复合材料制备的过流保护元件可按下述方法进行制备:The polymer-based conductive composite material of the present invention and the overcurrent protection element prepared from the polymer-based conductive composite material can be prepared as follows:
将高分子基材和导电填料按配比投入混合设备,在高于高分子基材熔点以上的温度进行熔融混合。混合设备可以是密炼机、开炼机、单螺杆挤出机或双螺杆挤出机。然后将熔融混合好的高分子导电复合材料通过挤出成型、模压成型或压延成型加工成的片材。一般来说,导电复合材料片材的厚度为0.01-3.0mm,优选为0.05-2.0mm,为了加工的方便更优为0.1-1.0mm。The polymer base material and the conductive filler are put into a mixing device at a mixing ratio, and melt-mixed at a temperature higher than the melting point of the polymer base material. The mixing equipment may be an internal mixer, an open mill, a single-screw extruder, or a twin-screw extruder. Then, the melted and mixed polymer conductive composite material is processed into a sheet material through extrusion molding, compression molding or calendar molding. Generally, the thickness of the conductive composite sheet is 0.01-3.0 mm, preferably 0.05-2.0 mm, and more preferably 0.1-1.0 mm for the convenience of processing.
过电流保护元件的芯材复合片的成型方法是在高分子基导电复合材料片材的两面复合金属电极箔,在导电复合材料片材两面复合金属电极箔的方法包括模压复合或导电复合材料从片材挤出模头挤出后且处于熔融状态时通过辊筒直接将电极箔与其压合在一起。复合好的片材可以通过蚀刻、层压、钻孔、沉铜、镀锡和划片等一系列PCB工艺加工成表面贴装式过流保护元件,也可以切割成单个小芯片后,与连接其他金属部件加工成SMT或Strap式过流保护元件。把过电流保护元件的芯材复合片分割成单个小芯片的方法包括从复合制品上分离出单个元件的任何方法,例如冲切、刻蚀、划切和激光切割。所述单个小芯片具有平面形状,即有与电流流过方向垂直的两个表面,且两个表面之间的距离相当小,即至多3.0mm,优选地是至多2.0mm,特别优选的是最多1.0mm,例如0.5mm。所述单个小芯片可以是任何形状,如长方形、三角形、圆形、矩形、环形、多边形或其它非规则形状。金属电极箔与所述高分子基导电复合材料层紧密结合。金属电极箔的厚度一般至多为0.2mm,优选至多为0.1mm,特别是至多0.08mm,例如,0.035mm。适用于金属电极箔的材质包括镍、铜、铝、锌及其复合物,例如铜箔、镍箔、单面镀镍铜箔、双面镀镍铜箔等。The method for forming the core material composite sheet of the overcurrent protection element is to composite metal electrode foils on both sides of the polymer-based conductive composite sheet, and the method of composite metal electrode foils on both sides of the conductive composite sheet includes molding composite or conductive composite material from After the sheet extrusion die is extruded and in a molten state, the electrode foil is directly pressed together by a roller. The composite sheet can be processed into surface-mount overcurrent protection components through a series of PCB processes such as etching, lamination, drilling, immersion copper, tin plating and dicing. It can also be cut into a single chip and connected with Other metal parts are machined into SMT or Strap-type overcurrent protection elements. The method of dividing the core material composite sheet of the overcurrent protection element into a single chiplet includes any method of separating the single element from the composite product, such as die cutting, etching, scribing, and laser cutting. The single chiplet has a planar shape, that is, there are two surfaces perpendicular to the current flowing direction, and the distance between the two surfaces is relatively small, that is, at most 3.0 mm, preferably at most 2.0 mm, and particularly preferably at most 1.0mm, for example 0.5mm. The single chiplet may be of any shape, such as a rectangle, a triangle, a circle, a rectangle, a ring, a polygon, or other irregular shapes. The metal electrode foil is tightly combined with the polymer-based conductive composite material layer. The thickness of the metal electrode foil is generally at most 0.2 mm, preferably at most 0.1 mm, especially at most 0.08 mm, for example, 0.035 mm. Suitable materials for metal electrode foils include nickel, copper, aluminum, zinc, and composites thereof, such as copper foil, nickel foil, single-sided nickel-plated copper foil, double-sided nickel-plated copper foil, and the like.
