New Circuit Protection Platforms. March 2011 APEC

Transcription

1 New Circuit Protection Platforms March 2011 APEC

2 TE is a World Leader Enabling Connectivity Serving Large Attractive Markets Consumer Industrial and Infrastructure Transportation Consumer Communications Energy Products Industrial Equipment With a Wealth of Technology Platforms Aerospace & Defense Medical Circuit Connectors Fiber Optics Touch Systems Sealing & Protection Protection And Extensive Global Resources Wireless Precision Wire & Cable 7,000 Engineers Close to our Customers 5,000 Salespeople Advising our Customers 150 Countries Served 97 Manufacturing Sites Serving Every Region page 2 /

3 Circuit Protection Markets NEW NEW page 3 /

4 Introducing Two New Technology Platforms Reflowable Thermal Protector (RTP) Device Simplified thermal protection in a SMD package Robust, vibration-insensitive, DC-rated, Pb-free device can be installed with standard high temperature SMD processes Metal Hybrid PPTC (MHP) Device Robust Bi-Metal protection with built-in superior arc suppression technology Rugged, space-saving, cost-effective solution for highrate-discharge battery applications at ratings above 30VDC/30A page 4 /

5 First of a Kind Reflowable Thermal Protection (RTP) Device Suitable for Automotive and Industrial Applications page 5 /

6 Innovation Drivers for RTP Influencing Trends Consumer Portability Battery Life Performance Mechanical Functions Automotive/Industrial Electromechanical In the early 1990s, electronics accounted for about 10% of an automobile's total cost. By 2010 that portion will rise to 40%. Source: Charlie Wade, analyst with consultancy Technology Forecasters Inc. Design Challenges Smaller Form Factor with Increased Power Density Increase in Electronic Components Smaller Tighter Designs Increase in Thermal Events Resistive Failure Mode PCB Trace Overheating page 6 /

7 Problem: Resistive Failure Mode A resistive short may occur leading to an unsafe thermal event Resistive shorts can produce unsafe temperatures due to I 2 R heating As little as 10W may generate a localized hot spot of more than 180 C, potentially damaging the board s epoxy structure page 7 /

8 Solution: The RTP Thermal Protection Device The RTP device interrupts current and helps stop thermal runaway conditions FET exceeds normal operating temperature window RTP trips and opens power line RTP tracks the FET temperature but stays below it, due to its low resistance page 8 /

9 RTP200 X-Ray Images AFTER REFLOW The device can survive up to three 260 C reflow passes without opening ARMED Arming timing is user-determined and can occur at powerup or during validation test phase OPEN The device will open after the critical junction temperature exceeds 200 C To check out videos on arming and reflow go to: and page 9 /

10 Device Comparison The RTP device combines the best features of conventional technologies to provide a robust, reflowable solution for automotive and industrial power electronics thermal protection page 10 /

11 RTP Device Benefits Robust thermal protection against damage resulting from failed power components and PCB trace overheating SMD packaging simplifies design standard surface-mount production methods reduce assembly costs removes unique challenges of post manufacturing qualifications typically associated with TCO (thermal cut off) designs optimizes thermal coupling Suitable for harsh environment applications, e.g., vibration-sensitive automotive and industrial applications Eliminates the need for heavy heat sinks, redundant FETs and relays page 11 /

12 Innovative Metal Hybrid PPTC (MHP) Device Protects Li-ion Batteries in High-Power Applications page 12 /

13 Market Trend Proliferation of Li-ion Batteries Due to their increased power and lower weight, Li-ion batteries are proliferating into new segments The market for lithium-ion batteries was estimated at 1.97 billion units in 2009 and is likely to grow to 3.4 billion units in 2015, a compound annual growth rate of 8.5%. Vishal Sapru, Research Manager for Energy & Power Systems at Frost & Sullivan. Demand will be driven by increase in usage of mobile phones with the launch of 3G and 4G devices, laptops/notebooks, stationary applications, heavy-duty cordless tools, data collection equipment, and HEV/PHEV/EV among others. Vishal Sapru, The markets for power tools and e-bikes are just two where we expect to see rapid growth as they move towards using lithium-ion batteries. Vishal Sapru page 13 /

14 New Technology - New Safety Standards While Li-ion batteries can be more powerful, lighter, and environmentally friendly, they require more rigorous safety designs than NiCd batteries Emerging safety standards that address Li-ion battery designs for high power applications, such as power tools, will require new levels of protection There is a clear need for cost-effective, battery circuit protection devices that are capable of 30A+ hold currents and voltage ratings over 30Vdc page 14 /

15 Problem: Overcurrent Leads to Over Heating For a power tool, an overcurrent condition may occur if the rotor locks when a drill bit gets stuck This over-current situation, if not addressed, can cause the battery to heat up and may lead to battery failure or more significant safety issues page 15 /

16 Solution: The MHP Device The MHP device consists of a small bi-metal in parallel with a PPTC device This combination facilitates a small protection device capable of arc suppression Normal Condition: Current passes through the bi-metal Fault Condition: Bi-metal opens, current shunts to PPTC Latch: PPTC generates heat and keeps bi-metal latched page 16 /

17 Device Comparison: MHP Advantages The MHP device satisfies battery protection requirements for device ratings above 30A and 30Vdc that traditional devices cannot, while also providing a lower-cost solution compared to more complex IC & MOSFET electronic designs page 17 /

18 MHP Device Benefits Safety: Suppresses arcing to protect the contacts from welding shut Reliability: Rugged, reliable design Design Flexibility: Device shape optimized to fit in battery packs with minimal design change Cost-reduction: Offers significant reductions in total design cost compared to electronic (IC + MOSFET) protection solutions Space Savings: Allows for a higher current rating in a smaller device package Warranty Cost Reduction: Protects Li-ion cells from heat damage due to abnormal high currents and reduces battery pack returns MHP30-36 Installed in a battery pack page 18 /

19 Media Communications Contacts Tyco Electronics Hope-Sutton Salvador Manager, Global Marketing Communications (650) WelComm North America Marsha Lisak, WelComm, Inc. Senior Account Executive (858) page 19 /