Patent ID: 6914416
Filing Date: 2005-07-05
Classification: H01L,H02H,H02J

Abstract:
1. A method for manufacturing a circuit protection device, comprising: forming a variable resistor having a thermally and electrically conductive surface; and securing a thermally and electrically conductive surface of a voltage regulator to the thermally and electrically conductive surface of the variable resistor such that the voltage regulator is thermally coupled to the variable resistor, wherein the variable resistor is formed by forming a substrate comprising a positive temperature coefficient material, applying a first electrically conductive layer to a first surface of the substrate, appying a first electrically insulating layer on the first conductive layer, and removing a portion of the first insulating layer to expose a portion of the first conductive layer, wherein the voltage regulator is secured to the variable resistor by positioning solder material on the exposed portion of the first conductive layer, positioning the thermally and electrically conductive surface of the voltage regulator in contact with the solder material, and heating the solder material to cause flow of the solder material, the voltage regulator comprising a transistor formed on a die, and a heat sink, the heat sink having a first surface and a second surface, the second surface comprising the thermally and electrically conductive surface of the voltage regulator, the die attached to the first heat sink surface such that the transistor is thermally coupled to the heat sink, and wherein the removed portion of the first insulating layer forms a window around the exposed portion of the first conductive surface, the window being sized such that, during flow of the solder material, the heat sink will self-center within the window.