Fuse and production method therefor

Abstract

A fuse and a production method therefor. The fuse includes upper and lower insulating layers provided with terminal electrodes, and a fuse element between the upper and lower insulating layers. The fuse further includes a functional layer provided between the fuse element and the insulating layers. The functional layer includes a substrate and an arc extinguishing material uniformly or substantially uniformly distributed in the substrate; the arc extinguishing material includes a sealed cavity; the substrate includes low temperature co-fired ceramic powder, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid, and phosphate ester polyester; the content of the arc extinguishing material is 1-50 wt %. The fuse overcomes the shortcomings of phenomena such as deformation, bending, and defects occurring to a fuse element caused by the shrinkage mismatch of the fuse element with a buffer layer and an arc extinguishing layer in a sintering process.

Claims

1. A fuse, comprising insulating layers and a fuse element, wherein the insulating layers comprise an upper insulating layer and a lower insulating layer, and the fuse element is arranged between the upper insulating layer and the lower insulating layer; the insulating layers are provided with terminal electrodes electrically connected with the fuse element, wherein the fuse further comprises a functional layer provided between the fuse element and one of the insulating layers; the functional layer comprises substrate and arc extinguishing material uniformly or substantially uniformly distributed in the substrate, wherein the arc extinguishing material comprises a sealed cavity, and wherein the substrate comprises low temperature co-fired ceramic powder, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid and phosphate ester polyester.

2. The fuse according to claim 1, wherein the insulating layers further comprise an interlayer, and the fuse comprises a plurality of the fuse elements and a plurality of the functional layers, and the functional layer is arranged above and/or below each of the fuse element, and the interlayer is arranged between adjacent two of the fuse elements.

3. The fuse according to claim 1, wherein the arc extinguishing material is hollow glass microsphere, glass body with a plurality of the sealed cavities, or ceramic body with a plurality of the sealed cavities.

4. The fuse according to claim 1, wherein the sphere diameter D50 of the arc extinguishing material is 10-80 microns.

5. A production method for the fuse according to claim 1, comprising the following steps: S1, preparing glass-ceramic slurry with low temperature co-fired ceramic powder and binder; S2, adding aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid and phosphate ester polyester to the glass-ceramic slurry, and fully stirring and grinding to prepare a pre-slurry of functional layer; S3, preparing functional layer slurry by adding arc extinguishing material to the pre-slurry of functional layer, wherein the arc extinguishing material is any one of hollow glass microspheres, glass powder mixed with foaming agent, or ceramic powder mixed with foaming agent; S4, coating a layer of the glass-ceramic slurry to form a slurry layer of glass-ceramic, which is a lower insulating layer slurry; S5, coating at least one layer of fuse element layer slurry, at least one layer of functional layer slurry and a layer of the glass-ceramic slurry on the lower insulating layer slurry, coating the functional layer slurry above and/or below the fuse element layer slurry, and coating the layer of the glass-ceramic slurry to be an uppermost layer as an upper insulating layer slurry, to form a green body of the fuse; S6, placing the green body of the fuse in a glue discharging furnace to discharge rubber from the green body of the fuse; S7, sintering the green body of the fuse; S8, performing processes of chamfering, mounting terminal electrodes, sintering silver, and electroplating on the green body of the fuse.

6. The production method according to claim 5, wherein, in Step S5, the at least one layer of functional layer slurry comprises a plurality of sublayers of functional layer slurry that are separated from each other and located in the same plane.

7. The production method according to claim 5, further comprising a step of cutting the green body of the fuse after Step S5 and before Step S6.

8. The production method according to claim 6, further comprising a step of cutting the green body of the fuse after Step S5 and before Step S6.

9. The production method according to claim 5, wherein a solid content in the glass-ceramic slurry is 40-80 wt %.

10. The production method according to claim 6, wherein a solid content in the glass-ceramic slurry is 40-80 wt %.

11. The production method according to claim 5, wherein content of the glass-ceramic slurry in the pre-slurry of functional layer is 40-80 wt %.

12. The production method according to claim 6, wherein content of the glass-ceramic slurry in the pre-slurry of functional layer is 40-80 wt %.