其他金属部件,可以通过点焊、激光焊、回流焊、电镀、化学沉积、喷涂、溅射或导电粘合剂中的一种及其组合方式连接在金属电极箔上,从而将过流保护连接进电路中。术语“金属部件”包括任何能与金属电极箔导通的结构部件,它可以是任何形状,例如,点状,线状、带状、层片状、柱状、全圆通孔、半圆通孔、弧形通孔、盲孔、其他不规则形状及它们的组合体。所述“金属部件”的基材可为任何能导电的金属及其合金,如镍、铜、铝、锌、锡、铋、铟、银、金及其合金。Other metal parts can be connected to the metal electrode foil by one or a combination of spot welding, laser welding, reflow soldering, electroplating, chemical deposition, spray coating, sputtering, or a conductive adhesive, thereby connecting overcurrent protection. Into the circuit. The term "metal part" includes any structural part that can communicate with the metal electrode foil, and it can be of any shape, for example, dot-shaped, linear, ribbon-shaped, lamellar, cylindrical, full-round through-hole, semi-circular through-hole, arc Through holes, blind holes, other irregular shapes, and combinations thereof. The substrate of the "metal part" can be any metal and alloy capable of conducting electricity, such as nickel, copper, aluminum, zinc, tin, bismuth, indium, silver, gold, and alloys thereof.
通常可借助交联和/或热处理的方法来提高过流保护元件性能的稳定性。交联可以是化学交联或辐照交联,例如可利用交联促进剂、电子束辐照或Co 60辐照来实现。过流保护元件所需的辐照剂量一般小于1000kGy,优选为1-500kGy,更优为1-200kGy。热处理可以是退火、热循 环、高低温交变,例如+85℃/-40℃高低温交变。所述退火的温度环境可以是高分子基材分解温度以下的任何温度,例如高于高分子基材熔融温度的高温退火和低于高分子基材熔融温度的低温退火。 Generally, the stability of the performance of the overcurrent protection element can be improved by means of crosslinking and / or heat treatment. Cross-linking can be chemical cross-linking or radiation cross-linking, for example, it can be achieved using a cross-linking accelerator, electron beam irradiation or Co 60 irradiation. The radiation dose required by the overcurrent protection element is generally less than 1000 kGy, preferably 1-500 kGy, and more preferably 1-200 kGy. The heat treatment may be annealing, thermal cycling, and high and low temperature alternation, for example, + 85 ° C / -40 ° C high and low temperature alternation. The temperature environment of the annealing may be any temperature below the decomposition temperature of the polymer substrate, such as a high temperature annealing above the melting temperature of the polymer substrate and a low temperature annealing below the melting temperature of the polymer substrate.
本发明的过流保护元件,其在25℃的电阻率小于0.1Ω·cm,优选小于0.05Ω·cm,最优为小于0.02Ω·cm,因此本发明的过流保护元件在25℃的电阻很低,例如1.0mΩ-20mΩ。The resistance of the overcurrent protection element of the present invention at 25 ° C is less than 0.1Ω · cm, preferably less than 0.05Ω · cm, and most preferably less than 0.02Ω · cm. Therefore, the resistance of the overcurrent protection element of the present invention at 25 ° C Very low, for example 1.0mΩ-20mΩ.
本发明的优越性在于:高分子基导电复合材料电阻率低,耐候性优良,容易加工,且成本较为低廉。由该高分子基导电复合材料制备的过流保护元件在具有低室温电阻率的同时,耐候性能优良,加工成本低。The advantages of the invention are that the polymer-based conductive composite material has low resistivity, excellent weather resistance, easy processing, and relatively low cost. The overcurrent protection element prepared from the polymer-based conductive composite material has a low room temperature resistivity, excellent weather resistance, and low processing cost.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1是本发明的过流保护元件的结构示意图;1 is a schematic structural diagram of an overcurrent protection element according to the present invention;
图2是本发明实施例1制备的带有引脚的过流保护元件的结构示意图。FIG. 2 is a schematic structural diagram of an overcurrent protection component with pins prepared in Embodiment 1 of the present invention.
具体实施方式detailed description
以下通过具体的实施例对本发明作进一步的详细说明。The present invention will be further described in detail through specific examples.
