JP3332040B2 - Thermal fuse, method of manufacturing the same, and battery using the thermal fuse - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermal fuse used for, for example, a battery or a power supply, and a method for manufacturing the thermal fuse, and a battery using the thermal fuse in order to prevent equipment damage due to excessive temperature rise.

[0002]

2. Description of the Related Art In recent years, the technical development of secondary batteries has been remarkably progressed. In particular, secondary batteries that are small and can be used for a long time with a single charge as batteries used in devices such as mobile phones, PHSs, and notebook computers. Secondary batteries are being developed and put into practical use.
Specifically, development and commercialization of Ni-Cd batteries, Ni-H batteries, and Li-ion batteries have progressed, and smaller and longer-lasting secondary batteries have been developed.

However, as a battery becomes smaller and has a longer life, the risk of the battery being damaged or exploding due to heat generated by rapid discharge due to a short circuit between the positive and negative electrodes of the battery increases. Therefore, in order to ensure the safety of the secondary battery, a thermal fuse that is disconnected due to heat generated during a short circuit is used. As this thermal fuse, a fuse using a low melting point fusible alloy is generally used. This low-melting-point fusible alloy is attached to a part of a battery or power supply that may generate heat by contacting it with an insulating layer. The molten alloy is melted to prevent the battery from being discharged or charged, thereby preventing abnormal heat generation of the battery and preventing thermal destruction of power supply equipment.

FIG. 21 is a configuration diagram showing an example of a conventional thermal fuse using a low melting point fusible alloy. 21, reference numerals 71 and 72 denote lead wires, 73 and 74 are polymer resin insulating adhesives, 75 and 76 are ceramic insulating cases, 77
78 is a thermal fuse element made of a low melting point fusible alloy, 78
Is the flux. The conventional thermal fuse uses a low melting point fusible alloy as the thermal fuse element 77, has lead wires 71 and 72, and has a ceramic insulating case 7.
The casing is hermetically sealed with the spaces 5, 76 and the polymer resin insulating adhesives 73, 74 while leaving a space in the case. The hermetic structure is used to prevent the low melting point fusible alloy 77 from leaking to the outside even when the thermal fuse operates. The manufacturing method is as follows.
And a flux 78 is applied to the surface of the low melting point fusible alloy 77.
Is applied, is passed through tubular ceramic insulating cases 75 and 76, and has a structure in which both ends are sealed with a two-liquid curing type epoxy resin (polymer resin insulating adhesive) 74 and 74.

[0005]

However, with the recent miniaturization of electronic devices, there are many demands for miniaturization and thinning of batteries and power supply devices, and miniaturization, thinning, and flexibility of thermal fuses have been demanded. Grant is required,
The conventional thermal fuse has the following problems.

A conventional thermal fuse using a tubular ceramic insulating case 75, 76 is not flexible enough to cope with the miniaturization and thinning of accessories accompanying the miniaturization and thinning of batteries and power supplies. There is.

[0007] With the miniaturization and thinning of accessories accompanying the miniaturization and thinning of batteries and power supplies, conventional thermal fuses using tubular ceramic insulating cases 75 and 76 are required when the thermal fuse operates. It is difficult to maintain the case strength and make the case thinner than 1 mm.

The use of the lead wires 71 and 72 makes it difficult to position a welding point when connecting terminals by welding.

The thermal fuse, the method of manufacturing the thermal fuse, the thermal fuse unit, the battery, and the power supply using the thermal fuse are required to have flexibility, a thin case of 1 mm, and easy positioning of a welding point. .

SUMMARY OF THE INVENTION An object of the present invention is to provide a manufacturing method which can easily manufacture a thermal fuse having flexibility, a case as thin as 1 mm, and easy positioning of a welding point.

[0011]

In order to solve this problem, a method for manufacturing a thermal fuse according to the present invention has an outermost end exposed.
Sealing insulating flop insulating plate having flexibility each of the pair of linear conductors or a pair of plate-shaped conductors to so that
Is fixed with the rate, the pair of linear conductors or a low melting point fusible alloy between the ends of said pair of plate-like conductor is <br/> fixed, a gap for accommodating the low-melting fusible alloy Form
Connect the cover insulating plate to the insulating plate
A method of manufacturing a combined thermal fuse, comprising:
Where Z is the thickness and M is the thickness of the low melting point fusible alloy,
The cover insulating plate and the insulating plate are welded by ultrasonic vibration so that 0.02 mm <M ≦ Z <0.8 mm, and the insulating plate and the sealing plate are welded .
Separate the insulating plate and the insulating plate for the cover
It is composed of a thermoplastic resin .

Thus, a method of manufacturing a thermal fuse having flexibility, a thin case having a thickness of 1 mm, and easily positioning a welding point can be obtained.

Further, the thermal fuse of the present invention has an insulating pre-
Sheet and the sealing insulating plate to which the insulating plate is bonded.
Sheet, the insulating plate and the sealing insulating plate.
A pair fixed between and provided to expose the extreme end
A linear conductor or a pair of plate-shaped conductors, a low-melting-point fusible alloy fixed between the ends of the pair of linear conductors or the pair of plate-shaped conductors, and provided on the insulating plate;
Provided so as to form a cavity for storing low melting point fusible alloy
An insulating plate for the cover, wherein a welding portion is provided by welding the insulating plate for the cover and the insulating plate by ultrasonic vibration, the thickness of the gap is Z, the melting point is
When the thickness of the fusible alloy is M, 0.02 mm <M ≦ Z
<0.8 mm, and the insulation
Rate, insulation plate for sealing and insulation for cover
Each plate is made of a thermoplastic resin .

Thus, a thermal fuse having flexibility and a case as thin as 1 mm can be obtained.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS According to the first aspect of the present invention , a pair of linear conductors or a pair of plate conductors are respectively sealed on a flexible insulating plate so that the outermost ends are exposed . While fixing using an insulating plate ,
The pair of linear conductors or a low melting point fusible alloy between the ends of the pair of plate-like conductor is fixed, yield the low-melting fusible alloy
Cover on the insulating plate so as to form a gap to accommodate
A method of manufacturing a thermal fuse in which an insulating plate for bonding is used, wherein the thickness of the air gap is Z, and the thickness of the low melting point fusible alloy is
Where M is 0.02 mm <M ≦ Z <0.8 mm
So as to the cover insulation plate and with said insulating plate welded by ultrasonic vibration, moreover the insulation pre
Sheet, the insulating plate for sealing and the insulating plate for the cover
Each rate is composed of thermoplastic resin ,
This has the effect that the tubular ceramic insulating case is not used and the body case is made thinner. In addition, since the cover insulating plate is frictionally vibrated by ultrasonic vibration and welded by frictional heat, heat generated for welding is concentrated on a welded portion, and welding can be performed with less heat energy. Therefore, the low melting point fusible alloy also has an effect of being able to be welded before fusing.

According to a second aspect of the present invention, in the first aspect, the thermoplastic resin is an ABS resin, a SAN
Resin, polysanfone resin, polycarbonate resin, Noryl, vinyl chloride resin, polyethylene resin, polyester resin, polypropylene resin, polyamide resin, PP
It is mainly composed of any one of S resin, polyacetal, fluororesin, and polyester, and has an effect that the tubular ceramic insulating case is not used and the main body case is thinned. In addition, since the cover insulating plate is frictionally vibrated by ultrasonic vibration and welded by frictional heat, heat generated for welding is concentrated on a welded portion, and welding can be performed with less heat energy. Therefore, the low melting point fusible alloy also has an effect of being able to be welded before fusing.

According to a third aspect of the present invention, in the first aspect, a pair of linear conductors or a pair of plate-like conductors is provided.
Has a surface roughness of 0.5 to 50 μm,
It has the effect of increasing the frictional force.

According to a fourth aspect of the present invention, in the first aspect of the invention, the cover insulating plate and the insulating plate are ultrasonically vibrated with the cover insulating plate or the projection provided on the insulating plate. The projections act as energy directors and ultrasonic vibrations are concentrated here, so frictional heat is concentrated on these projections and welding is performed with less heat energy. Therefore, the low melting point fusible alloy has an effect of being able to be welded before being melted.

According to a fifth aspect of the present invention, in the first aspect of the invention, the ends of the pair of linear conductors or the pair of plate conductors are arranged on an insulating plate having flexibility, and The pair of linear conductors or the pair of plate conductors is welded to the insulating plate by heat generation by applying a current to the linear conductor or the pair of plate conductors, and the insulating plate and the pair of linear conductors are welded. The conductor or the pair of plate-like conductors can be easily joined.

