EP2849185B1 - Contact materials for use in on-board high-voltage direct-current systems - Google Patents

Contact materials for use in on-board high-voltage direct-current systems Download PDF

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Publication number
EP2849185B1
EP2849185B1 EP14002972.9A EP14002972A EP2849185B1 EP 2849185 B1 EP2849185 B1 EP 2849185B1 EP 14002972 A EP14002972 A EP 14002972A EP 2849185 B1 EP2849185 B1 EP 2849185B1
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EP
European Patent Office
Prior art keywords
contact element
matrix
range
silver
amount
Prior art date
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Active
Application number
EP14002972.9A
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German (de)
French (fr)
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EP2849185A1 (en
Inventor
Jürgen STEINWANDEL
Dietrich P. Jonke
Helmut Piringer
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Airbus Defence and Space GmbH
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Airbus Defence and Space GmbH
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Publication of EP2849185A1 publication Critical patent/EP2849185A1/en
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H33/00—High-tension or heavy-current switches with arc-extinguishing or arc-preventing means
    • H01H33/02—Details
    • H01H33/04—Means for extinguishing or preventing arc between current-carrying parts
    • H01H33/08—Stationary parts for restricting or subdividing the arc, e.g. barrier plate
    • H01H33/10—Metal parts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00—Contacts
    • H01H1/02—Contacts characterised by the material thereof
    • H01H1/021—Composite material
    • H01H1/023—Composite material having a noble metal as the basic material
    • H01H1/0237—Composite material having a noble metal as the basic material and containing oxides
    • H01H1/02372—Composite material having a noble metal as the basic material and containing oxides containing as major components one or more oxides of the following elements only: Cd, Sn, Zn, In, Bi, Sb or Te
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00—Contacts
    • H01H1/02—Contacts characterised by the material thereof
    • H01H1/021—Composite material
    • H01H1/025—Composite material having copper as the basic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H11/00—Apparatus or processes specially adapted for the manufacture of electric switches
    • H01H11/04—Apparatus or processes specially adapted for the manufacture of electric switches of switch contacts
    • H01H11/048—Apparatus or processes specially adapted for the manufacture of electric switches of switch contacts by powder-metallurgical processes
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00—Contacts
    • H01H1/02—Contacts characterised by the material thereof
    • H01H2001/0208—Contacts characterised by the material thereof containing rhenium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2201/00—Contacts
    • H01H2201/022—Material
    • H01H2201/024—Material precious
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2201/00—Contacts
    • H01H2201/022—Material
    • H01H2201/026—Material non precious
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2201/00—Contacts
    • H01H2201/022—Material
    • H01H2201/03—Composite
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2239/00—Miscellaneous
    • H01H2239/044—High voltage application
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2300/00—Orthogonal indexing scheme relating to electric switches, relays, selectors or emergency protective devices covered by H01H
    • H01H2300/036—Application nanoparticles, e.g. nanotubes, integrated in switch components, e.g. contacts, the switch itself being clearly of a different scale, e.g. greater than nanoscale