实施例1Example 1
制备过流保护元件的导电复合材料的组成如表1所示。其中高分子为高密度聚乙烯,其熔融温度为131℃,密度为0.954g/cm 3,添加含量为50%;第一导电填料为固溶体碳化钛TiC,平均粒径为2.5um,添加量为44%;第二导电填料为具有层状结构的Ti3AlC2,平均粒径为2.0μm,添加量为6%。过流保护元件的制备过程如下:将密炼机温度设定在180℃,转速为30转/分钟,先加入高分子密炼3分钟后,然后加入导电填料继续密炼15分钟,得到高分子基导电复合材料。将熔融混合好的高分子基导电复合材料通过开炼机压延,得到厚度为0.20-0.25mm的高分子基导电复合材料11。 The composition of the conductive composite material for preparing the overcurrent protection element is shown in Table 1. The polymer is high-density polyethylene with a melting temperature of 131 ° C, a density of 0.954g / cm 3 , and an added content of 50%; the first conductive filler is solid solution titanium carbide TiC, with an average particle diameter of 2.5um, and the added amount is 44%; the second conductive filler is Ti3AlC2 with a layered structure, the average particle diameter is 2.0 μm, and the added amount is 6%. The preparation process of the overcurrent protection element is as follows: set the temperature of the mixer to 180 ° C and the rotation speed to 30 rpm, add the polymer for 3 minutes, and then add the conductive filler to continue the mixer for 15 minutes to obtain the polymer. Based conductive composites. The melt-mixed polymer-based conductive composite material is rolled through an open mill to obtain a polymer-based conductive composite material 11 having a thickness of 0.20-0.25 mm.
如图1是本发明的过流保护元件的结构示意图,高分子基导电复合材料11层置于上下对称的两金属电极箔12之间,金属电极箔12与高分子基导电复合材料层11紧密结合。通过热压合的方法将高分子基导电复合材料11和金属电极箔12紧密结合在一起。热压合的温度为180℃,先预热5分钟,然后以5MPa的压力热压3分钟,再以12MPa的压力热压10分钟,然后在冷压机上冷压8分钟,以模具将其冲切成3*4mm的单个元件,最后通过回流焊的方法将两个金属引脚13(图2所示)连接在两个金属电极箔12表面,形成一过流保护元件。FIG. 1 is a schematic structural diagram of an overcurrent protection element according to the present invention. A layer of polymer-based conductive composite material 11 is placed between two metal electrode foils 12 symmetrical to each other. The metal electrode foil 12 and the polymer-based conductive composite material layer 11 are tight. Combined. The polymer-based conductive composite material 11 and the metal electrode foil 12 are tightly bonded together by a thermocompression bonding method. The temperature of thermocompression is 180 ° C. Preheat for 5 minutes, then press for 3 minutes at a pressure of 5 MPa, then press for 10 minutes at a pressure of 12 MPa, and then cold press for 8 minutes on a cold press. Die-cut into a single component of 3 * 4mm, and finally, two metal pins 13 (shown in FIG. 2) are connected to the surfaces of two metal electrode foils 12 by reflow soldering to form an overcurrent protection component.
实施例2Example 2
制备高分子基导电复合材料及过流保护元件的步骤与实施例1相同,但将第一导电填料固溶体TiC的体积分数由44%变为38%,将第二导电填料Ti3AlC2的体积分数由6%变为12%。本实施例的高分子基导电复合材料的配方和过流保护元件的电气特性如表1所示。The steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as those in Example 1, but the volume fraction of the first conductive filler solid solution TiC was changed from 44% to 38%, and the volume fraction of the second conductive filler Ti3AlC2 was changed from 6 % Becomes 12%. The formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1.
实施例3Example 3
制备高分子基导电复合材料及过流保护元件的步骤与实施例1相同,但将第一导电填料固溶体TiC的体积分数由44%变为32%,将第二导电填料Ti3AlC2的体积分数由6%变为18%。本实施例的高分子基导电复合材料的配方和过流保护元件的电气特性如表1所示。The steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as in Example 1, but the volume fraction of the first conductive filler solid solution TiC is changed from 44% to 32%, and the volume fraction of the second conductive filler Ti3AlC2 is changed from 6 % Becomes 18%. The formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1.