According to a sixth aspect of the present invention, there is provided an insulating plate.
And an insulating plate for sealing to which the insulating plate is joined
Between the insulating plate and the sealing insulating plate
A pair of wires fixed and provided to expose the extreme end
A pair of plate- shaped conductors or a pair of plate-shaped conductors, a low-melting-point fusible alloy fixed between ends of the pair of linear-shaped conductors or a pair of plate-shaped conductors, and the low-melting-point alloy provided on the insulating plate.
Provided to form voids for storing point fusible alloys
A cover insulating plate, wherein a welding portion is provided by welding the cover insulating plate and the insulating plate by ultrasonic vibration, the thickness of the gap is Z, and the low melting point is soluble.
When the thickness of the alloy is M, 0.02 mm <M ≦ Z <
0.8 mm, and the insulation press
Sheet, the insulating plate for sealing and the insulating plate for the cover
Each rate is composed of thermoplastic resin ,
Thereby, a thermal fuse having flexibility and a thin case of 1 mm can be obtained.

According to a seventh aspect of the present invention, in the sixth aspect, the volume of the space formed between the insulating plate and the insulating plate for the cover is V, and the volume of the low melting point fusible alloy is When J, J × 2.5 ≦ V is satisfied, and has the effect of preventing leakage of the low melting point fusible alloy during operation of the thermal fuse.

[0022] The invention of claim 8 is the invention according to claim 6, between the insulation plate and the sealing insulating plate
Also has a welded portion welded by ultrasonic vibration , has flexibility, and the case is 1 m.
m can be obtained.

According to a ninth aspect of the present invention, in the invention according to the sixth aspect, at least one of the insulating plate and the cover insulating plate is recessed, so that the gap in the main body case can be easily formed. It has the effect that it can be secured.

According to a tenth aspect of the present invention, in the sixth aspect of the invention, the ends of the pair of plate-like conductors are partially cut off or the pair of linear moving bodies are partially bent. It has a function of improving the external stress resistance of the terminal due to frictional force.

According to an eleventh aspect of the present invention, in the sixth aspect of the invention, the pair of plate-shaped conductors or the pair of linear conductors is formed by using Ni metal, Fe metal, Cu metal or Ni alloy as a base material. This has the effect of simplifying welding to batteries and power supply equipment.

According to a twelfth aspect of the present invention, in the sixth aspect of the present invention, the pair of plate-like conductors are made of Fe, Ni, C
a metal or an alloy containing any one of u as a main component, and a part or the whole of the surface of the base material is formed of Cu, Bi, S
The film is formed of any one of n, In, and Pb, or an alloy of a mixture thereof, and has an effect of improving the solder wettability of a pair of linear conductors or a pair of plate conductors.

According to a thirteenth aspect of the present invention, in the sixth aspect, the pair of linear conductors or the pair of plate conductors have a surface roughness of 0.5 to 50 μm. Has the effect of increasing power.

According to a fourteenth aspect of the present invention, there is provided a battery main body,
A thermal fuse for detecting heat generated from the battery body; the thermal fuse includes an insulating plate;
A sealing insulating plate to which the edge plate is joined;
It is fixed between the edge plate and the sealing insulating plate.
A pair of linear conductors provided to expose the ends or
And a low melting fusible alloy which is secured a pair of plate-shaped conductors, between the ends of the pair of linear conductors or a pair of plate-shaped conductor, wherein
The low melting point fusible alloy provided on an insulating plate;
Cover is provided so as to form a space for storing
An edge plate; and a welded portion formed by welding the cover insulating plate and the insulating plate by ultrasonic vibration. The thickness of the gap is Z, and the thickness of the low melting point fusible alloy is
Where M is 0.02 mm <M ≦ Z <0.8 mm
And the insulating plate and the sealing
The insulating plate for stopping and the insulating plate for the cover.
Each of the batteries is made of a thermoplastic resin, and has a function of being able to be stored even if a portion where heat generation is to be detected is about 1 to 2 mm.

Hereinafter, an embodiment of the present invention will be described with reference to FIG.
This will be described with reference to FIG.

(Embodiment 1) FIG. 1 is a partially cutaway view showing a thermal fuse according to Embodiment 1 of the present invention. FIG.
1, 1 is an insulating plate, 2 and 3 are a pair of linear conductors, 4 is the end of the linear conductor 2, 5 is an end of the linear conductor 2,
6, 6a are a pair of sealing insulating plates, 7 is a low melting point fusible alloy, 8 is a flux, and 9 is a cover insulating plate.

The end 5 of the linear conductor 2 is sandwiched between the insulating plate 1 and the sealing insulating plate 6 and is in a hermetically sealed state. Alloy 7 is welded. Similar processing is performed on the other linear conductor 3. The low melting point fusible alloy 7 is disposed in a closed space formed by the insulating plate 1, the pair of sealing insulating plates 6 and 6 a, and the cover insulating plate 9, and is coated with a flux 8. .

The insulating plate 1, the sealing insulating plate 6,
6a, cover insulating plate 9 is made of ABS resin, SAN
Resin, polysanfone resin, polycarbonate resin, Noryl, vinyl chloride resin, polyethylene resin, polyester resin, polypropylene resin, polyamide resin, PP
It can be formed of a thermoplastic resin containing any one of S resin, polyacetal, fluororesin, and polyester as a main component. The linear conductors 2 and 3 are made of Ni metal, 42Ni alloy, Cu metal coated with Sn, or Cu metal.
And further formed of Fe metal or the like coated with Sn. End 4 of linear conductor 2
In order to easily weld the low melting point fusible alloy 7, Sn,
It can be formed by coating an alloy of any one of Cu, Bi, In, and Pb or a mixture of two or more of them (the same applies to the end portion of the linear conductor 3). As the low-melting-point fusible alloy 7, an alloy mainly containing an alloy such as Sn, In, Bi, Pb, and Cd is generally known. In this case, a trial production was made of an alloy containing Sn, In, Bi, and Pb, which does not contain harmful Cd. The flux 8 is used to help the low melting point fusible alloy 7 change its shape spherically when it reaches the melting point.

A similar structure can be obtained by using the linear conductors 2 and 3 as plate conductors. FIG. 2 is a partially cutaway view showing a thermal fuse using a plate-shaped conductor. In FIG. 2, 1
Reference numerals 1 and 12 denote a pair of plate-shaped conductors, 13 denotes an end portion of the plate-shaped conductor 11, 14 denotes an end of the plate-shaped conductor 11, 15, 15a denotes an insulating plate for sealing, 16 denotes a low melting point fusible alloy, Is a flux and 18 is a cover insulating plate. In FIG. 2, the plate-shaped conductors 11 and 12 can be manufactured similarly to the linear conductors 2 and 3 both structurally and materially.

Next, a method of manufacturing a thermal fuse will be described.
This will be described with reference to FIG. 3 (A) to 3 (E) are partially cutaway views showing steps of manufacturing the thermal fuse of FIG. FIG.
In (A) to (E), 19 is an insulating plate, 20,
21 is a linear conductor; 22, 23 are ends of the linear conductors 20, 21; 24, 25 are end portions of the linear conductors 20, 21;
27 is an insulating plate for sealing, 28 is a low melting point fusible alloy, 2
9 is a flux, 30 is a hatched portion, and 31 is an insulating plate for a cover.

First, as shown in FIG. 3A, the end portions 22 and 23 of the linear conductors 20 and 21 are arranged on the insulating plate 19 formed in the insulating plate forming step. Next, FIG.
As shown in (B), the end portions 2 of the linear conductors 20 and 21
The sealing insulating plate 26 with the exposed portions 4 and 25 exposed,
27 is arranged and welded at the positions of the ends 22 and 23 (sealing and fixing step). As a welding method, a method in which a hot plate heated near the softening point temperature of the thermoplastic resin used for the insulating plate 19 and the sealing insulating plates 26 and 27 is brought into contact, or the end portions 22 and 23 are used. A method in which the linear conductors 20 and 21 are energized so as to generate heat by themselves and the portions where the sealing insulating plates 26 and 27 are brought into pressure contact with the insulating plate 19 by resistance heating of the linear conductors is welded. However, in the present embodiment, the sealing insulating plates 26 and 27 are brought into pressure contact with the insulating plate 19, frictionally vibrated by ultrasonic vibration, and welded by frictional heat. By welding, the end portions 22 of the linear conductors 20, 21;
23 is an insulating plate 19 and sealing insulating plates 26, 2
7 and sealed. Here, if the sealing is insufficient, the sealing may be completely performed using an adhesive.

Next, as shown in FIG. 3C, the low melting point fusible alloy 28 is welded to the outermost ends 24, 25 of the linear conductors 20, 21 (low melting point fusible alloy fixing step). As a welding method, the end portions 24 and 25 of the linear conductors 20 and 21 are heated to a temperature higher than the melting point of the low-melting-point fusible alloy 28 and brought into contact with the low-melting-point fusible alloy 28. Next, as shown in FIG. 3D, a flux 29 is applied around the welded low-melting-point fusible alloy 28. Finally, cover insulating plate 31
Are arranged as shown in FIG.
It is welded to the shaded portion 30 so as to form a space (gap) for accommodating the low melting point fusible alloy between the sealing insulating plates 26 and 27 and the cover insulating plate 31 (space forming step). The welding can be performed by the method of bringing a heated hot plate into contact as described above. However, this time, since the low melting point fusible alloy 28 is in the space, welding using ultrasonic waves is preferable. Specifically, a horn having a shape capable of pressing the hatched portion 30 is prepared, and pressure is applied from above the cover insulating plate 31, and the cover insulating plate 3 is pressed by ultrasonic vibration.
A portion corresponding to the hatched portion 30 is frictionally vibrated and welded by frictional heat. According to this method, the generated heat is concentrated on the portion to be welded, and the welding can be performed with a small amount of heat energy. Therefore, the welding can be performed before the low melting point fusible alloy 28 is blown. Also, the cover insulating plate 31
A projection corresponding to the hatched portion 30 may be provided as an energy director so that the ultrasonic vibration is concentrated. This is shown in FIG.

