Abstract
A method of manufacturing a fuse includes stacking a base plate, an at least partially conductive fabric over the base plate and a cover layer over the fabric, each with an intervening bonding layer. At least one cavity is provided on both sides of the fabric, adjoining the fabric, between the respective edge regions. In addition, the fabric includes at least one first fiber which is electrically conductive and second fibers which are non-conductive and which have a lower melting temperature than the first fiber. The method further includes heating the stacked elements to a temperature below the melting temperature of the first fiber and above the melting temperature of the second fibers.
Claims
1. A method of manufacturing a fuse extending from a first end along a longitudinal axis to a second end comprising the steps of: providing a base plate; stacking an at least partially conductive fabric over the base plate; stacking a cover layer over the fabric; providing a bonding layer between the base plate and the fabric and between the fabric and the cover layer, at least in respective edge regions of the base plate, fabric and cover layer; wherein on both sides of the fabric, adjoining the fabric, at least one cavity is provided between the respective edge regions, wherein the fabric comprises at least one first fiber which is electrically conductive, and which extends along the longitudinal axis from the first end of the fuse to the second end of the fuse and comprises second fibers which are non-conductive and which extend at least transversely to the longitudinal axis, wherein the at least one first fiber has a higher melting temperature than the second fibers, heating the stacked elements to a temperature which is below the melting temperature of the at least one first fiber and which is above the melting temperature of the second fibers; maintaining the temperature for a period of time; whereby the second fibers melt at least in the region of the at least one first fiber, thereby at least partially releasing the at least one first fiber in the region of the cavities; and cooling the stacked elements to room temperature.
2. The method according to claim 1, wherein the base plate comprises a printed circuit board.
3. The method according to claim 1, comprising arranging electrical contact elements at the two ends of the fuse, wherein the electrical contact elements are electrically conductively connected to the at least one first fiber.
4. The method according to claim 3, wherein the contact elements extend over the entire surface of the respective end of the fuse.
5. The method according to claim 1, wherein the at least one cavity includes at least one first cavity formed in the base plate, between the edge regions of the base plate, and at least one second cavity formed in the cover layer, between the edge regions of the cover layer.
6. The method according to claim 1, further comprising arranging at least one frame-shaped spacer between the base plate and the fabric and/or between the fabric and the cover layer, wherein at least one third cavity is formed between the edge regions of the spacer.
7. The method according to claim 6, further comprising arranging an extinguishing layer on one or both sides of the fabric by means of a bonding layer in a corresponding cavity of the at least one cavity.
8. The method according to claim 7, wherein the base plate, the cover layer and the extinguishing layer are formed as closed surfaces.
9. The method according to claim 8, wherein each bonding layer comprises a closed circumferential frame and/or wherein further bonding layers are provided to form a closed circumferential frame.
10. The method according to claim 9, wherein each bonding layer comprises at least one web extending transversely to the longitudinal axis from one side of the frame to an opposite side of the frame and wherein the at least one spacer comprises at least one web extending transversely to the longitudinal axis from one side of the frame to an opposite side of the frame.
11. The method according to claim 6, wherein the base plate, the bonding layer, the fabric, the at least one spacer and the cover layer are substantially rectangular and comprise two opposite ends and two opposite sides.
12. The method according to claim 1, comprising arranging two or more fabrics, wherein between two adjacent fabrics an intermediate layer is provided, which is connected to the fabrics by bonding layers or which is connected to the fabrics by bonding layers and spacers.
13. The method according to claim 12, wherein at least a fourth cavity is formed in the intermediate layer, between edge regions of the intermediate layer.
14. The method according to claim 1, wherein the fabric comprises first fibers extending transversely to the longitudinal axis.
15. The method according to claim 14, wherein the fabric comprises second fibers extending along the longitudinal axis.
16. The method according to claim 1, wherein the fabric comprises second fibers having a first melting temperature and second fibers having a second melting temperature different from the first melting temperature.
17. The method according to claim 1, wherein the fabric includes a plurality of first fibers which are at least partially combined and/or wherein the fabric includes a plurality of second fibers which are at least partially combined.
18. The method according to claim 1, wherein the fabric comprises only second fibers at least in the region of its two sides.
19. The method according to claim 1, wherein a plurality of the first fibers are provided, and the first fibers and/or the second fibers have different diameters.
20. The method according to claim 1, wherein the at least one first fiber has a fully conductive cross-section, or wherein the at least one first fiber comprises a conductive coating or a conductive core.
