Method of manufacturing a fuse

Abstract

A method of manufacturing a fuse (1), the method comprising the steps of: - stacking a substrate (2), at least partially conductive fabric (4) above the substrate (2) and a cover layer (5) above the fabric (4), with an adhesive layer (3) in between in each case; wherein at least one cavity (200, 500; 700) is provided between the respective edge regions on both sides of the fabric (4) so as to abut the fabric (4), wherein the fabric (4) comprises at least one first fiber (400) which is electrically conductive and comprises a second fiber (401) which is not electrically conductive and has a lower melting temperature than the first fiber (400), - heating the stacked elements to a temperature which is below the melting temperature of the first fiber (400) and above the melting temperature of the second fiber (401).

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a fuse and a fuse manufactured by such a method, in particular a surface mountable fuse. BACKGROUND

[0002] Surface mount device fuses (SMD) are known in the prior art as passive electronic components, also referred to as chip fuses. Typically, such fuses are manufactured using printed circuit board technology. SMD fuses are usually applied to FR4 printed circuit boards automatically by pick-and-place machines and then soldered using a reflow soldering process or wave soldering. FR4 PCB material or ceramic are mainly used as base material for SMD fuses. Alternatively, SMD fuses can be designed as fuses in a ceramic housing.

[0003] FR4 PCB material consists of glass fiber reinforced epoxy resin when manufactured by PCB related electroplating. Copper foils of various thicknesses (6 pm, 9 pm, 12 pm, 18 pm, 35 pm and thicker) are pressed under pressure and temperature onto FR4, typically forming the base of the fusible conductor. The fusible conductor itself is structured using photolithography and wet etching processes. A disadvantage of PCB electroplating is the need for aggressive etching chemicals during production. In addition, this is a time-consuming and expensive process in terms of time and equipment. Furthermore, the cross-sectional geometry of the fusible conductor cannot be precisely reproduced due to the isotropic nature of the etching process and the insufficient etching of the photoresist. This has a significant impact especially on thick copper foils and leads to trapezoidal instead of the desired rectangular cross-section.

[0004] Another manufacturing method is to laminate fusible wires between circuit boards. A disadvantage of this is that each wire has to be individually fixed to the circuit board. The regularity of the distance between the metal wires parallel to each other and their straightness can only be guaranteed with great effort.

[0005] Another manufacturing process is wire bonding, which originates from semiconductor manufacturing and has been transferred to PCB technology. Wire bonding is derived from chip connection contacts and allows machine connection of the bonding pads by means of a wire. The wire is unwound from a reel and kept in contact with the respective contact pad. Subsequently, the wire and the contact pad are at least partially bonded together by a bonding process such as thermal ultrasonic or ultrasonic methods. For such fuses, the precise positioning of the wire is crucial. However, the precise positioning of the wire is complex and requires additional mechanical work. SUMMARY

[0006] It is an object of the present invention to provide a method for manufacturing a fuse, wherein the above-mentioned disadvantages are avoided.

[0007] This task is solved by a method having the features of claim 1. Further embodiments of the method as well as the fuse manufactured by this method are defined by the features of the further claims.

[0008] According to a method of manufacturing a fuse according to the present application, the fuse extends along a longitudinal axis from a first end to a second end, the method comprising the following steps:

[0009] - providing a substrate;

[0010] - stacking an at least partially electrically conductive fabric above the substrate;

[0011] - stacking a cover layer above the fabric;

[0012] - providing an adhesive layer between the substrate and the fabric and between the fabric and the cover layer at least in the respective edge regions;

[0013] wherein, on both sides of the fabric, at least one cavity is provided between the respective edge regions, which adjoins the fabric,

[0014] wherein the fabric comprises at least one first fiber, which is electrically conductive and extends along the longitudinal axis from the first end of the fuse to the second end of the fuse, and a second fiber, which is not electrically conductive and extends at least transversely to the longitudinal axis, wherein the melting temperature of the at least one first fiber is higher than the melting temperature of the second fiber,

[0015] - heating the stacked elements to a temperature below the melting temperature of the at least one first fiber and above the melting temperature of the second fiber;

[0016] - maintaining this temperature for a period of time;

[0017] thereby the second fiber melts at least in the region of the at least one first fiber, thereby at least partially releasing the at least one first fiber in the region of the cavity;

[0018] - cooling the stacked elements to room temperature.

[0019] With this method, a wire-in-air fuse can be manufactured. Due to the at least partially electrically conductive fabric, the position of the individual fibers of the fabric and the position of the fabric fibers relative to each other can be determined very precisely, whereby a time-consuming positioning of the at least one fusible electric line can be avoided. Likewise, the number and distribution of the fabric fibers can also be easily adjusted. Thus, the current-time characteristic, the temperature characteristic, the pulse strength, the breaking capacity, the insulation strength and the i 2t value. Such a fuse also requires low material and manufacturing costs. The cost of partially conductive fabric is low and the fuse can be manufactured using simple processes, for example batch processes such as processes used for manufacturing printed circuit boards. PCB manufacturing can also employ other low cost process steps such as lamination or hot pressing with prepreg. For example, the first fibres are made of copper and the second fibres are made of polyester. The melting temperature of copper is approximately 1000 °C and the melting temperature of polymers is typically approximately 100 °C to 400 °C.