FIG. 16A is a perspective view showing an energy director, and FIG. 16B is a sectional view of a portion A in FIG. 16A. In FIG. 16, reference numeral 79 denotes an energy director, and reference numeral 80 denotes a protrusion.

Although the welding method is different from that of the present embodiment, when welding is performed by a method of bringing a hot plate into contact,
It can be manufactured by heating the oblique line portion 30 while cooling the low melting point fusible alloy 28. The cooling method includes a method of cooling through the linear conductors 20 and 21 and a method of cooling the insulating plate 1.
9. There is a method of cooling through the cover insulating plate 31.

As described above, according to the present embodiment, the thermal fuse comprises the insulating plates 1 and 10 and the end portions 5 of the pair of linear conductors 2 and 3 or the end portions of the pair of plate conductors 11 and 12. The sealing insulating plate 14 is fixed to the insulating plates 1 and 10 with the end portions 4 of the pair of linear conductors 2 and 3 or the end portions 13 of the pair of plate conductors 11 and 12 exposed. 6, 6a, 15, 15a, and between the end portions 4 of the pair of linear conductors 2, 3 or the end portions 13 of the pair of plate-like conductors 11, 12.
Low melting point fusible alloys 7 and 16 fixed between them, insulating plates 1 and 10, and sealing insulating plates 6, 6a, 15, 1;
Cover insulating plates 9, 18 which are joined to the insulating plates 5 and 5a and form spaces between the insulating plates 1 and 10 and the sealing insulating plates 6, 6a, 15 and 15a for accommodating the low melting point fusible alloys 7 and 16. Therefore, there is no need to use a tubular ceramic insulating case, and the main body case of the thermal fuse can be made thin.

The insulating plates 1 and 10, the sealing insulating plates 6, 6a, 15, 15a, and the cover insulating plates 9, 18 are made of ABS resin, SAN resin, polysanphone resin, polycarbonate resin, noryl, chloride, and the like. Since it is made of a thermoplastic resin containing any one of vinyl resin, polyethylene resin, polyester resin, polypropylene resin, polyamide resin, PPS resin, polyacetal, fluorine resin and polyester, the heat of each resin The plasticity makes the main body case of the thermal fuse flexible.

Further, the linear conductors 2 and 3 are made of Ni metal, F
e metal, Cu metal or an alloy thereof, so that the battery of the thermal fuse can be
It can be easily attached to power supply equipment and the like.

Further, in order to easily weld the low melting point fusible alloy 7 to the extreme end 4 of the linear conductor 2, Sn, Cu, B
Any one of i, In, and Pb or a mixed alloy thereof can be formed by coating (the same is applied to the end of the linear conductor 3). Solder wettability can be improved.

As a material of the insulating plates 1 and 10 or a material of the insulating plates 9 and 18 for the cover, a ceramic mainly composed of alumina or magnesia, which is a material having good heat conductivity, is used. 6a, 1
Other insulating plates, including 5, 15a, are made by using the thermoplastic or epoxy resin.
Similarly, it is possible to reduce the thickness, and it is possible to bring the case portion having better heat conductivity than plastic into contact with the heat source, so that the thermal response becomes faster. Further, the material of the insulating plates 1 and 10 or the insulating plates 9 and 18 for the cover may be used.
Using glass or ceramic whose main component is silicon oxide or boron oxide, and using the above-mentioned thermoplastic or epoxy resin for other insulating plates including insulating plates 6, 6a, 15, and 15a for sealing. Accordingly, it is also possible to reduce the thickness.Since the glass material of silicon oxide and boron oxide is contained in the material component, the airtightness is better than that of the alumina or magnesia, so that the material can be thinned. is there.

(Example 1, Comparative Example 1) The dimensions used in Examples 1 and 2 and Comparative Examples 1 and 2 are shown in FIGS.
This will be described with reference to FIG. FIG. 4 is an exploded perspective view of the thermal fuse of FIG. 1, and FIG. 5 is a side view of the thermal fuse of FIG. In FIG. 4, 32 is an insulating plate, 33 and 34 are a pair of linear conductors, 35 and 36 are a pair of sealing insulating plates, 37 is a low melting point fusible alloy, and 38 is a cover insulating plate. In the figure, 40 is an insulating plate, 41 is a linear conductor, 42 is a sealing insulating plate, 43 is a low melting point fusible alloy, and 44 is a cover insulating plate. 4 and 5, the insulating plates 32, 4
0 is a1 in the horizontal direction, b1 in the vertical direction, and t1 in the thickness.
The sealing insulating plates 35, 36 and 42 have a horizontal length of a2, a vertical length of b2, a thickness of t2, and the cover insulating plates 38 and 44 have a horizontal length of a3 and a vertical length of a2. The length in the direction is b3, the thickness is t3, the low-melting-point fusible alloys 37 and 43 have a length L, a diameter of a circular cross section φ, a linear conductor 33,
The diameter of 34, 41 is defined as K. FIG. 7 is a partially cutaway view showing a modification of the thermal fuse of FIG. In FIG. 7, 50 is a linear conductor, and 51 is a sealing insulating plate. As shown in FIG. 7, the length when the linear conductor 50 covered with the sealing insulating plate 51 is bent is defined as U.

In the first embodiment, a1 = 11 mm and b1 = 5
mm, t1 = 0.4 mm, a2 = 2 mm, b2 = 3 m
m, t2 = 0.4 mm, a3 = 11 mm, b3 = 5 m
m, t3 = 0.2 mm, L = 5 mm, φ = 0.5 mm,
K = 0.5 mm, U = 2 mm, and K ×
1.5 = 0.75, (t1 + t2) = 0.4 + 0.4 =
0.8 mm, and satisfies the relationship of K × 1.5 ≦ (t1 + t2) and K × 1.5 ≦ U.

On the other hand, in Comparative Example 1, a1 = 11 m
m, b1 = 5 mm, t1 = 0.2 mm, a2 = 2 mm,
b2 = 3 mm, t2 = 0.2 mm, a3 = 11 mm, b
3 = 5 mm, t3 = 0.2 mm, L = 5 mm, φ = 0.
5 mm, K = 0.5 mm, U = 2 mm, K × 1.5 = 0.75, (t1 + t2) = 0.2 +
0.2 = 0.4 mm, which satisfies the relationship of K × 1.5 ≦ U, but does not satisfy the relationship of K × 1.5 ≦ (t1 + t2).

Each of the three samples produced under the conditions of Example 1 and Comparative Example 1
A pressure cooker test was performed on 0 samples to evaluate the sealability. The test method is as follows. The test was carried out at a temperature of 121 ° C., a humidity of 100%, and a pressure of 2 atm. Non-defective and defective products are determined by observing the appearance.
Those with no change in appearance are judged as good, and those with obvious change in appearance, such as leakage of the contents of the thermal fuse, looseness or detachment of the terminals, are judged as defective. Example 1 after the pressure cooker test
In the case of No., the number of generated defects was 0 and 100% non-defective, and in the case of Comparative Example 1, the number of generated defects was 25 and 83% defective (17% non-defective).

Example 2, Comparative Example 2 In Example 2, a
1 = 11 mm, b1 = 5 mm, t1 = 0.5 mm, a2
= 1.5 mm, b2 = 3 mm, t2 = 0.5 mm, a3
= 11 mm, b3 = 5 mm, t3 = 0.2 mm, L = 5
mm, φ = 0.5mm, K = 0.5mm, U = 1.5m
m, K × 1.5 = 0.75, (t1 +
t2) = 0.5 + 0.5 = 1 mm, and K × 1.5 ≦
(T1 + t2) and the relationship of K × 1.5 ≦ U are satisfied.

On the other hand, in Comparative Example 2, a1 = 11 m
m, b1 = 5 mm, t1 = 0.5 mm, a2 = 0.5 m
m, b2 = 3 mm, t2 = 0.5 mm, a3 = 11 m
m, b3 = 5 mm, t3 = 0.2 mm, L = 5 mm, φ
= 0.5 mm, K = 0.5 mm, U = 0.5 mm, K × 1.5 = 0.75, (t1 + t2) =
0.5 + 0.5 = 1 mm, and K × 1.5 ≦ (t1 +
The relationship of t2) is satisfied, but the relationship of K × 1.5 ≦ U is not satisfied.