实施例4Example 4
制备高分子基导电复合材料及过流保护元件的步骤与实施例1相同,但将第一导电填料固溶体TiC的体积分数由44%变为26%,将第二导电填料Ti3AlC2的体积分数由6%变为24%。本实施例的高分子基导电复合材料的配方和过流保护元件的电气特性如表1所示。The steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as those in Example 1, but the volume fraction of the first conductive filler solid solution TiC was changed from 44% to 26%, and the volume fraction of the second conductive filler Ti3AlC2 was changed from 6 % Becomes 24%. The formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1.
实施例5Example 5
制备高分子基导电复合材料及过流保护元件的步骤与实施例1相同,但将第一导电填料固溶体TiC的体积分数由44%变为20%,将第二导电填料Ti3AlC2的体积分数由6%变为30%。本实施例的高分子基导电复合材料的配方和过流保护元件的电气特性如表1所示。[0047]对比例The steps for preparing the polymer-based conductive composite material and the overcurrent protection element are the same as in Example 1, but the volume fraction of the first conductive filler solid solution TiC is changed from 44% to 20%, and the volume fraction of the second conductive filler Ti3AlC2 is changed from 6 % Becomes 30%. The formula of the polymer-based conductive composite material of this embodiment and the electrical characteristics of the overcurrent protection element are shown in Table 1. Comparative Example
对比例制备的高分子基导电复合材料及过流保护元件的步骤与实施例1相同,但将第一导电填料固溶体TiC的体积分数由44%变为50%,将第二导电填料Ti3AlC2的体积分数由6%变为0%,也即取消第二导电填料的添加。本对比例的高分子基导电复合材料的配方和过流保护元件的电气特性如表1所示。The steps of the polymer-based conductive composite material and the overcurrent protection element prepared in the comparative example are the same as in Example 1, but the volume fraction of the first conductive filler solid solution TiC is changed from 44% to 50%, and the volume of the second conductive filler Ti3AlC2 is changed. The score changed from 6% to 0%, that is, the addition of the second conductive filler was eliminated. The formula of the polymer-based conductive composite material of this comparative example and the electrical characteristics of the overcurrent protection element are shown in Table 1.
表1为由本发明的高分子基导电复合材料在混合设备加工过程中固定转子转速时扭矩和主机电流显示对比,以及制备过流保护元件在6V/50A的条件下触发后,在25℃的温度环境里放置1小时后的电阻值。表1中的R表示过流保护元件芯片也即导电复合材料表面覆金属电极箔12的电阻;R0表示过流保护元件的两个电极箔12表面上焊上两个金属引脚13之后的电阻;R1表示过流保护元件持续通电(6V/50A)6秒后,在25℃的温度环境里放置1小时后所测得的电阻值;R100表示过流保护元件持续通电(6V/50A)6秒后,断电60秒,如此循环100次,然后在25℃的温度环境里放置1小时后所测得的电阻值。高温高湿(High temperature and humidity)R1000h表示过流保护元件在85℃,85%RH的环境中放置1000个小时,然后在25℃的温度环境里放置1小时后所测得的电阻值。温度冲击(Heat Shock)R100表示过流保护元件在+85℃环境中存放1hr,于5min内转换至-40℃环境下存放1hr,如此循环100次,然后在25℃的温度环境里放置1小时后所测得的电阻值。Table 1 shows the comparison between the torque and the host current when the rotor speed is fixed during the processing of the hybrid device by the polymer-based conductive composite of the present invention, and the temperature at 25 ° C after the overcurrent protection element is triggered under the condition of 6V / 50A. Resistance value after 1 hour in the environment. In Table 1, R represents the resistance of the overcurrent protection element chip, that is, the surface of the conductive composite material covered with the metal electrode foil 12; R0 represents the resistance after the two electrode pins 12 are welded on the surface of the two electrode foils 12 of the overcurrent protection element ; R1 represents the resistance value measured after the overcurrent protection element is continuously energized (6V / 50A) for 6 seconds and placed in a 25 ° C temperature environment for 1 hour; R100 represents the overcurrent protection element is continuously energized (6V / 50A) 6 After 60 seconds, power off for 60 seconds, and then cycle 100 times, and then measure the resistance value after standing for 1 hour at 25 ° C. High temperature and high humidity (High temperature and humidity) R1000h indicates the resistance value measured after the overcurrent protection element is placed in an environment of 85 ° C and 85% RH for 1000 hours, and then placed in a temperature environment of 25 ° C for 1 hour. Heat shock (Rock Shock) R100 means that the overcurrent protection element is stored for 1hr in + 85 ° C environment, and converted to -40 ° C environment for 1hr in 5min. This cycle is repeated 100 times, and then placed in 25 ° C temperature environment for 1 hour The measured resistance value.
