Patent Application
20130099890
This invention relates to an element for protecting an electric circuit against an over-current or an over-voltage state, and a method for producing the circuit.
The present application asserts priority rights based on JP Patent Application 2010-135806 filed in Japan on Jun. 15, 2010. The total contents of disclosure of the Patent Application of the senior filing date are to be incorporated by reference into the present application.
Up to now, measures have been taken to protect an electrical circuit against at least one out of the over-current state and the over-voltage state.
In Patent Document 1, for example, melt-disruption of an interconnect pattern in case of over-current is disclosed, in which a solder is formed on part of interconnections of a printed circuit board to take advantage of the operation of erosion such as phenomenon of copper dissolution by the solder. In Patent Publication 1, it is stated that a pattern width of a melt disconnect part is made narrow to reduce the melt disconnect time, and that a slit is formed in the current flowing direction.
The protective function described in the above Patent Publication is, after all, a function as a fuse for protection against an over-current. Viz., the function is not such a function to promptly reliably disconnect a current path in response to a non-normal signal from a voltage detection IC adapted to detect the non-normal battery voltage. Such function to promptly reliably disconnect the current path is required in e.g., a secondary protection circuit for battery protection.
On the other hand, in the protective element, a lead-free substitution solder material is attracting notice. In this connection, it is desired that, even if a solder paste mainly composed of a metal having a melting point lower than that of a solder foil mainly composed of lead is used, reflow packaging on a printed circuit board is possible.
The present invention has been proposed in view of the above depicted status of the art. It is an object of the present invention to provide a protective element in which it is possible to promptly reliably disconnect a current path by exploiting the erosion phenomenon by a solder in the melted state, and a method for manufacturing the protective element. The solder, formed of a low melting alloy, is fed with current in response to a non-normal situation, such as an over-voltage, and is melted just by self-heating due to heat generated by a resistor or by over-current. A current path may be disconnected promptly reliably by taking advantage of the erosion phenomenon exhibited by the solder in the melted state,
To accomplish the above object, the present invention provides a protective element including a substrate, a plurality of electrodes formed on the substrate, low-melting metal connected to a current path between the electrodes and melt-disconnected on heating to disconnect the current path, and a resistor that, when fed with current, generates heat that melts the low-melting metal. Each of the electrodes is composed by a first electrically conductive layer deposited on the substrate and a plurality of second electrically conductive layers spaced apart from one another in the in-plane direction of the substrate on which the first electrically conductive layer is formed. The low melting metal has a wetting performance for the electrodes higher than that for the substrate, and is deposited on the first and second electrically conductive layers formed on the substrate. The low melting metal melts by at least one out of heat generated by the resistor and heat generated by a stack of the electrodes and the low melting metal, in such a manner that, as the low melting metal erodes the portion of the first electrically conductive layer intermediate between the electrodes, the metal is attracted towards the electrodes exhibiting higher wettability by the metal than that of the substrate.
The present invention also provides a method for manufacturing a protective element including a first depositing step of forming a first electrically conductive layer on a substrate provided with a resistor that, when fed with current, generates heat to melt low melting metal, a second depositing step and a third depositing step. The second depositing step forms a plurality of second electrically conductive layers spaced apart from one another in the in-plane direction of the substrate on which the first electrically conductive layer has been deposited by the first depositing step, thereby forming a plurality of electrodes. The third depositing step fauns low melting metal on the first and second electrically conductive layers formed on the substrate. The low melting metal has a wetting performance for the electrodes higher than that for the substrate. The low melting metal is melt-disconnected by at least one out of heat generated by the resistor and heat generated by a stack of the electrodes and the low melting metal, in such a manner that, as the low melting metal erodes the portion of the first electrically conductive layer intermediate between the electrodes, the metal is attracted towards the electrodes exhibiting higher wettability by the metal than that of the substrate.
In the present invention, the low melting metal is deposited between neighbored electrodes on top of the first electrically conductive layer. Hence, the erosive action to the first electrically conductive layer, which might cause disruption of a current path, is not produced except by heat generated by the resistor or by self-heating caused by the over-current. In addition, in the present invention, the electrodes are formed by a stack of layers presenting a film thickness difference with respect to the substrate. It is thus possible that the low melting metal in the melted state is attracted by surface tension towards the electrode, whose wettability by the low melting metal is higher than that of the substrate, as the melted metal erodes the first electrically conductive layer.