Definitions

  • the present invention relates to a contact element for high-voltage DC switches, a method for producing such a contact element and the use of the contact element in a high-voltage DC switch.
  • contact elements or joints are mainly known from AC circuits.
  • the known contact materials are for example silver / tin oxide, which are suitable for use at currents up to 50A.
  • High-current switches on the other side are plasma switches, such as those used in power plants, for example.
  • plasma switches such as those used in power plants, for example.
  • electronic switching elements are used for high voltage DC switches.
  • Object of the present invention is therefore to provide a contact element or a connection point available, which can be used in a high-voltage DC switch and in comparison to conventional contact elements or connection points a smaller formation of plasma flashovers is achieved, the one lower security risk leads.
  • Another object of the present invention is to provide a method of manufacturing such a contact element for high voltage DC switches. In particular, this method should have a low production cost.
  • the contact element according to the invention is suitable for use in a high-voltage DC switch. Another advantage is that the contact element has a greatly reduced tendency to form plasma flashovers or no plasma flashovers and thus offers a low security risk.
  • the contact element comprises the matrix in an amount of 75.0 to 99.9 wt .-%, based on the total weight of the contact element, and / or the contact element comprises the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of contact element.
  • the foreign phase is homogeneously distributed in the matrix.
  • the foreign phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 1000.0 nm, preferably in a range of 100.0 to 750.0 nm and more preferably in a range of 100.0 to 500.0 nm.
  • the contact element has a porosity of ⁇ 0.5 vol.% And preferably ⁇ 0.1 vol.%, Based on the total volume of the contact element.
  • the contact element is a thermally sprayed contact element.
  • the contact element has a layer thickness between 100.0 ⁇ m and 5.0 mm, preferably between 200.0 ⁇ m and 3.0 mm, more preferably between 250.0 ⁇ m and 2.0 mm and in particular between 300.0 ⁇ m and 1.0 mm.
  • the first material comprises particles having a diameter in the range from 5.0 to 100.0 ⁇ m, preferably in a range from 5.0 to 50.0 ⁇ m and more preferably in a range from 5.0 to 25.0 ⁇ m and / or the second material in step b) comprises nanoparticles with a diameter in a range of 100.0 to 1000.0 nm, preferably in one range from 100.0 to 750.0 nm, and more preferably in a range of 100.0 to 500.0 nm.
  • the second material is carbon and is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.
  • the first material is provided in an amount of 75.0 to 99.9 wt .-%, based on the total weight of the contact element, and / or the second material in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element , provided.
  • step c) takes place by grinding the first material with the second material.
  • step d) takes place by cold gas spraying or plasma spraying or flame spraying.
  • the present invention relates to the use of the contact element in a high voltage DC switch.
  • a high voltage DC switch for example, in an electric power drive, preferably in an aircraft.
  • the contact element comprises a matrix of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof.
  • the first material comprises molybdenum or copper.
  • the first material comprises silver or gold or palladium.
  • the first material comprises silver or gold, preferably silver.
  • the first material is silver or gold or palladium.
  • the first material is silver or gold, preferably silver.
  • a matrix comprising a first material, preferably consisting of silver, has the particular advantage that a contact element comprising such a matrix has a high electrical conductivity.
  • the first material comprises an alloy, wherein the base metal is selected from one of the above-mentioned elements.
  • the alloy preferably comprises a first element selected from the group consisting of copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel and gold as the base metal.
  • the alloy comprises at least a second element or a second compound selected from the group comprising palladium, tungsten, tungsten carbide, carbide, nickel, nickel carbide, ruthenium, iridium, silver copper, silver nickel, cobalt, copper, carbon, silver, and mixtures of these.
  • the first element is chemically different from the second element or the second compound.
  • the first element of the alloy ie, the base metal, silver
  • the second element or compound of the alloy selected from the group comprising palladium, tungsten, tungsten carbide, carbide, nickel, nickel carbide, ruthenium, iridium, silver copper, silver nickel, Cobalt, copper, carbon and mixtures of these.
  • the carbon is preferably selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.
  • the matrix comprises an alloy such as Ag-Pd, Ag-Cd, AgC, Ag-WC, Ag-WC-C, Ag-Ni, AgNiC, AgCu, Ag-W, Au-Ni, Au Co, AuAg, AuAgCu, AuAgNi, Pd-Ag, PdCu, PdRu, Ptlr, PtRu, PtW, W-Cu, Cu-W, Cu-Ag, etc.
  • the alloy preferably comprises the first element in an amount of 50.0 to 97.0% by weight, based on the total weight of the alloy.
  • the alloy comprises the first element in an amount of 60.0 to 95.0 wt% or in an amount of 70.0 to 90.0 wt%, based on the total weight of the alloy.
  • the alloy comprises the second element or compound in an amount of from 3.0 to 50.0 weight percent, based on the total weight of the alloy.
  • the alloy comprises the second element or the second compound in an amount of 5.0 to 40.0 wt% or in an amount of 10.0 to 30.0 wt% based on the total weight of the alloy.
  • the matrix comprises an alloy such as AgNi10, AgNi15, AgNi40, AgCu3, AgCu10, AgCu20, AgCu28, AgPd30, AgPd50, PdCu15 or PdCu40.
  • the amount of matrix in the contact element can vary within a wide range.
  • the contact element comprises the matrix in an amount of 75.0 to 99.9 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the matrix in an amount of 75.0 to 90.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the matrix in an amount of 80.0 to 90.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the foreign phase in an amount of 10.0 to 25.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the foreign phase in an amount of 10.0 to 20.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the matrix in an amount of 75.0 to 99.9 wt .-% and the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the matrix in an amount of 75.0 to 90.0 wt .-% and the foreign phase in an amount of 10.0 to 25.0 wt .-%, based on the total weight of the contact element.
  • the contact element comprises the matrix in an amount of 80.0 to 90.0 Wt .-% and the foreign phase in an amount of 10.0 to 20.0 wt .-%, based on the total weight of the contact element.
  • the contact element consists of the matrix in an amount of 75.0 to 99.9 wt .-% and the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element.
  • the contact element consists of the matrix in an amount of 75.0 to 90.0 wt .-% and the foreign phase in an amount of 10.0 to 25.0 wt .-%, based on the total weight of the contact element.
  • the contact element consists of the matrix in an amount of 80.0 to 90.0 wt .-% and the foreign phase in an amount of 10.0 to 20.0 wt .-%, based on the total weight of the contact element.
  • the contact element has a foreign phase distributed in the matrix.
  • the foreign phase comprises a second material selected from the group comprising carbon.
  • the use of carbon as the second material has the advantage that the contact element obtained has a high erosion protection and thus uniform wear of the contacts is ensured.
  • the second material is carbon
  • the second material is carbon and the carbon is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite and mixtures thereof.
  • the second material is chemically different from the first material.
  • the first material is tungsten
  • the second material is selected from the group comprising carbon.
  • the first material of the contact element comprises silver and the second material is selected from the group comprising carbon.
  • the first material of the contact element comprises silver and the second material comprises carbon.
  • the first material of the contact element is made of silver and the second material consists of carbon.
  • the foreign phase is homogeneously distributed in the matrix.
  • the foreign phase distributed in the matrix comprises nanoparticles.
  • nanoparticles particles having particle sizes in the nanometer to micrometer range.
  • the extraneous phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 1000.0 nm.
  • the extraneous phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 750.0 nm or in a range of 100.0 to 500.0 nm.
  • the use of nanoparticles has the advantage that this contributes to a more homogeneous distribution of the foreign phase in the matrix.
  • the contact element has a porosity of ⁇ 1.0 vol .-%, based on the total volume of the contact element on.
  • a low porosity is advantageous, since this leads to the reduction or avoidance of arcing and the contact element obtained has a high erosion protection and thus offers a lower security risk.
  • by grinding graphite on the matrix material a uniform distribution of the graphite in the matrix can be achieved.
  • the contact element has a porosity of ⁇ 0.5 vol .-%, based on the total volume of the contact element on.
  • the contact element has a porosity of ⁇ 0.1% by volume, based on the total volume of the contact element.
  • a porosity of ⁇ 1.0% by volume, preferably ⁇ 0.5% by volume and more preferably ⁇ 0.1% by volume, based on the total volume of the contact element, in the contact element is preferably obtained by producing it in a thermal spraying process , Accordingly, the inventive contact element is preferably a thermally sprayed contact element.
  • the layer thickness of the contact element is in typical areas for these elements.
  • the contact element has a layer thickness of between 100.0 ⁇ m and 5.0 mm.
  • the contact element has a layer thickness between 200.0 ⁇ m and 3.0 mm, more preferably between 250.0 ⁇ m and 2.0 mm and in particular between 300.0 ⁇ m and 1.0 mm.
  • This process offers in comparison to the previously customary melt metallurgical and powder metallurgy process the advantage that a complex production of precursors, such as sintered blocks, and their complex further processing by rolling, drawing and / or extrusion omitted.
  • the contact element can be sprayed directly onto the carrier used, so that the soldering of the contact element on the corresponding carrier or the stamping and embossing for the production of individual parts is eliminated.
  • the present method therefore has only a low production cost.
