Positive temperature coefficient over-current protection device

Abstract

A positive temperature coefficient over-current protection device comprises a first PTC assembly, a second PTC assembly, a first insulating layer, a first conductive through hole and a second conductive through hole. The first PTC element includes a first electrode, a second electrode, and a first PTC element sandwiched between the first electrode and the second electrode. The second PTC element includes a third electrode, a fourth electrode, and a second PTC element sandwiched between the third electrode and the fourth electrode. The first insulating layer is sandwiched between the first PTC component and the second PTC component. The first conductive through hole is electrically connected with the first electrode and the third electrode, and the second conductive through hole is electrically connected with the second electrode and the fourth electrode.

Description

Technical Field

[0001] The invention relates to a positive temperature coefficient overcurrent protection device, in particular to a positive temperature coefficient overcurrent protection device comprising two PTC components, an insulating layer and two conductive through holes. Background Art

[0002] A positive temperature coefficient (PTC) device has a PTC effect, which enables it to be used as an overcurrent protection device (such as a resettable fuse). The positive temperature coefficient device includes a PTC polymer element and two electrodes disposed on two opposite surfaces of the PTC polymer element.

[0003] The PTC polymer element includes a polymer substrate containing a crystalline region and an amorphous region, and a granular conductive filler. The granular conductive filler is dispersed in the amorphous region of the polymer substrate and forms a continuous conductive path for electrically connecting the two electrodes. The PTC effect refers to that when the temperature of the polymer substrate in the crystalline region is raised to its melting point, the crystals in the crystalline region begin to melt, thereby generating a new amorphous region. When the new amorphous region increases to the extent of merging into the original amorphous region, the conductive path of the granular conductive filler will be converted into a discontinuous path and the resistance of the PTC polymer element will increase sharply, resulting in electrical non-conduction between the two electrodes.

[0004] See also Figure 1 A conventional positive temperature coefficient overcurrent protection device comprises a PTC component 1, two electrodes 2 and two conductive leads 3. However, the electrical properties and reliability of the conventional positive temperature coefficient overcurrent protection device are not ideal. Summary of the invention

[0005] An object of the present invention is to provide a positive temperature coefficient overcurrent protection device, which can overcome at least one disadvantage of the above-mentioned background technology.

[0006] The positive temperature coefficient overcurrent protection device of the present invention comprises a first PTC component, a second PTC component, a first insulating layer, a first conductive through hole and a second conductive through hole.

[0007] The first PTC component includes a first electrode, a second electrode and a first PTC element, and the first PTC element is sandwiched between the first electrode and the second electrode. The second PTC component includes a third electrode, a fourth electrode and a second PTC element, and the second PTC element is sandwiched between the third electrode and the fourth electrode. The first insulating layer is sandwiched between the first PTC component and the second PTC component. The first conductive through hole electrically connects the first electrode and the third electrode, and the second conductive through hole electrically connects the second electrode and the fourth electrode.

[0008] In the positive temperature coefficient overcurrent protection device of the present invention, the second electrode is arranged adjacent to the first insulating layer relative to the first electrode, and the third electrode is arranged adjacent to the first insulating layer relative to the fourth electrode.

[0009] In the positive temperature coefficient overcurrent protection device of the present invention, the first conductive through hole and the second conductive through hole extend through the first PTC component, the first insulating layer and the second PTC component.

[0010] The positive temperature coefficient overcurrent protection device of the present invention comprises: the first electrode is formed with a first groove, the second electrode is formed with a second groove, the third electrode is formed with a third groove, the fourth electrode is formed with a fourth groove, the first conductive through hole is respectively spaced apart from the second electrode and the fourth electrode through the second groove and the fourth groove, and the second conductive through hole is respectively spaced apart from the first electrode and the third electrode through the first groove and the third groove.

[0011] The positive temperature coefficient overcurrent protection device of the present invention, the first groove extends through the first electrode to divide the first electrode into a first conductive part and a first separation part, the first conductive part is connected to the first conductive through hole, the first separation part is connected to the second conductive through hole and is separated from the first conductive part by the first groove, so that the second conductive through hole is separated from the first conductive part of the first electrode.

[0012] In the positive temperature coefficient overcurrent protection device of the present invention, the first groove is annular, and the first separation portion surrounds an opening on one side of the second conductive through hole.

[0013] In the positive temperature coefficient overcurrent protection device of the present invention, the second groove penetrates the second electrode, and the first conductive through hole extends through the second groove and is spaced apart from the second electrode.

[0014] In the positive temperature coefficient overcurrent protection device of the present invention, the third groove penetrates the third electrode, and the second conductive through hole extends through the third groove and is spaced apart from the third electrode.

[0015] The positive temperature coefficient overcurrent protection device of the present invention, the fourth groove extends through the fourth electrode to divide the fourth electrode into a fourth conducting part and a fourth separating part, the fourth conducting part is connected to the second conductive through hole, the fourth separating part is connected to the first conductive through hole and is separated from the fourth conducting part by the fourth groove, so that the first conductive through hole is separated from the fourth conducting part of the fourth electrode.