[0020] In the case of a laminated fuse, the outer shell of the fuse is made by the following methods before the second fibres melt:

[0021] - pressing the stacked elements in a direction substantially perpendicular to the substrate;

[0022] - heating the stacked elements to a temperature below the melting temperature of at least one of the first fibres and the second fibres;

[0023] - maintaining this temperature for a period of time;

[0024] For example, it is heated to a temperature of 190 °C and maintained for one hour. This ensures that at least the edge regions of the stacked elements are firmly bonded together. The stacked elements are then heated to a temperature below the melting temperature of the first fibres and above the melting temperature of the second fibres. This temperature is then maintained for a period of time. In a process using first copper fibres and second polyester fibres, the stacked elements of the fusible wire are heated from room temperature to a temperature of 250 °C in 3 minutes. This temperature is maintained for 90 seconds. Subsequently, the fuse is cooled to room temperature. The fuse can also be heated to a temperature above 250 °C, for example 300 °C, 350 °C, 400 °C or 450 °C.

[0025] The holding time can exceed 90 seconds, for example 120 seconds or 180 seconds or up to 900 seconds. For second fibers made of high-molecular materials with a lower melting temperature, a shorter heating time and a shorter holding time can be selected. The heating temperature should in any case be selected to be below the decomposition temperature of the material of the second fibers. The heating temperature should also be below the melting temperature or decomposition temperature of the base plate, the adhesive layer and the top layer. Due to the entropic elasticity of the second fibers, the second fibers are drawn into the edge region after melting in the region of at least one of the first fibers. The longer the heating temperature is maintained, the more completely the second fibers melt in the region of at least one of the first fibers in the region of the cavity. The heating or melting of the second fibers allows the thickness of the fabric or the melted fabric to be reduced in the edge region until they are completely filled. The adhesive layers can be formed as separate layers or they can be at least partially integrated into the elements of the fuse to be bonded. For example, the base plate and / or the fabric and / or the cover layer can comprise an adhesive material. For example, an adhesive lacquer or an adhesive film can be used to bond two adjacent layers of the fuse together. The heating can reduce the thickness of the adhesive layer. For example, a portion of the adhesive layer can penetrate into the fabric or can swell out of the edge region. This method can not only be used for fuses with a laminated connection. It can also be used for fuses with a pre-fabricated housing part. For example, a fabric with first fibers and second fibers can be bonded between two plastic housing parts. In this case, the first housing part corresponds to the base plate formed with the recess and the second housing part corresponds to the cover layer formed with the recess and the adhesive corresponds to the adhesive layer.

[0026] In one embodiment, the base plate comprises a printed circuit board. For example, an FR4 or FR5 circuit board. The printed circuit board can comprise a composite material, such as glass fiber reinforced epoxy resin. Alternatively, a ceramic material, such as a glass plate or a ceramic plate, can be used or a combination of plastic and ceramic can be used. Instead of epoxy resin, a double-sided adhesive polyimide film can be used as adhesive layer.

[0027] In one embodiment, electrical contact elements are provided at both ends of the fuse, which are electrically conductively connected to at least one of the first fibers. Such electrical contacts are also referred to as terminals or end outer contacts and are usually refined in an ENIG process, i.e. they comprise a gold top layer.

[0028] In one embodiment, the contact elements extend over the entire surface at both ends of the fuse. Alternatively, the contact elements can be provided only in the fabric region of the two end faces of the fuse. The contact elements can also partially surround the fuse laterally and / or above and below. In such an embodiment, the contact elements are designed in the form of a clip or a sleeve.

[0029] In one embodiment, at least one first cavity is formed in the substrate between edge regions of the substrate and at least one second cavity is formed in the cover layer between edge regions of the cover layer. For example, a plurality of cavities can be formed in the substrate and / or the cover layer. The individual cavities can be separated from one another by webs. The cavities can have different dimensions, i.e. they can be formed with different widths or depths. It is also conceivable that the individual cavities do not have constant dimensions, i.e. their dimensions vary along the longitudinal axis and / or transversely to the longitudinal axis. The size of the edge regions differs depending on the size of the fuse. For example, the width of the edge regions and the webs is between 0.3 mm and 10 mm. The width of the edge regions can be greater than, equal to or less than the width of the webs.

[0030] In one embodiment, at least one frame-like spacer is arranged between the substrate and the fabric and / or between the fabric and the cover layer, wherein at least one third cavity is formed between edge regions of the spacer. Thus, the third cavities are formed between the substrate and the fabric and / or between the fabric and the cover layer within the spacer. The spacer can be connected to the adjacent layers by means of an adhesive layer. Again, an adhesive lacquer or an adhesive film can be used here. The spacer and / or the adjacent layers can also be impregnated with an adhesive lacquer.

