Quick-response over-current protection component
By introducing heating components into the PPTC overcurrent protection components, heat is transferred to the PPTC main layer, the problem of the long response protection time of existing PPTC components is solved, and rapid protection under the specified current is achieved, avoiding the occurrence of motor motor burning or safety accidents.
Patent Information
- Application Number
- CN202421275613.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-05
- Publication Date
- 2025-03-25
- Estimated Expiration
- 2034-06-05
AI Technical Summary
The existing PPTC overcurrent protection components have a long response protection time under the minimum starting current, and cannot stop the motor or motor in time, resulting in motor burning or safety accidents.
The fast-responsive overcurrent protection components including PPTC composite chips and heating components are adopted to transfer heat to the PPTC main layer through the heating layer, which prompts the resistance value to quickly enter the high resistance state from low resistance to achieve rapid protection.
Under the specified current, PPTC can respond quickly to protection, avoiding excessive motor temperature burns or safety accidents, significantly shortening the protection response time.
Smart Images
Figure CN222672722U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of electronic product production, and particularly relates to a fast-response overcurrent protection component. Background Art
[0002] In existing motors, motor protection uses leaded PPTC products as overcurrent safety protection. The general processing flow is: PPTC chip processing, PPTC chip stamping, PPTC chip and lead welding molding packaging, and finally making a leaded structure PPTC.
[0003] Polymer Positive Temperature Coefficient (PPTC) protection components have over-current and over-temperature protection effects. When the current reaches the fault protection current, PPTC will start protection to reduce the loop current and ensure circuit safety. However, in the fields of motor protection, it is often necessary to start protection quickly at a specified current value. The normal rated current is 1.5A and the minimum starting current is 3.0A. Generally, the response protection time of PPTC at the minimum starting current is generally 60~120 seconds. The slow response time causes the motor to fail to stop working in time, resulting in motor burnout or safety accidents.
[0004] Specifically, the PPTC startup protection mechanism is a kind of energy balance. When current flows through the PPTC device, the PPTC itself generates heat, and the generated heat will be fully or partially dissipated into the environment. The heat that is not dissipated will increase the temperature of the PPTC device. When the generated heat and the dissipated heat reach a balance, the PPTC is in a normal working state. However, when the current flowing through is large or the ambient temperature is high, higher heat will be generated, thereby increasing the temperature of the PPTC device. When the temperature rises and breaks through the Curie temperature of the material, the resistance value changes rapidly and reaches a high resistance state, thereby reducing the loop current to achieve a safety protection effect. Therefore, the process of PPTC changing from a low resistance state to a stable high resistance state is the PPTC startup protection process. The speed of this process mainly depends on the response speed of PPTC itself. Generally, during use, customers need to be able to start protection within a limited time range under a specified current, and the response time must be fast, but the response speed of PPTC itself cannot meet the requirements, resulting in motor burnout or safety accidents.
[0005] In view of this, the utility model aims to provide a fast-response overcurrent protection component, so that under a specified current, the PPTC can quickly respond to protection and avoid the motor from burning due to overheating or safety accidents. Utility Model Content
[0006] The purpose of the utility model is to provide a fast-response overcurrent protection component to address the deficiencies of the prior art, so that under a specified current, the PPTC can quickly respond to protection and avoid the motor from burning out due to overheating or safety accidents.
[0007] In order to achieve the above purpose, the utility model adopts the following technical solutions:
[0008] A fast-response overcurrent protection component comprises a PPTC composite chip and a heating component, wherein the heating component comprises a heating layer, an FR4 substrate and a first copper foil layer arranged in sequence, the heating layer is connected to the first copper foil layer through a via hole, and a partial area of the heating layer is connected to a partial area of the PPTC composite chip by welding through a tin-plated conductive layer.
[0009] As an improvement of the fast-response overcurrent protection component of the utility model, a solder resist layer is formed on the non-soldering area between the heating layer and the PPTC composite chip.
[0010] As an improvement of the fast-response overcurrent protection component of the utility model, the PPTC composite chip includes a PPTC main body layer and a second copper foil layer and a third copper foil layer respectively attached to the upper surface and the lower surface of the PPTC main body layer.
[0011] As an improvement of the fast-response overcurrent protection component of the utility model, a first copper wire is welded on the first copper foil layer, and a second copper wire is welded on the third copper foil layer.
[0012] As an improvement of the fast-response overcurrent protection component of the utility model, the heating layer, the FR4 substrate and the first copper foil layer are formed into a plate structure through a pressing process.
[0013] As an improvement of the fast-response overcurrent protection component of the utility model, the specific material of the heating layer is copper or copper alloy.
[0014] As an improvement of the fast-response overcurrent protection component of the utility model, a nickel-tin plating layer is formed on the surface of the via.