  • an advantage of sprayed contact elements compared to extruded contact elements is that intermediate annealing steps are eliminated to re-dissolve the strain hardening resulting from high levels of strain and strain to make the material "flowable" again. During the spraying process, these steps are eliminated because the contact element is constructed generatively layer by layer and this is not done by forming steps with tools.
  • step a) comprises providing a first material as described above.
  • a requirement of the present invention is that a first material selected from the group consisting of copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold, and alloys thereof is provided therefrom.
  • the first material comprises molybdenum or copper.
  • the first material comprises silver or gold or palladium.
  • the first material comprises silver or gold, preferably silver.
  • the first material is silver or gold or palladium.
  • the first material is silver or gold, preferably silver.
  • the first material comprises an alloy, wherein the base metal is selected from one of the above-mentioned elements.
  • the alloy preferably comprises a first element selected from the group consisting of copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel and gold as the base metal.
  • the alloy comprises at least one second element or a second compound selected from the group consisting of palladium, tungsten, tungsten carbide, carbide, nickel, cobalt, copper, carbon, silver, and mixtures of these. It should be noted that the first element is chemically different from the second element or the second compound.
  • the first element of the alloy ie, the base metal, silver
  • the second element or compound of the alloy selected from the group comprising palladium, tungsten, tungsten carbide, carbide, nickel, nickel carbide, ruthenium, iridium, silver copper, silver nickel, Cobalt, copper, carbon and mixtures of these.
  • the carbon is preferably selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.
  • the alloy comprises, for example, Ag-Pd, Ag-Cd, AgC, Ag-WC, Ag-WC-C, Ag-Ni, AgNiC, AgCu, Ag-W, Au-Ni, Au-Co, AuAg, AuAgCu, AuAgNi, Pd-Ag, PdCu, PdRu, Ptlr, PtRu, PtW, W-Cu, Cu-W, Cu-Ag, etc.
  • the alloy preferably comprises the first element in an amount of 50.0 to 97.0% by weight, based on the total weight of the alloy.
  • the alloy comprises the first element in an amount of 60.0 to 95.0 wt% or in an amount of 70.0 to 90.0 wt%, based on the total weight of the alloy.
  • the alloy comprises the second element or compound in an amount of from 3.0 to 50.0 weight percent, based on the total weight of the alloy.
  • the alloy comprises the second element or the second compound in an amount of 5.0 to 40.0 wt% or in an amount of 10.0 to 30.0 wt% based on the total weight of the alloy.
  • the matrix comprises an alloy such as AgNi10, AgNi15, AgNi40, AgCu3, AgCu10, AgCu20, AgCu28, AgPd30, AgPd50, PdCu15 or PdCu40.
  • the first material has a certain particle size.
  • the first material in step a) comprises particles with a diameter in a range of 5.0 to 100.0 ⁇ m.
  • the first material in step a) comprises particles with a diameter in the range of 5.0 to 50.0 ⁇ m or of 5.0 to 25.0 ⁇ m.
  • the first material in step a) consists of particles with a diameter in the range of 5.0 to 100.0 ⁇ m.
  • the first material in step a) consists of particles with a diameter in the range of 5.0 to 50.0 ⁇ m or of 5.0 to 25.0 ⁇ m.
  • the first material is provided as a powder.
  • the first material is preferably provided in an amount of from 75.0 to 99.9% by weight, based on the total weight of the contact element.
  • the first material is provided in an amount of 75.0 to 90.0% by weight, based on the total weight of the contact element.
  • the first material is provided in an amount of from 80.0 to 90.0 weight percent, based on the total weight of the contact element.
  • the second material is carbon
  • the second material is carbon, and the carbon is preferably selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.
  • the second material has a certain particle size.
  • the second material in step b) comprises nanoparticles.
  • the second material in step b) comprises particles having a diameter in the range from 100.0 to 1000.0 nm.
  • the second material in step b) comprises particles having a diameter in a range from 100.0 to 750.0 nm or from 100.0 to 500.0 nm.
  • the second material is chemically different from the first material.
  • a material selected from the group consisting of carbon is provided as the second material.
  • the second material is provided in an amount of from 0.1% to 25.0% by weight, based on the total weight of the contact element.
  • the second material is provided in an amount of 10.0 to 25.0 wt%, based on the total weight of the contact element.
  • the second material is provided in an amount of from 10.0 to 20.0% by weight, based on the total weight of the contact element.
  • the second material is provided as a powder.
  • the first material and the second material are provided as a powder.
  • the foreign phase of the second material preferably homogeneous, in the matrix, ie the first material, is distributed. This is achieved, in particular, by bringing the first material into contact with the second material for producing a master alloy comprising the first material and the second material, preferably consisting of the first material and the second material.
  • the first material is preferably achieved by bringing the first material into contact with the second material in step c) by grinding the first material with the second material.
  • milling the first material with the second material may be carried out in a mill suitable therefor, e.g. Attritormühle, ball mill, etc., take place.
  • the second material can be rubbed onto the particles of the first material and thus lead to a homogeneous distribution of foreign phase in the matrix. This is usually done at temperatures of preferably not more than 100 ° C for preferably less than 10 minutes. For example, this occurs at room temperature, i. about 18 to 24 ° C, for preferably less than 10 minutes.
  • the contacting of the first material with the second material in step c) can be carried out by chemical attachment of the second material to the first material via conventional auxiliaries.
  • cladding processes are known in the art.
  • the contacting of the first material with the second material in step c) is used in particular for producing a master alloy comprising the first material and the second material, preferably consisting of the first material and the second material. It should be noted that the received in this step Pre-alloy has a preferably homogeneous distribution of the second material in the first material.
  • the master alloy for the production of the contact element is thermally sprayed.
  • the thermal spraying takes place by cold gas spraying or plasma spraying or flame spraying.
  • the thermal spraying in step d) takes place by flame spraying.
  • flame spraying is by high velocity flame spraying. Flame spraying and high speed flame spraying processes are known in the art. In particular, this occurs at temperatures of preferably more than 800 ° C. In one embodiment of the present invention, the process temperature ⁇ the melting temperature of the powder material to be processed.
  • the thermal spraying in step d) is carried out by plasma spraying.
  • Plasma spray techniques are known in the art. In particular, this happens in the normal or low pressure range.
  • the thermal spraying in the low-pressure region has the advantage that a more homogeneous distribution of the foreign phase, ie of the second material, in the matrix, ie the first material, can be achieved.
  • the plasma spraying process is carried out in the low-pressure range, this is preferably carried out in a range from 0.01 to 1 bar.
  • the plasma is preferably generated by passing a process gas through an arc burning continuously within the plasma torch.
  • the process gas used is preferably a gas selected from the group comprising argon, nitrogen, helium, hydrogen or mixtures of these.
  • a mixture of argon and helium and optionally nitrogen is used as the process gas.
  • a mixture of argon and hydrogen and optionally nitrogen is used as the process gas.
  • the plasma spraying process is carried out at temperatures of preferably more than 800 ° C.
  • the thermal spraying in step d) by cold gas spraying by cold gas spraying.
  • Cold gas spraying processes are known in the art.
  • a protective gas is accelerated to supersonic speed and the master alloy comprising the first material and the second material is injected into the gas jet.
  • the master alloy injected into the gas jet is accelerated to such a high speed that it is not necessary to premelt or reflow the master alloy.
  • the inert gas used is preferably a gas selected from the group comprising nitrogen, helium, compressed air or mixtures of these.
  • compressed air is used as protective gas.
  • the use of compressed air is preferably carried out in a pressure range of 30 to 70 bar, for example in a pressure range of 30 to 60 bar.
  • a mixture of nitrogen and helium is used as protective gas.
  • Cold gas spraying offers several advantages. On the one hand, contact elements with a very low porosity are obtained, preferably with a porosity of ⁇ 0.5 vol.% And more preferably ⁇ 0.1 vol.%, Based on the total volume of the contact element. On the other hand, the contact elements produced in this way have a very dense layer with a high hardness, with which a high adhesion to carrier materials can additionally be achieved. Furthermore, the cold gas spraying avoids oxidation of the first and / or second material in the master alloy. Another advantage of cold gas spraying is that a contact element can be made with a gradual fraction of the second material in the first material.
  • the present invention also relates to the use of the contact element in a high-voltage DC switch.
  • the contact element is used in an electric power drive.
  • the contact element is used in an electric power drive of an aircraft.
  • the formation of plasma flashovers are greatly reduced by the contact element according to the invention or the contact element according to the invention has no plasma flashovers. This reduces the security risk when using the contact element.
  • a contact element not according to the invention comprising a matrix of silver and a foreign phase of stannous oxide distributed in the matrix was prepared as explained below.
  • the visual inspection of the contact element by means of micrograph analysis showed that the contact element had a porosity of ⁇ 1.0% by volume, based on the total volume of the contact element; see also Fig. 1 , The particles of the foreign phase have a diameter of 5-35 microns. Furthermore, an adhesion of about 80 MPa was determined on the carrier tape for the contact element, so that a very high adhesion to the carrier material is given. The adhesion was determined by the AQL method (statistical control) according to Din 50014.