[0031] In one embodiment, the fire extinguishing layers are arranged on one or both sides of the fabric by means of an adhesive layer in the respective cavities. The respective fire extinguishing layers can be arranged in regions close to the fabric or they can be arranged in regions remote from the fabric. For example, the fire extinguishing layers comprise a fire extinguishing silicone or an inorganic material with a higher melting point than the second fibers, such as, for example, vermiculite, PDMS, etc. The fire extinguishing layers can be in the form of a fabric or a film. Alternatively, the fabric can comprise a fire extinguishing material. For example, when glass fibers are interwoven in the fabric. It is also possible to impregnate the fabric with a silicone, whereby the fibers of the fabric are surrounded by a fire extinguishing silicone matrix.

[0032] In one embodiment, the substrate, the cover layer and the individual fire extinguishing layers are formed as closed surfaces. I.e. they extend without substantial gaps over the entire length and width of the fuse. In one embodiment, the interconnection layers comprise a closed circumferential frame, i.e. they comprise at least one through-hole spaced apart from the edge regions. If the fuse layers are connected directly to the substrate or the cover layer by means of an adhesive layer, the respective adhesive layer can be frame-like, strip-like or a closed surface.

[0033] In one embodiment, the adhesive layer comprises at least one web extending from one side of the frame to the opposite side of the frame transversely to the longitudinal axis and the at least one spacer comprises at least one web extending from one side of the frame to the opposite side of the frame transversely to the longitudinal axis. It is also possible to provide two or more webs extending from one side of the frame to the opposite side of the frame from the side. In the case of one web, there are thus two through-holes in the adhesive layer and / or the spacer. Thus, two cavities are created adjacent to one another on one side of the fabric. Thus, there is one more cavity than web.

[0034] In one embodiment, the substrate, the at least one adhesive layer, the at least one fabric, the at least one spacer and the at least one cover layer are substantially rectangular in shape, i.e. they comprise a substantially rectangular plan view and comprise two opposite ends and two opposite sides. The ends are oriented along the longitudinal axis, while the sides are oriented transversely to the longitudinal axis. The angle between the ends and the sides can be rounded. The through-holes of the adhesive layer and the spacer can also have rounded corners. The through-holes can also be shaped as slots with rounded ends.

[0035] In one embodiment, the fabric is flat. Alternatively, the fabric is pleated and comprises a plurality of permanent folds, i.e. it is folded or crumpled and comprises segments that protrude from the plane of the fabric, i.e. from the connection plane, between the two ends of the fabric.

[0036] In one embodiment, two or more fabrics are arranged in the fuse, wherein an intermediate layer is arranged between two adjacent fabrics, which is connected to the fabrics by an adhesive layer or by an adhesive layer and a spacer.

[0037] In one embodiment, at least a fourth cavity is formed in the intermediate layer between the edge regions of the intermediate layer. The intermediate layer can comprise the same material as the substrate or the top layer.

[0038] In one embodiment, the fabric comprises first fibers extending transversely to the longitudinal axis. I.e. the fabric comprises electrically conductive fibers extending along the longitudinal axis and electrically conductive fibers extending transversely to the longitudinal axis. The fabric can be woven such that the longitudinal fibers contact the transverse fibers and form a current transmission contact.

[0039] In one embodiment, the fabric comprises second fibers extending along the longitudinal axis. I.e. the fabric comprises non-conductive fibers extending transversely to the longitudinal axis and non-conductive fibers extending along the longitudinal axis.

[0040] In one embodiment, the plurality of first fibers is at least partially combined, i.e. the plurality of first fibers forms a bundle of fibers that are woven together. Alternatively or additionally, the plurality of second fibers is at least partially combined. Thus, separate electrically conductive or non-conductive fibers can be woven together to form the fabric, or separate fibers can be woven together with a bundle of fibers to form the fabric, or bundles of fibers can be woven together. For example, a bundle of fibers can comprise a plurality of fibers that are fused together and arranged parallel to each other. Such a bundle of fibers acts similar to a single fiber having a larger diameter.

[0041] In one embodiment, the fabric comprises only second fibers at least in the regions of its two sides. I.e. the fabric is electrically non-conductive in the regions of the two sides.

[0042] In one embodiment, the first fibers and / or the second fibers have different diameters. For example, the electrically conductive fibers have a smaller diameter than the non-conductive fibers. Alternatively, the electrically conductive fibers can comprise a larger diameter than the non-conductive fibers. It is also possible to provide non-conductive fibers in the fabric having a first diameter and non-conductive fibers having a second diameter different from the first diameter. For example, the electrically conductive fibers comprise a diameter of 5 micrometers to 2,000 micrometers. The cross-section of the first fibers and / or the second fibers can be circular, elliptical or polygonal.