Each of the samples 3 manufactured under the conditions of Example 2 and Comparative Example 2
A pressure cooker test was performed on 0 samples to evaluate the sealability. The test method is the same as in Example 1 and Comparative Example 1. After the pressure cooker test, in the case of Example 2, the number of generated defects was 0 and 10
0% non-defective product, and the number of defectives generated in the case of Comparative Example 2 is 2
8 was 93% defective (7% good).

Example 3 and Comparative Example 3 Next, the linear conductors 2 and 3 as shown in FIG.
The case where the low-melting-point fusible alloy is replaced with plates 1 and 12 and formed into a plate shape will be described. FIG. 6 is an exploded view of a plate-shaped conductor and a plate-shaped thermal fuse made of a low-melting-point fusible alloy. 6, reference numeral 45 denotes an insulating plate, 46 denotes a plate-shaped conductor, 47 denotes a sealing insulating plate, 48 denotes a low-melting-point fusible alloy, and 49 denotes a cover insulating plate. As shown in FIG. 6, the vertical width of the plate-shaped conductor 46 is defined as E, the thickness thereof is defined as H, the thickness of the low melting point fusible alloy 48 is defined as T, the vertical width is defined as W, and the length is defined as W. Is defined as L (L is not shown). FIG. 8 is a partially cutaway view showing a thermal fuse using a plate-shaped conductor. As shown in FIG. 8, the length of the plate-shaped conductor 52 covered with the sealing insulating plate 53 is defined as G.

In the third embodiment, a1 = 11 mm and b1 = 5
mm, t1 = 0.2 mm, a2 = 2 mm, b2 = 4 m
m, t2 = 0.2 mm, a3 = 11 mm, b3 = 5 m
m, t3 = 0.2 mm, L = 5 mm, T = 0.2 mm,
W = 1 mm, E = 3 mm, H = 0.25 mm, G = 2 m
m, H × 1.2 = 0.3, (t1 + t
2) = 0.4 mm, E × 1.2 = 3.6, and H ×
1.2 ≦ (t1 + t2), E × 1.2 ≦ b1, E × 1.
Both the relations of 2 ≦ b2 and 0.3 mm ≦ G are satisfied.

On the other hand, in Comparative Example 3, a1 = 11 m
m, b1 = 5 mm, t1 = 0.2 mm, a2 = 2 mm,
b2 = 4 mm, t2 = 0.2 mm, a3 = 11 mm, b
3 = 5 mm, t3 = 0.2 mm, L = 5 mm, T = 0.
2 mm, W = 1 mm, E = 3 mm, H = 0.5 mm, G
= 2 mm, H × 1.2 = 0.6, (t
1 + t2) = 0.4 mm, E × 1.2 = 3.6,
E × 1.2 ≦ b1, E × 1.2 ≦ b2 and 0.3 mm
Although all of the relations of ≦ G are satisfied, H ×
The relationship of 1.2 ≦ (t1 + t2) is not satisfied.

Each of the three samples produced under the conditions of Example 3 and Comparative Example 3
A pressure cooker test was performed on 0 samples to evaluate the sealability. The test method is the same as in Example 1 and Comparative Example 1. After the pressure cooker test, in the case of Example 3, the number of defectives generated was 0 and 1
In the case of Comparative Example 3, the number of defectives generated was 21 and 70% defective (30% non-defective).

Example 4 and Comparative Example 4 In Example 4, a
1 = 11 mm, b1 = 5 mm, t1 = 0.2 mm, a2
= 2 mm, b2 = 4 mm, t2 = 0.2 mm, a3 = 1
1 mm, b3 = 5 mm, t3 = 0.2 mm, L = 5 m
m, T = 0.2 mm, W = 1 mm, E = 3 mm, H =
0.15 mm, G = 2 mm, and H × 1.
2 = 0.18, (t1 + t2) = 0.4 mm, E × 1.
2 = 3.6, H × 1.2 ≦ (t1 + t2), E ×
1.2 ≦ b1, E × 1.2 ≦ b2 and 0.3 mm ≦ G
All of the relationships are satisfied.

On the other hand, in Comparative Example 4, a1 = 11 m
m, b1 = 5 mm, t1 = 0.2 mm, a2 = 2 mm,
b2 = 3 mm, t2 = 0.2 mm, a3 = 11 mm, b
3 = 5 mm, t3 = 0.2 mm, L = 5 mm, T = 0.
2 mm, W = 1 mm, E = 3 mm, H = 0.15 mm,
G = 2 mm, H × 1.2 = 0.18,
(T1 + t2) = 0.4 mm, E × 1.2 = 3.6, and all of the relations of H × 1.2 ≦ (t1 + t2), E × 1.2 ≦ b1 and 0.3 mm ≦ G are satisfied. However, the relationship of E × 1.2 ≦ b2 is not satisfied.

Each 3 prepared under the conditions of Example 4 and Comparative Example 4
A pressure cooker test was performed on 0 samples. The test method is the same as in Example 1 and Comparative Example 1.

After the pressure cooker test, in the case of Example 4, the number of defectives occurred was 0, which is 100% non-defective, and in the case of Comparative Example 4, the number of defectives was 12, which was 40% defective (60% non-defective). Met.

Example 5 and Comparative Example 5 In Example 5, a
1 = 11 mm, b1 = 5 mm, t1 = 0.2 mm, a2
= 0.5 mm, b2 = 4 mm, t2 = 0.2 mm, a3
= 11 mm, b3 = 5 mm, t3 = 0.2 mm, L = 5
mm, T = 0.2 mm, W = 1 mm, E = 3 mm, H =
0.1 mm, G = 0.5 mm, and H ×
1.2 = 0.12, (t1 + t2) = 0.4 mm, Ex
1.2 = 3.6, H × 1.2 ≦ (t1 + t2),
E × 1.2 ≦ b1, E × 1.2 ≦ b2 and 0.3 mm
<G is satisfied.

On the other hand, in Comparative Example 5, a1 = 11 m
m, b1 = 5 mm, t1 = 0.2 mm, a2 = 0.2 m
m, b2 = 4 mm, t2 = 0.2 mm, a3 = 11 m
m, b3 = 5 mm, t3 = 0.2 mm, L = 5 mm, T
= 0.2 mm, W = 1 mm, E = 3 mm, H = 0.1 m
m, G = 0.2 mm, and H × 1.2 =
0.12, (t1 + t2) = 0.4 mm, E × 1.2 =
3.6, H × 1.2 ≦ (t1 + t2), E × 1.
Both the relations of 2 ≦ b1 and E × 1.2 ≦ b2 are satisfied, but the relation of 0.3 mm ≦ G is not satisfied.

Each of the three samples produced under the conditions of Example 5 and Comparative Example 5
A pressure cooker test was performed on 0 samples. The test method is the same as in Example 1 and Comparative Example 1.

After the pressure cooker test, in the case of Example 5, the number of defectives occurred was 0, which is 100% non-defective, and in the case of Comparative Example 5, the number of defectives was 29, which was 97% defective (3% non-defective). Met.

(Embodiment 6, Comparative Example 6) FIG.
(B), (C) is an exploded view showing a thermal fuse according to the first embodiment of the present invention. In FIG. 9, 54 is an insulating plate, 55 and 56 are sealing insulating plates, 57 is a cover insulating plate, and 58 is a gap (space). In FIG. 9, an insulating plate 54 and a sealing insulating plate 55,
The volume of a gap (portion shown by a horizontal line) 58 surrounded by 56 and the cover insulating plate 57 is defined as V, the horizontal length as X, the vertical length as Y, and the thickness as Z. , The volume of the low melting point fusible alloy disposed inside the gap 58 is defined as J, and the thickness is defined as M (J is not shown).

In the sixth embodiment, a1 = 11 mm and b1 = 5
mm, t1 = 0.2 mm, a2 = 2 mm, b2 = Y =
1.56 mm, t2 = Z = 0.5 mm, a3 = 11 m
m, b3 = 5 mm, t3 = 0.2 mm, L = 5 mm, W
= 1 mm, E = 1 mm, H = 0.15 mm, G = 2 m
m, V = 4.4 mm ³ , X = 7 mm, J = 0.8 mm ³ ,
M = 0.2 mm, J × 2.5 = 2, and the condition of J × 2.5 ≦ V is satisfied.

On the other hand, in Comparative Example 6, a1 = 11 m
m, b1 = 5 mm, t1 = 0.2 mm, a2 = 2 mm,
b2 = Y = 1.6 mm, t2 = Z = 0.2 mm, a3 =
11 mm, b3 = 5 mm, t3 = 0.2 mm, L = 5 m
m, W = 1 mm, E = 1 mm, H = 0.15 mm, G =
2 mm, V = 1.8 mm ³ , X = 7 mm, J = 0.8 m
m ³ , M = 0.2 mm, J × 2.5 =
2, which does not satisfy the condition of J × 2.5 ≦ V.