21. The method according to claim 1, wherein at least one first fiber is spirally wound around a second fiber or around a bundle of second fibers.
22. A fuse manufactured by a process according to claim 1 comprising a base plate, an at least partially conductive fabric and a cover layer, which are interconnected by bonding layers at least in respective edge regions, wherein the fabric comprises at least one first fiber which is electrically conductive and which extends along the longitudinal axis from the first end of the fuse to the second end of the fuse and comprises second fibers which are non-conductive, wherein the at least one first fiber has a higher melting temperature than the second fibers.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] Examples of embodiments of the present invention are explained in more detail below with reference to figures. These are for explanatory purposes only and are not to be construed restrictively. In the drawings:
[0060] FIG. 1 a sectional view of a first embodiment of a fuse according to the invention before heating;
[0061] FIG. 2 a sectional view of the fuse of FIG. 1 along the section A-A of FIG. 1;
[0062] FIG. 3 a sectional view of the finished fuse of FIG. 1;
[0063] FIG. 4 a sectional view of a second embodiment of a fuse according to the invention before heating;
[0064] FIG. 5 a sectional view of the fuse of FIG. 4 along section A-A of FIG. 4;
[0065] FIG. 6 a sectional view of the finished fuse of FIG. 4;
[0066] FIG. 7 a sectional view of a third embodiment of a fuse according to the invention before heating;
[0067] FIG. 8 a sectional view of a fourth embodiment of a fuse according to the invention before heating;
[0068] FIG. 9 a sectional view of a fifth embodiment of a fuse according to the invention before heating;
[0069] FIG. 10 a sectional view of a sixth embodiment of a fuse according to the invention before heating;
[0070] FIG. 11 a sectional view of a seventh embodiment of a fuse according to the invention before heating;
[0071] FIG. 12 a sectional view of an eighth embodiment of a fuse according to the invention before heating;
[0072] FIG. 13 a sectional view of a ninth embodiment of a fuse according to the invention before heating;
[0073] FIG. 14 a sectional view of a tenth embodiment of a fuse according to the invention before heating;
[0074] FIG. 15 a perspective view of a bonding layer;
[0075] FIGS. 16a-f fabric embodiments; and
[0076] FIG. 17a-b wound conductive first fibers.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0077] FIG. 1 shows a sectional view of a first embodiment of a fuse 1 according to the invention before heating. FIG. 2 shows a sectional view of the fuse of FIG. 1 along the line of intersection A-A and FIG. 3 shows a sectional view of the finished fuse of FIG. 1. The fuse extends along a longitudinal axis L from a first end 11 to a second end 12 opposite thereto. A base plate 2 was placed on a substantially flat base not shown here. A bonding layer 3, an at least partially conductive fabric 4, a further bonding layer or connecting layer 3 and a cover layer were stacked successively in alignment with each other thereover. The base plate 2 is a substantially rectangular printed circuit board and comprises a first end 21, a second end 22 opposite thereto, a first side 23 arranged transversely thereto and a second side 24 opposite thereto. A recess is formed in the base plate 2 at a distance from the edge regions of the upper surface of the base plate 2, which recess defines a first cavity 200 in the assembled state. The cover layer 5 is geometrically identical to the base plate 2 and comprises a printed circuit board having a first end 51, a second end 52, a first side 53, a second side 54 and a second recess which, when assembled, defines a second cavity 500. The connector layers 3 are frame-shaped and comprise a first end 31, a second end 32, a first side 33, a second side 34, as shown in FIG. 12. Unlike the connecting element of FIG. 12, the connecting element of the embodiment shown in FIGS. 1 to 3 does not comprise a central web extending between the two sides. Accordingly, only one through opening is formed at a distance from the edge regions. The at least partially conductive fabric 4 comprises a closed surface having a first end 41, a second end 42 opposite thereto, a first side 43 and a second side 44 opposite thereto. The fabric 4 comprises at least one electrically conductive first fiber 400 extending at least in the longitudinal direction from the first end 11 to the second end 12 of the fuse 1, and it comprises non-conductive second fibers 401 extending at least transversely to the longitudinal axis L. The first fibers 400 have a higher melting temperature than the second fibers 401. As can be seen in FIG. 2, the fabric 4 does not extend to the lateral outer contours of the fuse 1, whereby the fabric 4 is covered laterally outwardly by the material of the interconnection layer 3. Alternatively, the fabric 4 may extend laterally to the periphery of the fuse. Heating the stack shown in FIGS. 1 and 2 to a temperature higher than the melting temperature of the second fibers causes them to melt, thereby releasing the at least one first fiber 400, as shown in FIG. 3. Contact elements 6 are arranged at both ends 11, 12 of the fuse 1, which extend over the entire respective end surface and which are electrically conductively connected to the at least one first fiber 400.
