Low resistance polymer matrix fuse apparatus and method

A method of fabricating a low resistance fuse, said method comprising:

• providing a first intermediate insulating layer;
• metallizing the first intermediate insulating layer with a fuse element layer;
• forming a fusible link extending between first and second contact pads from the fuse element layer;
• and
• coupling a second intermediate insulation layer to the first intermediate insulating layer over the fuse element layer.

A low resistance fuse comprising:

• a thin foil fuse element layer;
• first and second intermediate insulation layers extending on opposite sides of said fuse element layer and coupled thereto, said fuse element layer formed on said first intermediate insulation layer and said second insulation layer laminated to said fuse element layer;
• a first outer insulating layer laminated to said first intermediate insulating layer;
• and
• a second outer insulating layer laminated to said second intermediate insulating layer.

A low resistance fuse comprising:

• a thin foil fuse element layer comprising first and second contact pads and a fusible link extending between said first and second contact pads;
• first and second intermediate insulation layers extending on opposite sides of said fuse element layer, at least one of said first and second intermediate insulation layers comprising an opening therethrough in the vicinity of said fusible link;
• a first outer insulating layer extending over said first intermediate insulating layer;
• a second outer insulating layer extending over said second intermediate insulating layer, at least one of said first and second outer insulating layer enclosing said opening of at least one of said first and second intermediate insulation layers.

A low resistance fuse comprising:

• a thin foil fuse element layer comprising a 1 micron to 20 micron electro deposited metal foil formed into first and second contact pads and a fusible link extending between said first and second contact pads;
• first and second intermediate insulation layers extending on opposite sides of said fuse element layer, each of said first and second intermediate insulation layers comprising an opening therethrough in the vicinity of said fusible link, at least one of said first and second intermediate insulation layers comprising a polyimide material;
• a first outer insulating layer extending over said first intermediate insulating layer;
• a second outer insulating layer extending over said second intermediate insulating layer, each of said first and second outer insulating layer enclosing said opening of at least one of said first and second intermediate insulation layers, at least one of said first and second outer insulating layer comprising a polyimide material.