US 5,852,397 A · Electrical devices

Abstract

A circuit protection device which comprises first and second laminar electrodes; a laminar PTC conductive polymer resistive element sandwiched between the electrodes; a third laminar conductive member which is secured to the same face of the PTC element as the second electrode but is separated therefrom; and an electrical connector which connects the third conductive member and the first electrode. This permits connection to both electrodes from the same side of the device, so that the device can be connected flat on a printed circuit board, with the first electrode on top, without any need for leads. The connector is preferably a cross-conductor which passes through an aperture in the PTC element, because this makes it possible to carry out the steps for preparing the devices on an assembly which corresponds to a number of individual devices, with division of the assembly as the final step.

Claims55

Dependent claims

A circuit protection device which comprises:

(1) a la first laminar electrode;
(2) a second laminar electrode;
(3) a laminar PTC resistive element which (i) exhibits PTC behavior, (ii) comprises a laminar element composed of a PTC conductive polymer, (iii) has a first face to which the first electrode is secured and an opposite second face to which the second electrode is secured, and (iv) defines an aperture which runs between the first and second faces;
(4) a third laminar conductive member which (i) is secured to the second face of the PTC resistive element in the area of the aperture, and (ii) is spaced apart from the second electrode;
and
(5) a transverse conductive member which
(a) lies within the aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to the first laminar electrode and to the third laminar conductive member, but is not connected to the second laminar electrode.

7 more elements

A circuit protection device which comprises

(1) a first laminar electrode;
(2) a second laminar electrode;
(3) a laminar PTC resistive element which (i) exhibits PTC behavior, (ii) comprises a laminar element composed of a PTC conductive polymer, (iii) has a first face to which the first electrode is secured and an opposite second face to which the second electrode is secured, and (iv) defines first and second apertures which runs between the first and second faces;
(4) a third laminar conductive member which (i) is secured to the second face of the PTC resistive element in the area of the first aperture, and (ii) is spaced apart from the second electrode;
(5) a fourth laminar conductive member which (i) is secured to the first face of the PTC resistive element in the area of the second aperture, and (ii) is spaced apart from the first electrode;
(6) a first transverse conductive member which
(a) lies within the first aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to the first laminar electrode and to the third laminar conductive member, but is not connected to the second laminar electrode;
and
(7) a second transverse conductive member which
(a) lies within the second aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to the second laminar electrode and to the fourth laminar conductive member, but is not connected to the first laminar electrode.

13 more elements

A leadless, discrete electrical device exhibiting PTC behavior and adapted for mounting to a generally planar surface of an associated electrical circuit, said device comprising:

a polymeric PTC element having generally planar opposite faces and opposing ends;
a first electrode secured to one of the PTC element faces and extending along the length of said PTC element from one end to a first intermediate location;
a second electrode secured to the other of the PTC element faces and extending along the length of said PTC element from the other end to a second intermediate location;
a first additional conductive member secured to said one face and extending along the length of said PTC element from the other end to a third intermediate location spaced from said first intermediate location;
a second additional conductive member secured to said other face and extending along the length of said PTC element from the one end to a fourth intermediate location spaced from said second intermediate location;
each of said PTC element, said first electrode and said second additional conductive member having an open aperture at said one end, thereby forming a first recess in said device;
a first cross-conductor plated in said first recess to electrically connect said first electrode and said second additional conductive member;
each of said second electrode, said PTC element and said first additional conductive member having an open aperture at said other end, thereby forming a second through hole in said device;
and
a second cross-conductor plated in said second recess to electrically connect said second electrode and said first additional conductive member.

7 more elements

A leadless, discrete electrical device exhibiting PTC behavior and adapted for mounting to a generally planar surface of an associated electrical circuit, said device comprising:

a polymeric PTC element having generally planar opposite faces and opposing ends;
a first electrode secured to one of the PTC element faces and extending along the length of said PTC element from one end to a first intermediate location;
a second electrode secured to the other of the PTC element faces and extending along the length of said PTC element from the other end to a second intermediate location;
a first additional conductive member secured to said one face and extending along the length of said PTC element from the other end to a third intermediate location spaced from said first intermediate location;
a second additional conductive member secured to said other face and extending along the length of said PTC element from the one end to a fourth intermediate location spaced from said second intermediate location;
each of said PTC element, said first electrode and said second additional conductive member having a closed aperture adjacent said one end, thereby forming a first through hole in said device;
a first cross-conductor plated in said first through hole to electrically connect said first electrode and said second additional conductive member;
each of said second electrode, said PTC element and said first additional conductive member having a closed aperture adjacent said other end, thereby forming a second through hole in said device;
and
a second cross-conductor plated in said second through hole to electrically connect said second electrode and said first additional conductive member.