[0016] The positive temperature coefficient overcurrent protection device of the present invention further comprises a first conductive lead connected to the first PTC component and a second conductive lead connected to the second PTC component.

[0017] In the positive temperature coefficient overcurrent protection device of the present invention, the first conductive through hole and the second conductive through hole are arranged on opposite edges of the positive temperature coefficient overcurrent protection device.

[0018] In the positive temperature coefficient overcurrent protection device of the present invention, the first conductive through hole and the second conductive through hole are arranged on the same edge of the positive temperature coefficient overcurrent protection device.

[0019] The positive temperature coefficient overcurrent protection device of the present invention further comprises a second insulating layer and a fifth electrode. The second insulating layer is arranged on the fourth electrode. The fifth electrode is arranged on the second insulating layer opposite to the fourth electrode and is electrically connected to the first conductive through hole.

[0020] In the positive temperature coefficient overcurrent protection device of the present invention, the first conductive through hole and the second conductive through hole extend through the first PTC component, the first insulating layer, the second PTC component, the second insulating layer and the fifth electrode.

[0021] The positive temperature coefficient overcurrent protection device of the present invention comprises: the first electrode is formed with a first groove, the second electrode is formed with a second groove, the third electrode is formed with a third groove, the fourth electrode is formed with a fourth groove, the fifth electrode is formed with a fifth groove, the first conductive through hole is respectively spaced apart from the second electrode and the fourth electrode through the second groove and the fourth groove, and the second conductive through hole is respectively spaced apart from the first electrode, the third electrode and the fifth electrode through the first groove, the third groove and the fifth groove.

[0022] The positive temperature coefficient overcurrent protection device of the present invention,

[0023] The first trench extends through the first electrode to separate the first electrode into a first conducting portion and a first separating portion, the first conducting portion is connected to the first conductive through hole, the first separating portion is connected to the second conductive through hole and is separated from the first conducting portion by the first trench, so that the second conductive through hole is separated from the first conducting portion of the first electrode, and

[0024] The fifth trench extends through the fifth electrode to divide the fifth electrode into a fifth conductive portion and a fifth separated portion, the fifth conductive portion is connected to the first conductive through hole, the fifth separated portion is connected to the second conductive through hole and is separated from the fifth conductive portion by the fifth trench, so that the second conductive through hole is separated from the fifth conductive portion of the fifth electrode.

[0025] The positive temperature coefficient overcurrent protection device of the present invention further comprises a third insulating layer and a sixth electrode. The third insulating layer is arranged on the first electrode. The sixth electrode is arranged on the third insulating layer opposite to the first electrode and is electrically connected to the second conductive through hole.

[0026] In the positive temperature coefficient overcurrent protection device of the present invention, the first conductive through hole and the second conductive through hole extend through the first PTC component, the first insulating layer, the second PTC component, the second insulating layer, the fifth electrode, the third insulating layer and the sixth electrode.

[0027] The positive temperature coefficient overcurrent protection device of the present invention comprises: the first electrode is formed with a first groove, the second electrode is formed with a second groove, the third electrode is formed with a third groove, the fourth electrode is formed with a fourth groove, the fifth electrode is formed with a fifth groove, and the sixth electrode is formed with a sixth groove; the first conductive through hole is respectively spaced apart from the second electrode, the fourth electrode and the sixth electrode through the second groove, the fourth groove and the sixth groove, and the second conductive through hole is respectively spaced apart from the first electrode, the third electrode and the fifth electrode through the first groove, the third groove and the fifth groove.

[0028] In the positive temperature coefficient overcurrent protection device of the present invention, the first insulating layer, the second insulating layer and the third insulating layer are made of epoxy resin glass fiber.

[0029] The beneficial effect of the present invention is that the positive temperature coefficient overcurrent protection device can improve conductivity and has good electrical properties and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Other features and effects of the present invention will be clearly presented in the embodiments with reference to the accompanying drawings, in which:

[0031] Figure 1 It is a three-dimensional schematic diagram of an existing positive temperature coefficient overcurrent protection device;

[0032] Figure 2 1 is a three-dimensional schematic diagram of an embodiment 1 (E1) of a positive temperature coefficient overcurrent protection device of the present invention;

[0033] Figure 3A and Figure 3B is a cross-sectional schematic diagram of embodiment 1 (E1) of the positive temperature coefficient overcurrent protection device of the present invention;

[0034] Figure 4A and Figure 4B 1 is a three-dimensional schematic diagram of Embodiment 2 (E2) of the positive temperature coefficient overcurrent protection device of the present invention;

[0035] Figure 5 1 is a three-dimensional schematic diagram of Embodiment 3 (E3) of the positive temperature coefficient overcurrent protection device of the present invention;