Description

Die vorliegende Erfindung betrifft ein Kontaktelement für Hochspannungs-Gleichstromschalter, ein Verfahren zur Herstellung eines solchen Kontaktelements sowie die Verwendung des Kontaktelements in einem Hochspannungs-Gleichstromschalter.The present invention relates to a contact element for high-voltage DC switches, a method for producing such a contact element and the use of the contact element in a high-voltage DC switch.

Hintergrund der ErfindungBackground of the invention

Kontaktelemente und Verbindungsstellen für Hochspannungs-Gleichstromkreise (100 - 1000 V) sind potentielle Schwachstellen bzgl. Plasmaüberschlägen. Aufgrund der Ausbildung stationärer elektrischer Felder ist eine Plasmaausbildung bei Gleichströmen kritischer im Vergleich zu den alternierenden Wechselstromfeldern, die eine Plasmaausbildung erschweren. Plasmaüberschläge sollten vermieden werden, da diese ein erhebliches Sicherheitsrisiko darstellen und eine Ursache von Kurzschlüssen sein können, mit der Gefahr eines Totalausfalls des elektrischen Systems und ggf. eines Brandschadens. Dieses gilt unabhängig von der jeweiligen Gleichstromquelle (Batterien, Brennstoffzellen oder Wechselstrom-Gleichrichtung).Contact elements and junctions for high-voltage DC circuits (100 - 1000 V) are potential weak points with regard to plasma flashovers. Due to the formation of stationary electric fields, plasma formation at DC currents is more critical compared to the alternating AC fields which make plasma formation more difficult. Plasma flashovers should be avoided, as they present a significant safety risk and may be the cause of short circuits, with the risk of total failure of the electrical system and possibly fire damage. This applies regardless of the respective DC power source (batteries, fuel cells or AC rectification).

