Fuse, battery pack using the fuse, and method of manufacturing the fuse

• US 20050001710A1
• Filed: 06/29/2004
• Published: 01/06/2005
• Est. Priority Date: 07/01/2003
• Status: Active Grant

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Izaki, Masatoshi, Mukai, Takahiro, Sakamoto, Yoshio, Senda, Kenji
• Granted Patent: US 7,106,165 B2
• Time in Patent Office: Days
• US Class Current: 337/297
• CPC Class Codes: H01H 2085/025 Structural association with a binding post of a storage battery
• CPC Class Codes: H01H 37/761 with a fusible element forming part of the switched circuit H01H37/767 takes precedence
• CPC Class Codes: H01H 85/143 Electrical contacts; Fastening fusible members to such contacts
• CPC Class Codes: H01M 50/581 in response to temperature
• CPC Class Codes: H01M 50/583 in response to current, e.g. fuses
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A fuse has a pair of lead terminals disposed on a substrate, an intermediate layers for welding formed on the surface of at least one of the lead terminals, and a fuse element. The fuse element is welded to the pair of lead terminals through the intermediate layer so as to span the same. Further, the intermediate layer is formed on at least one of the lead terminals except a face thereof opposing each other. Owing to this configuration, after the fuse has melted down, the melted fuse element is prevented from being spread out into the space between the opposing faces of the lead terminals and insulation therebetween is secured.

Claims

1. A fuse comprising:

a substrate;

a pair of lead terminals disposed on the substrate;

an intermediate layer for welding formed on a surface of at least one of the lead terminals except a portion of a face where the pair of lead terminals opposing each other; and

a fuse element made of a fusible member and welded to the pair of lead terminals through the intermediate layer so as to span the pair of lead terminals.

2. The fuse according to claim 1, wherein

the intermediate layer includes a plated layer.

3. The fuse according to claim 2, wherein

the intermediate layers further includes a meltable layer for welding disposed on the plated layer.

4. The fuse according to claim 1, wherein

the intermediate layer is formed at portion set back a predetermined distance from the face where the lead terminals opposing each other.

5. The fuse according to claim 1, wherein

at least one of lead terminals has a protruded portion formed on a end portion where the lead terminals opposing each other.

6. The fuse according to claim 5, wherein

the protruded portion prevents the intermediate layer from being formed on the face where the lead terminals opposing each other.

7. The fuse according to claim 5, wherein

the protruded portion is edge burr present on the end portion of at least one of the lead terminals.

8. The fuse according to claim 5, wherein

the protruded portion is a raised portion present at the end portion of at least one of the lead terminals and having a curved surface.

9. The fuse according to claim 5, wherein

the protruded portion is formed on a cut face of the end portion of at least one of the lead terminals.

10. The fuse according to claim 1, further comprising a cover film for covering the fuse element.

11. The fuse according to claim 10, further comprising flux containing rosin as a main component and sealed in the cover film.

12. The fuse according to claim 1, wherein

the fuse is at least one of a temperature fuse and a current fuse.

13. A pack battery comprising:

a battery;

a body housing the battery;

a wiring led out from the body and electrically connected to the battery; and

a fuse including;

a substrate;

a pair of lead terminals disposed on the substrate;

an intermediate layer for welding formed on a surface of at least one of the lead terminals except a portion of a face where the pair of lead terminals opposing each other; and

a fuse element made of a fusible member and welded to the pair of lead terminals through the intermediate layer so as to span the pair of lead terminals.

14. The pack battery according to claim 13, wherein

the fuse is in contact with the body.

15. The pack battery according to claim 13, wherein

the fuse is in contact with the battery.

16. A method of manufacturing a fuse comprising the steps of:

A) bonding a pair of lead terminals on a substrate;

B) forming an intermediate layer for welding on a surface of at least one of a pair of lead terminals except portions of faces where the lead terminals opposing each other; and

C) welding the fuse element to the intermediate layer.

17. The method of manufacturing a fuse according to claim 16, wherein step B comprises the steps of

D) forming a plated layer on one of the lead terminals except faces where the lead terminals opposing each other;

and

E) forming a meltable layer for welding on top face of the plated layer, wherein

the fuse element is welded to the meltable layer for welding at step C.

18. The method of manufacturing a fuse element according to claim 16, further comprising the step of:

F) producing the pair of lead terminals by cutting work and providing a protrusion on end portion where the lead terminals opposing each other.