CN1153577A - 面上安装式保险丝 - Google Patents
面上安装式保险丝 Download PDFInfo
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- CN1153577A CN1153577A CN95193295.0A CN95193295A CN1153577A CN 1153577 A CN1153577 A CN 1153577A CN 95193295 A CN95193295 A CN 95193295A CN 1153577 A CN1153577 A CN 1153577A
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Abstract
一种薄膜面上安装式保险丝(58)具有两种材料不同的配件。第一配件具有熔断丝(42)及其支承衬底(13)和端子衬垫(34、36)。第二配件具有位于熔断丝(42)上方的保护层(56),用以防止冲击和氧化。保护层(56)最好用聚合材料制成。优选的聚合材料为聚碳酸酯粘合剂。此外,优选的支承衬底(13)材料为FR-4环氧树脂或聚酰亚胺。
Description
本发明一般涉及在表面上安装的保险丝,用以装入和保护印刷电路板电路。
印刷电路板在各种电气和电子装备中的应用日益广泛。在这类印刷电路板上制成的电路如大规模集成电路、普通电路要求进行超载保护。这种保护较典型的是通过在印刷电路板上作机械固定的超小型保险丝取得的。
这种超小型面上安装式保险丝作为一例见之于美国专利5,166,656(以下简称为专利656)。这种面上安装式保险丝的熔断丝覆有三层复合材料:一钝化层、一绝缘层和一层用以将钝化层粘结在绝缘层上的环氧树脂层,见专利656,说明书第6栏第4-7行。钝化层较典型的是化学汽相沉积的二氧化硅层或厚层印刷玻璃,见专利656说明书第3栏第39-41行。绝缘面层可以是玻璃面层,见专利′656说明书第4栏第43-46行。与此不同,本发明不用三层而只用一层材料来保护熔断丝。
本发明为薄膜面上安装式保险丝,具有两种材料不同的配件。第一种配件为熔断丝及其支承衬底和端子衬垫。第二种配件为熔断丝上设置的保护层,用以防止其受冲击和氧化。
保护层最好用聚合材料制成。优选的聚合材料为聚碳酸酯粘合剂。此外,优选的支承衬底为FR-4环氧树脂或聚酰亚胺。
本发明第二种薄膜面上安装式保险丝具有用导电金属制成的熔断丝。第一导电金属最好、但并非无例外地、选自铜、银、镍、钛、铝及其合金一类金属。第二导电金属不同于第一导电金属而是沉积在这种熔断丝表面上的。本发明面上安装式保险丝所采用的一种优选金属为铜。第二优选导电金属为锡。
第二导电金属可在熔断丝上作长方形、圆形或其他任一形状如S形或螺旋形的沉积。如采用长方形或圆形沉积,这种导电金属最好沉积在熔断丝中部。
照相平版印刷、机械加工和激光加工技术可用以产生几何形状极为精致而复杂的熔断丝。这些技术与电化学、物理汽相沉积超薄膜涂敷技术相结合就可取得超小型保险丝来控制熔断元件的熔断面积而保护用于微安级和安级电流的电路。这是一种很独特的技术,因为现有的在这种高电流下起保护作用的保险丝是用灯丝制成的。制造这样的灯丝时是很难控制的。
本发明将熔断丝置于保险丝的衬底顶部,这就可用激光加工作为高精度辅助工序来微调熔断丝的最后电阻值。
图1为制造本发明超小型面上安装式保险丝所用FR-4环氧树脂镀铜薄片的透视图。
图2为图1薄片沿图1中2-2线的局部剖面图。
图3为图1 FR-4环氧树脂薄片在去除铜镀层并在其四分部分内开出切口后的透视图,切口的宽度为W,长度为L。
图4为图2薄片在开出切口并重新镀铜后的局部放大透视图。
图5为重镀铜的薄片在其上平面上用紫外线屏蔽物质作方格体屏蔽后的顶视图。
图6为图5重镀铜薄片背面的透视图,示出背面上经去除铜镀层的长条形部分。
图7为图6长条体26顶面38的透视图,用虚线示出长条区40。
