Conductive polymer electronic devices with surface mountable configuration and methods for manufacturing same

Patent metadata

Field	Value
Publication number	US-9552909-B2
Application number	US-201314034092-A
Country	US
Kind code	B2
Filing date	Sep 23, 2013
Priority date	Apr 14, 2006
Publication date	Jan 24, 2017
Grant date	Jan 24, 2017

Abstract

Surface-mountable devices include a conductive polymer layer between first and second electrodes, on which are disposed first and second insulation layers, respectively, with first and second planar terminals on the second insulation layer. A first cross-conductor connects the second electrode to the first terminal, and is separated from the first electrode by a portion of the first insulation layer. A second cross-conductor connects the first electrode to the second terminal, and is separated from the second electrode by a portion of the second insulation layer. At least one cross-conductor may include a beveled portion through the first insulation layer. Alternatively, at least one cross-conductor may contact an anchor pad on the first insulation layer, the anchor pad having a small area relative to the areas of the terminals. Enhanced adhesion between the cross-conductor(s) and the first insulation layer is provided, while allowing thermal expansion without excessive stress.

First claim

What is claimed is:

1. A surface-mountable electronic device ( 230 ), comprising:
a conductive polymer layer ( 232 ) between a first electrode ( 234 ) and a second electrode ( 236 );
a first insulation layer ( 242 ) on the first electrode and a second insulation layer ( 244 ) on the second electrode;
first and second planar conductive terminals ( 246 , 248 ) spaced apart from each other on the second insulation layer ( 244 ) adjacent first and second ends, respectively, of the second insulation layer;
a first cross-conductor ( 256 ) connecting the second electrode ( 236 ) and the first terminal ( 246 ), and separated from the first electrode ( 234 ) by a portion ( 238 ) of the first insulation layer ( 242 ); and
a second cross-conductor ( 258 ) connecting the first electrode ( 234 ) and the second terminal ( 248 ), and separated from the second electrode ( 236 ) by a portion ( 240 ) of the second insulation layer ( 244 );
and wherein at least one of the first and second cross-conductors ( 256 , 258 ) includes a metallized beveled or chamfered portion ( 260 , 262 ) extending through the first insulation layer ( 242 ).

2. A surface-mountable electronic device ( 430 ), comprising:
a conductive polymer layer ( 432 ) between a first electrode ( 434 ) and a second electrode ( 436 );
a first insulation layer ( 442 ) on the first electrode and a second insulation layer ( 444 ) on the second electrode;
first and second planar conductive terminals ( 446 , 448 ) spaced apart from each other on the second insulation layer ( 444 ) adjacent first and second ends, respectively, of the second insulation layer;
a first cross-conductor ( 456 ) connecting the second electrode ( 436 ) and the first terminal ( 446 ), and separated from the first electrode ( 434 ) by a portion ( 438 ) of the first insulation layer ( 442 ); and
a second cross-conductor ( 458 ) connecting the first electrode ( 434 ) and the second terminal ( 448 ), and separated from the second electrode ( 436 ) by a portion ( 440 ) of the second insulation layer ( 444 );
and wherein the first cross-conductor ( 456 ) is in physical contact with a metallized anchor pad ( 460 ) on the first insulation layer ( 442 ), and the second cross-conductor ( 458 ) includes a metallized beveled or chamfered portion ( 462 ) extending through the first insulation layer ( 442 ).

3. A surface-mountable electronic device ( 330 ), comprising:
a conductive polymer layer ( 332 ) between a first electrode ( 334 ) and a second electrode ( 336 );
a first insulation layer ( 342 ) on the first electrode ( 334 ) and a second insulation layer ( 344 ) on the second electrode ( 336 );
first and second planar conductive terminals ( 346 , 348 ) spaced apart from each other on the second insulation layer ( 344 ) adjacent first and second ends, respectively, of the second insulation layer, each of the first and second planar conductive terminals having a first area;
a first cross-conductor ( 356 ) formed as a first metallized via connecting the second electrode ( 336 ) and the first terminal ( 346 ), and separated from the first electrode ( 334 ) by a portion ( 338 ) of the first insulation layer ( 342 ); and
a second cross-conductor ( 358 ) formed as a second metallized via connecting the first electrode ( 334 ) and the second terminal ( 348 ), and separated from the second electrode ( 336 ) by a portion ( 340 ) of the second insulation layer ( 344 );
wherein the first cross-conductor ( 356 ) is in physical contact with a first anchor pad ( 360 ) formed as a first arcuate metallized area on the first insulation layer ( 342 ) adjacent the first metallized via, and the second cross-conductor ( 358 ) is in physical contact with a second anchor pad ( 362 ) formed as a second arcuate metallized area on the first insulation layer ( 342 ) adjacent the second metallized via;
wherein the area of each of the first and second anchor pads has a second area less than the first area.