Derzeit eingesetzte Kontaktelemente bzw. Verbindungsstellen sind vorwiegend aus Wechselstromkreisen bekannt. Die bekannten Kontaktmaterialien sind z.B. Silber/Zinnoxid, welche sich für die Verwendung bei Strömen bis 50A eignen. Hochstromschalter auf der anderen Seite sind Plasmaschalter, wie diese z.B. in Kraftwerken zum Einsatz kommen. Für Hochspannungs-Gleichstromschalter werden üblicherweise elektronische Schaltelemente verwendet. Es ist jedoch in solchen Kreisen erforderlich zusätzlich mechanische oder plasmabasierte Schalter mit kompletter galvanischer Abtrennung einzusetzen.Currently used contact elements or joints are mainly known from AC circuits. The known contact materials are for example silver / tin oxide, which are suitable for use at currents up to 50A. High-current switches on the other side are plasma switches, such as those used in power plants, for example. For high voltage DC switches usually electronic switching elements are used. However, it is necessary in such circles additionally use mechanical or plasma-based switch with complete galvanic separation.

Aufgabe der vorliegenden Erfindung ist es daher, ein Kontaktelement bzw. eine Verbindungsstelle zur Verfügung zu stellen, das/die in einem Hochspannungs-Gleichstromschalter verwendet werden kann und im Vergleich zu herkömmlichen Kontaktelementen bzw. Verbindungsstellen eine geringere Ausbildung von Plasmaüberschlägen erzielt wird, die zu einem geringeren Sicherheitsrisiko führt. Eine weitere Aufgabe der vorliegenden Erfindung ist es, ein Verfahren zur Herstellung eines solchen Kontaktelements für Hochspannungs-Gleichstromschalter zur Verfügung zu stellen. Insbesondere soll dieses Verfahren einen niedrigen Fertigungsaufwand aufweisen.Object of the present invention is therefore to provide a contact element or a connection point available, which can be used in a high-voltage DC switch and in comparison to conventional contact elements or connection points a smaller formation of plasma flashovers is achieved, the one lower security risk leads. Another object of the present invention is to provide a method of manufacturing such a contact element for high voltage DC switches. In particular, this method should have a low production cost.

Diese Aufgaben werden durch die in den Ansprüchen definierten Gegenstände gelöst. Vorteilhafte Ausführungsformen sind Gegenstand von Unteransprüchen.

  • L. Wang et al., A new Silver-Based Graded Composite as Electrical Contact Material, Key Engineering Materils Vols. 336-338 (2007), Seiten 2616-2618 beschreibt elektrische Schaltelemente basierend auf Silber/Metalloxid-Materialien. Diese Veröffentlichung beschreibt insbesondere die graduelle Verteilung von verschiedenen Oxiden (NiO und SnO2) innerhalb der Silbermatrix.
These objects are achieved by the objects defined in the claims. Advantageous embodiments are the subject of dependent claims.
  • L. Wang et al., A New Silver-Based Graded Composite as Electrical Contact Material, Key Engineering Materils Vols. 336-338 (2007), pages 2616-2618 describes electrical switching elements based on silver / metal oxide materials. In particular, this publication describes the gradual distribution of various oxides (NiO and SnO 2 ) within the silver matrix.

F.L. Miguel et al., Electroless deposition of a AG matrix on semiconducting one-dimensional nanostructures, Thin solid Films Bd. 536, 2. April 2013, Seiten 54-56 beschreibt die Herstellung von Kompositmaterialien bestehend aus eindimensionalen halbleitenden Nanostrukturen die in eine Silbermatrix eingebettet sind. FL Miguel et al., Electroless deposition of a AG matrix on semiconducting one-dimensional nanostructures, Thin solid Films Bd. 536, 2 April 2013, pages 54-56 describes the preparation of composite materials consisting of one-dimensional semiconducting nanostructures embedded in a silver matrix.

Zusammenfassung der ErfindungSummary of the invention

Ein erster Gegenstand der vorliegenden Erfindung ist dementsprechend ein Kontaktelement für Hochspannungs-Gleichstromschalter, das Kontaktelement umfassend

  1. a) eine Matrix aus einem ersten Material ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen, und
  2. b) eine in der Matrix verteilte Fremdphase aus einem zweiten Material, wobei das zweite Material Kohlenstoff ist und ausgewählt ist aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen,
wobei das Kontaktelement eine Porosität von ≤ 1.0 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, aufweist.A first subject of the present invention is accordingly a contact element for high voltage DC switches, comprising the contact element
  1. a) a matrix of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof, and
  2. b) a second phase dispersed in the matrix of a second material, wherein the second material is carbon and is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these,
wherein the contact element has a porosity of ≤ 1.0 vol .-%, based on the total volume of the contact element comprises.

Das erfindungsgemäße Kontaktelement ist zur Verwendung in einem Hochspannungs-Gleichstromschalter geeignet. Ein weiterer Vorteil ist, dass das Kontaktelement eine stark reduzierte Neigung zur Ausbildung von Plasmaüberschlägen bzw. keine Plasmaüberschläge aufweist und so ein geringes Sicherheitsrisiko bietet.The contact element according to the invention is suitable for use in a high-voltage DC switch. Another advantage is that the contact element has a greatly reduced tendency to form plasma flashovers or no plasma flashovers and thus offers a low security risk.

Beispielsweise umfasst das Kontaktelement die Matrix in einer Menge von 75.0 bis 99.9 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, und/oder das Kontaktelement umfasst die Fremdphase in einer Menge von 0.1 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements.For example, the contact element comprises the matrix in an amount of 75.0 to 99.9 wt .-%, based on the total weight of the contact element, and / or the contact element comprises the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of contact element.

Beispielsweise ist die Fremdphase homogen in der Matrix verteilt.For example, the foreign phase is homogeneously distributed in the matrix.