图8为单体长条体26在浸入镀铜槽液再浸入镀镍槽液而在端子衬垫的铜底层上镀上铜度层和镍镀层后的视图。
图9为图8长条体在紫外线固化处理前的透视图,示出熔断丝42中部用紫外线屏蔽物质屏蔽的部分50。
图10为图9长条体在浸入镀锡槽液以便在铜和镍上镀上另一镀层并在熔断丝中部镀上锡以后的透视图。
图11为图10长条体26在其顶部加上热塑性粘合剂层后的透视图。
图12示出本发明最后制成的单件保险丝,这是用金刚石锯沿各平行面切割长条体取得这种单件面上安装式保险丝的。
虽然对本发明可以作出很多不同的实施例,但是这里在附图中仅示出一个优选实施例并对此作出具体说明。可以理解这些说明只是对本发明原理的示例说明。本发明并不受所示实施例的限制。
图12示出本发明的一优选实施例。薄膜面上安装式保险丝为在印刷电路板上或在厚膜混合电路上作面上安装的超小型保险丝。这种保险丝在本专业中一般称作“A”类保险丝。这种保险丝的标准工业尺寸为长125mil、宽60mil。这种保险丝简称1206保险丝。但是可以理解,本发明可用于所有其他标准尺寸的保险丝如1210、0805、0603和0402保险丝。也可用于非标准尺寸的保险丝。
概括地说,本发明具有两种材料不同的配件。第一种配件包括熔断元件或熔断丝42及其支承衬底或芯体13以及端部衬垫34、36,衬垫用以将保险丝58接到印刷电路板上。第二种配件构成位于熔断丝42和保险丝顶部主要部分上面的保护层56,用以保护熔断丝免受自动组装中的冲击和使用中的氧化。
在第一配件上装有两个金属电极或衬垫以及熔断元件,成为一单体连续薄膜粘结在衬底或芯体上。衬垫位于衬底或芯体的底部和侧面,熔断丝位于衬底或芯体的顶部。
可以看出,在优选实施例中,衬垫由若干层构成,包括基底铜层、补加铜层、镍层和锡层。衬垫的基底铜层和薄膜熔断丝是通过(1)·电化学处理,如以下优选实施例中所述的电镀或通过(2)·物理汽相沉积同时沉积成的。同时沉积可保证熔断丝和端子衬垫之间良好的导电通路。这种沉积也方便了制造并可十分准确地控制熔断丝的厚度。
在衬底或芯体上形成熔断丝和基底铜层后再在端子衬垫上形成附加的导电金属层。这些附加层可分别通过照相平版印刷和沉积技术在衬垫上形成。
这种保险丝可通过以下步骤制成。图1、2所示为带铜镀层12的FR-4环氧树脂实体薄片10。图2清楚地示出这一实体薄片10的铜镀层12和FR-4环氧树脂芯体13。这种镀铜的FR-4环氧树脂薄片10采用从New York州的Hoosick Falls市的Allied Signal LaminateSystems购得的0200BED130C1/C1GFN0200C1/C1A2C号构件。FR-4环氧树脂为优选材料,但也可采用任一其他与制造印刷电路板的合适材料相容的材料,也就是任一其他具有类似化学、物理和结构性质的合适材料。这样,另一种用于这种实体薄片10的合适材料为聚酰亚胺。FR-4环氧树脂和聚酰亚胺属于具有与印刷电路工业中所用标准衬底材料几乎相同物理性质的一种材料。这样,本发明的保除丝和在其上装保险丝的印刷电路板具有配合良好的热和机械性能。本发明保险丝衬底还具有所需电弧跟踪特性而同时呈现出足够的机械挠性,在燃弧快速释放能量下可保持完好无损。
在制造本发明保险丝的下一步骤中,通过普通腐蚀处理从实体薄片10上清除铜镀层12。在此普通的腐蚀处理中,用氯化铁溶液将铜从衬底上蚀除。
可以理解,在完成这一步骤后,图2铜层12完全被从实体薄片10的FR-4环氧树脂芯体13上作了腐蚀清除,但FR-4环氧树脂薄片10上剩下的环氧树脂芯体13却不同于原来未经镀铜处理的“纯”FR-4环氧树脂薄片。具体地说,化学腐蚀表面处理的作用在铜层12经腐蚀清除后仍在环氧树脂芯体13上保留下来。处理过的环氧树脂芯体13表面对以后的处理更容易接受,而这对于本发明面上安装式超小型保险丝的制造来说是很必要的。