表1Table 1
Figure PCTCN2019100508-appb-000001
Figure PCTCN2019100508-appb-000001
从表1可以看出:实施例1-5中的过电流保护元件的电阻低于20毫欧,经过电流冲击100次、高温高湿和温度冲击环境实验后,过电流保护元件的电阻变化较小,低于常规无第二导电填料配方体系。本发明的过流保护元件采用的高分子基导电复合材料因包含电阻率较低且具有层状结构的第二导电填料,因第二导电填料的自润滑性,其加工过程中密炼机的扭矩和主机电流均低于单一导电填料体系的导电复合材料,说明新的体系具有优良的加工性能,同时具有较低的室温电阻率、优良的耐候性能,无需通过包封的方式来保护高分子基导电复合材料,因此可以制备厚度为0.2mm-2.0mm,承载电流面积为1210、1206、0805、0603等小尺寸的过流保护元件。It can be seen from Table 1 that the resistance of the overcurrent protection element in Examples 1-5 is less than 20 milliohms. After 100 times of current shock, high temperature, high humidity, and temperature shock environment experiments, the resistance change of the overcurrent protection element is relatively Small, lower than conventional non-second conductive filler formulation systems. The polymer-based conductive composite material used in the overcurrent protection element of the present invention contains a second conductive filler with a low resistivity and a layered structure, and the self-lubricating property of the second conductive filler. Both the torque and the host current are lower than the conductive composite material of a single conductive filler system, which shows that the new system has excellent processing performance, at the same time has lower room temperature resistivity, excellent weather resistance, and does not need to be encapsulated to protect the polymer Based on the conductive composite material, over-current protection elements with a thickness of 0.2mm-2.0mm and a current carrying area of 1210, 1206, 0805, 0603, etc. can be prepared.
本发明的内容和特点已揭示如上,然而前面叙述的本发明仅仅简要地或只涉及本发明的特定部分,本发明的特征可能比在此公开的内容涉及的更多。因此,本发明的保护范围应不限于实施例所揭示的内容,而应该包括在不同部分中所体现的所有内容的组合,以及各种不背离本发明的替换和修饰,并为本发明的权利要求书所涵盖。The content and features of the present invention have been disclosed as above, however, the present invention described above only briefly or only relates to a specific part of the present invention, and the features of the present invention may be more than what is disclosed herein. Therefore, the protection scope of the present invention should not be limited to the content disclosed in the embodiments, but should include the combination of all the content embodied in different parts, as well as various substitutions and modifications that do not depart from the present invention, and are the rights of the present invention. Covered by the request.

Claims (8)

  1. 一种高分子基导电复合材料,其特征在于,其包含:A polymer-based conductive composite material characterized in that it comprises:
    高分子基材,占所述高分子基导电复合材料的体积分数的20%~75%;A polymer substrate, which accounts for 20% to 75% of the volume fraction of the polymer-based conductive composite material;
    第一导电填料,为一种固溶体,占所述导电复合材料的体积分数的10%~80%,其粒径为0.1μm~10μm,且体积电阻率不大于200μΩ·cm,所述导电填料分散于所述的高分子基材之中;所述的固溶体为金属硼化物、金属氮化物、金属碳化物或金属硅化物中的一种或两种以上的组合物;The first conductive filler is a solid solution, which accounts for 10% to 80% of the volume fraction of the conductive composite material, has a particle size of 0.1 μm to 10 μm, and has a volume resistivity not greater than 200 μΩ · cm. The conductive filler is dispersed In the polymer substrate; the solid solution is a combination of one or two or more of metal boride, metal nitride, metal carbide or metal silicide;
    第二导电填料,为具有层状结构的导电填料,其粒径为0.1μm~20μm,且粒径分布范围为0.01μm~100μm,体积电阻率小于1×10-3Ω·cm,占所述高分子基导电复合材料的体积分数的2%~50%,分散于所述高分子基材中;所述具有层状结构的导电填料分子式为:M n+1AX n,其中, The second conductive filler is a conductive filler having a layered structure, and has a particle diameter of 0.1 μm to 20 μm, a particle size distribution range of 0.01 μm to 100 μm, and a volume resistivity of less than 1 × 10-3 Ω · cm, which accounts for the high 2% to 50% of the volume fraction of the molecular-based conductive composite material is dispersed in the polymer substrate; the molecular formula of the conductive filler having a layered structure is: M n + 1 AX n , where:
    M元素为过渡金属元素Sc、Ti、V、Cr、Zr、Nb、Mo、Hf、Ta之中的一种;M element is one of transition metal elements Sc, Ti, V, Cr, Zr, Nb, Mo, Hf, Ta;
    A元素为IIIA族、IVA族、VA族或VIA族元素Al、Si、P、S、Ga、Ge、As、Cd、In、Sn、Tl、Pb之中的一种;Element A is one of Group IIIA, Group IVA, Group VA or Group VIA elements Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl, Pb;
    X元素为碳或氮元素;1≤n≤3且为整数。Element X is a carbon or nitrogen element; 1 ≦ n ≦ 3 and is an integer.