Each of the three samples produced under the conditions of Example 6 and Comparative Example 6
A fusing test was performed on 0 samples. The test method is to connect the electrodes of the sample to a continuity checker,
The temperature of the atmosphere is raised so that the temperature rises at a rate of 1 ° C per minute, and the temperature at which conduction is lost is defined as the fusing temperature. Judge as good. After the fusing test, in the case of Example 6, the number of generated defects was 0, which is 100% non-defective, and in the case of Comparative Example 6, the number of defectives was 3, which was 10% defective (90%).
Good product).

The sample of Example 6 was 0.02 mm < M ≦
Prototypes have been manufactured in the dimension range of Z < 0.8 mm . M is 0.
In the case of not more than 02 mm, the production and handling of the low melting point fusible alloy was difficult due to being too thin, and a trial production was not possible. Further, when Z is 0.8 mm or more, the thickness of the product is about 1.5 mm, so there is no difference from a product using a tubular ceramic which is a conventional method. The thickness of the sample of Example 6 was measured to be 0.5 to 1.0 mm,
It could be set as a temperature fuse 87 of the battery of FIG. 17 described later.

Example 7, Comparative Example 7 In Example 7, a
1 = 11 mm, b1 = 5 mm, t1 = 0.2 mm, a2
= 2 mm, b2 = Y = 3.2 mm, t2 = Z = 0.2 m
m, a3 = 11 mm, b3 = 5 mm, t3 = 0.2 m
m, L = 5 mm, W = 1 mm, E = 1 mm, H = 0.1
5 mm, G = 2 mm, V = 3.6 mm ³ , X = 7 mm,
J = 0.4 mm ³ and M = 0.1 mm are set,
J × 2.5 = 1, which satisfies the condition of J × 2.5 ≦ V.

On the other hand, in Comparative Example 7, as in Comparative Example 6, a1 = 11 mm, b1 = 5 mm, and t1 = 0.2
mm, a2 = 2 mm, b2 = Y = 1.6 mm, t2 = Z
= 0.2 mm, a3 = 11 mm, b3 = 5 mm, t3 =
0.2 mm, L = 5 mm, W = 1 mm, E = 1 mm, H
= 0.15 mm, G = 2 mm, V = 1.8 mm ³ , X =
7 mm, J = 0.8 mm ³ , M = 0.2 mm, J × 2.5 = 2, and does not satisfy the condition of J × 2.5 ≦ V.

Each of the three samples produced under the conditions of Example 7 and Comparative Example 7
A fusing test was performed on 0 samples. The test method is the same as in Example 6 and Comparative Example 6. After the fusing test, in the case of Example 7, the number of generated defects was 0 and 100.
%, And in the case of Comparative Example 7, the number of defectives occurred was 3 and 10% defective (90% non-defective).

The sample of Example 7 was 0.02 mm < M ≦
Prototypes have been manufactured in the dimension range of Z < 0.8 mm . M is 0.
In the case of not more than 02 mm, the production and handling of the low melting point fusible alloy was difficult due to being too thin, and a trial production was not possible. Further, when Z is 0.8 mm or more, the thickness of the product is about 1.5 mm, so there is no difference from a product using a tubular ceramic which is a conventional method. The thickness of the sample of Example 7 was measured to be 0.5 to 1.0 mm,
It could be set as a temperature fuse 87 of the battery of FIG. 17 described later.

As can be seen from the above, the following can be said about this embodiment.

In the present embodiment, first, the insulating plate and the ends of the pair of linear conductors or the pair of plate conductors are exposed by exposing the end portions of the pair of linear conductors or the pair of plate conductors. Insulating plate sealed and fixed to the insulating plate in a state where it is fixed, a low-melting-point fusible alloy fixed between the end portions of a pair of linear conductors or a pair of plate-shaped conductors, and an insulating plate and sealing insulation A tubular ceramic insulating case is used by having a configuration in which a cover insulating plate which is joined to a plate and forms a space for accommodating the low melting point fusible alloy between the insulating plate and the sealing insulating plate is formed. Instead, the main body case can be made thinner.

Second, at least one of the insulating plate and the cover insulating plate is made of a ceramic mainly composed of alumina or magnesia, a glass mainly composed of silicon oxide or boron oxide, or a ceramic mainly composed of silicon oxide or boron oxide. The use of a thermoplastic material for the other insulating plate has an effect that the body case can be easily assembled by thermal bonding.
In addition, since the use of ceramics has better thermal conductivity than plastics, it has the effect of being thin and having good thermal responsiveness.

Third, at least one of the insulating plate, the sealing insulating plate, and the cover insulating plate is made of ABS resin, SAN resin, polysanphone resin, polycarbonate resin, Noryl, vinyl chloride resin, polyethylene resin. The main body case is made flexible by thermoplasticity by being formed of a thermoplastic resin containing any one of polyester resin, polypropylene resin, polyamide resin, PPS resin, polyacetal, fluorine resin, and polyester. Having.

Fourth, the pair of linear conductors or the pair of plate conductors are formed from Ni metal, Fe metal, Cu metal or Ni alloy as a base material, which facilitates welding to batteries and power supply equipment. It has the effect of being converted.

Fifth, the pair of linear conductors or the pair of plate conductors are made of a metal or an alloy mainly containing any of Fe, Ni, and Cu as a base material, and a part or the whole of the surface of the base material. Is formed of any one of Ni, Cu, Bi, Sn, In, and Pb or an alloy obtained by mixing them, whereby the solder wettability of a pair of linear conductors or a pair of plate conductors is improved. Has an action.

Sixth, when the thickness of the insulating plate is t1, the thickness of the sealing insulating plate is t2, and the diameter and length of the linear conductor are K and U, K × 1.5 ≦ (t1 + t
By setting the relation of 2) and K × 1.5 ≦ U, there is an effect that the terminal strength is ensured when the thermal fuse operates.

Seventh, the thickness and vertical length of the insulating plate are t1 and b1, the thickness and vertical length of the sealing insulating plate are t2 and b2, and the width and thickness of the plate-like conductor. And when the lengths are E, H and G, H × 1.2
≦ (t1 + t2), E × 1.2 ≦ b1, E × 1.2 ≦ b
2 and G ≧ 0.3 mm,
This has the effect of ensuring the terminal strength when the thermal fuse operates.

Eighth, when the volume of the space formed between the insulating plate and the insulating plate for sealing and the insulating plate for the cover is V, and the volume of the low melting point fusible alloy is J, J × 2 By setting the relation of 0.5 ≦ V, there is an effect that leakage of the low melting point fusible alloy does not occur during operation of the thermal fuse.

Ninth, a space having a thickness of Z and a low melting point
0.02 mm when the thickness of the alloy is M<M ≦ Z<
By making the relationship 0.8mm, low melting point melting
It is said that the necessary gap is cut in the vertical direction when gold melts
Has an action.

Tenth, by bending the ends of the pair of linear conductors into a U-shape, an S-shape, or a combination of the U-shape and the S-shape in the same plane, a terminal is formed. It has the effect of improving external stress resistance.

Eleventh, an insulating plate forming step of forming an insulating plate, and the end portions of a pair of linear conductors or a pair of plate conductors are connected to the end portions of a pair of linear conductors or a pair of plate conductors. A sealing and fixing step of sealing and fixing the insulating plate to the insulating plate in a state of being exposed; Fixing the melting-point fusible alloy, bonding the insulating plate for the cover to the insulating plate and the insulating plate for sealing, and storing the low-melting-point fusible alloy between the insulating plate and the insulating plate for sealing and the insulating plate for the cover And a space forming step of forming a space for forming the thermal fuse.

(Embodiment 2) FIG. 10 is a partially cutaway view showing a thermal fuse according to Embodiment 2 of the present invention.

In FIG. 10, 1 is an insulating plate, 59
Is a concave portion of the insulating plate 1. By providing such a concave portion 59, the space V having the volume of the sixth and seventh embodiments can be easily secured. Although the concave portion is provided in the insulating plate this time, the concave portion may be provided by drawing the cover insulating plate side.

In the present embodiment, at least one of the insulating plate and the cover insulating plate is recessed, and has an effect that a gap in the main body case can be easily secured and the thickness can be reduced.

(Embodiment 3) FIG. 11 is a partially cutaway view showing a thermal fuse according to Embodiment 3 of the present invention.

In FIG. 11, reference numeral 1 denotes an insulating plate,
Reference numeral 3 denotes a linear conductor, 6 denotes a sealing insulating plate, 7 denotes a low melting point fusible alloy, and 60 denotes an end portion of the linear conductor 2. As shown in FIG. 11, the end 60 of the linear conductor 2 is
(The same applies to the end of the linear conductor 3). Thus, when a tensile stress is applied to the linear conductors 2 and 3 from the outside, the sealed portions are hardly removed. further,
Since the welding of the low-melting-point fusible alloy 7 is performed in a planar portion,
The welding positioning becomes easy.