4. A surface-mountable electronic device ( 130 ), comprising:
a conductive polymer layer ( 132 ) between a first electrode ( 134 ) and a second electrode ( 136 );
a first insulation layer ( 142 ) on the first electrode and a second insulation layer ( 144 ) on the second electrode;
first and second planar conductive terminals ( 146 , 148 ) spaced apart from each other on the second insulation layer ( 144 ) adjacent first and second ends, respectively, of the second insulation layer;
a first cross-conductor ( 156 ) connecting the second electrode ( 136 ) and the first terminal ( 146 ), and separated from the first electrode ( 134 ) by a portion ( 138 ) of the first insulation layer ( 142 ); and
a second cross-conductor ( 158 ) connecting the first electrode ( 134 ) and the second terminal ( 148 ), and separated from the second electrode ( 136 ) by a portion ( 140 ) of the second insulation layer ( 144 );
wherein the portion ( 138 ) of the first insulation layer separating the first cross-conductor from the first electrode comprises a first isolation area, and the portion ( 140 ) of the second insulation layer separating the second cross-conductor from the second electrode comprises a second isolation area; and
wherein the first isolation area is configured as a first lateral band spaced from the first cross-conductor by an upper metal area ( 139 ), and the second isolation area is configured as a second lateral band spaced from the second cross-conductor by a lower metal area ( 141 ).

5. A surface-mountable electronic device ( 270 ), comprising:
a first conductive polymer layer ( 272 a ) between a first electrode ( 274 a ) and a second electrode ( 274 b );
a second conductive polymer layer ( 272 b ) between a third electrode ( 274 c ) and a fourth electrode ( 274 d );
a first insulation layer ( 280 ) between the second and third electrodes ( 274 b , 274 c );
a second insulation layer ( 282 ) on the first electrode ( 274 a ) and a third insulation layer ( 284 ) on the fourth electrode ( 274 d );
first and second planar conductive terminals ( 286 , 288 ) spaced apart from each other on the third insulation layer ( 284 ) adjacent first and second ends, respectively, of the third insulation layer;
a first cross-conductor ( 296 ) connecting the second electrode ( 274 b ), the third electrode ( 274 c ), and the first terminal ( 286 ), and separated from the first electrode by a portion ( 276 a ) of the second insulation layer ( 282 ) and separated from the fourth electrode by a portion ( 276 b ) of the third insulation layer ( 284 ); and
a second cross-conductor ( 298 ) connecting the first electrode ( 274 a ), the fourth electrode ( 274 d ), and the second terminal ( 288 ), and separated from the second and third electrodes by portions ( 278 a , 278 b ) of the first insulation layer ( 280 );
and wherein at least one of the first and second cross-conductors ( 296 , 298 ) includes a metallized beveled or chamfered portion ( 300 , 302 ) extending through the second insulation layer ( 282 ).

6. A surface-mountable electronic device ( 470 ), comprising:
a first conductive polymer layer ( 472 a ) between a first electrode ( 474 a ) and a second electrode ( 474 b );
a second conductive polymer layer ( 472 b ) between a third electrode ( 474 c ) and a fourth electrode ( 474 d );
a first insulation layer ( 480 ) between the second and third electrodes ( 474 b , 474 c );
a second insulation layer ( 482 ) on the first electrode ( 474 a ) and a third insulation layer ( 484 ) on the fourth electrode ( 474 d );
first and second planar conductive terminals ( 486 , 488 ) spaced apart from each other on the third insulation layer ( 484 ) adjacent first and second ends, respectively, of the third insulation layer;
a first cross-conduc

Assignees

• Bourns Inc

Inventors

• Bourns Gordon L
• Chu Stelar
• Grindell Daniel E
• Huang David
• Kelly John
• Meijer Erik

Classifications

• Y10T29/49165

  by forming conductive walled aperture in base · CPC title

• H01C17/02

  adapted for manufacturing resistors with envelope or housing (apparatus or processes for filling or compressing insulating material in heating element tubes H05B3/52) · CPC title

• H01C7/18 Primary

  comprising a plurality of layers stacked between terminals · CPC title

• H01C7/049

  mainly consisting of organic or organo-metal substances · CPC title

• H01C7/041

  formed with two or more layers · CPC title