Process for manufacturing an electrical device comprising a PTC element

A method for manufacturing an electrical device comprising the steps of:

• providing a laminar resistive element having a top and bottom surface and first and second sides, the top and bottom surfaces each having end portions separated by a mid-portion;
• forming a first electrode on the top surface of the resistive element;
• forming a second electrode on the bottom surface of the resistive element;
• coating the first and second electrodes and the first and second sides of the resistive element with an insulating layer;
• removing a first portion of the insulating layer to form a first contact point;
• removing a second portion of the insulating layer to form a second contact point;
• applying a first conductive layer to the insulating layer, the first contact point and the second contact point;
• removing portions of the first conductive layer to form first and second end terminations separated by electrically non-conductive gaps;
• and,
• applying a second conductive layer to the first conductive layer.

A method for manufacturing an electrical device comprising the steps of:

• providing a laminar conductive sheet having a top and bottom surface, a first electrode formed on the top surface and a second electrode formed on the bottom surface;
• creating a plurality of strips in a regular pattern in the laminar conductive sheet;
• coating the strips in the laminar conductive sheet with an insulating layer;
• removing portions of the insulating layer to expose the electrodes and form a plurality of contact points;
• coating the strips in the laminar conductive sheet with a first conductive layer, the first conductive layer being in contact with the electrodes at each contact point;
• forming a plurality of electrically non-conductive gaps in the first conductive layer in a regular pattern on the top and bottom surfaces of each strip in the laminar conductive sheet;
• and,
• dividing each strip in the laminar conductive sheet into a plurality of electrical devices.

A method for manufacturing an electrical device comprising the steps of:

• providing a laminar conductive sheet having a top and bottom surface, a first electrode formed on the top surface and a second electrode formed on the bottom surface;
• creating a plurality of strips in the laminar conductive sheet;
• coating the strips in the laminar conductive sheet with an insulating layer leaving portions of the first and second electrodes exposed to form a plurality of contact points;
• coating the strips in the laminar conductive sheet with a first conductive layer, the first conductive layer being in contact with the electrodes at each contact point;
• forming a plurality of electrically non-conductive gaps in the first conductive layer;
• and,
• dividing each strip in the laminar conductive sheet into a plurality of electrical devices.