Beispielsweise umfasst die in der Matrix verteilte Fremdphase Nanopartikel mit einem Durchmesser in einem Bereich von 100.0 bis 1000.0 nm, bevorzugt in einem Bereich von 100.0 bis 750.0 nm und weiter bevorzugt in einem Bereich von 100.0 bis 500.0 nm.For example, the foreign phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 1000.0 nm, preferably in a range of 100.0 to 750.0 nm and more preferably in a range of 100.0 to 500.0 nm.

Beispielsweise weist das Kontaktelement eine Porosität von ≤ 0.5 Vol.-% und bevorzug ≤ 0.1 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, auf.For example, the contact element has a porosity of ≦ 0.5 vol.% And preferably ≦ 0.1 vol.%, Based on the total volume of the contact element.

Beispielsweise ist das Kontaktelement ein thermisch gespritztes Kontaktelement.For example, the contact element is a thermally sprayed contact element.

Beispielsweise weist das Kontaktelement eine Schichtdicke zwischen 100.0 µm und 5.0 mm, bevorzugt zwischen 200.0 µm und 3.0 mm, weiter bevorzugt zwischen 250.0 µm und 2.0 mm und insbesondere zwischen 300.0 µm und 1.0 mm auf.For example, the contact element has a layer thickness between 100.0 μm and 5.0 mm, preferably between 200.0 μm and 3.0 mm, more preferably between 250.0 μm and 2.0 mm and in particular between 300.0 μm and 1.0 mm.

Die vorliegende Erfindung stellt ferner ein Verfahren zur Herstellung eines Kontaktelements für Hochspannungs-Gleichstromschalter, das Verfahren umfassend

  1. a) Bereitstellen eines ersten Materials ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen,
  2. b) Bereitstellen eines zweiten Materials, wobei das zweite Material Kohlenstoff ist und ausgewählt ist aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen,
  3. c) Inkontaktbringen des ersten Materials aus Schritt a) mit dem zweiten Material aus Schritt b) zur Herstellung einer Vorlegierung umfassend das erste Material und das zweite Material, und
  4. d) Thermisches Spritzen der in Schritt c) erhaltenen Vorlegierung zur Herstellung des Kontaktelements umfassend eine Matrix aus dem ersten Material und eine in der Matrix verteilte Fremdphase aus dem zweiten Material.
The present invention further provides a method of manufacturing a contact element for high voltage DC switches comprising the method
  1. a) providing a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof,
  2. b) providing a second material, wherein the second material is carbon and is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these,
  3. c) contacting the first material from step a) with the second material from step b) to produce a master alloy comprising the first material and the second material, and
  4. d) thermal spraying of the master alloy obtained in step c) to produce the contact element comprising a matrix of the first material and a third phase of the second material distributed in the matrix.

Beispielsweise umfasst das erste Material in Schritt a) Partikel mit einem Durchmesser in einem Bereich von 5.0 bis 100.0 µm, bevorzugt in einem Bereich von 5.0 bis 50.0 µm und weiter bevorzugt in einem Bereich von 5.0 bis 25.0 µm und/oder das zweite Material in Schritt b) umfasst Nanopartikel mit einem Durchmesser in einem Bereich von 100.0 bis 1000.0 nm, bevorzugt in einem Bereich von 100.0 bis 750.0 nm und weiter bevorzugt in einem Bereich von 100.0 bis 500.0 nm.For example, in step a) the first material comprises particles having a diameter in the range from 5.0 to 100.0 μm, preferably in a range from 5.0 to 50.0 μm and more preferably in a range from 5.0 to 25.0 μm and / or the second material in step b) comprises nanoparticles with a diameter in a range of 100.0 to 1000.0 nm, preferably in one range from 100.0 to 750.0 nm, and more preferably in a range of 100.0 to 500.0 nm.

Das zweite Material ist Kohlenstoff und ist ausgewählt aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen.The second material is carbon and is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.

Beispielsweise wird das erste Material in einer Menge von 75.0 bis 99.9 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt wird und/oder das zweite Material in einer Menge von 0.1 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt.For example, the first material is provided in an amount of 75.0 to 99.9 wt .-%, based on the total weight of the contact element, and / or the second material in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element , provided.

Beispielsweise erfolgt das Inkontaktbringen in Schritt c) durch Vermahlen des ersten Materials mit dem zweiten Material.For example, the contacting in step c) takes place by grinding the first material with the second material.

Beispielsweise erfolgt das thermische Spritzen in Schritt d) durch Kaltgasspritzen oder Plasmaspritzen oder Flammspritzen.For example, the thermal spraying in step d) takes place by cold gas spraying or plasma spraying or flame spraying.

Ebenso betrifft die vorliegende Erfindung die Verwendung des Kontaktelements in einem Hochspannungs-Gleichstromschalter. Beispielsweise in einem elektrischen Leistungsantrieb, bevorzugt in einem Luftfahrzeug.Likewise, the present invention relates to the use of the contact element in a high voltage DC switch. For example, in an electric power drive, preferably in an aircraft.

Detaillierte Beschreibung der ErfindungDetailed description of the invention

Die vorliegende Erfindung betrifft ein Kontaktelement für Hochspannungs-Gleichstromschalter, das Kontaktelement umfassend

  1. a) eine Matrix aus einem ersten Material ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen, und
  2. b) eine in der Matrix verteilte Fremdphase aus einem zweiten Material, wobei das zweite Material Kohlenstoff ist und ausgewählt ist aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen,
wobei das Kontaktelement eine Porosität von ≤ 1.0 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, aufweist.The present invention relates to a contact element for high-voltage DC switch, comprising the contact element
  1. a) a matrix of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof, and
  2. b) a foreign phase distributed in the matrix of a second material, wherein the second material is carbon and is selected from the Group comprising fullerenes, carbon nanotubes, graphene, graphite and mixtures of these,
wherein the contact element has a porosity of ≤ 1.0 vol .-%, based on the total volume of the contact element comprises.