[0036] Figure 6 1 is a three-dimensional schematic diagram of Embodiment 4 (E4) of the positive temperature coefficient overcurrent protection device of the present invention;

[0037] Figure 7 1 is a three-dimensional schematic diagram of Embodiment 5 (E5) of the positive temperature coefficient overcurrent protection device of the present invention;

[0038] Figure 8 1 is a three-dimensional schematic diagram of Embodiment 6 (E6) of the positive temperature coefficient overcurrent protection device of the present invention;

[0039] Fig.9A and Fig. 9B is a cross-sectional schematic diagram of Embodiment 7 (E7) of the positive temperature coefficient overcurrent protection device of the present invention; and

[0040] Fig. 10A and Fig. 10B It is a cross-sectional schematic diagram of Example 8 (E8) of the positive temperature coefficient overcurrent protection device of the present invention. DETAILED DESCRIPTION

[0041] Before the present invention is described in detail, it should be noted that similar elements are represented by the same reference numerals in the drawings in the following description. The elements in the drawings are not drawn to scale.

[0042] See also Figure 2 , Figure 3A and Figure 3B The embodiment of the positive temperature coefficient overcurrent protection device of the present invention includes a first PTC component 10 , a second PTC component 20 , a first insulating layer 31 , a first conductive through hole 41 and a second conductive through hole 42 .

[0043] The first PTC component 10 includes a first electrode 11, a second electrode 12 and a first PTC element 13, and the first PTC element 13 is sandwiched between the first electrode 11 and the second electrode 12. The first PTC element 13 can be a PTC polymer layer, and the PTC polymer layer includes a polymer substrate and a conductive filler dispersed in the polymer substrate. The polymer substrate is made of a polymer composition, and the polymer composition contains a non-grafted olefin polymer. In some specific embodiments of the present invention, the non-grafted olefin polymer is a high-density polyethylene (HDPE). In other specific embodiments of the present invention, the polymer composition also includes an olefin polymer grafted with a carboxylic anhydride. The conductive filler may include but is not limited to carbon black powder, metal powder, conductive ceramic powder or a combination thereof. The first electrode 11 and the second electrode 12 can each be a copper foil (such as a nickel-plated copper foil).

[0044] The second PTC assembly 20 includes a third electrode 21, a fourth electrode 22, and a second PTC element 23, wherein the second PTC element 23 is sandwiched between the third electrode 21 and the fourth electrode 22. The material of the second PTC element 23 may be the same as that of the first PTC element 13. The materials of the third electrode 21 and the fourth electrode 22 may be similar to those of the first electrode 11 and the second electrode 12.

[0045] The first insulating layer 31 is sandwiched between the first PTC component 10 and the second PTC component 20. In this embodiment, the second electrode 12 is disposed adjacent to the first insulating layer 31 relative to the first electrode 11, and the third electrode 21 is disposed adjacent to the first insulating layer 31 relative to the fourth electrode 22. The first insulating layer 31 can be made of epoxy glass fiber.

[0046] In this embodiment, the first conductive through hole 41 electrically connects the first electrode 11 and the third electrode 21, and the second conductive through hole 42 electrically connects the second electrode 12 and the fourth electrode 22. In this embodiment, the first conductive through hole 41 and the second conductive through hole 42 extend through the first PTC component 10, the first insulating layer 31 and the second PTC component 20.

[0047] In this embodiment, the first conductive through hole 41 and the second conductive through hole 42 are spaced apart on the positive temperature coefficient overcurrent protection device. The diameters of the first conductive through hole 41 and the second conductive through hole 42 can be 0.20 mm to 2.00 mm respectively. In a specific embodiment of the present invention, the diameters of the first conductive through hole 41 and the second conductive through hole 42 are 0.6 mm respectively.

[0048] Optionally, see Figure 4A and Figure 4B The first conductive through hole 41 and the second conductive through hole 42 may be disposed at opposite edges of the positive temperature coefficient overcurrent protection device. Figure 5 The first conductive through hole 41 and the second conductive through hole 42 can be disposed on the same edge of the positive temperature coefficient overcurrent protection device.

[0049] See also Figures 2 to 5 The first electrode 11 is formed with a first groove 111, the second electrode 12 is formed with a second groove 121, the third electrode 21 is formed with a third groove 211, and the fourth electrode 22 is formed with a fourth groove 221. The first conductive through hole 41 is spaced apart from the second electrode 12 and the fourth electrode 22 through the second groove 121 and the fourth groove 221, respectively, and the second conductive through hole 42 is spaced apart from the first electrode 11 and the third electrode 21 through the first groove 111 and the third groove 211, respectively.