[0078] FIGS. 4 to 6 show a second embodiment of a fuse according to the invention, before and after heating. In contrast to the first embodiment, the base plate 2 and the cover layer 5 do not comprise any recesses. Instead, frame-shaped spacers 7 are provided, the interior of which delimit third cavities 700 in the assembled state. Before heating, a printed circuit board 2, a connecting layer 3, a spacer 7, a further connecting layer 3, an at least partially conductive fabric 4, a further connecting layer 3, a spacer 7, a further connecting layer 3 and a cover layer 5 are thus stacked on top of each other. The fabric 4 extends to the two sides 13,14 of the fuse 1, but the two lateral regions 43,44 of the fabric 4 are electrically non-conductive. Such a fabric 4 is shown, for example, in FIGS. 13a and 13f. Contact elements 6 are arranged at the two ends 11, 12 of the fuse 1, which extend over the area of the respective end face which contains the fabric 4.
[0079] These contact elements 6 are also electrically conductively connected to the at least one first fiber 400.
[0080] FIG. 7 shows a sectional view of a third embodiment of a fuse 1 according to the invention before heating. In contrast to the embodiment of FIGS. 4 to 6, the connecting layers 3 and the spacers 7 are frame-shaped and have a web (30;70). Accordingly, not only are the edge regions of the individual layers connected to each other, but a central region 20 of the base plate 2, a web 70 of the spacer 7, a central region 40 of the fabric 4 and a central region 50 of the cover layer 5 are connected to each other by webs 30 of the corresponding connecting layer 3. The connecting layer 3 extends along the longitudinal axis L from a first end 31 to a second end 32 opposite thereto and comprises a closed circumferential frame with two frame parts 31,32 near the end and two lateral frame parts 33,34, as shown for example in FIG. 12. A web 30 extends from the centre of the lateral first frame part 33 through a central region of the interconnection layer 3 to a lateral second frame part 34 opposite thereto.
[0081] Accordingly, the base plate 2 is only partially connected to the fabric 4, i.e., in the region of the frame parts of the interconnection layer 3. Accordingly, a first end 21, a second end 22, a first side, a second side and a central region 20 of the base plate 2 are connected to a first end 41, a second end 42, a first side, a second side and a central region 40 of the fabric. Similarly, the aforementioned regions of the fabric 4 are correspondingly connected to a first end 51, a second end 52, a first side, a second side and a central region 50 of the cover layer 5 by a further connection layer 3. The spacers 7 comprise a frame-shaped structure with dimensions corresponding to those of the connecting layer 3. The frame-shaped structure of the connecting layers 3 and the spacers 7 creates third cavities 700 between the base plate 2 and the fabric 4, or between the fabric 4 and the covering layer 5 in the areas of the through-holes of the connecting layers 3.
[0082] FIG. 8 shows a sectional view of a fourth embodiment of a fuse according to the invention before heating. This embodiment corresponds to that of FIGS. 1 to 3, but extinguishing layers 9 are arranged in the cavities 200, 500 by means of connecting layers 3. The quenching layers 9 are designed as closed surfaces which extend through the cavities 200,500 to the two ends 11,12 and the two sides of the fuse.
[0083] FIG. 9 shows a sectional view of a fifth embodiment of a fuse according to the invention before heating. This embodiment corresponds to that of FIGS. 4 to 6, but extinguishing layers 9 are arranged in the cavities 700 by means of connecting layers 3, the extinguishing layers 9 extending laterally and in the longitudinal direction to the periphery of the fuse 1.
[0084] FIG. 10 shows a sectional view of a sixth embodiment of a fuse according to the invention before heating and FIG. 11 shows a corresponding sixth embodiment. These embodiments correspond to those of FIGS. 9 and 10, but the extinguishing layers 9 are connected to the base plate 2, or to the cover layer 5, by closed-surfaced connecting layers 35. In the embodiment of FIG. 10, the extinguishing layer 9 extends over the entire surface of the recess of the base plate 2 or the cover layer 5 facing the fabric 4. In the embodiment of FIG. 11, the extinguishing layer 9 extends from the first end 11 of the fuse 1 to its second end 12 over the entire surface of the base plate 2 or the cover layer 5 facing the fabric 4.