Thus, according to the present invention, the solder formed of the low melting metal is melted just by self-heating due to over-current or by heat generated by the resistor fed with current in response to a non-normal situation such as over-voltage. The current path may promptly reliably be disconnected by taking advantage of the phenomenon of erosion by the solder in the so melted state.
A preferred mode of carrying out the present invention will now be described in detail with reference to the drawings. It should be noted that the present invention is not to be restricted to the following embodiment such that a wide variety of modifications may be made without departing from the scope of the invention.
<Global Configuration>
The protective element according to the present invention is configured to safeguard an electrical circuit against at least one out of the over-current state and the over-voltage state. The protective element is used as it is built into a battery pack 1 including a battery 10 composed by four chargeable/dischargeable battery cells 11 to 14.
Viz., the battery pack 1 includes the battery 10, a charging/discharging controlling circuit 20, controlling the charging/discharging of the battery 10, and a protective element 100 that protects the battery 10 and the charging/discharging controlling circuit 20. In addition, the battery pack includes a detection circuit 40 that detects the voltage of each of the battery cells 11 to 14 and a current control element 50 that controls the operation of the voltages of the protective element 100 in response to the result of detection by the detection circuit 40.
The battery 10 is made up of a series connection of the battery cells 11 to 14 that need to be controlled so as not to fall into the over-charging or over-discharging state, such as lithium ion cells. The battery is removable connected to the charging device 2 via a positive electrode terminal 1a and a negative electrode terminal 1b of the battery pack 1 and hence is fed with a charging voltage from the charging device 2.
The charging/discharging controlling circuit 20 includes two current controlling elements 21, 22, connected in series with each other on a current path for the current flowing from the battery 10 to the charging device 2, and a controller 23 that controls the operation of the current controlling elements 21, 22. Each of the current controlling elements 21, 22 is made up of, for example, a field effect transistor, referred to below as FET, whose gate voltage is controlled by the controller 23 to control the on/off of the current path through the battery 10. The controller is run into operation by power delivered from the charging device 2 to control the operation of the current controlling elements 21, 22, depending on the result of detection by the detection circuit 40, such as to turn off the current path in case the battery 10 is in the over-discharged or over-charged state.
The protective element 100 is provided on a charging/discharging current path between the battery 10 and the charging/discharging controlling circuit 20, and has its operation controlled by the current control element 50.
The detection circuit 40 is connected to each of the battery cells 11 to 14 to detect voltage values of the battery cells 11 to 14 to transmit respective voltage values detected to the controller 23 of the charging/discharging controlling circuit 20. The detection circuit 40 outputs a control signal to control the current control element 50 in case any one or more of the battery cells 11 to 14 has fallen into the over-charging state or into the over-discharging voltage state.
It may sometimes occur that a detection signal, output from the detection circuit 40, indicates that the voltage value of any of the battery cells 11 to 14 has become offset from a pre-set range, more specifically, has fallen into the over-charging or over-discharging state. In such case, the current control element 50 sets the protective element 100 into operation to turn off the charging/discharging current path of the battery 10.
In the above described configuration of the battery pack 1, the configuration of the protective element 100 will now be explained in detail.
<Configuration of a Protective Circuit>
To protect the above mentioned electrical circuit within the battery pack 1 from the over-current or over-voltage state, the protective element 100 according to the present invention has the circuit configuration shown in
Viz., the protective element 100 includes fuses 101, 102 formed of low-melting metal which melts and becomes disrupted on heating, and a resistor 103 which, when fed with current, emits heat to melt the fuses 101, 102, as shown in
The fuses 101, 102 are inherently formed by a single member which is formed of low melting metal and which is split into two parts to form a circuit shown. Viz., the two parts are joined together at a junction point P1 to form a series circuit composed by the two parts. The fuses are connected in series with each other on a charging/discharging current path between the battery 10 and the charging/discharging controlling circuit 20. For example, the fuse 101 is connected to the battery 10 via a junction point A1 not connected to the fuse 102, whereas the fuse 102 is connected to the battery charging/discharging controlling circuit 20 via a junction point A2 not connected to the fuse 101.
The resistor 103 has one end connected via the junction point P1 to the fuses 101, 102, while having the other end connected via another junction point P2 to the current control element 50.