[0050] The first trench 111 extends through the first electrode 11 to separate the first electrode 11 into a first conducting portion 112 and a first separating portion 113. The first conducting portion 112 is connected to the first conductive via 41. The first separating portion 113 is connected to the second conductive via 42 and is separated from the first conducting portion 112 by the first trench 111, so that the second conductive via 42 is separated from the first conducting portion 112 of the first electrode 11. Figure 2 In the embodiment, the first groove 111 is annular, and the first separation portion 113 surrounds an opening on one side of the second conductive through hole 42. Figure 2 In the embodiment, the outer diameter of the first groove 111 may be 1.5 mm to 4.5 mm, and the outer diameter of the first separation portion 113 may be 0.50 mm to 3.50 mm. In some specific embodiments of the present invention, the width of the first groove 111 may be 1.0 mm to 4.5 mm, for example, 1.0 mm. Figure 4B and Figure 5 In the embodiment, the first groove 111 is partially annular.

[0051] The second groove 121 penetrates the second electrode 12, and the first conductive through hole 41 extends through the second groove 121 and is spaced apart from the second electrode 12. The second groove 121 may be a through hole with a diameter of 0.50 mm to 3.50 mm. In some specific embodiments of the present invention, the diameter of the second groove 121 is 1.8 mm.

[0052] The third groove 211 penetrates the third electrode 21, and the second conductive through hole 42 extends through the third groove 211 and is spaced apart from the third electrode 21. The third groove 211 may be a through hole with a diameter of 0.50 mm to 3.50 mm. In some specific embodiments of the present invention, the diameter of the third groove 211 is 1.8 mm.

[0053] The fourth trench 221 extends through the fourth electrode 22 to separate the fourth electrode 22 into a fourth conducting portion 222 and a fourth separating portion 223. The fourth conducting portion 222 is connected to the second conductive through hole 42, and the fourth separating portion 223 is connected to the first conductive through hole 41 and is separated from the fourth conducting portion 222 by the fourth trench 221, so that the first conductive through hole 41 is separated from the fourth conducting portion 222 of the fourth electrode 22. Similar to the first trench 111, the fourth trench 221 may be annular, and the fourth separating portion 223 surrounds an opening on one side of the first conductive through hole 41. The outer diameter and width of the fourth trench 221 and the outer diameter of the fourth separating portion 223 are similar to those of the first trench 111 and the first separating portion 113, respectively.

[0054] See also Figures 6 to 8Each of the positive temperature coefficient overcurrent protection devices may further include a first conductive lead 71 connected to the first PTC component 10 and a second conductive lead 72 connected to the second PTC component 20 .

[0055] See also Fig.9A and Fig. 9B Another embodiment of the positive temperature coefficient overcurrent protection device of the present invention is similar to the above-mentioned Figure 2 , Figure 3A and Figure 3B The embodiment presented is similar, except that, in the present embodiment, the positive temperature coefficient overcurrent protection device further comprises a second insulating layer 32 and a fifth electrode 5, the second insulating layer 32 is arranged on the fourth electrode 22 opposite to the second PTC element 23, and the fifth electrode 5 is arranged on the second insulating layer 32 opposite to the fourth electrode 22 and electrically connected to the first conductive through hole 41. The fifth electrode 5 can be a copper foil (such as a nickel-plated copper foil). The first conductive through hole 41 and the second conductive through hole 42 extend through the first PTC component 10, the first insulating layer 31, the second PTC component 20, the second insulating layer 32 and the fifth electrode 5. Similar to the previous embodiment, each electrode is formed with a groove, and the fifth electrode 5 is formed with a fifth groove 51. The second insulating layer 32 can be made of epoxy glass fiber.

[0056] In this embodiment, the first conductive through hole 41 is spaced apart from the second electrode 12 and the fourth electrode 22 through the second groove 121 and the fourth groove 221, respectively, and the second conductive through hole 42 is spaced apart from the first electrode 11, the third electrode 21 and the fifth electrode 5 through the first groove 111, the third groove 211 and the fifth groove 51, respectively.

[0057] In this embodiment, the shapes of the first trench 111, the second trench 121 and the third trench 211 are the same as those of the previous embodiment. The fourth trench 221 is a through hole, and the first conductive through hole 41 extends through the fourth trench 221 to be spaced apart from the fourth electrode 22. The fifth trench 51 extends through the fifth electrode 5 to separate the fifth electrode 5 into a fifth conductive portion 52 and a fifth separation portion 53, the fifth conductive portion 52 is connected to the first conductive through hole 41, the fifth separation portion 53 is connected to the second conductive through hole 42 and is spaced apart from the fifth conductive portion 52 by the fifth trench 51, so that the second conductive through hole 42 is spaced apart from the fifth conductive portion 52 of the fifth electrode 5.