7 more elements

A leadless, discrete electrical device exhibiting PTC behavior and adapted for mounting to a generally planar surface of an associated electrical circuit, said device comprising:

a polymeric PTC element having generally planar opposite faces and opposing ends;
a first foil electrode secured to one of the PTC element faces and extending along more than one-half the length of said PTC element from one end to a first intermediate location;
a second foil electrode secured to the other of the PTC element faces and extending along more than one-half the length of said PTC element from the other end to a second intermediate location;
a first additional conductive foil member secured to said one face and extending along the length of said PTC element from the other end to a third intermediate location spaced form said first intermediate location;
a second additional conductive foil member secured to said other face and extending along the length of said PTC element from the one end to a fourth intermediate location spaced from said second intermediate location;
each of said PTC element, said first electrode and said second additional conductive member having an open aperture at said one end, thereby forming a first recess in said device;
a first cross-conductor plated in said first recess to electrically connect said first electrode and said second additional conductive member;
each of said second electrode, said PTC element and said first additional conductive member having an open aperture at said other end, thereby forming a second recess in said device;
and
a second cross-conductor plated in said second recess to electrically connect said second electrode and said first additional conductive member.

7 more elements

A circuit protection device which comprises

(A) a main portion which comprises
(a) a main part of a first laminar electrode;
(b) a main part of a second laminar electrode;
(c) a main part of a laminar resistive element, said laminar resistive element (i) exhibiting PTC behavior, (ii) comprising a laminar element composed of a PTC conductive polymer, and (iii) having a first face to which the first electrode is secured and an opposite second face to which the second electrode is secured;
and
(B) a connection leg which extends away from the main portion, and which comprises
(a) a distal portion which
(i) is spaced away from the main portion;
and
(ii) comprises a residual laminar conductive member which is secured to the second face of the laminar resistive element and is spaced apart from the second electrode;
a distal part of the first electrode;
a distal part of the resistive element;
and an electrical connector which contacts the distal part of the first electrode and the distal part of the resistive element, and which extends beyond the second face of the resistive element to contact the residual laminar conductive member;
and
(b) a bridge portion which
(i) lies between the distal portion and the main portion of the device,
(ii) emends across the width of the connection leg,
(iii) comprises a bridge pant of the first electrode and a bridge part of the resistive element, and
(iv) does not include any part of the second electrode;
the main, bridge and distal parts of the first electrode being integral with each other;
the main, bridge and distal parts of the resistive element being integral with each other;
and the residual conductive member being such that, in the absence of the bridge portion, it would be integral with the second electrode;
whereby the device can be placed flat on a planar insulating substrate having first and second appropriately spaced-apart metal conductors on the surface thereof, with the electrical connector adjacent the first metal conductor, and the second electrode adjacent the second metal conductor;
and electrical connection can be made (a) between the first metal conductor and the first electrode, through the electrical connector, and (b) between the second conductor and the second electrode.

21 more elements

A circuit protection device which comprises

(A) a main portion which comprises
(a) a main part of a fist laminar electrode;
(b) a main part of a second laminar electrode;
(c) a main part of a laminar resistive element, said laminar resistive element (i) exhibiting PTC behavior, (ii) comprising a laminar element composed of a PTC conductive polymer, and (iii) having a first face to which the first electrode is secured and an opposite second face to which the second electrode is secured;
(B) a first connection leg which extends away from the main portion, and which comprises
(a) a first distal portion which
(i) is spaced away from the main portion;
and
(ii) comprises a first residual conductive member which is secured to the second face of the laminar resistive element and is spaced apart from the second electrode;
a distal part of the first electrode;a first distal part of the resistive element;
and a first electrical connector which contacts the distal part of the first electrode and the first distal part of the resistive element, and which extends beyond the second face of the laminar resistive element into contact with the first residual conductive member;
and
(b) a first bridge portion which
(i) lies between the first distal portion and the main portion of the device,
(ii) extends across the width of the first connection leg,
(iii) comprises a bridge part of the first electrode and a first bridge part of the resistive element, and
(iv) does not include any part of the second electrode;
the main, bridge and distal parts of the first electrode being integral with each other;
the main, first bridge and first distal parts of the resistive element being integral with each other;
and the first residual conductive member being such that, in the absence of the first bridge portion, it would be integral with the second electrode;
and
(C) a second connection leg which extends away from the main portion, and which comprises
(a) a second distal portion which
(i) is spaced away from the main portion, and
(ii) comprises a second residual conductive member;
a distal part of the second electrode;
a second distal part of the resistive element;
and a second electrical connector which contacts the distal part of the second electrode and the second distal part of the resistive element, and which extends beyond the second face of the laminar resistive element into contact with the second residual conductive member;
and
(b) a second bridge portion which
(i) lies between the second distal portion and the main portion of the device,
(ii) extends across the width of the second connection leg,
(iii) comprises a bridge part of the second electrode and a second bridge part of the resistive element, and
(iv) does not include any part of the first electrode;
the main, bridge and distal parts of the second electrode being integral with each other;
the main, second bridge and second distal parts of the resistive element being integral with each other;
and the second residual conductive member being such that in the absence of the second bridge portion it would be integral with the first electrode;
whereby the device can be placed either way up flat on a planar insulating substrate having first and second appropriately spaced-apart metal conductors on the surface thereof, with the first or the second electrical connector adjacent the first metal conductor, and the second or the first electrode adjacent the second metal conductor;
and electrical connection can be made (a) between the first metal conductor and the first electrode, through the first electrical connector, or between the first metal conductor and the second electrode, through the second electrical connector, and (b) between the second conductor and the second electrode, or between the second conductor and the first electrode.