If, in the above described circuit configuration of the protective element 100, the resistor 103 is fed with current, the resistor emits heat which will melt the fuses 101, 102, by the operation of the current control element 50. With the fuses 101, 102 thus melted, it is possible to protect the electrical circuit within the battery pack 1.
In the protective element 100, it is necessary to use a solder formed of low melting metal for operation as fuses 101, 102 to promptly reliably disconnect a current path by taking advantage of the erosion phenomenon by the solder. To this end, the protective element is manufactured by the following process.
The method of manufacturing the protective element 100 according to the present invention will now be described with reference to
Referring to
Initially, in a first layering step, the first electrically conductive layer 112 of an excellently electrically conductive material, such as Ag or Pt, is formed on a substrate 111 to a film thickness d1 by printing or the like processing.
Then, in a second layering step, a plurality of second electrically conductive layers 113 of an excellently electrically conductive material, such as Ag or Pt, are deposited on the first electrically conductive layer 112 already formed on the substrate 111. The second electrically conductive layers 113 are formed at a plurality of locations separated from one another in the in-plane direction on the substrate 111 to the same film thickness d2 by printing or the like processing. This forms a plurality of electrodes 114a, 114b and 114c. It should be noted that the site of the electrode 114a corresponds to the junction point A1 in the circuit configuration of
It should be noted that both the first and second electrically conductive layers 112, 113 are formed of excellently electrically conductive materials, such as Ag or Pt. It is preferred that, to relatively promote the action of erosion of the first electrically conductive layer 112 by the solder, the physical properties of the raw materials for the first electrically conductive layer 112 are adjusted so that the layer 112 will be eroded by the solder more readily than the second electrically conductive layer 113, as later explained.
Then, in a third layering step, a lead-free solder 116, such as SnAg based solder, as low-melting metal, is applied by printing or the like processing on the substrate 111 on which the electrodes 114 are already deposited as described above. Note that the lead-free solder 116 is layered at this time in contact with the first and second electrically conductive layers 112, 113, as shown in
It is sufficient that the metallic material, applied in the third layering step, has, in a melted state, a wetting performance for the electrodes 114 higher than that that for the substrate 111. Viz., the metallic material is not limited to the SnAg based metallic material.
For ease in layering the solder 116 to an even film thickness, a film-forming step of forming a plurality of insulation films 117 is preferably carried out before the third layering step on each of the electrodes 114 formed by the second layering step. By forming the insulation films 117 on each of the electrodes 114, in the manufacturing method for the protective element 100, the solder 116 in the liquidus state may be retained in locations 116a, 116b, delimited by the insulation films 117, until the solder solidifies after printing. As a result, the solder 116 may be deposited to an even film thickness. The locations 116a, 116b may be seen in a plan view of
Referring to
Referring to
In the protective element 100, described above, the solder 116 begins to melt by at least one out of heat generated by the resistor 103 and heat generated by a layered site 121 formed by part of the electrode 114 and part of the solder 116, as shown in
In the protective element 100, melt residues 131 composed by the solder 116 and the first electrically conductive layer 112 are left over, as shown in
In the protective element 100, the electrodes 114 are formed by a stack of layers in which the first and second electrically conductive layers 112, 113 provide a step of a film thickness difference relative to the substrate 111. It is thus possible that the solder 116 is drawn onto the electrodes 114 as the solder erodes only the first electrically conductive layer 112.
Moreover, in the protective element 100, the solder 116 is layered in an area of the first electrically conductive layer 112 delimited between the neighbored electrodes 114. It is thus possible to prevent the protective element 100 from being melt-disconnected under heat applied e.g., when the protective element 100 is reflow-packaged on a circuit substrate within the battery 1. Viz., the protective element 100 is not subjected to an erosive action at the first electrically conductive layer 112, and hence the current path is not disconnected, unless the protective element is self-heated due to over-current or heated by the resistor 103.
Thus, in the protective element 100, according to the present invention, the solder 116, formed of low-melting metal, is melted just due to self-heating in case of over-current or under heat generated by the resistor 103 through which the current flows in response to a non-normal state such as over-voltage. The current path may be disconnected promptly reliably by taking advantage of the phenomenon of erosion by the solder in the melted state.
In the protective element, according to the present invention, a lead-free paste-like solder is preferably used. It is because the above mentioned third layering processing may readily be performed by printing as the range of selection of solder materials is made broader. It should be noted that, in the protective element, according to the present invention, not only the lead-free paste-like solder but also a lead-based solder or a solder other than the paste-like solder, such as a solder foil, may also be used.