The sealing performance is maintained by setting the surface roughness of the portion to be sealed by contacting the insulating plate 1 and the sealing insulating plate 6 with the linear conductors 2 and 3 to 0.5 μm to 50 μm. When a tensile stress is applied to the linear conductors 2 and 3 from the outside in this state, the sealed portion becomes difficult to come off. When the surface roughness is less than 0.5 μm, there is no difference in the tensile strength as compared with the case where the surface is not exposed, and 5
If the thickness exceeds 0 μm, air may be caught in the sealing with the insulating plate 1 and the sealing insulating plate 6 and the sealing may be insufficient, which is not preferable as a thermal fuse.

In this embodiment, the ends of a pair of linear conductors are crushed in a plane in the same plane, and have the effect of improving the external stress resistance of the terminal.

The pair of linear conductors or the pair of plate conductors has a surface roughness of not less than 0.5 μm and not more than 50 μm, which is in contact with the insulating plate and the sealing insulating plate and is sealed.
The following effects have an effect of improving the external stress resistance of the terminal.

(Embodiment 4) FIG. 12 is a partially cutaway view showing a thermal fuse according to Embodiment 4 of the present invention.

In FIG. 12, reference numeral 10 denotes an insulating plate,
Reference numerals 1 and 12 denote plate conductors, 13 denotes an end portion of the plate conductor 11, 1
4 is an end of the plate-like conductor 11, 15 is a sealing insulating plate,
16 is a low melting point fusible alloy, 61 is a hole, and 62 and 63 are notches. As shown in FIG. 12, the end portion 14 of the plate-shaped conductor 11 has a hole 61 or a notch 62, 63.
Drilled or notched (plate-like conductor 12
Is the same). Thus, when a tensile stress is applied to the plate-shaped conductors 11 and 12 from the outside, the sealed portions are hardly removed. Further, heat applied when welding the low-melting-point fusible alloy 16 is less likely to escape from the outermost end 13 of the plate-shaped conductor 11 via the end portion 14, so that the welding heat balance is improved.

The sealing performance is maintained by setting the surface roughness of the portion to be sealed by contacting the insulating plate 10 and the sealing insulating plate 15 with the plate-shaped conductors 11 and 12 to 0.5 μm to 50 μm. When a tensile stress is applied to the plate-shaped conductors 11 and 12 from the outside in this state, the sealed portions are not easily removed. When the surface roughness is less than 0.5 μm, there is no difference in the tensile strength as compared with the case where the surface is not exposed, and when the surface roughness exceeds 50 μm, air is used when sealing with the insulating plate 10 and the sealing insulating plate 15. Is not preferable as a thermal fuse because the sealing may be insufficient in some cases.

In the present embodiment, a pair of plate-shaped conductors are processed into a shape in which the ends are partially cut or partially bent, and the external stress resistance of the terminal is improved. Has an action.

Further, the pair of linear conductors or the pair of plate conductors has a surface roughness of 0.5 μm or more and 50 μm or more at a portion which is in contact with the insulating plate and the sealing insulating plate and is sealed.
The following effects have an effect of improving the external stress resistance of the terminal.

(Embodiment 5) FIG. 13 is a partially cutaway view showing a thermal fuse according to Embodiment 5 of the present invention.

In FIG. 13, 1 is an insulating plate,
3 is a linear conductor, 9 is an insulating plate for a cover, 64 is a plate-like conductor, 65 is an external terminal of the linear conductor 3, 66 is a tubular conductor,
67 is an external terminal of the linear conductor 2 and 68 is a hole terminal of the tubular conductor 66.

As shown in FIG. 13, the linear conductor 3 is welded to the plate conductor 64 at the position of the external terminal 65. Thereby, the external terminal of the thermal fuse manufactured by the linear conductor 2 can be formed in a plate shape. The linear conductor 2 is crimped to the tubular conductor 66 at the position of the external terminal 67. Thereby, the external terminal of the thermal fuse manufactured by the linear conductor 2 can be a tubular crimp terminal.

In the present embodiment, a plate-like conductor or a tubular conductor is fixed to the other end of a pair of linear conductors, so that positioning of welding is simplified, or connection to a lead wire is performed. This has the effect of being performed by caulking or the like.

(Embodiment 6) FIG. 14 is a configuration diagram showing a thermal fuse section according to Embodiment 6 of the present invention. FIG.
4, reference numerals 1a to 1e denote insulating plates, and 69 denotes a connecting member for connecting adjacent insulating plates (for example, insulating plates 1b and 1c). As shown in FIG. 14, by connecting the insulating plates 1a to 1e of the thermal fuse with the connecting member 69, the thermal fuse can be continuously assembled on one line.

In this embodiment, a plurality of thermal fuses are provided, and adjacent thermal fuses are connected by a connecting member for connecting insulating plates, so that a product can be assembled in a continuous process. It has the action of:

(Embodiment 7) FIG. 15 is a configuration diagram showing a thermal fuse section according to Embodiment 7 of the present invention. FIG.
5, 1a to 1e are insulating plates, 9a to 9e are insulating plates for a cover, 70 is a lead frame, 70
A and 70B are vertical plates of the lead frame 70, 70a and 70B.
b is a connecting portion for connecting the thermal fuse to the lead frame 70.

As shown in FIG. 15, by connecting the thermal fuses using the connection portions 70a and 70b (five in FIG. 15 each) of the lead frame, several to several tens of batches can be assembled. Alternatively, the thermal fuse can be assembled continuously in one line.

This embodiment has a plurality of thermal fuses and a lead frame having a plurality of plate-like connecting portions formed inside, and each thermal fuse is fixed to each connecting portion. There is an effect that the product can be assembled in a continuous process.

(Eighth Embodiment) FIG. 17 is a perspective view showing a battery according to an eighth embodiment of the present invention with the lid opened.

In FIG. 17, reference numeral 81 denotes a secondary battery, 82 denotes an electric circuit pack for controlling input and output of the secondary battery 81,
83 is a conductor for wiring, 84 is a case for protecting the secondary battery 81, 85 is a cover for protecting the secondary battery 81 and its peripheral circuits, 86 is for input and output control of the secondary battery 81 Terminals 87 for inputting and outputting from the electric circuit to the outside, and 87 are the thermal fuses according to the first to fifth embodiments.

As shown in FIG.
Are electrically and mechanically connected to the electrodes of the main body of the secondary battery 81 via conductors 83, and the terminals 8 taken out from the input / output control electric circuit pack 82 of the secondary battery 81
9 is connected in series. Here, as described above,
Since the thermal fuses according to the first to fifth embodiments can be made thin with a plate-like outer shape, they can be housed in a narrow gap of about 1 to 2 mm between the main body of the secondary battery 81 and the cover 85 where heat is to be detected. . Further, since the thermal fuses according to Embodiments 1 to 5 can be designed so that the front and rear insulating areas are equal while having a plate shape, the thermal fuse can be assembled without distinguishing the front and rear surfaces during assembly. It is possible.

The present embodiment uses the thermal fuses of the first to fifth embodiments, and has an effect that the thermal fuse is easily connected.

(Embodiment 9) FIG. 18 is a perspective view showing a power supply according to Embodiment 9 of the present invention. In FIG. 18, reference numeral 101 denotes a power supply case for combined use of a battery pack and
Is a power supply case, 103 is a charging electrode terminal, 104 is AC
-DC conversion circuit section, 105 is an AC power cord, 106,
107 is a thermal fuse according to the first to fifth embodiments.

In the power supply device shown in FIG.
A temperature fuse 107 that is attached to or attached to the DC conversion circuit unit 104 and a temperature fuse 106 that is attached to the battery pack / connection power supply case 101 closest to the battery pack are connected to the charging electrode terminals 103 and A.
It is electrically connected to the C-DC conversion circuit unit 104. Here, since the thermal fuses 106 and 107 have a plate-like outer shape and can be made thin, they can be accommodated in a narrow gap of about 1 to 2 mm in a portion where temperature due to abnormal heat generation is to be detected.
Further, since the thermal fuses 106 and 107 can be designed so that the front and rear insulator areas are equal while having a plate shape, it is possible to assemble without distinguishing the front and back during assembly.

The present embodiment uses the thermal fuse of the first to fifth embodiments, and has an effect that the thermal fuse is easily connected.

(Embodiment 10) FIG. 19 is a partially cutaway view showing a thermal fuse according to Embodiment 10 of the present invention. In FIG. 19, reference numeral 91 denotes an insulating plate, 92 denotes a pair of linear conductors, 93 denotes a sealing insulating plate, 94 denotes a low melting point fusible alloy, and 95 denotes a cover insulating plate.

In the thermal fuse shown in FIG. 19, a pair of linear conductors 92 are arranged in parallel on an insulating plate 91, and the insulating plate 91 is formed in the same manner as in the first embodiment.
And a pair of parallel linear conductors 92 are sealed by the sealing insulating plate 93. Next, a low melting point fusible alloy 94 is welded between the pair of linear conductors 92 on the insulating plate 91. A flux is applied around the low melting point fusible alloy 94, and the low melting point fusible alloy 94 and its surrounding space are sealed with a cover insulating plate 95. The construction method is the same as that of the first embodiment.