13. The production method according to claim 11, wherein the total amount of aerosol silicon oxide and silicon oxide in the pre-slurry of functional layer is 0.1-20 wt %.

14. The production method according to claim 11, wherein content of the low temperature co-fired ceramic powder in the pre-slurry of functional layer is 0-20 wt %.

15. The fuse according to claim 1, wherein two of the functional layers are arranged above and below the fuse element, respectively.

16. The fuse according to claim 1, wherein the functional layer comprises a plurality of sub-functional layers separated from each other in a same plane.

17. The fuse according to claim 1, wherein content of the arc extinguishing material of the functional layer is 1-50 wt %.

18. The production method according to claim 5, comprising, in Step S5, coating a plurality of layers of the functional layer slurry, and coating the slurry layer of glass-ceramic between two adjacent layers of the fuse element layer slurry.

19. The production method according to claim 5, wherein content of the arc extinguishing material in Step S3 is 1-50 wt %.

Description

BRIEF DESCRIPTION

(1) Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denotes like members, wherein:

(2) FIG. 1 is a schematic structure diagram of the fuse in Embodiment 1 of the present disclosure;

(3) FIG. 2 is a schematic structure diagram of the fuse in Embodiment 2 of the present disclosure;

(4) FIG. 3 is a schematic structure diagram of the fuse in Embodiment 3 of the present disclosure;

(5) FIG. 4 is a schematic diagram of a cross-sectional photograph of the internal structure of the fuse in Embodiment 3 of the present disclosure;

(6) FIG. 5 is a bar graph comparing the maximum rated voltage of the fuse in Embodiment 3 of the present disclosure with other products;

(7) FIG. 6 is a bar graph comparing the breaking capacity of the fuse in Embodiment 3 of the present disclosure with other products at the maximum rated voltage;

(8) FIG. 7 is a schematic diagram of a cross-sectional photograph of the internal structure of the fuse in Embodiment 4 of the present disclosure;

(9) FIG. 8 is a bar graph comparing the maximum rated voltage of the fuse in Embodiment 4 of the present disclosure with other products;

(10) FIG. 9 is a bar graph comparing the breaking capacity of the fuse in Embodiment 4 of the present disclosure with other products at the maximum rated voltage;

(11) FIG. 10 is a schematic structure diagram of the fuse in Embodiment 5 of the present disclosure;

(12) reference symbols as following: 1—fuse element; 2—insulating layer; 21—interlayer; 3—functional layer; 31—arc extinguishing material; 32—substrate; 4—terminal electrode.

(13) In the following, the present disclosure is further illustrated combining with the accompanying drawings and specific embodiments.

DETAILED DESCRIPTION

(14) The specific embodiments of the present disclosure given below can be used to further understand the present disclosure, but they are not a limitation of the present disclosure.

Embodiment 1

(15) As shown in FIG. 1, the present disclosure provide a fuse comprising insulating layers 2 and a fuse element 1, the insulating layers comprise an upper insulating layer and a lower insulating layer, the fuse element 1 is arranged between the upper insulating layer and the lower insulating layer, the insulating layers 2 are provided with terminal electrodes 4 electrically connected with the fuse element 1 thereon, and the fuse further comprises a functional layer 3 provided between the fuse element 1 and one of the insulating layers 2, the functional layer 3 comprises a substrate 32 and an arc extinguishing material 31 uniformly or substantially uniformly distributed in the substrate 32, the arc extinguishing material 31 is a glass body and/or ceramic body having sealed cavities, and the substrate 32 comprises low temperature co-fired ceramic powder, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid and phosphate ester polyester, and the content of the arc extinguishing material 31 of the functional layer is 1-50 wt %.

(16) The arc extinguishing material 31 in the functional layer 3 can generate voids under the pressure and temperature conditions when the fuse element is fused, specifically, the interface of the glass body or ceramic body in the arc extinguishing material is melted and broken, and the cavities preset in the glass body or ceramic body absorb the heat and shock waves generated when the fuse element is fused, and absorb the generated metal vapor to quench the arc. These sealed cavities wrapped in the glass body can be produced by prefabricated hollow glass microspheres, or heated gas-generating materials can be added to the glass body or ceramic body to form sealed cavities in the glass body or ceramic body during co-firing.