A modification of the protective element according to the present invention is shown in
Viz., in the protective element 100, according to the present invention, the portion of the first electrically conductive layer 112, located between the neighbored electrodes 114 on the substrate 111, is divided by the slits(s) 112a into separate sections, as shown in
In the manufacturing process for the protective element 100 of the present modification, a plurality of insulation films 117 may be provided on the electrodes 114. It is thus possible to deposit the solder 116 to an even film thickness on location sites 116a, 116b, delimited by the insulation films 117, as indicated in a plan view of
Referring to
In the protective element 100 of the present modification, obtained as described above, the solder 116 in the melted state is intruded into the slits 112a, as shown in the cross-sectional view of
In the protective element 100 according to the present invention, the first and second electrically conductive layers 112, 113 are used to provide an electrically conductive layer having a step by film thickness difference relative to the substrate 111 to form the electrodes 114. In particular, the film thickness ratio of the electrode 114 to the first electrically conductive layer 112 of 2 or more is desirable from the solder erosion characteristic against the film thickness of an electrically conductive layer. The result of a test which yielded solder erosion characteristic will now be described.
The solder erosion characteristic related to the film thickness of the electrically conductive layer was evaluated by a test which makes use of a test substrate 200 shown in
Under the present test conditions, the lead-based solder 204, melting at a temperature higher than with a SnAg based material, was used. However, a lead-free solder, such as SnAg based solder, is preferred in that it melts at a lower temperature and hence may erode more readily.
Under the above mentioned test conditions, heating was carried out using three different film thicknesses 7 [μm], 14 [μm] and 22 [μm] of the electrically conductive layer 203. It was found that areas eroded by the solder 204 were as indicated in the following Table 1:
It is seen from the above Table 1 that, under the constant heating conditions, the electrically conductive layer 203, with the film thickness d on the order of 7 [μm], is eroded severely and may properly be used as the first electrically conductive layer 112 operating as the melt-disconnect part 132. The electrically conductive layer 203, with the film thickness d on the order of 14 [μm], is eroded only mildly and may properly be used as the electrode 114 operating as the solder sink 133. The electrically conductive layer 203, with the film thickness d on the order of 22 [μm], is not eroded and may properly be used as the electrode 114.
As may be seen from the above results, in the protective element 100, it is preferred that the ratio of the film thickness of the electrode 114 to that of the first electrically conductive layer 112 is not less than 2 and, in particular, not less than 3, from the perspective of reliable melt-disconnection of the current path between the electrodes 114. By the film thickness of the electrode 114 are meant the film thicknesses of the first and second electrically conductive layers 112, 113 summed together. The ratio of the film thickness of the electrode 114 to that of the first electrically conductive layer 112 ranging between 2 and 3 is desirable in preventing the erosion from occurring in the electrodes 114 as the low cost for the raw materials of the electrically conductive layers is maintained.
As may be apparent from the above test, the film thickness of the first electrically conductive layer 112 is desirably 7 [μm] or less in view of efficient demonstration of the erosive operation. It is desirably not less than 1 [μm] which is the minimum film thickness for which no erosion may occur even in reflow packaging.
The film thickness of the electrode 114, viz., the sum of the film thicknesses of the first and second electrically conductive layers 112, 113, is desirably not less than 14 [μm] and, in particular, not less than 22 [μm], for preventing the erosive action from occurring.
The area of the melt-disconnect part 132, where the first electrically conductive layer 112 is eroded, is preferably on the order of 0.5 to 2 [mm] (width)×0.2 to 0.4 [mm] (length). If a slit is formed by way of a modification, the slit size is preferably ca. 0.5 to 2 [mm] along the width of the gap between the neighbored electrodes 114 and ca. 0.1 to 0.2 [mm] along the length of the gap between the neighbored electrodes 114 perpendicular thereto.
It is to be noted that the protective element according to the present invention may promptly reliably disconnect a current path by taking advantage of the solder erosion phenomenon in case the element is mounted in electrical circuits other than the above mentioned battery pack 1. The reason is that the protective element according to the present invention is aimed to protect a device of interest against at least one out of the over-current state and the over-voltage state.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-135806 | Jun 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/063648 | 6/15/2011 | WO | 00 | 12/17/2012 |