[0043] In one embodiment, the first fibers comprise a cross-section that is fully electrically conductive. Such fibers can comprise only one material, or they can comprise an electrically conductive core of a first material and an electrically conductive coating of a second material. Alternatively, the first fibers comprise an electrically conductive coating or an electrically conductive core.

[0044] In one embodiment, at least one electrically conductive first fiber is helically wound around an electrically non-conductive second fiber or around a bundle of electrically non-conductive fibers. The winding can be uniform, i.e. the pitch of the turns is uniformly distributed over the entire length of the fabric. Alternatively, the electrically conductive fiber can be wound more tightly around the electrically non-conductive fiber locally, i.e. with a reduced winding distance. In the areas of the more tightly wound electrically conductive fiber, the electrically conductive fiber heats up faster, causing the fibers of this section to melt first. Thus, the areas of the more tightly wound electrically conductive fiber form the target melting point.

[0045] In one embodiment, the second fibers of the fabric can comprise different materials. For example, some fibers can comprise a material that melts upon heating, while some fibers can comprise a material that does not melt upon heating. For example, the second fibers oriented in the longitudinal direction can not melt, while the second fibers oriented in the transverse direction can melt. Some of the second fibers oriented in the transverse direction can also not melt, thereby ensuring that the at least one first fiber is centrally positioned within the cavity. I.e. the at least one first fiber can be held in a plane defined by the mid-plane of the fabric by the second fibers.

[0046] In one embodiment, the non-conductive fibers comprise a material selected from the group comprising silicone (e.g. PDMS), polyimide, polyester, polyamide (Nylon), aramid (Kevlar), polytetrafluoroethylene (Teflon), polyethylene terephthalate (PET), ethylene-tetrafluoroethylene (ETFE), polybenzimidazole (PBI), polyacrylonitrile (PAN), oxidized polyacrylonitrile (Pyron), polycarbonate (PC), polyphenylene sulfide (PPS), aromatic polyester (e.g. Vectran), polyethylene naphthalate (PEN), polyether ether ketone (PEEK), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF) and polypropylene (PP).

[0047] In one embodiment, the fabric comprises non-conductive third fibers interwoven with the at least one first and second fibers. The third fibers have a higher melting point than the second fibers. The third fibers can comprise substantially the same material as the second fibers. Preferably, the third fibers comprise a material selected from the group comprising glass fibers, polyimide (Kapton), aramid (Kevlar), polybenzimidazole (PBI) and inorganic fibers or more precisely ceramic fibers (e.g. aluminosilicate or aluminoborosilicate).

[0048] In one embodiment, the fire extinguishing layer and / or the substrate and / or the cover layer and / or the conductive and non-conductive fibers comprise a mineral coated surface, e.g. with a coating of vermiculite.

[0049] In one embodiment, the conductive and / or non-conductive fibers can be provided with a surface coating, wherein the surface coating can be applied by a PVD / CVD process or by plasma polymerization. Alternative coating processes for surface metallization of non-conductive fiber cores include immersion in a colloidal solution and electroless deposition. The surface coating protects the underlying fiber, e.g. from mechanical and / or electrical and / or chemical influences.

[0050] In one embodiment, the conductive fibers can be coated with a fire extinguishing material.

[0051] In one embodiment, the surface coating comprises a material selected from the group comprising polyurethane (PU), polyethylene terephthalate (PET), polyamide (PA) and imides such as polyimide (PI) or a composite material such as a copolymer or a derivative of the above materials.

[0052] In one embodiment, the conductive fibers comprise a material selected from the group comprising gold, copper, silver, tin and alloys thereof. The fibers can consist entirely of such a material or can comprise a conductive core or coating. The coating can be partial or complete. For example, aramid fibers can be coated with gold or nylon fibers can be coated with copper. For example, copper wires can also be partially or completely coated with tin or silver.

[0053] In one embodiment, the plurality of fuses is laminated together and then separated from each other. In this case, each layer has the size of the plurality of fuses. For example, a plurality of substrates assembled in one direction can form a long strip or when assembled in two perpendicular directions can form a larger sheet. The fabric ensures that the conductive fibers are located in predetermined areas. Thus, each fuse can be separated in a first step only in the area of the conductive fibers, for example by holes or cutouts, and can be completely separated in a second step. Alternatively, each fuse can be separated from each other in one step, for example by cutting, milling or sawing.