FR-4环氧树脂薄片10上经处理过的无铜表面经冲孔而在其上开出分布在薄片10四分部分上的切口14如图3所示。在图3中虚线示出四个单独的四分部分。开口14(图4)的宽度W约为0.0625时。开口14的长度L(图3)约为5.125英寸。
在完成冲孔后,对图3中经腐蚀和冲孔的薄片10再镀以铜。重新镀铜是将图3中经腐蚀和冲孔的薄片浸入化学镀铜槽液中进行的。这是本专业中常用的镀铜处理。
这一镀铜的步骤使薄片10的裸露表面呈现一厚度均匀的铜层。例如,如图4所示,从这一步骤取得的铜镀层18覆盖了(1)薄片10的上平面22;(2)至少部分地构成切口14的垂直隙沿区16。此隙沿区16必须镀铜,因其最后会是成品保险丝端子衬垫的一部分。
铜镀层均匀的厚度取决于用户的最终要求。具体地说,如图4所示,对要求在1/16A下熔断的保险丝,铜镀层18的厚度为2,500。对于要求在5A下熔断的保险丝铜镀层18的厚度约为75,000。
在完成镀铜而取得图4镀铜构件后,在构件的整个裸露表面上涂上所谓的光致个抗蚀聚合物。
在涂上光致抗蚀剂后,在重镀铜的薄片20上放上另一种透明屏蔽体。这里采用作均匀分隔排列的方格屏蔽体。这些方格体是由紫外线屏蔽物质构成的,其尺寸相当于图5所示方格体30的尺寸。实际上,由于在重镀铜的薄片20上放上这些方格屏蔽体,重镀铜薄片20的上平面22上的若干部分就受到对紫外线的有效屏蔽。
这些方格体实际上限定所谓的熔断丝42和保险丝上部22宽端区60,62的形状和尺寸。熔断丝42与宽端区60,62作电气连通。熔断丝42和这些宽端区60,62的长、宽和形状可通过改变这些紫外线屏蔽方格体的形状和尺寸来改变。
此外,薄片的背面涂有光致抗蚀材料,在重镀铜薄片20上涂上光致抗蚀材料后再放上另一种透明屏蔽体。这里采用长格形屏蔽体。长格体是由紫外线屏蔽物质构成的,具有与图6所示长格体28尺寸相当的尺寸。实际上,在重镀铜薄片20上放上长格体后,重镀铜薄片20的一些长格形下平面28就受到对紫外线的有效屏蔽。
长格体实际上限定长条体26下面宽端区34,36的形状和尺寸。
长条体26下面一部分的铜镀层是由光致抗蚀剂的屏蔽体限定的。具体来说,长条件26下面的中部28上的铜镀层是去除了的。长条体26下面的中部28直接位于透明环氧树脂区30的下方。图6示出重镀薄片20这一区段的透视图。
这时将整个重镀而涂有光致 抗蚀剂的薄片20、也就是薄片的顶面和底面、置于紫外线的作用下。使重镀薄片20在紫外线下保持足够的时间以使所有未盖上方格体和长格体的光致抗蚀剂固化。然后从重义薄片上取去方格和长格屏蔽体。位于方格体下面的光致抗蚀剂并未固化。未固化的光致抗蚀剂仍处于液态,因而可从重镀薄片20上洗除。
在重底铜薄片20的其余部分上固化的光致抗蚀剂对下一处理步骤起有保护作用。具体来说,固化的光致抗蚀剂防止其下面的铜被清除。在方格体下面的区域无固化的光致抗蚀剂,因而无这种保护作用。这样,对这些区域的铜就可被腐蚀清除。这种腐蚀处理是用氯化铁溶液进行的。
清除铜之后,如图5、6所示,方格和长格屏蔽体下面的区域就完全外露。也就是,这些区现在是透明环氧树脂区28,30。
这时将重镀薄片20放进化学槽液以便从薄片20已固化的区域上清除所有固化的光致学抗蚀剂。
为了便于说明,薄片20上相邻切口14之间的部分称作长条体26。长条体26如图4所示具有保险丝长度的尺寸D。在完成说明书所述的一些操作以后,将长条体26最后切成若干片,每片就成为本发明的保险丝。
如图6所示,条长体26的下侧32沿其边缘具有仍覆有铜镀层的区域。长条体26的下侧32上的这些边缘区34,36构成衬垫部分。这些衬垫最后用作将整个成品保险丝固定在印刷电路板上的装置。
图7为图6长条体26顶侧38的透视图。顶侧38上长条区40直接与长条体26下面中部28相对并相重。这些长条区40在图7中用虚线示出。
图7涉及本发明制造的下一步骤。在此步骤中,沿长条体26顶侧38的长条区40覆盖光致抗蚀聚合物。通过覆盖长条区40,光致抗蚀聚合物也就形成包括熔断丝42在内的薄层部分。熔断丝42是用导电金属、这里是铜、制成的。这时用紫外线处理光致抗蚀聚合物,使其在包括熔断丝42在内的长条区40上固化。