  2. 根据权利要求1所述的高分子基导电复合材料,其特征在于,所述高分子基材为:聚乙烯、氯化聚乙烯、氧化聚乙烯、聚氯乙烯、丁二烯-丙烯腈共聚物、丙烯腈-丁二烯-苯乙烯共聚物、聚苯乙烯、聚碳酸酯、聚酰胺、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚苯醚、聚苯硫醚、聚甲醛、酚醛树脂、聚四氟乙烯、四氟乙烯-六氟丙烯共聚物、聚三氟乙烯、聚氟乙烯、马来酸酐接枝聚乙烯、聚丙烯、聚偏氟乙烯、环氧树脂、乙烯-醋酸乙烯共聚物、聚甲基丙烯酸甲酯、乙烯-丙烯酸共聚物中的一种或两种以上的混合物。The polymer-based conductive composite material according to claim 1, wherein the polymer base material is: polyethylene, chlorinated polyethylene, oxidized polyethylene, polyvinyl chloride, butadiene-acrylonitrile copolymer , Acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyamide, polyethylene terephthalate, polybutylene terephthalate, polyphenylene ether, polybenzene Sulfide, polyformaldehyde, phenolic resin, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, polytrifluoroethylene, polyfluoroethylene, maleic anhydride grafted polyethylene, polypropylene, polyvinylidene fluoride, ring One or a mixture of two or more of oxyresin, ethylene-vinyl acetate copolymer, polymethyl methacrylate, and ethylene-acrylic acid copolymer.
  3. 根据权利要求1所述的高分子基导电复合材料,其特征在于,所述金属硼化物为硼化钽、二硼化钽、硼化钒、二硼化钒、二硼化锆、二硼化钛、硼化铌、二硼化铌、硼化二钼、五硼化二钼、二硼化铪、硼化二钨、硼化钨、硼化二铬、硼化铬、二硼化铬或三硼化五铬之中的至少一种。The polymer-based conductive composite material according to claim 1, wherein the metal boride is tantalum boride, tantalum diboride, vanadium boride, vanadium diboride, zirconium diboride, or diboride Titanium, niobium boride, niobium diboride, dimolybdenum boride, dimolybdenum pentaboride, hafnium diboride, tungsten diboride, tungsten boride, dichromium boride, chromium boride, chromium diboride or At least one of pentachrome triboride.
  4. 根据权利要求1所述的高分子基导电复合材料,其特征在于,所述金属氮化物为氮化钽、氮化钒、氮化锆、氮化钛、氮化铌或氮化铪中的至少一种。The polymer-based conductive composite material according to claim 1, wherein the metal nitride is at least one of tantalum nitride, vanadium nitride, zirconium nitride, titanium nitride, niobium nitride, or hafnium nitride. One.
  5. 根据权利要求1所述的高分子基导电复合材料,所述碳化物为碳化钽、碳化钒、碳化锆、碳化钛、碳化铌、碳化二钼、碳化铪、碳化钨、碳化二钨或二碳化三铬之中的一种。The polymer-based conductive composite material according to claim 1, wherein the carbide is tantalum carbide, vanadium carbide, zirconium carbide, titanium carbide, niobium carbide, molybdenum carbide, hafnium carbide, tungsten carbide, tungsten carbide, or dicarbide One of three chromium.