(17) In this embodiment, the arc extinguishing material 31 is a mixed glass of one or more of boron oxide, silicon oxide and aluminum oxide. The distribution of sphere diameter of the arc extinguishing material is 1-120 microns; the sphere diameter D50 of the arc extinguishing material is 10-80 microns.

(18) The production method for a fuse in this embodiment, comprises following steps:

(19) S1, glass-ceramic slurry was prepared by low temperature co-fired ceramic powder and binder, wherein the solid content in the glass-ceramic slurry was controlled to be 40-80 wt %, and the viscosity was 2.2 kcps after sufficient stirring;

(20) S2, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid and phosphate ester polyester were added to the glass-ceramic slurry, and fully stirred and grinded to prepare a pre-slurry of functional layer; the total amount of aerosol silicon oxide and silicon oxide was 0.1-20 wt %.

(21) S3, an arc extinguishing material was added to the pre-slurry of functional layer and fully stirred and grinded to prepare a functional layer slurry with arc extinguishing and press relief functions, wherein the arc extinguishing material was any one of hollow glass microspheres, glass powder mixed with foaming agent, or ceramic powder mixed with foaming agent, and the content of the arc extinguishing material of the functional layer was 1-50 wt %;

(22) S4, a layer of the glass ceramic slurry was coated to form a slurry layer of glass-ceramic to form a lower insulating layer slurry;

(23) S5, a layer of fuse element layer slurry having a layer of UV-curable binder was printed above the slurry layer of glass-ceramic using screen printing, wherein a silver content of the fuse element layer slurry was between 55-85%, and a layer of functional layer slurry layer was printed above the fuse element layer slurry through a steel screen, and a layer of slurry layer of glass-ceramic was coated above the functional layer slurry layer to form a green body of fuse in which an uppermost layer was an upper insulating layer slurry comprising the slurry layer of glass-ceramic;

(24) the green body of fuse was cut;

(25) S6, the green body of fuse was placed in a glue discharging glue discharging furnace to discharge the glue, wherein the temperature for glue discharging was 300-450° C., and the time for glue discharging was 1-40 hours;

(26) S7, the green body of fuse was sintered, wherein the temperature for sintering was 600-1000° C., and the time for sintering was 30-240 minutes;

(27) S8, chamfering, mounting terminal electrodes, sintering silver, and electroplating processes were performed on the green body of fuse to form a fuse having a functional layer, the functional layer comprised hollow glass and/or hollow ceramic body.

Embodiment 2

(28) As shown in FIG. 2, this embodiment provides a fuse, differing from Embodiment 1 in that the functional layer 3 in the fuse comprises two functional layers 3 arranged above the fuse element 1 and below the fuse element 1, and the functional layer 3 is in contact with the corresponding fuse element 1. The production method for the corresponding fuse is different from the production method of Embodiment 1 in step S5, which is specifically as follows:

(29) S5, a layer of functional layer slurry layer was printed above the slurry layer of glass-ceramic through steel screen printing, and a layer of fuse element layer slurry having a layer of UV-curable binder was printed above the functional slurry layer using screen printing, wherein the silver content of the fuse element layer slurry was between 55-85%, and a layer of functional layer slurry layer was printed above the fuse element layer slurry through steel screen printing, and a layer of slurry layer of glass-ceramic was coated above the functional layer slurry layer to form a green body of fuse in which an uppermost layer was an upper insulating layer slurry comprising the slurry layer of glass-ceramic.

Embodiment 3

(30) As shown in FIGS. 3-4, this embodiment provides a fuse, differing from Embodiment 1 in that the fuse element 1 comprises three layers of fuse elements 1 in sequence, a functional layer 3 is provided above each layer of fuse element 1, and the functional layer 3 is in contact with the corresponding fuse element 1, and adjacent fuse elements 1 are separated by insulating materials, namely interlayer 21.