由于光致抗蚀聚合物在包括熔断丝42在内的长条区40上固化,在将长条体26浸入装有电镀金属的电解槽液时金属就不会附着在长条区40上。
此外,如上所述,长条体26下侧32的中部28在将长条体26浸入电解镀液时也不会受到镀敷。原来覆盖此中部的铜金属已被去除,因而显出裸露的构成薄片20的基底环氧树脂。采用电解电镀处理,金属不会附着在或镀在此裸露的环氧树脂上。
将整个长条体26浸入电解镀铜槽液中,再浸入电解镀镍槽液中。如图8所示,铜层46和镍层48就会镀在基底铜层44上。在镀上铜层46和镍层48后,从长条区40上清除包括熔断丝42在内的长条区40上固化的光致抗蚀聚合物。
这时立即将光致抗蚀聚合物涂在整个长条区40上。但是如图9所示,熔断丝42中部50是用紫外线屏蔽物体屏蔽的。这时使紫外线作用在整个长条区40上,光致抗蚀聚合物就在除受屏蔽的熔断丝42中部50外的整个长条区上固化。清除熔断丝中部50上的屏蔽层,并清洗长条体。熔断丝42中部50上未固化的光致抗蚀聚合物就被从熔断丝上清除。但是固化的光致抗蚀聚合物仍留在长条区40其余部分上。
长条体26上覆有固化的光致抗蚀聚合物的部分不会镀上金属。但是,由于在熔断丝42中部50上无光致抗蚀聚合物,在中部50上就会镀上金属。
在将图9所示长条体浸入电解镀锡槽液时,在铜层46和镍层48上就会镀上锡层52(图10)。在熔断丝42中部50表面上通过电解电镀处理也就形成了锡区54。这一电解电镀处理实际上就是薄膜沉积处理。但是可以理解,在熔断丝42表面上也可采用照相平版印刷处理或物理汽相沉积处理如在高真空沉积室内进行的溅镀和蒸镀处理。
镀区54是由不同于熔断丝42铜金属的第二导电金属锡构成的。形成锡区54的第二导电金属是呈长方形沉积在熔断丝42上的。
熔断丝42上的锡区54使熔断丝42具有某些优点。首先,锡区54在电流超载情况下会熔化而产生锡铜合金熔断丝42。锡铜合金使熔断丝42具有较锡和铜都低的熔化温度。较低的熔化温度降低了本发明保险丝的工作温度,从而改进了保险丝的性能。
在此示例中,是使锡沉积在铜熔断丝42上的,对熟悉本专业的人来说,可以理解,在熔断丝42上可以加上其他的导电金属以降低其熔化温度,就熔断丝42本身来说也可采用铜以外的导电金属。此外,沉积在熔断丝42上的锡或其他金属不一定是长方形的而可取任何其他的形状。
可将第二导电金属加在熔断丝的凹口、开孔或孔隙中。也可采用平行的几个熔断丝。因此,保险丝的具体电气特性最终取决于用户不同要求。
如上所述,对熔断丝可采用螺旋形。采用螺旋形熔断丝可在保持熔断丝相对两端的距离不变下加长其长度。这样,螺旋形状可提供较长的熔断丝而不加大保险丝本身的尺寸。
本发明保险丝的下一制造步骤是沿长条体26整个顶部38的长度设置保护层56(图11)。保护层56为本发明保除丝的第二配件而形成包括熔断丝42在由整个长条体26顶部38的气密部分。这样保护层56在其整个使用期内可防止熔断丝42的腐蚀。保护层56还可防止将保险丝装上印刷电路板时的氧化和冲击。保护层还提供利用真空提取工具进行提取和安放操作时所需表面。
保护层56有助于控制电流超载时在熔断丝42中产生的熔化、电度和燃弧。保护层56或覆盖材料应具有所需电弧猝熄特性,这在熔断丝42熔断时特别重要。
保持层56可用聚合物制成,最好用聚碳酸酯粘合剂制成。优选的聚碳酸酯粘合剂为LOCTITE 3981。其他类似的粘合剂也可用于本发明。除聚合体外,保护层56也可采用塑料、保形涂料和环氧树脂。
保护层56用硬模敷在长条体26上。具体来说,硬模具有模腔,模腔对应于长条体26的宽度。将聚碳酸酯粘合剂涂在硬模模腔边缘以内部分,因而使其仅覆盖长条体26。这时将长条体26和硬模置于紫外线下保持7分钟左右。7分钟后聚碳酸酯粘合剂固化而形成保护层56。