[0085] FIG. 12 shows a sectional view of a seventh embodiment of a fuse according to the invention before heating. Two fabrics 4 are arranged in a common cavity 700. The two fabrics 4 are separated from each other by a spacer 7. The fabrics 4 are separated from the base plate 2, or from the cover layer 5, by spacers 7 on the sides facing outwards, or upwards and downwards. The base plate 2, the spacers 7, the fabrics 4 and the cover layer 5 are connected to each other by frame-shaped connecting layers 3. Of course, two fabrics separated from each other by a spacer can also be arranged between a base plate and a cover layer, as shown for example in FIG. 10.
[0086] FIG. 13 shows a sectional view of an eighth embodiment of a fuse according to the invention before heating. Two essentially flat fabrics 4 are arranged in layers between the base plate 2 and the cover layer 5. A printed circuit board is provided as an intermediate layer 8 between the two fabrics 4. In the intermediate layer 8, recesses are formed at a distance from the edge regions of the upper and lower surfaces of the intermediate layer 8, which in the assembled state delimit a fourth cavity 800. The individual layers are connected to each other by connecting layers 3.
[0087] FIG. 14 shows a sectional view of a sixth embodiment of a fuse according to the invention before heating. In contrast to the embodiment in FIG. 13, the base plate 2, the cover layer 5 and the intermediate layer 8 do not have any recesses. The cavities 700 are formed by the corresponding spacers 7, which are arranged between the base plate 2 and the fabric 4, the fabric 4 and the intermediate layer 8 and the fabric 4 and the cover layer 5 by means of corresponding connecting layers 3.
[0088] FIG. 16a shows a first embodiment of a fabric 4, with an electrically conductive first fiber 400 extending along the longitudinal axis L and with non-conductive fibers 401 extending transversely to the longitudinal axis L and parallel thereto.
[0089] FIG. 16b shows a second embodiment of a fabric 4, with electrically conductive first fibers 400 extending along the longitudinal axis L and with non-conductive fibers 401 extending transversely to the longitudinal axis L.
[0090] FIG. 16c shows a third embodiment of a fabric 4. The fabric 4 comprises a plurality of first fibers 400 extending along and transverse to the longitudinal axis L and second fibers 401 extending along and transverse to the longitudinal axis.
[0091] FIG. 16d shows a fourth embodiment of a fabric 4, wherein bundles of first fibers 400 are interwoven with individual second fibers 401.
[0092] FIG. 16e shows a fifth embodiment of a fabric 4, wherein individual first fibers 400 are interwoven with bundles of second fibers 401.
[0093] FIG. 16f shows a sixth embodiment of a fabric, wherein a plurality of second fibers 401 are interwoven between individual first fibers 400 extending along the longitudinal axis L from the first end 41 to the second end 42 of the fabric 4. The distance between the two conductive first fibers 400 can thus be adjusted very precisely. The more non-conductive second fibers 401 are arranged between two adjacent conductive fibers 400, the greater their spacing. In the area of the first side 43 and the second side 44 of the fabric 4 only non-conductive fibers 401 are provided, which is why the two lateral areas of the fabric 4 are non-conductive.
[0094] FIG. 17a shows a conductive first fiber 400 wound helically around a non-conductive second fiber 401 and FIG. 17b shows a first fiber 400 wound around a bundle of second fibers 401. Such wound first fibers 400 can be used in the previously described fabrics.
TABLE-US-00001 REFERENCE SIGNS LIST 1 fuse 11 first end 12 second end 13 first side 14 second side 2 base plate 20 middle section 21 first end 22 second end 23 first side 24 second side 200 cavity 3 connecting layer 30 web 31 first end 32 second end 33 first side 34 second side 35 Bonding layer 4 melt element/fabric 40 middle section 41 first end 42 second end 43 first side 44 second side 400 first fibers 401 second fibers 402 melted second fibers 5 top layer 50 middle section 51 first end 52 second end 53 first side 54 second side 500 cavity 6 contact element 7 spacer 70 web 71 first end 72 second end 700 cavity 8 intermediate layer 800 cavity 9 extinguishing layer L Longitudinal axis