[0058] See also Fig. 10A and Fig. 10B Another embodiment of the positive temperature coefficient overcurrent protection device of the present invention is the same as the above Fig.9A and Fig. 9BThe embodiment presented is similar, except that, in the present embodiment, the positive temperature coefficient overcurrent protection device further comprises a third insulating layer 33 and a sixth electrode 6, the third insulating layer 33 is disposed on the first electrode 11, and the sixth electrode 6 is disposed on the third insulating layer 33 opposite to the first electrode 11 and is electrically connected to the second conductive through hole 42. The sixth electrode 6 may be a copper foil (such as a nickel-plated copper foil). The first conductive through hole 41 and the second conductive through hole 42 extend through the first PTC component 10, the first insulating layer 31, the second PTC component 20, the second insulating layer 32, the fifth electrode 5, the third insulating layer 33 and the sixth electrode 6. Similar to the aforementioned embodiment, each electrode is formed with a groove, and the sixth electrode 6 is formed with a sixth groove 61. In addition, the third insulating layer 33 may be made of epoxy glass fiber.

[0059] In this embodiment, the first conductive through hole 41 is spaced apart from the second electrode 12, the fourth electrode 22 and the sixth electrode 6 through the second groove 121, the fourth groove 221 and the sixth groove 61, respectively, and the second conductive through hole 42 is spaced apart from the first electrode 11, the third electrode 21 and the fifth electrode 5 through the first groove 111, the third groove 211 and the fifth groove 51, respectively.

[0060] In this embodiment, the shapes of the second trench 121, the third trench 211, the fourth trench 221 and the fifth trench 51 are the same as those of the previous embodiment. The first trench 111 is a through hole, and the second conductive through hole 42 extends through the first trench 111 to be spaced apart from the first electrode 11. The sixth trench 61 extends through the sixth electrode 6 to separate the sixth electrode 6 into a sixth conductive portion 62 and a sixth separation portion 63, the sixth conductive portion 62 is connected to the second conductive through hole 42, the sixth separation portion 63 is connected to the first conductive through hole 41 and is spaced apart from the sixth conductive portion 62 by the sixth trench 61, so that the first conductive through hole 41 is spaced apart from the sixth conductive portion 62 of the sixth electrode 6.

[0061] Based on actual needs, the positive temperature coefficient overcurrent protection device of the present invention may include more than two PTC components, and the corresponding insulating layer may be sandwiched between two adjacent PTC components.

[0062] The present invention will be further described with reference to the following examples, but it should be understood that the examples are only for illustration and should not be construed as limitations of the present invention.

[0063] Example

[0064] <Example 1 (E1)>

[0065] First, 10.25 g of HDPE (purchased from Formosa Plastics Corporation, product model: HDPE9002) was used as a non-grafted olefin polymer, 10.25 g of HDPE grafted with maleic anhydride (purchased from DuPont, product model: MB100D) was used as an olefin polymer grafted with carboxylic anhydride, and 29.5 g of carbon black powder (purchased from Columbian Chemicals, product model: Raven 430UB) was used as a conductive filler. The above ingredients were mixed in a mixer (brand: Brabender) at a temperature of 200° C. and a stirring speed of 30 rpm for 10 minutes to obtain a mixture of ingredients.

[0066] The mixed ingredients were placed in a mold and hot pressed at a temperature of 200°C and a pressure of 80 kg / cm 2 The film was hot-pressed for 4 minutes under the conditions of to obtain a PTC layer sheet with a thickness of 0.35 mm (as a PTC component).

[0067] The PTC layer sheet was sandwiched between two nickel-plated copper foils (as electrodes) and heated at 200°C and 80 kg / cm 2 The PTC laminate was hot pressed for 4 minutes to obtain a PTC laminate with a thickness of 0.42 mm. The PTC laminate was cut into a plurality of PTC chips with a size of 13.5 mm×13.5 mm, and then irradiated with Co-60 gamma rays with a total radiation dose of 150 kGy. The PTC chips were used as the first PTC component 10 and the second PTC component 20.

[0068] Subsequently, the second groove 121 (a through hole with a diameter of 1.8 mm) is formed in the second electrode 12 of the first PTC component 10, and the third groove 211 (a through hole with a diameter of 1.8 mm) is formed in the third electrode 21 of the second PTC component 20. Next, the first PTC component 10, the epoxy resin glass fiber board (as the first insulating layer 31) and the second PTC component 20 are stacked in sequence so that the second electrode 12 and the third electrode 21 are adjacent to the epoxy resin glass fiber board to form a stacked structure. The stacked structure is hot pressed at a hot pressing temperature of 170°C for 1 hour.

[0069] Next, the stacked structure is drilled to form two through holes with a diameter of 0.65 mm each, and then electroplated to form the first conductive through hole 41 and the second conductive through hole 42 (each with a diameter of 0.6 mm). Afterwards, the first groove 111 (with a width of 1 mm) is formed in the first electrode 11, and the fourth groove 221 (with a width of 1 mm) is formed in the fourth electrode 22. In this way, a positive temperature coefficient overcurrent protection device E1 is obtained, which has the following characteristics: Figure 2 The structure shown.