虽然无色透明的聚碳酸酯粘合剂从审美观点看是可取的,但也可采用其他的粘合剂。例如可采用有色透明粘合剂。有色的粘合剂可简单地在透明的聚碳酸酯粘合剂中添加染料制成。采用有色粘合剂可取得色标作用。也就是,不同颜色的粘合剂可对应于不同的安倍数,使用户可立时识别所得任意保险丝的安倍数。这两种透明的敷层使用户在使用熔断丝42装入电子装备之前可进行目视检查。
采用这种保护层56具有明显胜过现有技术,包括现有所谓“加盖”法、的优点。由于将保护层56置于保险丝的整个顶部38上面,保护层相对于熔断丝42的位置就不很重要了。
这时就可对长条体26进行切割而将长条体26切割成单件保险丝。在切割中,用金刚石锯或类似工具沿平行面57(图11)将长条体26切割成单件薄膜面上安装式保险丝58(图12)。切割时也就切开了铜型薄膜状宽端区60,62。宽端区60,62位于熔断丝42的两侧。
通过切割就完成了本发明薄膜面上安装式保险丝58(图12)的制造。
本发明保险丝的电压和电流额定值大于现有保险丝。试验表明,本发明保险丝的交流电压额定值为60V,电流额定值在1/16-5A之间。本发明保险丝可在保持其实际尺寸不变的情况下在范围很宽的额定安倍数下保护电路。
总之,本发明保险丝显示出在通过调整熔断丝42两端电压降控制,熔断特性方面的改进。恒定的熔断时间可通过以下两点得到保证:(1)通过沉积和照相平版印刷法控制熔断丝42和宽端60、62的尺寸和形状;(2)合理选用熔断丝42的材料。再点火的倾向通过精选衬底13和保护层56的材料可降低到最低程度。
以上对具体实施例作了图示和说明,但还可作出很多变型方案而不脱离本发明的精神实质,因此,保护范围只能由所附权利要求书的范围来限定。
Claims (16)
1.一种薄膜面上安装式保险丝,具有:
a.一熔断丝,用第一导电金属制成;
b.一第二导电金属,不同于第一导电金属,沉积在所述熔断丝的表面上。
2.按权利要求1所述面上安装式保险丝,其特征在于:所述第一导电金属选自铜、银、镍、钛、铝或其合金这类金属。
3.按权利要求1所述面上安装式保险丝,其特征在于:所述第二导电金属为锡。
4.按权利要求3所述面上安装式保险丝,其特征在于:所述第二导电金属在所述熔断丝上作长方体沉积。
5.按权利要求4所述面上安装式保险丝,其特征在于:所述长方体沿所述熔断丝中部沉积。
6.一种薄膜面上安装式保险丝,具有两种材料不同的配件:
a.第一配件具有一熔断丝及其支承衬底和端部衬垫;
b.第二配件构成一保护层,位于熔断丝上方,用以防止冲击和氧化。
7.按权利要求6所述面上安装式保险丝,其特征在于:所述保护层用聚合物材料制成。
8.按权利要求6所述面上安装式保险丝,其特征在于:所述保护层用聚碳酸酯粘合剂制成。
9.按权利要求6所述面上安装式保险丝,其特征在于:所述支承衬底用FR-4环氧树脂或聚酰亚胺制成。
10.按权利要求7所述面上安装式保险丝,其特征在于:所述聚合材料是透明无色的。
11.按权利要求7所述面上安装式保险丝,其特征在于:所述聚合物材料是透明有色的。
12.一种制造薄膜面上安装式保险丝的方法,具有在一衬底顶部上同时沉积的一熔断丝和在所述熔断丝相对两端的宽端部分。
13.按权利要求12所述方法,其特征在于还包括:在一衬底两侧和底部沉积端子衬垫,与所述宽端部分作电连接,所述衬垫用以使所述面上安装式保险丝与印刷电路板连接。
14.按权利要求12所述方法,其特征在于:所述熔断丝和宽端部分采用汽相沉积。
15.按权利要求12所述方法,其特征在于:所述熔断丝和宽端部分采用电化学沉积。
16.一种保护薄膜面上安装式保险丝的方法,保险丝具有一位于一衬底顶面上的熔断丝,所述方法包括在所述整个衬底顶面上方设置一保护层。
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US08/247,584 US5552757A (en) | 1994-05-27 | 1994-05-27 | Surface-mounted fuse device |