As shown in FIG. 19, a pair of linear conductors 92
Are arranged in parallel, the lead wires are aligned in one direction. As a result, the degree of freedom in arranging the thermal fuse at a portion where heat generation is to be detected is improved. For example, it is possible to mount the wiring on a printed board without bending the wiring.

(Eleventh Embodiment) FIG. 20 is a partially cutaway view showing a thermal fuse according to an eleventh embodiment of the present invention. 20, reference numeral 96 denotes an insulating plate, 97 denotes a pair of plate-shaped conductors, 98 denotes a low-melting-point fusible alloy, 99 denotes a sealing insulating plate, and 100 denotes a cover insulating plate.

In the thermal fuse shown in FIG. 20, a pair of plate-like conductors 97 are arranged in parallel on an insulating plate 96, and the insulating plate 96 is formed in the same manner as in the first embodiment.
And a pair of parallel plate-like conductors 97 are sealed by the sealing insulating plate 99. Next, a low melting point fusible alloy 98 is welded between the pair of plate-like conductors 97 on the insulating plate 96. A flux is applied around the low melting point fusible alloy 98, and the low melting point fusible alloy 98 and its surrounding space are sealed with a cover insulating plate 100. The construction method is the same as that of the first embodiment.

As shown in FIG. 20, a pair of plate-like conductors 97
Are arranged in parallel, the lead wires are aligned in one direction. As a result, the degree of freedom in arranging the thermal fuse at a portion where heat generation is to be detected is improved. For example, it becomes easy to arrange the main body case inside a coil wire that generates heat like a power transformer.

[0119]

As described above, according to the method for manufacturing a thermal fuse according to the first aspect of the present invention, the outermost end is exposed.
A pair of linear conductors or a pair of plate-like conductors are each sealed on a flexible insulating plate by an insulating insulating plate.
And a low melting point fusible alloy is fixed between the ends of the pair of linear conductors or the pair of plate conductors.
It is to form a gap for accommodating the low-melting fusible alloy
The cover insulation plate is joined to the insulation plate
A method of manufacturing a thermal fuse, wherein the thickness of the gap is reduced.
Z, when the thickness of the low melting point fusible alloy is M, 0.0
2mm <M ≦ Z <and the cover insulating plate so as to be 0.8mm and the insulating plate welded by ultrasonic vibration moreover the insulating plate, the insulating pre for the sealing
The cover and the insulating plate for the cover are each made of thermoplastic
By using resin, there is no need to use a tubular ceramic insulating case, and an advantageous effect that the thickness of the thermal fuse body case can be reduced can be obtained. In addition, since the cover insulating plate is frictionally vibrated by ultrasonic vibration and welded by frictional heat, the heat generated for welding concentrates on the welded part and before the low melting point fusible alloy melts. The advantageous effect that welding can be performed and the production of the thermal fuse becomes easy is also obtained.

According to the second aspect of the present invention,
The method for manufacturing a thermal fuse according to claim 1, wherein the thermoplastic resin is an ABS resin, a SAN resin, a polysamphon resin, a polycarbonate resin, a noryl, a vinyl chloride resin, a polyethylene resin, a polyester resin, a polypropylene resin, a polyamide resin, By using any one of PPS resin, polyacetal, fluorine-based resin, and polyester as a main component, the advantageous effect that the tubular ceramic insulating case is not used and the thickness of the thermal fuse body case can be reduced is obtained. In addition, since the cover insulating plate is frictionally vibrated by ultrasonic vibration and welded by frictional heat, heat generated for welding is concentrated on a welded portion, and welding can be performed with less heat energy. Therefore, there is an advantageous effect that the low melting point fusible alloy can be welded before being melted.

According to the third aspect of the present invention,
The method of manufacturing a thermal fuse according to claim 1, One
A pair of linear conductors or a pair of plate conductors is 0.5 to 50 μm.
m surface roughness, which increases the frictional force
Can be reliably improved.

According to the fourth aspect of the present invention,
2. The method of manufacturing a thermal fuse according to claim 1, wherein the cover insulating plate and the insulating plate are frictionally vibrated by ultrasonic vibration in a state where a protrusion is provided on the cover insulating plate or the insulating plate to generate frictional heat. By welding and fixing, the projections act as energy directors and the ultrasonic vibration concentrates here, so frictional heat concentrates on these projections, and welding can be performed with less heat energy, so that the melting point is low. An advantageous effect is obtained that welding can be more reliably performed before the alloy is melted.

According to the fifth aspect of the present invention,
In the invention according to claim 1, ends of a pair of linear conductors or a pair of plate conductors are arranged on an insulating plate having flexibility, and electricity is supplied to the pair of linear conductors or the pair of plate conductors. Heat and weld the pair of linear conductors or the pair of plate conductors to the insulating plate, and easily join the insulating plate to the pair of linear conductors or the pair of plate conductors can do.

According to the sixth aspect of the present invention,
Insulation plate and sealing for joining the insulation plate
An insulating plate, the insulating plate and the sealing insulating plate;
It is fixed between the rates and is provided to expose the extreme end.
A pair of linear conductors or a pair of plate conductors, and a low melting point fusible alloy fixed between the ends of the pair of linear conductors or the pair of plate conductors, and provided on the insulating plate.
Both together form a space for accommodating the low melting point fusible alloy.
A cover insulating plate provided on the base plate, a welded portion obtained by welding the cover insulating plate and the insulating plate by ultrasonic vibration is provided , and the thickness of the gap is Z,
When the thickness of the low melting point fusible alloy is M, 0.02 mm
<M ≦ Z <0.8 mm.
Insulating plate, said sealing insulating plate and said cover
Since each of the insulating plates is made of a thermoplastic resin, it has an advantageous effect that it has flexibility and can reduce the thickness of the thermal fuse body case.

According to the invention of claim 7, according to claim 6,
In the invention described in (1), when the volume of the space formed between the insulating plate and the insulating plate for the cover is V, and the volume of the low melting point fusible alloy is J, J × 2.5 ≦ V Accordingly, it is possible to prevent leakage of the low-melting-point fusible alloy during the operation of the thermal fuse, so that an advantageous effect of eliminating defective products can be obtained.

According to the invention of claim 8, according to claim 6,
In the invention described in the above, the insulating plate and the sealing insulating press
A welded portion welded by ultrasonic vibration is also provided between the ports , and has flexibility and a case.
Is as small as 1 mm.

According to the ninth aspect, in the sixth aspect,
In the invention described in (1), by forming at least one of the insulating plate and the cover insulating plate into a concave shape, an advantageous effect that a gap in the main body case can be easily secured and the thickness can be reduced can be obtained.

According to the tenth aspect of the present invention, in the sixth aspect of the present invention, a pair of plate-like conductors are partially cut off at ends or a pair of linear moving bodies are partially folded. The bent shape has the advantageous effect of improving the external stress resistance of the terminal.

According to the eleventh aspect, in the sixth aspect, the pair of plate-shaped conductors or the pair of linear conductors is made of Ni metal, Fe metal, Cu metal or Ni metal.
By forming the alloy as a base material, an advantageous effect that welding to a battery or a power supply device can be simplified can be obtained.

According to a twelfth aspect of the present invention, in the sixth aspect of the present invention, the pair of plate-like conductors are made of Fe, Ni, C
a metal or an alloy containing any one of u as a main component, and a part or the whole of the surface of the base material is formed of Cu, Bi, S
By forming a film using any one of n, In, and Pb or an alloy of a mixture thereof, the solder wettability of the pair of linear conductors or the pair of plate conductors can be improved, and the pair of plate conductors can be improved. This has an advantageous effect that the soldering is facilitated.

According to a thirteenth aspect, in the sixth aspect, a pair of linear conductors or a pair of plate conductors is made to have a surface roughness of 0.5 to 50 μm.
The advantageous effect that the frictional force can be increased and the external stress property of the terminal can be surely improved can be obtained.

According to the fourteenth aspect of the present invention, there is provided a battery main body, and a thermal fuse for detecting heat generated from the battery main body, wherein the thermal fuse includes an insulating plate,
A sealing insulating plate to be bonded to the insulating plate,
Fixed between the insulating plate and the sealing insulating plate
And a pair of linear conductors provided to expose the outermost part.
Body or a pair of plate-shaped conductors, a low-melting-point fusible alloy fixed between ends of the pair of linear-shaped conductors or the pair of plate-shaped conductors, and the low-melting- point
Capacitors provided to form voids for storing fusible alloy
An insulating plate for a bar, a welding portion in which the insulating plate for the cover and the insulating plate are welded by ultrasonic vibration is provided , and the thickness of the gap is Z, and the low melting point is meltable.
When the thickness of the gold is M, 0.02 mm <M ≦ Z <0.
8 mm, and the insulating plate
G, the insulating plate for sealing and the insulating plate for the cover.
Since the battery is made of a thermoplastic resin , the outer shape of the battery can be reduced to a plate shape.
An advantageous effect of being able to be stored in a narrow gap of about mm is obtained.