[0054] The above-described embodiments of the fuse can be used in any combination, as long as they do not contradict each other. BRIEF DESCRIPTION OF DRAWINGS

[0055] Examples of embodiments of the application are explained in more detail below with reference to the drawings. These are for illustrative purposes only and should not be interpreted in a limiting manner. The drawings show:

[0056] Figure 1 is a cross-sectional view of a first embodiment of a fuse according to the application before heating;

[0057] Figure 2 is a cross-sectional view of a fuse according to the application along the intersection line A-A; Figure 1

[0058] Figure 3 is a cross-sectional view of a finished fuse according to the application; Figure 1

[0059] is a cross-sectional view of a second embodiment of a fuse according to the application before heating; Figure 4

[0060] is a cross-sectional view of a fuse according to the application along the intersection line A-A; Figure 5 Figure 4 is a cross-sectional view of a finished fuse according to the application;

[0061] Figure 6 Figure 4 is a cross-sectional view of a third embodiment of a fuse according to the application before heating;

[0062] Figure 7 is a cross-sectional view of a fourth embodiment of a fuse according to the application before heating;

[0063] Figure 8 is a cross-sectional view of a fifth embodiment of a fuse according to the application before heating;

[0064] Figure 9 is a cross-sectional view of a fifth embodiment of a fuse according to the application before heating;

[0065] Figure 10 ​​​This is a cross-sectional view of the sixth embodiment of the fuse according to the present invention before heating;

[0066] Figure 11 This is a cross-sectional view of the seventh embodiment of the fuse according to the present invention before heating;

[0067] Figure 12 This is a cross-sectional view of the eighth embodiment of the fuse according to the present invention before heating;

[0068] Figure 13 This is a cross-sectional view of the ninth embodiment of the fuse according to the present invention before heating;

[0069] Figure 14 This is a cross-sectional view of the tenth embodiment of the fuse according to the present invention before heating;

[0070] Figure 15 This is a 3D view of the adhesive layer;

[0071] Figures 16a to 16f It is a fabric implementation method; and

[0072] Figures 17a to 17b It is a wound conductive first fiber. Detailed Implementation

[0073] Figure 1 A cross-sectional view of a first embodiment of the fuse 1 according to the invention before heating is shown. Figure 2 It shows Figure 1 The cross-sectional view of the fuse along the AA intersection line, and Figure 3 It shows Figure 1 A cross-sectional view of the finished fuse. The fuse extends along a longitudinal axis L from a first end 11 to a second end 12 opposite thereto. A substrate 2 is disposed on a generally flat base (not shown here). An adhesive layer 3, a fabric 4 that is at least partially conductive, another adhesive layer 3, and a cover layer are stacked sequentially on the base, aligned with each other. The substrate 2 is a generally rectangular printed circuit board and includes a first end 21, a second end 22 opposite to the first end 21, a first side 23 arranged transversely to the second end 22, and a second side 24 opposite to the first side 23. A recess is formed in the substrate 2 at a distance from the edge region of the upper surface of the substrate 2, which defines a first cavity 200 in the assembled state. The cover layer 5 is geometrically identical to the substrate 2 and includes a printed circuit board having a first end 51, a second end 52, a first side 53, a second side 54, and a second recess, which defines a second cavity 500 in the assembled state. Figure 12 As shown, connector layer 3 is frame-shaped and includes a first end 31, a second end 32, a first side 33, and a second side 34. (The last sentence appears to be incomplete and possibly refers to a different type of connector.) Figure 12 The connecting elements are different. Figures 1 to 3The connecting element of the illustrated embodiment does not comprise a central web extending between the two sides. Thus, only one through-hole is formed at a distance from the edge region. The at least partially electrically conductive fabric 4 comprises a closed surface having a first end 41, a second end 42 opposite the first end 41, a first side 43 and a second side 44 opposite the first side 43. The fabric 4 comprises at least one electrically conductive first fiber 400 extending at least in the longitudinal direction from the first end 11 to the second end 12 of the fuse 1 and it comprises at least one non-conductive second fiber 401 extending transversely to the longitudinal axis L. The first fiber 400 has a higher melting temperature than the second fiber 401. As can be seen from Figure 2 The fabric 4 does not extend to the lateral outer contour of the fuse 1, whereby the fabric 4 is laterally outwardly covered by the material of the interconnection layer 3. Alternatively, the fabric 4 can laterally extend to the outer periphery of the fuse. The Figure 1 and Figure 2 heating of the stack illustrated to a temperature above the melting temperature of the second fiber melts the second fiber, thereby releasing the at least one first fiber 400, as illustrated in Figure 3 The contact elements 6 are arranged at both ends 11, 12 of the fuse 1, they extend over the entire respective end surface and are electrically conductively connected to the at least one first fiber 400.

[0074] Figures 4 to 6 A second embodiment of a fuse according to the invention is shown before and after heating. In contrast to the first embodiment, the substrate 2 and the cover layer 5 do not comprise any recesses. Instead, a frame-like spacer 7 is provided, the interior of which delimits a third cavity 700 in the assembled state. Before heating, the printed circuit board 2, the adhesive layer 3, the spacer 7, a further adhesive layer 3, the at least partially electrically conductive fabric 4, a further adhesive layer 3, the spacer 7, a further adhesive layer 3 and the cover layer 5 thus one atop the other. The fabric 4 extends to both sides 13, 14 of the fuse 1, but both lateral regions 43, 44 of the fabric 4 are electrically non-conductive. Such a fabric 4 is shown, for example, in Figure 16a and Figure 16f The contact elements 6 are arranged at both ends 11, 12 of the fuse 1, they extend over the region of the respective end face comprising the fabric 4. These contact elements 6 are also electrically conductively connected to the at least one first fiber 400.