[0015] As an improvement of the fast-response overcurrent protection component of the utility model, a partial area of the FR4 substrate is welded and connected to a partial area of the PPTC composite chip through a welding fixing layer, and the welding fixing layer is not conductive to the heating layer.
[0016] Compared with the prior art, the utility model provides a fast response protection overcurrent component, which adopts a series structure connection. The current flows in from the first copper wire, passes through the first copper foil layer, the conductive hole, the heating layer, the tinned conductive layer, the second copper foil layer, the PPTC main layer, and the third copper foil layer in sequence, and then flows out from the second copper wire to realize the electrical function of the product. When the current exceeds the rated working current or reaches the fault current, the heating layer will heat up rapidly and transfer the heat to the PPTC main layer. In addition to generating heat itself, the PPTC main layer also receives heat from the heating layer, causing the resistance value to quickly change from a low resistance to a high resistance state, entering safety protection, and the loop current is reduced. Because the current is reduced, the heating output of the heating layer stops, but the PPTC main layer continues to maintain a high resistance state for safety protection by relying on the residual current after protection until the fault is resolved.
[0017] In short, the utility model can achieve that under the specified current, the PPTC can quickly respond to protection, avoiding the motor from burning due to overheating or safety accidents. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 It is a schematic diagram of the cross-sectional structure of the utility model.
[0019] Figure 2 It is a front structural schematic diagram of the heating component in the utility model.
[0020] Figure 3 for Figure 2 Schematic diagram of the structure of the AA section. DETAILED DESCRIPTION
[0021] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.
[0022] It should be noted that all directional indications (such as up, down, left, right, front, back...) in the embodiments of the present invention are only used to explain the relative position relationship, movement status, etc. between the components under a specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.
[0023] In addition, the descriptions of "first", "second", etc. in the present utility model are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present utility model.
[0024] Comparative Example
[0025] According to the traditional method, 240V PPTC rods are selected, 16.8mm diameter PPTC chips are punched, 0.8mm diameter copper wires are selected, and the products are welded, assembled and packaged into the traditional PPTC lead structure product R1.
[0026] Example
[0027] like Figure 1-3 As shown, this embodiment provides a fast-response overcurrent protection component, including a PPTC composite chip 1 and a heating component 2, the heating component 2 includes a heating layer 21, a FR4 substrate 22 and a first copper foil layer 23 arranged in sequence, the heating layer 21 is connected to the first copper foil layer 23 through a conductive hole 24, and a partial area of the heating layer 21 is connected to a partial area of the PPTC composite chip 1 by welding through a tin-plated conductive layer 25.
[0028] A solder resist layer 26 is formed on the non-soldering area between the heating layer 21 and the PPTC composite chip 1 to ensure the insulation effect.
[0029] The PPTC composite chip 1 includes a PPTC main layer 11 and a second copper foil layer 12 and a third copper foil layer 13 respectively attached to the upper surface and the lower surface of the PPTC main layer 11 . The heating layer 21 and a partial area of the second copper foil layer 12 are welded and connected by a tin-plated conductive layer 25 .
[0030] The first copper wire 3 is welded onto the first copper foil layer 23 , and the second copper wire 4 is welded onto the third copper foil layer 13 .
[0031] The heating layer 21, the FR4 substrate 22 and the first copper foil layer 23 are pressed together to form a plate structure. The FR4 substrate 22 is the abbreviation of a glass fiber reinforced epoxy resin material with a flame retardant grade of 4.
[0032] The specific material of the heating layer 21 is copper or copper alloy.
[0033] A nickel-tin plating layer is formed on the surface of the via hole 23 to ensure that the heating layer 21 is electrically connected to the first copper foil layer 23 .
[0034] Part of the FR4 substrate 22 is welded to part of the PPTC composite chip 1 (specifically part of the second copper foil layer 12 ) via the welding fixing layer 27 . The welding fixing layer 27 is not connected to the heating layer 21 , so as to improve the welding strength.
[0035] The specific implementation scheme of the product structure of the utility model is as follows:
[0036] The first step is to laminate the second copper foil layer 12 and the third copper foil layer 13 on the upper and lower surfaces of the PPTC main body layer 11 to make a plastic sheet;
[0037] The second step is to punch the plastic sheet into a shape required by the product characteristics, such as a circle, a square, etc., to obtain the PPTC composite chip 1;
[0038] The third step is to implement the heating component processing as follows:
[0039] (1) Laminating the first copper foil layer 23, the FR4 substrate 22 and the heating layer 21 to form a plate;
[0040] (2) The heating layer 21 is processed by the inner layer etching method: a. The heating layer 21 is processed into a required shape, such as a circular ring, a square ring, etc., and the area pattern required by different products is as follows: Figure 3 As shown; b. The tinned conductive layer 25 is processed in the middle, and the reserved area can be calculated and tinned according to the welding strength requirements, and it is ensured that the tinned conductive layer 25 and the heating layer 21 are connected and conductive. c. The welding fixing layer 27 is processed: multiple shape areas can be reserved around without etching as the welding fixing layer 27. The welding fixing layer 27 is not conductive with the heating layer 21, which plays a role in improving the welding strength; d. The via hole 24 is processed: the via hole 24 is processed at the outer port of the heating layer 21, and the copper is deposited on the via hole 24 and nickel-tin is electroplated to make the heating layer 21 and the first copper foil layer 23 conductive; e. Except for the tinned conductive layer 25 and the welding fixing layer 27 area, the solder mask 26 is evenly printed to ensure the insulation effect.