US08/247,584 | 1994-05-27 |
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- 1995-05-23 DE DE69512519T patent/DE69512519T2/de not_active Expired - Fee Related
- 1995-06-07 US US08/474,940 patent/US6023028A/en not_active Expired - Lifetime
- 1995-06-07 US US08/482,829 patent/US5943764A/en not_active Expired - Lifetime
- 1995-10-23 US US08/551,900 patent/US5844477A/en not_active Expired - Lifetime
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101542670B (zh) * | 2007-08-08 | 2012-06-20 | 釜屋电机株式会社 | 芯片熔丝及其制造方法 |
CN102568969A (zh) * | 2010-10-14 | 2012-07-11 | 阿维科斯公司 | 弱电流熔丝 |
US9847203B2 (en) | 2010-10-14 | 2017-12-19 | Avx Corporation | Low current fuse |
CN104576254A (zh) * | 2013-10-11 | 2015-04-29 | 保险丝公司 | 利用麦特卡尔夫效应改善电熔丝性能的阻挡层 |
CN109791861A (zh) * | 2016-10-14 | 2019-05-21 | 大陆汽车有限公司 | 包括熔断器的电路安排、机动车辆、以及制造所述电路安排的方法 |
US10593504B2 (en) | 2016-10-14 | 2020-03-17 | Continental Automotive Gmbh | Circuit arrangement |
CN109791861B (zh) * | 2016-10-14 | 2020-08-11 | 大陆汽车有限公司 | 包括熔断器的电路安排、机动车辆、以及制造所述电路安排的方法 |
Also Published As
Publication number | Publication date |
---|---|
KR100238986B1 (ko) | 2000-01-15 |
US6023028A (en) | 2000-02-08 |
EP0761012A1 (en) | 1997-03-12 |
DE69512519T2 (de) | 2000-01-13 |
JP3160294B2 (ja) | 2001-04-25 |
US5552757A (en) | 1996-09-03 |
WO1995033276A1 (en) | 1995-12-07 |
CN1189913C (zh) | 2005-02-16 |
AU2602495A (en) | 1995-12-21 |
EP0761012B1 (en) | 1999-09-29 |
CA2191346A1 (en) | 1995-12-07 |
US5844477A (en) | 1998-12-01 |
AU691620B2 (en) | 1998-05-21 |
DE69512519D1 (de) | 1999-11-04 |
US5943764A (en) | 1999-08-31 |
JPH09510824A (ja) | 1997-10-28 |
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