Subminiature fuse

Abstract

A subminiature fuse is disclosed comprising two terminals, a substrate, a fusible conductor, and a unitary housing. The unitary housing is sealed and provides increased mechanical strength, thus reducing the risk of a catastrophic failure of the fuse. The upper portion of the fuse terminals are shaped into finger like projections adaptable to mechanically fastening the fusible conductor and the substrate thereto thus facilitating the manufacturing process. In one embodiment the fusible conductor and adjacent portions of the terminals and substrate are coated with a ceramic coating or adhesive. The housing is sealed by utrasonic welding or preferably in an insert molded plastic enclosure which is substantially devoid of air.

We claim: 
     
       1. An electrical circuit protector which is adapted to be inserted into a printed circuit board, comprising: (a) a first terminal and a second terminal each having a top portion and a bottom portion;   (b) insulating means having two ends for electrically and thermally insulating said first terminal from said second terminal and for holding said first terminal and said second terminal in substantially parallel relationship and spaced apart from each other by a predetermined distance, said top portions of said first terminal and said second terminal being disposed intermediate the ends of said insulating means;   (c) a fusible conductor connected between said first terminal and said second terminal and supported on said insulating means, the combination of said insulating means, said fusible conductor, and the portions of said first terminal and said second terminal defining an assembly;   (d) an electrically insulative material coating said assembly; and   (e) unitary one piece enclosure means for housing said assembly.   
     
     
       2. An electrical circuit protector according to claim 1, wherein said insulative material comprises ceramic. 
     
     
       3. An electrical circuit protector according to claim 1, wherein said unitary enclosure means comprises epoxy. 
     
     
       4. An electrical circuit protector according to claim 1, wherein said unitary enclosure means is formed from molded plastic. 
     
     
       5. An electrical circuit protector according to claim 1, wherein said insulative material comprises an adhesive. 
     
     
       6. An electrical circuit protector according to claim 4, wherein said unitary enclosure means comprises a plastic housing, which is substantially devoid of air. 
     
     
       7. An electrical circuit protector according to claim 1, wherein said top portion of said first terminal comprises a plurality of fingers which are disposed in a fork-like configuration and which are adapted to receive said insulating means and to position said first terminal with respect to said insulating means. 
     
     
       8. An electrical circuit protector according to claim 1, wherein said insulating means has at least one aperture intermediate said two edges such that a portion of said conductor crosses over said aperture in said insulating means. 
     
     
       9. An electrical circuit protector according to claim 1, wherein said bottom portions of said first terminal and said second terminal are flat and define two ends. 
     
     
       10. An electrical circuit protector according to claim 1, wherein said bottom portion of said first terminal includes stop means, projecting from said bottom portion at a predetermined distance from one end of said first terminal for limiting the distance said first terminal and said second terminal can be inserted into a printed circuit board. 
     
     
       11. An electrical circuit protector according to claim 1, wherein said enclosure means has integrally molded plastic stand off means for limiting the distance that said first terminal and said second terminal can be inserted into a printed circuit board. 
     
     
       12. An electrical circuit protector according to claim 1, wherein said insulating means comprises a ceramic substrate. 
     
     
       13. An electrical circuit protector according to claim 12, wherein said insulating means has a general box-like rectangular shape. 
     
     
       14. An electrical circuit protector according to claim 1, wherein said edges of said insulating means are coated with a metal to facilitate soldering of said first terminal and second terminal thereto. 
     
     
       15. An electrical circuit protector according to claim 1, wherein said fusible conductor is connected to said first terminal and said second terminal by soldering. 
     
     
       16. An electrical circuit protector according to claim 1, wherein the cross section of said unitary enclosure means is substantially rectangular originally having one opened end and sealed around assembly. 
     
     
       17. An electrical circuit protector according to claim 16, wherein said unitary enclosure means is made of a plastic material. 
     
     
       18. An electrical circuit protector according to claim 1, wherein said unitary enclosure means is in the form of a box-like structure comprising two oppositely disposed pair of faces, defining a generally rectangular opening.[.,.]. .Iadd.between .Iaddend.said two pair of faces, one .Iadd.of .Iaddend.said pair of faces having V-shaped notches which are oppositely disposed to each other, said opening defining two lips which are oppositely disposed from each other and which are disposed adjacent to each other for sealing said opening. 
     
     
       19. An electrical circuit protector according to claim 1, wherein said enclosure means is comprised of an insert molded plastic body. 
     
     
       20. A method of manufacturing a subminature fuse, comprising the steps of: (a) positioning two blade type terminals generally parallel to one another, each of said terminals having an upper portion and a lower portion with said upper portions having a pair of fingers;   (b) assembling a ceramic substrate between said .[.two.]. .Iadd.pair of .Iaddend.fingers on an upper portion of each of said blade type terminals such that the blade type terminals are oppositely disposed along an edge of said ceramic substrate;   (c) connecting a fuse conductor between said blade type terminals so as to form an assembly; and   (d) enclosing said assembly in a one piece housing.   
     
