Internal combustion engines are traditionally used as a key source of heat in conventional vehicles. However, this source is absent in electric vehicles (EVs) so alternative heating elements like foil heaters are needed. And, EVs aren’t the only applications that must find alternative heating as solutions are increasingly employed in applications across the medical*, household and other types of transportation sectors.
Unfortunately, implementing these new heating solutions comes with their own set of challenges, primarily the risk of overheating. Without protection, overheating of the elements can lead to potential hazards such as fires or damage to the device itself. Causes of overheating are due to factors like electrical overload, thermal runaway and environmental conditions. This is where Bourns® mini-breakers step in, providing a reliable and compact safeguard against these threats.
What are Bourns® Mini-Breakers?
Bourns® mini-breakers are miniature Thermal Cutoff (TCO) devices, specifically designed to offer overtemperature protection with an incredibly small footprint (6.95 x 3.75 x 1.4 mm). These devices are engineered to enhance safety by automatically disconnecting the electrical current when excessive temperatures are detected. This function is achieved through a precision mechanism that involves a bimetal disc flipping at a pre-specified trip temperature.
Key Features and Benefits
The design of Bourns® mini-breakers incorporates a mix of bimetal and ceramic polymer temperature coefficient materials, ensuring high accuracy (±5 ˚C) and extremely low resistance (<1 mΩ). The main benefit of their innovative construction is that the mini-breakers operate efficiently and reliably without significantly impacting the electrical system’s performance.
Safety and Efficiency
Along with high reliability and efficiency, Bourns® mini-breakers give designers the ability to provide their systems independent overtemperature protection. With trip temperatures that can be calibrated from 55 °C to 150 °C and repeatability up to 10,000 cycles, these devices offer a robust solution for maintaining optimal operating temperatures, preventing damage and ensuring the longevity of the heating system.
Compact, Automotive Grade Design
Despite their small size, Bourns® mini-breakers do not compromise on performance. Bourns® mini-breakers meet automotive grade standards and are compliant with AEC-Q200 equivalent standards, making them suitable for a wide range of applications—from EVs to household appliances and industrial equipment.
Applications Across Industries — Bourns® Mini-breakers provide a versatile overtemperature solution that can be integrated into various heating systems including those used in smart cities and advanced medical equipment*. Their reliability and compact design make them particularly suitable for applications where space is at a premium and safety cannot be compromised.
Conclusion
With the increasing reliance on electronic and electrical systems for heating solutions, the need for effective and reliable protection that increases safety becomes more essential in these designs. Bourns® Mini-breakers offer not just protection but also peace of mind for manufacturers and users alike. By integrating these tiny, yet powerful devices, engineers can enhance the safety, efficiency, and reliability of their heating element and module designs, helping to further advance the next generation of heating technology.
A new Bourns white paper provides more information on using mini-breakers in alternative heating applications. This is just one way that Bourns is continuing to be at the forefront of thermal protection innovation.
*Bourns® products have not been designed for and are not intended for use in “lifesaving,” “life-critical” or “life-sustaining” applications nor any other applications where failure or malfunction of the Bourns® product may result in personal injury or death. See Legal Disclaimer Notice http://www.bourns.com/docs/legal/disclaimer.pdf.
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