[0075] Figure 7 A cross-sectional view of a third embodiment of a fuse 1 according to the invention is shown before heating. In contrast to the first and second embodiments, the substrate 2 and the cover layer 5 do not comprise any recesses. Instead, a frame-like spacer 7 is provided, the interior of which delimits a third cavity 700 in the assembled state. Before heating, the printed circuit board 2, the adhesive layer 3, the spacer 7, a further adhesive layer 3, the at least partially electrically conductive fabric 4, a further adhesive layer 3, the spacer 7, a further adhesive layer 3 and the cover layer 5 thus one atop the other. The fabric 4 extends to both sides 13, 14 of the fuse 1, but both lateral regions 43, 44 of the fabric 4 are electrically non-conductive. Such a fabric 4 is shown, for example, in Figures 4 to 6Compared to the previous implementation, the adhesive layer 3 and the spacer 7 are frame-shaped and have webs (30; 70). Therefore, not only are the edge regions of each layer connected to each other, but the central region 20 of the substrate 2, the web 70 of the spacer 7, the central region 40 of the fabric 4, and the central region 50 of the cover layer 5 are also connected to each other via the webs 30 of the corresponding adhesive layer 3. The adhesive layer 3 extends along the longitudinal axis L from the first end 31 to the second end 32 opposite to the first end 31 and includes a closed circumferential frame having two frame portions 31, 32 near the end and two lateral frame portions 33, 34, as shown below. Figure 12 As shown in the example, the web 30 extends from the center of the laterally first frame portion 33 through the central region of the interconnecting layer 3 to the laterally second frame portion 34 opposite to the first frame portion 33. Therefore, the substrate 2 is only partially connected to the fabric 4, i.e., in the region of the frame portion of the interconnecting layer 3. Thus, the first end 21, the second end 22, the first side, the second side, and the central region 20 of the substrate 2 are connected to the first end 41, the second end 42, the first side, the second side, and the central region 40 of the fabric. Similarly, the aforementioned regions of the fabric 4 are correspondingly connected to the first end 51, the second end 52, the first side, the second side, and the central region 50 of the cover layer 5 via another adhesive layer 3. The spacer 7 includes a frame-like structure whose dimensions correspond to those of the adhesive layer 3. The frame-like structures of the adhesive layer 3 and the spacer 7 create a third cavity 700 between the substrate 2 and the fabric 4 or between the fabric 4 and the cover layer 5 in the through-hole region of the adhesive layer 3.

[0076] Figure 8 A cross-sectional view of a fourth embodiment of the fuse according to the invention before heating is shown. This embodiment corresponds to... Figures 1 to 3 In this embodiment, the fire extinguishing layer 9 is arranged in the cavities 200 and 500 by means of the adhesive layer 3. The fire extinguishing layer 9 is designed as a closed surface that extends through the cavities 200 and 500 to the two ends 11 and 12 and both sides of the fuse.

[0077] Figure 9 A cross-sectional view of a fifth embodiment of the fuse according to the invention before heating is shown. This embodiment corresponds to... Figures 4 to 6 In this embodiment, the fire extinguishing layer 9 is arranged in the cavity 700 by means of the adhesive layer 3, and the fire extinguishing layer 9 extends laterally and in the longitudinal direction to the periphery of the fuse 1.

[0078] Figure 10 A cross-sectional view of a sixth embodiment of the fuse according to the invention before heating is shown, and Figure 11 The corresponding sixth embodiment is shown. These embodiments correspond to... Figure 9 and Figure 10 In those embodiments, however, the fire extinguishing layer 9 is connected to the substrate 2 or the cover layer 5 via an adhesive layer 35 that seals the surface.Figure 10 In one embodiment, the fire extinguishing layer 9 extends over the entire surface of the recess of the substrate 2 or the cover layer 5 facing the fabric 4. Figure 11 In one embodiment, the fire extinguishing layer 9 extends from the first end 11 of the fuse 1 to the second end 12 of the fuse 1 on the entire surface of the substrate 2 or the cover layer 5 facing the fabric 4.

[0079] Figure 12 A cross-sectional view of a seventh embodiment of the fuse according to the invention before heating is shown. Two fabrics 4 are arranged in a common cavity 700. The two fabrics 4 are separated from each other by spacers 7. The fabrics 4 are separated from the substrate 2 or the cover layer 5 by the spacers 7 on the outward or upward and downward sides. The substrate 2, spacers 7, fabrics 4 and cover layer 5 are connected to each other by a frame-like adhesive layer 3. Of course, the two fabrics separated from each other by spacers can also be arranged between the substrate and the cover layer, as shown. Figure 10 As shown in the example.