[Brief description of the drawings]

FIG. 1 is a partially cutaway view showing a thermal fuse according to a first embodiment of the present invention.

FIG. 2 is a partially cutaway view showing a thermal fuse using a plate-shaped conductor.

3A is a partially cutaway view showing a manufacturing process of the thermal fuse of FIG. 1; FIG. 3B is a partially cutaway view showing a manufacturing process of the thermal fuse of FIG. 1; (D) Partial cutaway view showing the manufacturing process of the thermal fuse of FIG. 1 (E) Partial cutaway view showing the manufacturing process of the thermal fuse of FIG. 1

FIG. 4 is an exploded perspective view of the thermal fuse of FIG. 1;

FIG. 5 is a side view when the thermal fuse of FIG. 1 is disassembled.

FIG. 6 is an exploded view of a plate-shaped conductor and a plate-shaped thermal fuse made of a low-melting-point fusible alloy.

FIG. 7 is a partially broken view showing a modification of the thermal fuse of FIG. 1;

FIG. 8 is a partially cutaway view showing a thermal fuse using a plate-shaped conductor.

FIG. 9A is an exploded view showing a thermal fuse according to the first embodiment of the present invention; FIG. 9B is an exploded view showing a thermal fuse according to the first embodiment of the present invention; Exploded view showing a fuse

FIG. 10 is a partially cutaway view showing a thermal fuse according to a second embodiment of the present invention.

FIG. 11 is a partially cutaway view showing a thermal fuse according to a third embodiment of the present invention.

FIG. 12 is a partially cutaway view showing a thermal fuse according to a fourth embodiment of the present invention.

FIG. 13 is a partially cutaway view showing a thermal fuse according to a fifth embodiment of the present invention.

FIG. 14 is a configuration diagram showing a thermal fuse unit according to a sixth embodiment of the present invention.

FIG. 15 is a configuration diagram showing a thermal fuse section according to a seventh embodiment of the present invention.

16A is a perspective view showing an energy director, and FIGS.

FIG. 17 is a perspective view showing a battery according to an eighth embodiment of the present invention with the lid opened.

FIG. 18 is a perspective view showing a power supply device according to a ninth embodiment of the present invention.

FIG. 19 is a partially cutaway view showing a thermal fuse according to a tenth embodiment of the present invention.

FIG. 20 is a partially cutaway view showing a thermal fuse according to an eleventh embodiment of the present invention.

FIG. 21 is a configuration diagram showing an example of a conventional thermal fuse using a low melting point fusible alloy.

[Explanation of symbols]

1, 10, 19, 32, 40, 45, 54, 91, 96
Insulation plate 2, 3, 20, 21, 33, 34, 41, 50, 92
Linear conductors 4, 13, 24, 25, 60 Ends 5, 14, 22, 23, 61, 62, 63 Ends 6, 6a, 15, 15a, 26, 27, 35, 36 Sealing insulating plate 7, 16, 28, 37, 43, 48, 94, 98 Low melting point fusible alloy 8, 17, 29, 39 Flux 9, 18, 31, 38, 44, 49, 57, 95 Insulating plate for cover 11, 12 , 46, 52, 64, 97 Plate-shaped conductor 30 Oblique portion 42, 47, 51, 53, 55, 56, 93, 99 Sealing insulating plate 58 Void (space) 59 Depression 61 Hole 62, 63 Notch 65, 67 External terminal 66 Tubular conductor 68 Hole terminal 69 Connecting member 70 Lead frame 79 Energy director 80 Projection 81 Secondary battery 82 Input and output control electric circuit pack 83 Conductor 84 S 85 Cover 86, 89 Terminal 87, 106, 107 Thermal fuse 88 Welded part 90 Cross section of low melting point fusible alloy 100 Cover insulating plate 101 Pack battery connection and power supply case 102 Power supply case 103 Charging electrode terminal 104 AC-DC conversion circuit Part 105 AC power cord

────────────────────────────────────────────────── ─── Continuation of front page (56) References JP-A-11-16466 (JP, A) JP-A-2001-229796 (JP, A) JP-A-9-63454 (JP, A) JP-A-4-2023 (JP, A) JP-A-9-17303 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01H 37/76

Claims (14)

(57) [Claims] When a pair of linear conductors or a pair of plate conductors is fixed to a flexible insulating plate using a sealing insulating plate so that the end portions are exposed.
Both low-melting fusible alloy is fixed between the ends of the pair of linear conductors or the pair of plate-like conductor, the low melting point soluble
The insulating plate so as to form a void for containing the alloy;
A method of manufacturing a thermal fuse, wherein the thickness of the gap is Z, and the low melting point is
When the thickness of the alloy is M, 0.02 mm <M ≦ Z <
The cover insulating plate and the insulating plate are welded by ultrasonic vibration so as to be 0.8 mm , and
The insulating plate, the sealing insulating plate and the casing
A method for manufacturing a thermal fuse, wherein each of the bar insulating plates is made of a thermoplastic resin . 2. The thermoplastic resin is made of ABS resin, SAN resin, polysamphone resin, polycarbonate resin, noryl, vinyl chloride resin, polyethylene resin, polyester resin, polypropylene resin, polyamide resin, PPS.
The method for producing a thermal fuse according to claim 1, wherein the main component is any one of resin, polyacetal, fluororesin, and polyester. 3. A pair of linear conductors or a pair of plate conductors.
The method for manufacturing a thermal fuse according to claim 1, wherein the thermal fuse has a surface roughness of 0.5 to 50 μm . 4. The cover insulating plate or the insulating plate having projections provided thereon, the cover insulating plate and the insulating plate are frictionally vibrated by ultrasonic vibration and welded and fixed by frictional heat. The method for manufacturing a thermal fuse according to the above. 5. An end of a pair of linear conductors or a pair of plate conductors is arranged on an insulating plate, and a current is applied to the pair of linear conductors or the pair of plate conductors to generate the pair of wires by heat generation. The method for manufacturing a thermal fuse according to claim 1, wherein the insulating conductor or the pair of plate-shaped conductors is welded to the insulating plate. 6. A connection between an insulating plate and said insulating plate.
Sealing insulating plate to be combined with said insulating plate
It is fixed between the sealing insulating plates to expose the
A pair of linear conductors or a pair of plate-like conductors
And body, and a low melting fusible alloy that is fixed between the ends of the pair of linear conductors or a pair of plate-like conductor, said insulating plate
And a space for accommodating the low melting point fusible alloy.
And a cover insulating plate provided to form
Comprising, providing a welded portion which is welded to the cover insulating plate and the insulating plate by ultrasonic vibration, the gap
Is Z and the thickness of the low melting point fusible alloy is M
In this case, the structure is such that 0.02 mm <M ≦ Z <0.8 mm.
The insulating plate and the sealing insulating press.
The cover and the insulating plate for the cover are each made of thermoplastic
A thermal fuse characterized by being made of resin . 7. When the volume of the space formed between the insulating plate and the cover insulating plate is V and the volume of the low melting point fusible alloy is J, J × 2.5 ≦ V. 6
Thermal fuse according to the item. 8. Between an insulating plate and a sealing insulating plate.
7. A welding part welded by ultrasonic vibration as well.
Thermal fuse according to the item. 9. The thermal fuse according to claim 6, wherein at least one of the insulating plate and the cover insulating plate is recessed. 10. The thermal fuse according to claim 6, wherein ends of the pair of plate-shaped conductors are partially cut away or a pair of linear moving bodies are partially bent. 11. The thermal fuse according to claim 6, wherein the pair of plate conductors or the pair of linear conductors is formed using a Ni metal, an Fe metal, a Cu metal, or a Ni alloy as a base material. 12. A pair of plate conductors are made of Fe, Ni, Cu
The base material is a metal or alloy whose main component is either
A part or the whole of the surface of the base material is Cu, Bi, Sn,
7. The thermal fuse according to claim 6, wherein a film is formed of one of In and Pb or an alloy of a mixture thereof. 13. The thermal fuse according to claim 6, wherein the pair of linear conductors or the pair of plate conductors has a surface roughness of 0.5 to 50 μm. 14. A battery main body, and a thermal fuse for detecting heat generated from the battery main body, wherein the thermal fuse is connected to an insulating plate and the insulating plate.
An insulating plate for sealing, the insulating plate and the sealing plate
It is fixed between the insulating plates so that the end is exposed
A pair of linear conductors or a pair of plate-like conductor provided a low-melting fusible alloy that is fixed between the ends of the pair of linear conductors or a pair of plate-shaped conductors, et al provided in the insulating plate
To form a space for accommodating the low melting point fusible alloy.
A cover insulating plate provided so as to provide a welding portion in which the cover insulating plate and the insulating plate are welded by ultrasonic vibration to reduce the thickness of the gap.
Z, when the thickness of the low melting point fusible alloy is M, 0.0
It is configured so that 2 mm <M ≦ Z <0.8 mm, and
Mosquito insulating plate, sealing insulating plate and front
Insulation plate for cover is made of thermoplastic resin
Batteries and composed.