[0041] In the fourth step, a layer of solder paste is covered on the tin-plated conductive layer 25 and the solder fixing layer 27 on the surface of the heating component 2, and the PPTC composite chip 1 is covered thereon, and the PPTC composite chip 1 and the heating component 2 are soldered together by heating.
[0042] In the fifth step, after the first copper wire 3 and the second copper wire 4 are processed and formed, a layer of tin is covered on the bent part of the wire, and the welded PPTC composite chip 1 and the heating component 2 are welded together with the first copper wire 3 and the second copper wire 4. The finished product after welding is an ultra-fast response overcurrent protection component.
[0043] According to the above processing flow, select 240V PPTC rods, punch 16.8mm diameter PPTC chips, and make heating component 2 with the same diameter of 16.8mm according to the processing method of heating component 2. Select 0.8mm diameter copper wire, assemble according to the processing method, and finally make a fast-response overcurrent protection component R2.
[0044] When 3A / 240V is supplied to R1 and R2 respectively, the startup protection time of R1 is about 85 seconds; the protection time of R2 is 5 seconds. It can be seen that the utility model can achieve a quick response result.
[0045] In summary, the utility model provides a fast response protection overcurrent component, which adopts a series structure connection. The current flows in from the first copper wire 13, passes through the first copper foil layer 23, the conductive hole 24, the heating layer 21, the tinned conductive layer 25, the second copper foil layer 12, the PPTC main layer 11, and the third copper foil layer 13 in sequence, and then flows out from the second copper wire 14 to realize the electrical function of the product. When the current exceeds the rated working current or reaches the fault current, the heating layer 21 will heat up rapidly and transfer the heat to the PPTC main layer 11. In addition to generating heat itself, the PPTC main layer 11 also receives heat from the heating layer 21, causing the resistance value to quickly change from a low resistance to a high resistance state, enter safety protection, and the loop current is reduced. Because the current is reduced, the heating output of the heating layer 21 stops, but the PPTC main layer 11 continues to maintain a high resistance state for safety protection by relying on the residual current after protection until the fault is resolved.
[0046] In short, the utility model can achieve the goal that under the specified current, the PPTC can quickly respond to protection, thereby preventing the motor from burning due to excessive temperature or safety accidents.
[0047] According to the disclosure and teaching of the above description, the technicians in the field of the utility model can also make appropriate changes and modifications to the above implementation. Therefore, the utility model is not limited to the specific implementation methods disclosed and described above, and some modifications and changes to the utility model should also fall within the scope of protection of the claims of the utility model. In addition, although some specific terms are used in this specification, these terms are only for the convenience of description and do not constitute any limitation to the utility model.
Claims
1. A fast-response overcurrent protection component, characterized in that: It includes a PPTC composite chip and a heating component, wherein the heating component includes a heating layer, an FR4 substrate and a first copper foil layer arranged in sequence, the heating layer is connected to the first copper foil layer through a conductive hole, and a partial area of the heating layer is connected to a partial area of the PPTC composite chip by welding through a tin-plated conductive layer.
2. The fast-response overcurrent protection component according to claim 1, characterized in that: A solder resist layer is formed on the non-soldering area between the heating layer and the PPTC composite chip.
3. The fast-response overcurrent protection component according to claim 1, characterized in that: The PPTC composite chip includes a PPTC main body layer and a second copper foil layer and a third copper foil layer respectively attached to the upper surface and the lower surface of the PPTC main body layer.
4. The fast-response overcurrent protection component according to claim 3, characterized in that: A first copper wire is welded on the first copper foil layer, and a second copper wire is welded on the third copper foil layer.
5. The fast-response overcurrent protection component according to claim 1, characterized in that: The heating layer, the FR4 substrate and the first copper foil layer are formed into a plate structure through a lamination process.
6. The fast-response overcurrent protection component according to claim 1, characterized in that: The specific material of the heating layer is copper or copper alloy.
7. The fast-response overcurrent protection component according to claim 1, characterized in that: A nickel-tin plating layer is formed on the surface of the via hole.
8. The fast-response overcurrent protection component according to claim 1, characterized in that: A partial area of the FR4 substrate is welded and connected to a partial area of the PPTC composite chip via a welding fixing layer, and the welding fixing layer is not conductively connected to the heating layer.