Method of manufacturing a PTC circuit protection device
First Claim
1. A method of making an electrical device comprising the steps of:
- providing a PTC element having first and second surfaces, said PTC element including a polymer with conductive particles dispersed therein;
coating said first surface of said PTC element with a conductive layer;
coating said second surface of said PTC element with a conductive layer;
bringing said first coated surface of said PTC element into contact with a first electrode, said electrode having an inner surface and an outer surface with a plurality of voids;
bringing said second coated surface of said PTC element into contact with a second electrode, said electrode having an inner surface and an outer surface with a plurality of voids;
heating and applying pressure to said PTC element, said conductive layers and said electrodes causing a portion of each electrode to extend through each conductive layer, respectively, and physically contact the PTC element to form a laminate; and
,forming said laminate into a plurality of electrical devices.
0 Assignments
0 Petitions
Accused Products
Abstract
Electrical devices comprising a PTC element comprised of a polymer having conductive particles dispersed therein. The PTC element is coated with a conductive layer and has electrodes with a plurality of voids affixed to opposing surfaces. The devices are made by dispersing conductive particles into a polymer to form a polymer PTC composition. The polymer PTC composition is melt-shaped to form a laminar shaped PTC element. First and second opposing surfaces of the PTC element are coated with a conductive layer. The electrodes, characterized by a plurality of voids, are brought into contact with the coated surfaces of the PTC element, and heated while applying pressure to form a laminate. The laminate is then further shaped into a plurality of PTC electrical circuit protection devices.
-
Citations
36 Claims
-
1. A method of making an electrical device comprising the steps of:
-
providing a PTC element having first and second surfaces, said PTC element including a polymer with conductive particles dispersed therein; coating said first surface of said PTC element with a conductive layer; coating said second surface of said PTC element with a conductive layer; bringing said first coated surface of said PTC element into contact with a first electrode, said electrode having an inner surface and an outer surface with a plurality of voids; bringing said second coated surface of said PTC element into contact with a second electrode, said electrode having an inner surface and an outer surface with a plurality of voids; heating and applying pressure to said PTC element, said conductive layers and said electrodes causing a portion of each electrode to extend through each conductive layer, respectively, and physically contact the PTC element to form a laminate; and
,forming said laminate into a plurality of electrical devices. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 24, 36)
-
-
18. A method of making an electrical device comprising the steps of:
-
providing a PTC element having first and second surfaces, said PTC element including a polymer with conductive particles dispersed therein; coating said first surface of said PTC element with a conductive layer; coating said second surface of said PTC element with a conductive layer; bringing the first coated surface of said PTC element into contact with a first electrode and bringing said second coated surface of said PTC element into contact with a second electrode, said electrodes having a three-dimensional, initially open cellular structure characterized by an inner surface and an outer surface; heating and applying pressure to said PTC element, said conductive layers and said electrodes causing the inner surface of each said electrode to extend through each said conductive layer, respectively, and contact said PTC element to form a laminate; and
,forming said laminate into a plurality of PTC electrical devices. - View Dependent Claims (19, 20, 21, 22, 23, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
-
Specification