[0070] <Examples 2 and 3 (E2 and E3)>

[0071] The process conditions of the positive temperature coefficient overcurrent protection devices E2 and E3 are similar to those of E1, except that the first conductive through hole 41 and the second conductive through hole 42 of E2 are disposed at opposite edges of the positive temperature coefficient overcurrent protection device. Figure 4A and Figure 4B The structure shown; E3's first conductive through hole 41 and the second conductive through hole 42 are disposed on the same edge of the positive temperature coefficient overcurrent protection device, which has such Figure 5 The structure shown.

[0072] <Examples 4 to 6 (E4-E6)>

[0073] The process conditions of the positive temperature coefficient overcurrent protection devices E4-E6 are similar to those of E1-E3, except that: E4-E6 further include the first conductive lead 71 and the second conductive lead 72, each of which has a diameter of 0.8 mm and has the following characteristics: Figure 6-Figure 8 The structures shown (see Table 1).

[0074] <Example 7 (E7)>

[0075] The process conditions of the positive temperature coefficient overcurrent protection device of E7 are similar to those of E1, except that: in the process of Example 7, before stacking, similar to the second groove 121 and the third groove 211, the fourth groove 221 (a through hole with a diameter of 1.8 mm) is formed in the fourth electrode 22. Then, the first PTC component 10, the first insulating layer 31, the second PTC component 20, the epoxy resin glass fiber board (as the second insulating layer 32) and the nickel-plated copper foil (as the fifth electrode 5) are stacked in sequence to form a stacked structure. The stacked structure is hot-pressed at a hot-pressing temperature of 170°C for 1 hour. Then, similar to Example 1, the first conductive through hole 41 and the second conductive through hole 42 are formed. Afterwards, the first groove 111 (with a width of 1 mm) is formed in the first electrode 11, and the fifth groove 51 (with a width of 1 mm) is formed in the fifth electrode 5. Then, the first conductive lead 71 and the second conductive lead 72 (each conductive lead has a diameter of 0.8 mm) are connected to the first electrode 11 and the fifth electrode 5 respectively. Thus, the positive temperature coefficient overcurrent protection device E7 is obtained, which has the following features: Fig.9A and Fig. 9B The structure shown (the first conductive lead 71 and the second conductive lead 72 are not shown in the figure).

[0076] <Example 8 (E8)>

[0077] The process conditions of the positive temperature coefficient overcurrent protection device of E8 are similar to those of E7, except that: in the process of Example 8, before stacking, similar to the second groove 121, the third groove 211 and the fourth groove 221, the first groove 111 (a through hole with a diameter of 1.8 mm) is formed in the first electrode 11. Then, the nickel-plated copper foil (as the sixth electrode 6), the epoxy resin glass fiber board (as the third insulating layer 33), the first PTC component 10, the first insulating layer 31, the second PTC component 20, the second insulating layer 32 and the fifth electrode 5 are stacked in sequence to form a stacking structure. The stacking structure is hot-pressed at a hot-pressing temperature of 170° C. for 1 hour. Then, similar to Example 1, the first conductive through hole 41 and the second conductive through hole 42 are formed. Afterwards, the fifth groove 51 (with a width of 1 mm) is formed in the fifth electrode 5, and the sixth groove 61 (with a width of 1 mm) is formed in the sixth electrode 6. Then, the first conductive lead 71 and the second conductive lead 72 (each conductive lead has a diameter of 0.8 mm) are connected to the sixth electrode 6 and the fifth electrode 5, respectively. Thus, the positive temperature coefficient overcurrent protection device E8 is obtained, which has the following features: Fig. 10A and Fig. 10B The structure shown (the first conductive lead 71 and the second conductive lead 72 are not shown in the figure).

[0078] <Example 9 (E9)>

[0079] The process conditions of the positive temperature coefficient overcurrent protection device of E9 are similar to those of E4, except that the diameters of the first conductive lead 71 and the second conductive lead 72 of E9 are both 1.0 mm (see Table 1).

[0080] <Comparative Example 1 (CE1)>

[0081] The positive temperature coefficient overcurrent protection device of CE1 is the PTC chip of E1 (see Table 1).

[0082] <Comparative Example 2 (CE2)>

[0083] The process conditions of the positive temperature coefficient overcurrent protection device of CE2 are similar to those of CE1, except that CE2 further comprises the first conductive lead 71 and the second conductive lead 72, each conductive lead having a diameter of 0.8 mm. Figure 1 The structures shown (see Table 1).

[0084] <Comparative Example 3 (CE3)>

[0085] The process conditions of the positive temperature coefficient overcurrent protection device of CE3 are similar to those of CE2, and the difference is that the diameters of the first conductive lead 71 and the second conductive lead 72 of CE3 are both 1.0 mm (see Table 1).

[0086] Table 1

[0087]

[0088] “--” means there is no such component.