(31) The production method for a fuse in this embodiment, comprises following steps:

(32) S1, glass-ceramic slurry was prepared by low temperature co-fired ceramic powder and binder, wherein the solid content in the glass-ceramic slurry was controlled to be 71.43 wt %, and the viscosity was 2.2 kcps after sufficient stirring;

(33) S2, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid and phosphate ester polyester were added to the glass-ceramic slurry, and fully stirred and grinded to prepare a pre-slurry of functional layer; the total amount of aerosol silicon oxide and silicon oxide was 9.32 wt %, D50=0.8 micron and the proportion of low temperature co-fired ceramic powder was 2.6 wt %.

(34) S3, an arc extinguishing material was added to the pre-slurry of functional layer and fully stirred and grinded to prepare a functional layer slurry with a viscosity of 39.5 kcps and arc extinguishing and press relief functions, wherein the arc extinguishing material was any one of hollow glass microspheres, glass powder mixed with foaming agent, or ceramic powder mixed with foaming agent, and the content of the arc extinguishing material was 14.9 wt %;

(35) S4, a layer of the glass ceramic slurry was coated to form a slurry layer of glass-ceramic to form a lower insulating layer slurry;

(36) S5, a layer of fuse element layer slurry having a layer of UV-curable binder was printed above the slurry layer of glass-ceramic using screen printing, wherein a silver content of the fuse element layer slurry was between 55-85%, and a layer of functional layer slurry layer was printed above the fuse element layer slurry through steel screen printing, a layer of slurry layer of glass-ceramic was coated above the functional layer slurry layer, and repeated three times to prepare a three-layer electrode structure, to form a green body of fuse in which an uppermost layer was an upper insulating layer slurry comprising the slurry layer of glass-ceramic;

(37) the green body of fuse was cut;

(38) S6, the green body of fuse was placed in a glue discharging furnace to discharge the glue, wherein the temperature for glue discharging was 360° C., and the time for glue discharging was 36 hours;

(39) S7, the green body of fuse was sintered, wherein the temperature for sintering was 850-900° C., and the time for sintering was 30 minutes;

(40) S8, chamfering, mounting terminal electrodes, sintering silver, and electroplating processes were performed on the green body of fuse to form a fuse having a functional layer, and the fuse was a 5-ampere fuse (Size: 0603).

(41) The experimental results shown in FIGS. 5-6 and Table 1 show that by adding the function layer with the arc extinguishing and pressure relief functions of the present disclosure, its breaking capacity is increased from 35 A/32 VDC to 80 A/75 VDC compared with products without this functional layer. At the same time, it has better breaking capacity than the product with a buffer layer (the invention patent CN106206201 of our company). Table 1 shows the experimental comparison results of products with or without this functional layer.

(42) TABLE-US-00001 TABLE 1 Rated Maximum Breaking Current rated voltage capacity Size: 0603 (A) (VDC) (A) Product with a functional layer 5 75 80 A/75 VDC Product without adding a layer 5 32 35 A/32 VDC Product with a buffer layer 5 70 50 A/70 VDC

Embodiment 4

(43) As shown in FIG. 7, this embodiment provides a fuse, differing from Embodiment 1 in that the fuse element 1 comprises five layers of fuse elements 1 in sequence, a functional layer 3 is provided above each layer of fuse element 1, and the functional layer 3 is in contact with the corresponding fuse element 1, and adjacent fuse elements 1 are separated by insulating materials, namely interlayer.

(44) The production method for a fuse in this embodiment, comprises following steps:

(45) S1, glass-ceramic slurry was prepared by low temperature co-fired ceramic powder and binder, wherein the solid content in the glass-ceramic slurry was controlled to be 71.43 wt %, and the viscosity was 2.2 kcps after sufficient stirring;

(46) S2, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid and phosphate ester polyester were added to the glass ceramic slurry, and fully stirred and grinded to prepare a pre-slurry of functional layer; the total amount of aerosol silicon oxide and silicon oxide was 9.15 wt %, D50=0.8 micron and the proportion of low temperature co-fired ceramic powder was 2.3 wt %.