     
       21. A method of manufacturing a subminiature fuse according to claim 20, wherein said blade type terminals have solder alloy cladding on an inside surface of said fingers, wherein said substrate has metallized ends which contact said fingers of said terminals and, wherein said fuse conductor has two ends, said fuse conductor is connected to said terminals by placing between said metallized ends of said cladding by solder reflow between said fingers and the substrate. 
     
     
       22. A method of manufacturing a subminiature fuse according to claim 20, wherein said assembly is covered with an insulative material. 
     
     
       23. An electrical circuit protector which is adapted to be inserted into a printed circuit board, comprising: (a) a first terminal and a second terminal each having a top portion and a bottom portion;   (b) insulating means having two ends for electrically and thermally insulating said first terminal from said second terminal and for holding said first terminal and said second terminal in substantially parallel relationship and spaced apart from each other by a predetermined distance, said top portions of said first terminal and said second terminal being disposed intermediate the ends of said insulating means, wherein said top portion of said first terminal comprises a plurality of fingers which are disposed in a fork-like configuration and which are adapted to receive said insulating means and to position said first terminal with respect to said insulating means;   (c) a fusible conductor connected between said first terminal and said second terminal and supported on said insulating means, the combination of said insulating means, said fusible conductor, and the portions of said first terminal and said second terminal defining an assembly; and   (d) unitary one piece enclosure means for housing said assembly.   
     
     
       24. An electrical circuit protector according to claim 23, wherein said fusible conductor is disposed between one of said fingers and said insulating means. 
     
     
       25. An electrical circuit protector according to claim 23, wherein said fingers at said top portion of said first terminal are coated with a solder alloy cladding material. 
     
     
       26. An electrical circuit protector which is adapted to be inserted into a printed circuit board, comprising: (a) a first terminal and a second terminal each having a top portion and a bottom portion;   (b) insulating means having two ends for electrically and thermally insulating said first terminal from said second terminal and for holding said first terminal and said second terminal in substantially parallel relationship and spaced apart from each other by a predetermined distance, said top portions of said first terminal and said second terminal being disposed intermediate the ends of said insulating means;   (c) a fusible conductor connected between said first terminal and said second terminal and supported on said insulating means, the combination of said insulating means, said fusible conductor, and the portions of said first terminal and said second terminal defining an assembly;   (d) unitary one piece enclosure means for housing said assembly wherein said unitary enclosure means is in the form of a box-like structure comprising two oppositely disposed pair of faces, defining a generally rectangular opening.[.,.]. .Iadd.between .Iaddend.said two pair of faces, one of said pair of faces having V-shaped notches which are oppositely disposed to each other, said opening defining two lips which are oppositely disposed from each other and which are disposed adjacent to each other for sealing said opening. .Iadd.   
     
     
       27.  An electrical circuit protector comprising: (a) a first terminal and a second terminal;   (b) insulating means for holding said first terminal and said second terminal spaced apart from each other by a predetermined distance and electrically insulating said first terminal from said second terminal;   (c) a fusible conductor electrically connected to said first terminal and said second terminal;   (d) the combination of said insulating means, said fusible conductor and said first terminal and said second terminal defining an assembly;   (e) an electrically insulative and arc quenching material of ceramic, coating said assembly..Iaddend. .Iadd.   
     
     
       28.  An electrical circuit protector as in claim 27, wherein said insulative material is nonporous..Iaddend. .Iadd.29. An electrical circuit protector as in claim 27, wherein said coated assembly is housed in an enclosure means. .Iaddend. .Iadd.30. An electrical protector according to claim 29, wherein said enclosure means comprises epoxy..Iaddend. .Iadd.31. An electrical circuit protector according to claim 29, wherein said 
     
     
        enclosure means is formed from molded plastic..Iaddend. .Iadd.32.  An electrical circuit protector according to claim 31, wherein said enclosure means comprises a plastic housing, which encloses said coated assembly in a manner which results in a circuit protector which is substantially devoid of air..Iaddend. .Iadd.33. An electrical circuit protector according to claim 27, wherein a top portion of said first terminal and said second terminal comprises a plurality of fingers which are disposed in a fork-like configuration and which are adapted to receive said insulating means and to position said terminals with respect to said insulating means..Iaddend. .Iadd.34. An electrical circuit protector according to claim 27, wherein said insulating means has at least one aperture such that a portion of said conductor crosses over said aperture in said insulating means..Iaddend. .Iadd.35. An electrical circuit protector according to claim 34, wherein said insulative material fills said aperture..Iaddend. .Iadd.36. An electrical circuit protector comprising: (a) a first terminal and a second terminal having terminal fingers and a bottom portion;   (b) insulating means for holding said first terminal and said second terminal at said terminal fingers spaced apart by a predetermined distance and electrically insulating said first terminal from said second terminal, said bottom portions projecting outward from said insulating means;   (c) a fusible conductor electrically connected to said first terminal and said second terminal at said terminal finger portion exterior said insulating means;   (d) the combination of said insulating means, said fusible conductor and said first terminal and said second terminal defining an assembly;   (e) an electrically insulative arc quenching material, coating at least a   
     