  6. 根据权利要求1所述的高分子基导电复合材料,其特征在于,所述金属硅化物为二硅化钽、三硅化五钽、硅化三钒、二硅化钒、二硅化锆、二硅化钛、三硅化五钛、二硅化铌、二硅化钼、二硅化铪、二硅化钨、硅化三铬或二硅化铬之中的至少一种。The polymer-based conductive composite material according to claim 1, wherein the metal silicide is tantalum disilicide, pentatanium trisilicide, trivanadium silicide, vanadium disilicide, zirconium disilicide, titanium disilicide, At least one of pentatitanium silicide, niobium disilicide, molybdenum disilicide, hafnium disilicide, tungsten disilicide, trichrome silicide, or chromium disilicide.
  7. 根据权利要求1所述的高分子基导电复合材料,其特征在于,所述具有层状结构的导电填料为Sc 2InC、Ti 2AlC、Ti 2GaC、Ti 2InC、Ti 2TlC、V 2AlC、V 2GaC、Cr 2GaC、Ti 2AlN、Ti 2GaN、Ti 2InN、V 2GaN、Cr 2GaN、Ti 2GeC、Ti 2SnC、Ti 2PbC、V 2GeC、Cr 2SiC、Cr 2GeC、V 2PC、V 2AsC、Ti 2SC、Zr 2InC、Zr 2TlC、Nb 2AlC、Nb 2GaC、Nb 2InC、Mo 2GaC、Zr 2InN、Zr 2TlN、Zr 2SnC、Zr 2PbC、Nb 2SnC、Nb 2PC、Nb 2AsC、Zr 2SC、Nb 2SC、Hf 2SC、Hf 2InC、Hf 2TlC、Ta 2AlC、Ta 2GaC、 Hf 2SnC、Hf 2PbC、Hf 2SnN、Ti 3AlC 2、V 3AlC 2、Ta 3AlC 2、Ti 3SiC 2、Ti 3GeC 2、Ti 3SnC 2、Ti 4AlN 3、V 4AlC 3、Ti 4GaC 3、Nb 4AlN 3、Ta 4AlC 3、Ti 4SiC 3、Ti 4GeC 3之中的一种或两种以上的混合物。 The polymer-based conductive composite material according to claim 1, wherein said electrically conductive filler having a layered structure of Sc 2 InC, Ti 2 AlC, Ti 2 GaC, Ti 2 InC, Ti 2 TlC, V 2 AlC, V 2 GaC, Cr 2 GaC, Ti 2 AlN, Ti 2 GaN, Ti 2 InN, V 2 GaN, Cr 2 GaN, Ti 2 GeC, Ti 2 SnC, Ti 2 PbC, V 2 GeC, Cr 2 SiC, cr 2 GeC, V 2 PC, V 2 AsC, Ti 2 SC, Zr 2 InC, Zr 2 TlC, Nb 2 AlC, Nb 2 GaC, Nb 2 InC, Mo 2 GaC, Zr 2 InN, Zr 2 TlN, Zr 2 SnC, Zr 2 PbC, Nb 2 SnC, Nb 2 PC, Nb 2 AsC, Zr 2 SC, Nb 2 SC, Hf 2 SC, Hf 2 InC, Hf 2 TlC, Ta 2 AlC, Ta 2 GaC, Hf 2 SnC, Hf 2 PbC, Hf 2 SnN, Ti 3 AlC 2 , V 3 AlC 2 , Ta 3 AlC 2 , Ti 3 SiC 2 , Ti 3 GeC 2 , Ti 3 SnC 2 , Ti 4 AlN 3 , V 4 AlC 3 , Ti 4 One or a mixture of two or more of GaC 3 , Nb 4 AlN 3 , Ta 4 AlC 3 , Ti 4 SiC 3 , and Ti 4 GeC 3 .
  8. 一种过流保护元件,其特征在于,由两个金属电极箔间夹固权利要求1-7任意一项所述高分子基导电复合材料层构成,所述金属电极箔与所述高分子基导电复合材料层之间紧密复合。An overcurrent protection element, comprising a polymer-based conductive composite material layer according to any one of claims 1 to 7 sandwiched between two metal electrode foils, the metal electrode foil and the polymer-based foil The conductive composite material layers are tightly compounded.
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