[0080] Figure 13 A cross-sectional view of an eighth embodiment of the fuse according to the invention before heating is shown. Two substantially flat fabrics 4 are arranged in layers between a substrate 2 and a cover layer 5. A printed circuit board is provided as an intermediate layer 8 between the two fabrics 4. In this intermediate layer 8, recesses are formed at a certain distance from the edge regions of the upper and lower surfaces of the intermediate layer 8, and the intermediate layer 8 defines a fourth cavity 800 in the assembled state. The layers are connected to each other by adhesive layers 3.

[0081] Figure 14 A cross-sectional view of a sixth embodiment of the fuse according to the invention before heating is shown. Figure 13 Compared to the previous implementation, the substrate 2, cover layer 5, and intermediate layer 8 have no recesses. The cavity 700 is formed by corresponding spacers 7, which are arranged between the substrate 2 and the fabric 4, the fabric 4 and the intermediate layer 8, and the fabric 4 and the cover layer 5 by means of corresponding adhesive layers 3.

[0082] Figure 16a A first embodiment of fabric 4 is shown, wherein a conductive first fiber 400 extends along the longitudinal axis L and non-conductive fibers 401 extend transversely to the longitudinal axis L and parallel to the longitudinal axis L, respectively.

[0083] Figure 16b A second embodiment of fabric 4 is shown, wherein a conductive first fiber 400 extends along the longitudinal axis L and a non-conductive fiber 401 extends transversely to the longitudinal axis L.

[0084] Figure 16cA third embodiment of the fabric 4 is shown. The fabric 4 comprises a plurality of first fibres 400 extending along the longitudinal axis L and transverse to the longitudinal axis L and second fibres 401 extending along the longitudinal axis and transverse to the longitudinal axis.

[0085] Figure 16d A fourth embodiment of the fabric 4 is shown, wherein the bundle of first fibres 400 is interwoven with each individual second fibre 401.

[0086] Figure 16e A fifth embodiment of the fabric 4 is shown, wherein each individual first fibre 400 is interwoven with a bundle of second fibres 401.

[0087] Figure 16f A sixth embodiment of the fabric is shown, wherein a plurality of second fibres 401 are interwoven between each individual first fibre 400 extending along the longitudinal axis L from the first end 41 to the second end 42 of the fabric 4. The distance between two conductive first fibres 400 can thus be adjusted very precisely. The more non-conductive second fibres 401 arranged between two adjacent conductive fibres 400, the larger their distance. Only non-conductive fibres 401 are provided in the area of the first side 43 and the second side 44 of the fabric 4, which is the reason why the two lateral areas of the fabric 4 are not conductive.

[0088] Figure 17a A conductive first fibre 400 is shown spirally wound around a non-conductive second fibre 401, and Figure 17b A first fibre 400 is shown wound around a bundle of second fibres 401. Such wound first fibres 400 can be used in the fabrics described previously.

[0089] List of reference signs

[0090] 1 fuse

[0091] 11 first end

[0092] 12 second end

[0093] 13 first side

[0094] 14 second side

[0095] 2 base plate

[0096] 20 central area

[0097] 21 first end

[0098] 22 second end

[0099] 23 first side

[0100] 24 second side

[0101] 200 cavity

[0102] 3 adhesive layer

[0103] 30 web

[0104] 31 first end

[0105] 32 second end

[0106] 33 first side

[0107] 34 second side

[0108] 35 adhesive layer

[0109] 4 melt element / fabric

[0110] 40 central region

[0111] 41 first end

[0112] 42 second end

[0113] 43 first side

[0114] 44 second side

[0115] 400 first fiber

[0116] 401 second fiber

[0117] 402 melted second fiber

[0118] 5 top layer

[0119] 50 central region

[0120] 51 first end

[0121] 52 second end

[0122] 53 first side

[0123] 54 second side

[0124] 500 cavity

[0125] 6 contact element

[0126] 7 spacer

[0127] 70 web

[0128] 71 first end

[0129] 72 second end

[0130] 700 cavity

[0131] 8 intermediate layer

[0132] 800 cavity

[0133] 9 fire extinguishing layer

[0134] L longitudinal axis

Claims

1. A method of manufacturing a fuse (1) extending from a first end (11) along a longitudinal axis (L) to a second end (12), the method comprising the steps of: -Set the substrate (2); - A fabric (4) that is at least partially conductive is stacked on top of the substrate (2); - A covering layer (5) is stacked on top of the fabric (4); - At least in their respective edge regions, an adhesive layer (3) is provided between the substrate (2) and the fabric (4) and between the fabric (4) and the cover layer (5); Wherein, on both sides of the fabric (4), adjacent to the fabric (4), at least one cavity (200, 500; 700; 800) is provided between their respective edge regions. The fabric (4) includes at least one first fiber (400), which is conductive and extends along the longitudinal axis (L) from the first end (11) of the fuse (1) to the second end (12) of the fuse (1), and the fabric (4) includes a second fiber (401), which is non-conductive and extends at least transversely to the longitudinal axis (L), wherein the melting temperature of the at least one first fiber (400) is higher than the melting temperature of the second fiber (401). - Heat the stacked components to a temperature below the melting temperature of the at least one first fiber (400) and above the melting temperature of the second fiber (401); - Maintain this temperature for a period of time; The second fiber (401) thus melts at least in the region of the at least one first fiber (400), thereby releasing at least partially the at least one first fiber (400) in the region of the cavity (200, 500; 700; 800); - Cool the stacked components to room temperature.

