Claims
- 1. A method of making a fuse element subassembly comprising the steps of:
- providing a substrate of insulating material;
- producing two separate metallized areas on the substrate;
- bonding one end of a fusible element to one of the separate metallized areas without using solder or flux;
- extending the fusible element across the substrate to the other of the separate metallized areas;
- bonding the other end of the fusible element to the other separate metallized area to electrically connect the metallized areas on the substrate; and
- attaching a lead to each one of the separate metallized areas without causing the lead to contact the fusible element.
- 2. A method of making a fuse element subassembly as in claim 1 wherein said substrate is ceramic.
- 3. A method of making a fuse element subassembly as in claim 1 wherein said substrate is glass.
- 4. A method of making a fuse element subassembly as in claim 1 wherein said substrate is alumina.
- 5. A method of making a fuse element subassembly as in claim 1 wherein said substrate is forsterite.
- 6. A method of making a fuse element subassembly as in claim 1 wherein said substrate is separated from a larger piece of insulating material by breaking along scribe lines.
- 7. A method of making a fuse element subassembly as in claim 1 wherein said substrate is separated from a larger piece of insulating material by breaking along lines cut part way through the larger piece.
- 8. A method of making a fuse element subassembly as in claim 7 wherein said cutting is by dicing.
- 9. A method of making a fuse element subassembly as in claim 7 wherein said cutting is by water jet.
- 10. A method of making a fuse element subassembly as in claim 7 wherein said cutting is by laser.
- 11. A method of making a fuse element subassembly as in claim 1 wherein said substrate is separated from a larger piece of insulating material by breaking along score lines preformed in the insulating material during the making of said material.
- 12. A method of making a fuse element subassembly as in claim 1 wherein said metallized areas are printed onto said substrate using thick film metal ink.
- 13. A method of making a fuse element subassembly as in claim 12 wherein said metallized areas are printed with a metal ink selected from a group of metal inks comprised of copper, gold, silver, nickel, palladium, platinum and combinations thereof.
- 14. A method of making a fuse element subassembly as in claim 1 wherein said metallized area is provided on said substrate by metal vapor deposition.
- 15. A method of making a fuse element subassembly as in claim 1 wherein said metallized area is provided on said substrate by thermal evaporation in vacuum.
- 16. A method of making a fuse element subassembly as in claim 1 wherein said metallized area is provided on said substrate by electron beam vaporization in vacuum.
- 17. A method of making a fuse element subassembly as in claim 1 wherein said metallized area is provided on said substrate by sputtering.
- 18. A method of making a fuse element subassembly as in claim 1 wherein said metallized area is provided by selective etching of a larger metallized region.
- 19. A method of making a fuse element subassembly as in claim 1 wherein said metallized area is provided by laminating metal pads to said substrate.
- 20. A method of making a fuse element subassembly as in claim 1 wherein said bonding is accomplished by ultrasonic bonding.
- 21. A method of making a fuse element subassembly as in claim 1 wherein said bonding is accomplished by laser welding.
- 22. A method of making a fuse element subassembly as in claim 1 wherein said bonding is accomplished by thermosonic bonding.
- 23. A method of making a fuse element subassembly as in claim 1 wherein said bonding is accomplished by thermocompression bonding.
- 24. A method of making a fuse element subassembly as in claim 1 wherein said bonding is accomplished by resistance welding.
- 25. A method of making a fuse comprising the steps of:
- providing a substrate of insulating material;
- producing two separate metallized areas on the substrate;
- bonding one end of a fusible element to one of the separate metallized areas without using solder of flux;
- extending the fusible element across the substrate to the other of the separate metallized areas;
- bonding the other end of the fusible element to the other separate metallized area to electrically connect the metallized areas on the substrate;
- attaching one lead to each of the metallized areas;
- coating the substrate with an insulating material; and
- injection molding the substrate, bonded fusible element, and leads in an insulating housing.
- 26. A method of making a fuse as in claim 25 wherein said insulating housing is plastic.
- 27. A method of making a fuse as in claim 25 wherein at least a portion of said substrate, metallized areas, and fusible element are covered with arc quenching material prior to injection molding the insulating housing.
- 28. A method of making a fuse as in claim 27 wherein said arc quenching material is ceramic.
- 29. A method of making a fuse comprising the steps of:
- providing a substrate of insulating material;
- producing two separate metallized areas on the substrate;
- bonding one end of a fusible element to one of the separate metallized areas without using solder or flux;
- extending the fusible element across the substrate to the other of the separate metallized areas;
- bonding the other end of the fusible element to the other separate metallized area to electrically connect the metallized areas on the substrate;
- attaching one lead to each of the metallized areas; and
- applying an arc quenching material only to that portion of the substrate having the metallized areas and fusible element.
- 30. A method of making a fuse as in claim 29 wherein said arc quenching material is ceramic.
- 31. A method of making a fuse as in claim 29 wherein said substrate, metallized areas, fusible element, and attached ends of said leads are enclosed in an insulating housing.
- 32. A method of making a fuse as in claim 31 wherein said insulating housing is plastic.
- 33. A method of making a fuse as in claim 31 or 25 wherein said insulating housing is a molded ceramic.
- 34. A method of making a fuse element subassembly as in claim 1 wherein said fusible element is selected from a group consisting of aluminum, gold, silver or copper.
- 35. A method of making a fuse element subassembly as in claim 1 wherein said fusible element is a wire.
- 36. A method of making a fuse element subassembly as in claim 1 wherein said fusible element is a metal ribbon.
- 37. A method of making a fuse as in claim 25 or 29 wherein said lead is flattened on the end attached to said metallized area.
- 38. A method of making a fuse as in claim 25 or 29 wherein said lead end is offset to center the substrate in said insulated housing.
Parent Case Info
This is a continuation of co-pending U.S. Patent Application Ser. No. 07/148,263, filed Jan. 25, 1988, now abandoned which is a divisional application of U.S. Patent Application Ser. No. 07/029,831 filed Mar. 24, 1987, now U.S. Pat. No. 4,771,260.
US Referenced Citations (8)
Foreign Referenced Citations (2)
Number |
Date |
Country |
1135871 |
Nov 1982 |
CAX |
3304263 |
Aug 1984 |
DEX |
Divisions (1)
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Number |
Date |
Country |
Parent |
29831 |
Mar 1987 |
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Continuations (1)
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Number |
Date |
Country |
Parent |
148263 |
Jan 1988 |
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