Ein Erfordernis der vorliegenden Erfindung ist demnach, dass das Kontaktelement eine Matrix aus einem ersten Material ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen umfasst.Accordingly, a requirement of the present invention is that the contact element comprises a matrix of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof.

In einer Ausführungsform der vorliegenden Erfindung umfasst, vorzugsweise besteht, das erste Material aus Molybdän oder Kupfer.In one embodiment of the present invention, preferably, the first material comprises molybdenum or copper.

In einer weiteren Ausführungsform der vorliegenden Erfindung umfasst das erste Material Silber oder Gold oder Palladium. Beispielsweise umfasst das erste Material Silber oder Gold, vorzugsweise Silber.In a further embodiment of the present invention, the first material comprises silver or gold or palladium. For example, the first material comprises silver or gold, preferably silver.

In einer Ausführungsform der vorliegenden Erfindung besteht das erste Material aus Silber oder Gold oder Palladium. Beispielsweise besteht das erste Material aus Silber oder Gold, vorzugsweise Silber. Eine Matrix aus einem ersten Material umfassend, vorzugsweise bestehend aus, Silber hat insbesondere den Vorteil, dass ein Kontaktelement umfassend eine solche Matrix eine hohe elektrische Leitfähigkeit aufweist.In one embodiment of the present invention, the first material is silver or gold or palladium. For example, the first material is silver or gold, preferably silver. A matrix comprising a first material, preferably consisting of silver, has the particular advantage that a contact element comprising such a matrix has a high electrical conductivity.

In einer Ausführungsform der vorliegenden Erfindung umfasst das erste Material eine Legierung, wobei das Basismetall ausgewählt ist aus einem der oben genannten Elemente. Dementsprechend umfasst die Legierung vorzugsweise ein erstes Element ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel und Gold als Basismetall. Weiterhin umfasst die Legierung mindestens ein zweites Element oder eine zweite Verbindung ausgewählt aus der Gruppe umfassend Palladium, Wolfram, Wolframcarbid, Carbid, Nickel, Nickelcarbid, Ruthenium, Iridium, SilberKupfer, SilberNickel, Cobalt, Kupfer, Kohlenstoff, Silber und Gemische von diesen. Hierbei ist festzuhalten, dass sich das erste Element chemisch von dem zweiten Element oder der zweiten Verbindung unterscheidet. Beispielsweise, ist das erste Element der Legierung, d.h. das Basismetall, Silber, ist das zweite Element oder die zweite Verbindung der Legierung ausgewählt aus der Gruppe umfassend Palladium, Wolfram, Wolframcarbid, Carbid, Nickel, Nickelcarbid, Ruthenium, Iridium, SilberKupfer, SilberNickel, Cobalt, Kupfer, Kohlenstoff und Gemische von diesen.In one embodiment of the present invention, the first material comprises an alloy, wherein the base metal is selected from one of the above-mentioned elements. Accordingly, the alloy preferably comprises a first element selected from the group consisting of copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel and gold as the base metal. Furthermore, the alloy comprises at least a second element or a second compound selected from the group comprising palladium, tungsten, tungsten carbide, carbide, nickel, nickel carbide, ruthenium, iridium, silver copper, silver nickel, cobalt, copper, carbon, silver, and mixtures of these. It should be noted that the first element is chemically different from the second element or the second compound. For example, the first element of the alloy, ie, the base metal, silver, is the second element or compound of the alloy selected from the group comprising palladium, tungsten, tungsten carbide, carbide, nickel, nickel carbide, ruthenium, iridium, silver copper, silver nickel, Cobalt, copper, carbon and mixtures of these.

Ist das zweite Element der Legierung Kohlenstoff, ist der Kohlenstoff vorzugsweise ausgewählt aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen.When the second element of the alloy is carbon, the carbon is preferably selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.

In einer Ausführungsform der vorliegenden Erfindung umfasst die Matrix eine Legierung wie beispielsweise Ag-Pd, Ag-Cd, AgC, Ag-WC, Ag-WC-C, Ag-Ni, AgNiC, AgCu, Ag-W, Au-Ni, Au-Co, AuAg, AuAgCu, AuAgNi, Pd-Ag, PdCu, PdRu, Ptlr, PtRu, PtW, W-Cu, Cu-W, Cu-Ag etc.In one embodiment of the present invention, the matrix comprises an alloy such as Ag-Pd, Ag-Cd, AgC, Ag-WC, Ag-WC-C, Ag-Ni, AgNiC, AgCu, Ag-W, Au-Ni, Au Co, AuAg, AuAgCu, AuAgNi, Pd-Ag, PdCu, PdRu, Ptlr, PtRu, PtW, W-Cu, Cu-W, Cu-Ag, etc.

Umfasst das erste Material eine Legierung, umfasst die Legierung das erste Element vorzugsweise in einer Menge von 50.0 bis 97.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung. Beispielsweise umfasst die Legierung das erste Element in einer Menge von 60.0 bis 95.0 Gew.-% oder in einer Menge von 70.0 bis 90.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung. Zusätzlich oder alternativ umfasst die Legierung das zweite Element oder die zweite Verbindung in einer Menge von 3.0 bis 50.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung. Beispielsweise umfasst die Legierung das zweite Element oder die zweite Verbindung in einer Menge von 5.0 bis 40.0 Gew.-% oder in einer Menge von 10.0 bis 30.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung.If the first material comprises an alloy, the alloy preferably comprises the first element in an amount of 50.0 to 97.0% by weight, based on the total weight of the alloy. For example, the alloy comprises the first element in an amount of 60.0 to 95.0 wt% or in an amount of 70.0 to 90.0 wt%, based on the total weight of the alloy. Additionally or alternatively, the alloy comprises the second element or compound in an amount of from 3.0 to 50.0 weight percent, based on the total weight of the alloy. For example, the alloy comprises the second element or the second compound in an amount of 5.0 to 40.0 wt% or in an amount of 10.0 to 30.0 wt% based on the total weight of the alloy.