[0089] Performance Testing

[0090] [Resistance test]

[0091] Take 10 positive temperature coefficient overcurrent protection devices of E1-E9 and CE1-CE3 as test samples, and measure the voltage at 16V using a micro ohm meter. dc The resistance test is carried out at a voltage of 100A and a current of 100A to determine the initial resistance (R i ). The average values ​​of the test results are shown in Table 1.

[0092] The results in Table 1 show that the average initial resistance of the test samples E1-E9 ranges from 1.02 mΩ to 3.75 mΩ, which is generally lower than the test samples CE1-CE3 (4.02 mΩ to 7.25 mΩ).

[0093] [Trip current test]

[0094] Take 10 positive temperature coefficient overcurrent protection devices E1-E9 and CE1-CE3 as test samples respectively and test them at 16V dc The trip current test is carried out at a voltage of 1000V to determine the trip current of the test sample when the trip time is 20-30 seconds. The average values ​​of the test results are shown in Table 2.

[0095] The results in Table 2 show that the average tripping current of the test samples E1-E9 is between 27A and 34A, which is significantly higher than the test samples CE1-CE3 (16A to 20A), and can protect the circuit at an appropriate time. The positive temperature coefficient overcurrent protection device of the present invention can provide better heat conduction and lower resistance than the existing positive temperature coefficient overcurrent protection device, and thus has a higher tripping current.

[0096] Table 2

[0097]

[0098] [Switching cycle test]

[0099] Ten positive temperature coefficient overcurrent protection devices of E1-E9 and CE1-CE3 are taken as test samples, and a switching cycle test is performed to determine the resistance change of the test samples.

[0100] The switching cycle test is to measure the post-test resistance (R f1 ) and calculate the resistance change rate (R f1 / R i × 100%), 16V dc The test samples E1-E9 and CE1-CE3 were connected for 60 seconds at a voltage of 100A and a current of 100A, and then disconnected for 60 seconds. This switching cycle was repeated 6000 times. The resistance after the test of each test sample was measured and the resistance change rate was calculated. The average values ​​of the test results are shown in Table 2.

[0101] The results in Table 2 show that the average resistance change rate of the test samples E1-E9 is between 557% and 941%, which is significantly lower than that of the test samples CE1-CE3 (1430% to 1768%), indicating that the positive temperature coefficient overcurrent protection device of the present invention having a stacked structure and the conductive through hole has better reliability.

[0102] [Aging test]

[0103] Ten positive temperature coefficient overcurrent protection devices of E1-E9 and CE1-CE3 are taken as test samples, and an aging test is performed to determine the resistance change of the test samples.

[0104] The aging test is to measure the post-test resistance (R f2 ) and calculate the resistance change rate (R f2 / R i × 100%), using a power supply (purchased from Qinghong Electronics Enterprise Co., Ltd., product model: DSP-060-050HD) to apply 16V dc The test results are shown in Table 2.

[0105] The results in Table 2 show that the average resistance change rate of the test samples E1-E9 is between 344% and 592%, which is significantly lower than that of the test samples CE1-CE3 (906% to 1125%), indicating that the positive temperature coefficient overcurrent protection device of the present invention having a stacked structure and the conductive through hole has better reliability.

[0106] In summary, the positive temperature coefficient overcurrent protection device of the present invention can improve conductivity and have good electrical properties and reliability by forming a stacked structure, the first conductive through hole 41 and the second conductive through hole 42, so the purpose of the present invention can be achieved.

[0107] The above descriptions are merely embodiments of the present invention and should not be used to limit the scope of the present invention. That is, any simple equivalent changes and modifications made according to the claims and description of the present invention still fall within the scope of the present invention.

Claims

1. A positive temperature coefficient overcurrent protection device, characterized in that It contains: A first PTC component comprises a first electrode, a second electrode and a first PTC element, wherein the first PTC element is sandwiched between the first electrode and the second electrode; A second PTC component comprises a third electrode, a fourth electrode and a second PTC element, wherein the second PTC element is sandwiched between the third electrode and the fourth electrode; A first insulating layer is sandwiched between the first PTC component and the second PTC component; A first conductive through hole electrically connects the first electrode and the third electrode; and The second conductive through hole electrically connects the second electrode and the fourth electrode.

2. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that: The second electrode is disposed adjacent to the first insulating layer relative to the first electrode, and the third electrode is disposed adjacent to the first insulating layer relative to the fourth electrode.

3. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that: The first conductive through hole and the second conductive through hole extend through the first PTC component, the first insulating layer and the second PTC component.

4. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that: The first electrode is formed with a first groove, the second electrode is formed with a second groove, the third electrode is formed with a third groove, the fourth electrode is formed with a fourth groove, the first conductive through hole is respectively spaced apart from the second electrode and the fourth electrode through the second groove and the fourth groove, and the second conductive through hole is respectively spaced apart from the first electrode and the third electrode through the first groove and the third groove.

