Embedded PTC Circuit Protection Assembly
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Solution Overview
Problem
Traditional circuit protection components face challenges in miniaturization and environmental reliability due to space limitations and external environmental impacts, especially in high-current applications like intelligent mobile terminals.
Innovation Solution
A circuit protection assembly with a positive temperature coefficient (PTC) resistance element embedded in a copper clad laminate, featuring a polymer-based conductive composite layer between metal electrode plates, which reduces thickness constraints and enhances environmental reliability by sealing the PTC elements within the laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional circuit protection components are mounted on the surface of the circuit board, then installation and replacement are easier, but the battery pack space is limited and miniaturization is difficult
Solution Approach 1:
The PTC protection element is merged with the copper clad laminate to form an integrated circuit protection assembly. The PTC element is embedded within the laminate structure, combining the protection function with the circuit board material itself, thereby reducing overall volume while maintaining functionality
Solution Approach 2:
The PTC protection element is nested inside the copper clad laminate structure. The element is placed within a through-hole of the laminate and secured with adhesive, creating a nested configuration that saves space while preserving the protection function
2Reliability
If PTC elements are exposed to external environment, then manufacturing and installation are simpler, but environmental reliability deteriorates due to negative impacts from external environment
Solution Approach 1:
The copper clad laminate acts as a protective shell enclosing the PTC element. The laminate structure provides environmental isolation while maintaining electrical functionality, protecting the sensitive PTC material from external factors such as moisture, oxygen, and mechanical damage
Solution Approach 2:
The circuit protection assembly uses composite material structure combining PTC polymer material with copper-clad laminate. This composite structure provides both the electrical protection function of the PTC element and the environmental protection of the laminate enclosure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively saves installation space and improves environmental reliability by reducing external impacts on PTC elements, enabling more compact and reliable circuit protection in miniaturized electronic devices.
Implementation Method 1
the resistance of polymer-based conductive composite material remains extremely low at room temperature and is sensitive to temperature change. In other word, the resistance will instantly increase to thousand times to open-circuit conditions when the temperature reaches a critical temperature or the circuit has over current
Data Source
AI summary
A circuit protection assembly has a protection element having a positive temperature coefficient of resistance and consisting of a polymer-based conductive composite material layer tightly clamped and fixed between two metal electrodes and a copper clad laminate having a through hole in a middle thereof, wherein the protection element is provided in the through hole, the copper clad laminate serves as a substrate for the circuit protection assembly and has an adhesive layer on an upper surface and a lower surface thereof, so as to cover the protection element in a space formed by the copper clad laminate and the upper and the lower adhesive layers. The protection element having a positive temperature coefficient of resistance is electrically connected to a protected circuit via a conductive part.