2. The method according to claim 1, wherein, The substrate (2) includes a printed circuit board.

3. The method according to claim 1 or 2, wherein the method comprises: Contact elements (6) are arranged at both ends (11, 12) of the fuse (1), wherein the contact elements (6) are electrically connected to the at least one first fiber (400).

4. The method according to claim 3, wherein, The contact element (6) extends over the entire surface of the corresponding ends (11, 12) of the fuse (1), or the contact element (6) is provided only in the area of ​​the fabric (4) at the first end (11) and the second end (12).

5. The method according to claim 1, wherein, In the substrate (2), at least one first cavity (200) is formed between the edge regions of the substrate (2), and in the cover layer (5), at least one second cavity (500) is formed between the edge regions of the cover layer (5).

6. The method according to claim 1, wherein the method comprises: At least one frame-shaped spacer (7) is arranged between the substrate (2) and the fabric (4) and / or between the fabric (4) and the cover layer (5), wherein at least one third cavity (700) is formed between the edge regions of the spacer (7).

7. The method according to claim 1, wherein the method comprises: Fire extinguishing layers (9) are arranged on one or both sides of the fabric (4) in the corresponding cavities (200, 500; 700) by means of an adhesive layer (3).

8. The method according to claim 7, wherein, The substrate (2), the cover layer (5), and the fire extinguishing layer (9) are formed as closed surfaces.

9. The method according to claim 6, wherein, The adhesive layer (3) includes a closed circumferential frame, and / or wherein, The additional adhesive layer (35) is formed as a closed surface.

10. The method according to claim 9, wherein, The adhesive layer (3) includes at least one web (30) extending transversely to the longitudinal axis (L) from one side (33) of the frame to the opposite side (34) of the frame, and wherein the at least one spacer (7) includes at least one web (70) extending transversely to the longitudinal axis (L) from one side (71) of the frame to the opposite side (72) of the frame.

11. The method according to claim 6, wherein, The substrate (2), at least one adhesive layer (3), at least one fabric (4), at least one spacer (7) and at least one cover layer (5) are substantially rectangular and include two opposite ends (11, 12) and two opposite sides (13, 14).

12. The method according to claim 6, wherein the method comprises: Two or more fabrics (4) are arranged, wherein an intermediate layer (8) is provided between two adjacent fabrics (4), the intermediate layer (8) being connected to the fabrics (4) by an adhesive layer (3) or by an adhesive layer (3) and a spacer (7).

13. The method according to claim 12, wherein, In the intermediate layer (8), at least a fourth cavity (800) is formed between the edge regions of the intermediate layer (8).

14. The method according to claim 1, wherein, The fabric (4) includes a first fiber (400) extending transversely to the longitudinal axis (L).

15. The method according to claim 1, wherein, The fabric (4) includes a second fiber (401) extending along the longitudinal axis (L).

16. The method according to claim 1, wherein, The fabric (4) includes a second fiber (401) having a first melting temperature and a second fiber (401) having a second melting temperature different from the first melting temperature.

17. The method according to claim 1, wherein, At least partially, a plurality of first fibers (400) are combined, and / or at least partially, a plurality of second fibers (401) are combined.

18. The method according to claim 1, wherein, The fabric (4) includes only the second fiber (401) in at least the regions on both sides (43, 44).

19. The method according to claim 1, wherein, The first fiber (400) and / or the second fiber (401) have different diameters.

20. The method according to claim 1, wherein, The first fiber (400) has a fully conductive cross-section, or the first fiber (400) includes a conductive coating or a conductive core.

21. The method according to claim 1, wherein, At least one first fiber (400) is spirally wound around a second fiber (401) or around a bundle of the second fiber (401).

22. A fuse (1) manufactured by the method according to any one of claims 1 to 21, said fuse (1) comprising a substrate (2) interconnected at least in its respective edge regions by an adhesive layer (3), a fabric (4) that is at least partially conductive, and a cover layer (5), in, The fabric (4) includes at least one first fiber (400), which is conductive and extends along a longitudinal axis (L) from a first end (11) of the fuse (1) to a second end (12) of the fuse (1), and the fabric (4) includes a second fiber (401), which is non-conductive, wherein the melting temperature of the at least one first fiber (400) is higher than the melting temperature of the second fiber (401). Furthermore, the adhesive layer (3) includes a closed circumferential frame and at least one web (30), the at least one web (30) extending transversely to the longitudinal axis (L) from one side (33) of the circumferential frame to the opposite side (34) of the circumferential frame.

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