5. The positive temperature coefficient overcurrent protection device according to claim 4, characterized in that: The first groove extends through the first electrode to divide the first electrode into a first conductive portion and a first separation portion, the first conductive portion is connected to the first conductive through hole, the first separation portion is connected to the second conductive through hole and is separated from the first conductive portion by the first groove, so that the second conductive through hole is separated from the first conductive portion of the first electrode.

6. The positive temperature coefficient overcurrent protection device according to claim 5, characterized in that: The first groove is annular, and the first separation portion surrounds an opening on one side of the second conductive through hole.

7. The positive temperature coefficient overcurrent protection device according to claim 4, characterized in that: The second trench penetrates the second electrode, and the first conductive through hole extends through the second trench and is spaced apart from the second electrode.

8. The positive temperature coefficient overcurrent protection device according to claim 4, characterized in that: The third trench penetrates the third electrode, and the second conductive through hole extends through the third trench and is spaced apart from the third electrode.

9. The positive temperature coefficient overcurrent protection device according to claim 4, characterized in that: The fourth trench extends through the fourth electrode to divide the fourth electrode into a fourth conductive portion and a fourth separation portion, the fourth conductive portion is connected to the second conductive through hole, the fourth separation portion is connected to the first conductive through hole and is separated from the fourth conductive portion by the fourth trench, so that the first conductive through hole is separated from the fourth conductive portion of the fourth electrode.

10. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that The device further comprises a first conductive lead connected to the first PTC component and a second conductive lead connected to the second PTC component.

11. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that: The first conductive through hole and the second conductive through hole are disposed at opposite edges of the positive temperature coefficient overcurrent protection device.

12. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that: The first conductive through hole and the second conductive through hole are arranged on the same edge of the positive temperature coefficient overcurrent protection device.

13. The positive temperature coefficient overcurrent protection device according to claim 1, characterized in that The invention further comprises: a second insulating layer and a fifth electrode. The second insulating layer is arranged on the fourth electrode. The fifth electrode is arranged on the second insulating layer opposite to the fourth electrode and is electrically connected to the first conductive through hole.

14. The positive temperature coefficient overcurrent protection device according to claim 13, characterized in that: The first conductive through hole and the second conductive through hole extend through the first PTC component, the first insulating layer, the second PTC component, the second insulating layer and the fifth electrode.

15. The positive temperature coefficient overcurrent protection device according to claim 13, characterized in that: The first electrode is formed with a first groove, the second electrode is formed with a second groove, the third electrode is formed with a third groove, the fourth electrode is formed with a fourth groove, and the fifth electrode is formed with a fifth groove. The first conductive through hole is respectively spaced apart from the second electrode and the fourth electrode through the second groove and the fourth groove, and the second conductive through hole is respectively spaced apart from the first electrode, the third electrode, and the fifth electrode through the first groove, the third groove, and the fifth groove.

16. The positive temperature coefficient overcurrent protection device according to claim 15, characterized in that: The first trench extends through the first electrode to separate the first electrode into a first conducting portion and a first separating portion, the first conducting portion is connected to the first conductive through hole, the first separating portion is connected to the second conductive through hole and is separated from the first conducting portion by the first trench, so that the second conductive through hole is separated from the first conducting portion of the first electrode, and The fifth trench extends through the fifth electrode to divide the fifth electrode into a fifth conductive portion and a fifth separated portion, the fifth conductive portion is connected to the first conductive through hole, the fifth separated portion is connected to the second conductive through hole and is separated from the fifth conductive portion by the fifth trench, so that the second conductive through hole is separated from the fifth conductive portion of the fifth electrode.

17. The positive temperature coefficient overcurrent protection device according to claim 13, characterized in that The invention further comprises: a third insulating layer and a sixth electrode. The third insulating layer is arranged on the first electrode. The sixth electrode is arranged on the third insulating layer opposite to the first electrode and is electrically connected to the second conductive through hole.

18. The positive temperature coefficient overcurrent protection device according to claim 17, characterized in that: The first conductive through hole and the second conductive through hole extend through the first PTC component, the first insulating layer, the second PTC component, the second insulating layer, the fifth electrode, the third insulating layer and the sixth electrode.

19. The positive temperature coefficient overcurrent protection device according to claim 17, characterized in that: The first electrode is formed with a first groove, the second electrode is formed with a second groove, the third electrode is formed with a third groove, the fourth electrode is formed with a fourth groove, the fifth electrode is formed with a fifth groove, and the sixth electrode is formed with a sixth groove. The first conductive through hole is respectively spaced apart from the second electrode, the fourth electrode, and the sixth electrode through the second groove, the fourth groove, and the sixth groove, and the second conductive through hole is respectively spaced apart from the first electrode, the third electrode, and the fifth electrode through the first groove, the third groove, and the fifth groove.

20. The positive temperature coefficient overcurrent protection device according to claim 17, characterized in that: The first insulating layer, the second insulating layer and the third insulating layer are made of epoxy resin glass fiber.

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