(47) S3, an arc extinguishing material was added to the pre-slurry of functional layer and fully stirred and grinded to prepare a functional layer slurry with a viscosity of 30 kcps and arc extinguishing and press relief functions, wherein the arc extinguishing material was any one of hollow glass microspheres, glass powder mixed with foaming agent, or ceramic powder mixed with foaming agent, and the content of the arc extinguishing material was 14.5 wt %;

(48) S4, a layer of the glass ceramic slurry was coated to form a slurry layer of glass-ceramic to form a lower insulating layer slurry;

(49) S5, a layer of fuse element layer slurry having a layer of UV-curable binder was printed above the slurry layer of glass-ceramic using screen printing, wherein a silver content of the fuse element layer slurry was between 55-85%, and a layer of functional layer slurry layer was printed above the fuse element layer slurry through steel screen printing, a layer of slurry layer of glass-ceramic was coated above the functional layer slurry layer, and repeated five times to prepare a five-layer electrode structure, to form a green body of fuse in which an uppermost layer was an upper insulating layer slurry comprising the slurry layer of glass-ceramic;

(50) the green body of fuse was cut;

(51) S6, the green body of fuse was placed in a glue discharging furnace to discharge the glue, wherein the temperature for glue discharging was 340° C., and the time for glue discharging was 34 hours;

(52) S7, the green body of fuse was sintered, wherein the temperature for the sintering was 910° C., and the time for sintering was 30 minutes;

(53) S8, chamfering, mounting terminal electrodes, sintering silver, and electroplating processes were performed on the green body of fuse to form a fuse having a functional layer, and the fuse was a 20-ampere fuse (Size 1206).

(54) The experimental results shown in Table 2 and FIGS. 8-9 show that by adding the function layer with the arc extinguishing and pressure relief functions of the present disclosure, its breaking capacity is increased from 200 A/24 VDC to 200 A/48 VDC. Table 2 shows the experimental comparison results of products with or without this functional layer.

(55) TABLE-US-00002 TABLE 2 Rated Maximum Breaking Current rated voltage capacity Size: 1206 (A) (VDC) (A) Product with a functional layer 20 48 200 A/48 VDC Product without adding a layer 20 24 200 A/24 VDC Product with a buffer layer 20 35 150 A/35 VDC

Embodiment 5

(56) As shown in FIG. 10, this embodiment provides a fuse, differing from Embodiment 1 in that the functional layer 3 in the fuse comprises three sub-functional layers separated from each other in the same plane, the composition of each sub-functional layer is the same as that of the functional layer 3, and each sub-functional layer is in contact with the corresponding fuse element 1. The production method for the corresponding fuse is different from the production method of Embodiment 1 in step S5, which is specifically as follows:

(57) S5, a layer of fuse element layer slurry having a layer of UV-curable binder was printed above the slurry layer of glass-ceramic using screen printing, wherein a silver content of the fuse element layer slurry was between 55-85%, and a layer of functional layer slurry layer having a plurality of sub-functional layer slurry layers was printed above the fuse element layer slurry through steel screen printing, the plurality of sub-functional layer slurry layers separated from each other was in the same plane, and a layer of slurry layer of glass-ceramic was coated above the functional layer slurry layer to form a green body of fuse in which an uppermost layer was an upper insulating layer slurry comprising the slurry layer of glass-ceramic.

(58) The arc extinguishing material 31 of the functional layer 3 will produce voids only after/when the fuse element 1 is fused, and stable support among the components in the entire functional layer is provided during the production process, so that during the low temperature co-firing process of preparing the fuse, the functional layer can provide stable support for the fuse element layer and the insulating layers, and produce a dependent shrinkage at the contact part, which overcomes shrinkage mismatching of the fuse element with the buffer layer (the pressure relief spaces or cavities) and the arc extinguishing layer (arc layer) in the conventional art due to unsupporting during the sintering process, further to overcome disadvantages such as deformation, bending, and defects of the fuse element caused by such a shrinkage mismatching, and to ensure the flatness, consistency and integrity of the fuse element.

(59) The embodiments described above are only preferable embodiments, should not be concluded to limit the scope of rights of this disclosure, any equivalent variations according to the claims of the present disclosure should be covered by the scope of the present disclosure.

(60) For the sake of clarity, it is to be understood that the use of ‘a’ or ‘an’ throughout this application does not exclude a plurality, and ‘comprising’ does not exclude other steps or elements.