     
        portion of said fusible conductor..Iaddend. .Iadd.37.  An electrical circuit protector as in claim 36, wherein said assembly is housed in an enclosure means..Iaddend. .Iadd.38. An electrical circuit protector comprising: (a) a first terminal and a second terminal;   (b) insulating means for holding said first terminal and said second terminal spaced apart from each other by a predetermined distance and electrically insulating said first terminal from said second terminal;   (c) a fusible conductor electrically connected to said first terminal and said second terminal;   (d) the combination of said insulating means, said fusible conductor and said first terminal and said second terminal defining an assembly;   (e) unitary one piece enclosure means for housing said assembly..Iaddend. .Iadd.39. A method of manufacturing a subminiature fuse, comprising the steps of:   (a) positioning two terminals, adjacent each other one end of each of said terminals having fingers;   (b) assembling an insulating means between said fingers on said terminals such that each terminal holds an edge of said insulating means..Iaddend.   (c) connecting a fusible conductor between said terminals so as to form an assembly; and   (d) coating at least a portion of said fusible conductor with an insulative   
     
     
        material. .Iadd.40.  A method of manufacturing a subminiature fuse according to claim 39, wherein said assembly is substantially coated with an insulative material..Iaddend. .Iadd.41. A method of manufacturing a subminiature fuse according to claim 39 or 40, wherein said assembly is housed in an enclosure means..Iaddend. .Iadd.42. A method of manufacturing a subminiature fuse according to claim 39, wherein said assembly is inserted into a hollow enclosure and filling said enclosure with 
     
     
        insulative material..Iaddend. .Iadd.43.  An electrical circuit protector according to claim 27 or 36, wherein said insulative material comprises ceramic..Iaddend. .Iadd.44. An electrical circuit protector according to claim 38, wherein said unitary enclosure means comprises epoxy..Iaddend. .Iadd.45. An electrical circuit protector according to claim 38, wherein said unitary enclosure means is formed from molded plastic..Iaddend. .Iadd.46. An electrical circuit protector according to claim 27 or 36, wherein said insulative material comprises an adhesive..Iaddend. .Iadd.47. An electrical circuit protector according to claim 38, wherein said enclosure means has integrally molded plastic stand off means for limiting the distance that said first terminal and said second terminal can be inserted into a printed circuit board..Iaddend. .Iadd.48. An electrical circuit protector according to claim 27 or 36, wherein said insulating means comprises a ceramic substrate..Iaddend. .Iadd.49. An electrical circuit protector according to claim 27 or 36, wherein said fusible conductor is connected to said first terminal and said second terminal by 
     
     
        soldering..Iaddend. .Iadd.50.  An electrical circuit protector according to claim 38, wherein the cross section of said unitary enclosure means is substantially rectangular originally having one opened end and sealed around assembly..Iaddend. .Iadd.51. An electrical circuit protector according to claim 38, wherein said unitary enclosure means is in the form of a box-like structure comprising two oppositely disposed pair of faces, defining a generally rectangular opening, between said two pair of faces, one said pair of faces having V-shaped notches which are oppositely disposed to each other, said opening defining two lips which are oppositely disposed from each other and which are disposed adjacent to each other for sealing said opening..Iaddend. .Iadd.52. An electrical circuit protector according to claim 29 or 37, wherein said enclosure 
     
     
        means is comprised of an insert molded plastic body..Iaddend. .Iadd.53. An electrical circuit protector as in claim 36, wherein said insulative material is nonporous..Iaddend. .Iadd.54. An electrical circuit protector according to claim 37, wherein said enclosure means comprises epoxy..Iaddend. .Iadd.55. An electrical circuit protector according to claim 37, wherein said enclosure means is formed from molded 
     
     
        plastic..Iaddend. .Iadd.56.  An electrical circuit protector according to claim 36, wherein a top portion of said first terminal comprises a plurality of fingers which are disposed in a fork-like configuration and which are adapted to receive said insulating means and to position said terminals with respect to said insulating means..Iaddend. .Iadd.57. An electrical circuit protector according to claim 36, wherein said insulating means has at least one aperture such that a portion of said conductor crosses over said aperture in said insulating means..Iaddend. .Iadd.58. An electrical circuit protector according to claim 55, wherein said enclosure means comprises a plastic housing, which encloses said coated assembly in a matter which results in a circuit protector which is substantially devoid of air..Iaddend. .Iadd.59. An electrical circuit protector according to claim 57, wherein said insulative material fills said aperture..Iaddend.