PTC Device Through-Hole Electrode Connection
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Solution Overview
Problem
The PTC device's metal plated layer tends to peel at the connection portion between the laminar electrode and the side electrode, leading to operational failures over time.
Innovation Solution
Direct electrical connection is established between the edge portion of the insulation layer and the laminar electrode of the PTC component through a through-hole with an electrically conductive element, such as a metal plated layer or conductive paste, to enhance the connection area and alleviate mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal plated layer is used to connect the laminar electrode and the side electrode, then electrical connection is established, but the metal plated layer peels at the connection portion over time
Solution Approach 1:
The invention transitions from a planar connection (metal plated layer on surface) to a three-dimensional connection (through-hole penetrating the insulation layer). The through-hole creates a vertical pathway that allows the conductive element to directly connect the laminar electrode and side electrode, eliminating the peeling issue of surface-mounted metal layers.
Solution Approach 2:
The through-hole acts as an intermediary structure that facilitates direct connection between the laminar electrode and side electrode. By filling the through-hole with conductive material or plating its inner wall, a robust conductive pathway is created that mediates the electrical connection while resisting mechanical stress and peeling.
2Strength
If the connection area between the laminar electrode and side electrode is increased, then connection strength is improved, but the device structure becomes more complex
Solution Approach 1:
The through-hole connection utilizes the thickness dimension of the insulation layer to create an extended connection path. This vertical dimension allows for increased connection area and strength without expanding the planar footprint or adding lateral complexity to the device structure.
Solution Approach 2:
The through-hole and its conductive filling create a localized high-strength connection region at the critical interface between laminar electrode and side electrode. This concentrated local quality improvement provides enhanced connection strength precisely where needed, without requiring complex structures throughout the entire device.
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 prevents peeling and ensures a more stable connection by increasing the contact area and reducing mechanical stress caused by volume expansion or contraction of the PTC component during activation.
Implementation Method 1
providing an electrically conductive element (42) in this through-hole to electrically connect the laminar electrode and the side electrode
Implementation Method 2
providing an electrically conductive metal layer (for example, a plated layer) on the wall defining the through-hole
Implementation Method 3
alleviate mechanical stress caused by volume expansion or contraction of the PTC component during activation
Data Source
AI summary
The present invention provides a PTC device having a laminate which includes a PTC component having a laminar PTC element defined by main surfaces which are facing each other, laminar electrodes extending on the main surfaces, and a first insulation layer, the PTC component, and a second insulation layer laminated in this listed order. The laminate has a first end and a second end, and a first side electrode and a second side electrode are disposed on the first end and the second end, respectively; one of laminar electrodes of the PTC component extends while being separated from the first side electrode and the second side electrode; the other is separated from the first end, and extends to the second end and is electrically connected to the second side electrode. At least the first side electrode extends at the first end along an entirety of a thickness direction of the laminate and further extends on a first edge portion of one of the insulation layers; and the first edge portion has a through-hole which reaches the one laminar electrode. The through-hole has an electrically conductive element which electrically connects the one laminar electrode and the first side.