36 more elements

An assembly which can be divided into a plurality of circuit protection devices, each of said devices comprising

(1) a first laminar electrode;
(2) a second laminar electrode;
(3) a laminar PTC resistive element which (i) exhibits PTC behavior, (ii) comprises a laminar element composed of a PTC conductive polymer, (iii) has a first face to which the first electrode is secured and an opposite second face to which the second electrode is secured, and (iv) defines an aperture which runs between the first and second faces;
(4) a transverse conductive member which
(a) lies within the aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to the first laminar electrode but is not connected to the second laminar electrode;
and
(5) a third laminar conductive member which(a) is secured to the second face of the PTC resistive element in the area of the aperture,(b) is electrically connected to the transverse conductive member, and (c) is spaced apart from the second electrode;
the assembly comprising
(1) a plurality of first laminar conductive members in the form of parallel strips;
(2) a plurality of second laminar conductive members in the form of strips which are parallel to each other and to the first laminar conductive members, but which are staggered in relation to the first conductive members;
(3) a laminar PTC resistive element which (i) exhibits PTC behavior, (ii) comprises a laminar element composed of a PTC conductive polymer, (iii) has a first face to which the first conductive members are secured and an opposite second face to which the second conductive members are secured, and (iv) defines a plurality of apertures which run between the first and second faces;
and
(4) a plurality of transverse conductive members which are arranged in a plurality of straight lines parallel to the first and second laminar conductive members, and each of which
(a) lies within an aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to one of the first laminar conductive members and to one of the second laminar conductive members.

17 more elements

A method of making a plurality of circuit protection devices, each of said devices comprising

(1) a first laminar electrode;
(2) a second laminar electrode;
(3) a laminar PTC resistive element which (i) exhibits PTC behavior, (ii) comprises a laminar element composed of a PTC conductive polymer, (iii) has a first face to which the first electrode is secured and an opposite second face to which the second electrode is secured, and (iv) defines an aperture which runs between the first and second faces;
(4) a third laminar conductive member which (i) is secured to the second face of the PTC resistive element in the area of the aperture, and (ii) is spaced apart from the second electrode;
and
(5) a transverse conductive member which
(a) lies within the aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to the first laminar electrode and to the third laminar conductive member, but is not connected to the second laminar electrode;
and
the method comprising the steps of
(A) providing an assembly which comprises
(1) a plurality of first laminar conductive members in the form of parallel strips;
(2) a plurality of second laminar conductive members in the form of strips which are parallel to each other and to the first laminar conductive members, but which are staggered in relation to the first conductive members;
(3) a laminar PTC resistive element which (i) exhibits PTC behavior, (ii) comprises a laminar element composed of a PTC conductive polymer, (iii) has a first face to which the first conductive members are secured and an opposite second face to which the second conductive members are secured, and (iv) defines a plurality of apertures which run between the first and second faces;
and
(4) a plurality of transverse conductive members, each of which
(a) lies within an aperture defined by the PTC resistive element,
(b) runs between the first and second faces of the PTC element,
(c) is secured to the PTC element, and
(d) is physically and electrically connected to one of the first laminar conductive members and to one of the second laminar conductive members;
(B) dividing the assembly along dividing lines which are parallel to the conductive members and along lines which are at right angles to the conductive members.

20 more elements

Dependencies are inferred from the claim text.

Electrical devices

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Electrical devices

Life of this patent

Abstract

Claims55