In einer Ausführungsform der vorliegenden Erfindung umfasst die Matrix eine Legierung wie beispielsweise AgNi10, AgNi15, AgNi40, AgCu3, AgCu10, AgCu20, AgCu28, AgPd30, AgPd50, PdCu15 oder PdCu40.In one embodiment of the present invention, the matrix comprises an alloy such as AgNi10, AgNi15, AgNi40, AgCu3, AgCu10, AgCu20, AgCu28, AgPd30, AgPd50, PdCu15 or PdCu40.

Die Menge der Matrix in dem Kontaktelement kann in einem weiten Bereich variieren.The amount of matrix in the contact element can vary within a wide range.

Insbesondere umfasst das Kontaktelement die Matrix in einer Menge von 75.0 bis 99.9 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. Beispielsweise umfasst das Kontaktelement die Matrix in einer Menge von 75.0 bis 90.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. In einer Ausführungsform der vorliegenden Erfindung umfasst das Kontaktelement die Matrix in einer Menge von 80.0 bis 90.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements.In particular, the contact element comprises the matrix in an amount of 75.0 to 99.9 wt .-%, based on the total weight of the contact element. For example, the contact element comprises the matrix in an amount of 75.0 to 90.0 wt .-%, based on the total weight of the contact element. In one embodiment of the present invention, the contact element comprises the matrix in an amount of 80.0 to 90.0 wt .-%, based on the total weight of the contact element.

Zusätzlich oder alternativ, umfasst das Kontaktelement die Fremdphase in einer Menge von 0.1 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. Beispielsweise umfasst das Kontaktelement die Fremdphase in einer Menge von 10.0 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. In einer Ausführungsform der vorliegenden Erfindung umfasst das Kontaktelement die Fremdphase in einer Menge von 10.0 bis 20.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements.Additionally or alternatively, the contact element comprises the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element. For example, the contact element comprises the foreign phase in an amount of 10.0 to 25.0 wt .-%, based on the total weight of the contact element. In one embodiment of the present invention, the contact element comprises the foreign phase in an amount of 10.0 to 20.0 wt .-%, based on the total weight of the contact element.

Beispielsweise umfasst das Kontaktelement die Matrix in einer Menge von 75.0 bis 99.9 Gew.-% und die Fremdphase in einer Menge von 0.1 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. Beispielsweise umfasst das Kontaktelement die Matrix in einer Menge von 75.0 bis 90.0 Gew.-% und die Fremdphase in einer Menge von 10.0 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. In einer Ausführungsform der vorliegenden Erfindung umfasst das Kontaktelement die Matrix in einer Menge von 80.0 bis 90.0 Gew.-% und die Fremdphase in einer Menge von 10.0 bis 20.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements.For example, the contact element comprises the matrix in an amount of 75.0 to 99.9 wt .-% and the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element. For example, the contact element comprises the matrix in an amount of 75.0 to 90.0 wt .-% and the foreign phase in an amount of 10.0 to 25.0 wt .-%, based on the total weight of the contact element. In one embodiment of the present invention, the contact element comprises the matrix in an amount of 80.0 to 90.0 Wt .-% and the foreign phase in an amount of 10.0 to 20.0 wt .-%, based on the total weight of the contact element.

In einer Ausführungsform besteht das Kontaktelement aus der Matrix in einer Menge von 75.0 bis 99.9 Gew.-% und der Fremdphase in einer Menge von 0.1 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. Beispielsweise besteht das Kontaktelement aus der Matrix in einer Menge von 75.0 bis 90.0 Gew.-% und der Fremdphase in einer Menge von 10.0 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements. In einer Ausführungsform der vorliegenden Erfindung besteht das Kontaktelement aus der Matrix in einer Menge von 80.0 bis 90.0 Gew.-% und der Fremdphase in einer Menge von 10.0 bis 20.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements.In one embodiment, the contact element consists of the matrix in an amount of 75.0 to 99.9 wt .-% and the foreign phase in an amount of 0.1 to 25.0 wt .-%, based on the total weight of the contact element. For example, the contact element consists of the matrix in an amount of 75.0 to 90.0 wt .-% and the foreign phase in an amount of 10.0 to 25.0 wt .-%, based on the total weight of the contact element. In one embodiment of the present invention, the contact element consists of the matrix in an amount of 80.0 to 90.0 wt .-% and the foreign phase in an amount of 10.0 to 20.0 wt .-%, based on the total weight of the contact element.

Ein weiteres Erfordenis der vorliegenden Erfindung ist, dass das Kontaktelement eine in der Matrix verteilte Fremdphase aufweist. Dabei umfasst die Fremdphase ein zweites Material ausgewählt aus der Gruppe umfassend Kohlenstoff. Die Verwendung von Kohlenstoff als zweites Material hat den Vorteil, dass das erhaltene Kontaktelement einen hohen Abbrandschutz aufweist und so eine gleichmäßige Abnutzung der Kontakte gewährleistet ist.Another requirement of the present invention is that the contact element has a foreign phase distributed in the matrix. In this case, the foreign phase comprises a second material selected from the group comprising carbon. The use of carbon as the second material has the advantage that the contact element obtained has a high erosion protection and thus uniform wear of the contacts is ensured.

In einer Ausführungsform der vorliegenden Erfindung besteht das zweite Material aus Kohlenstoff.In one embodiment of the present invention, the second material is carbon.

Ist dDas zweite Material ist Kohlenstoff und der Kohlenstoff ist ausgewählt aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen.The second material is carbon and the carbon is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite and mixtures thereof.

Hierbei ist festzuhalten, dass sich das zweite Material chemisch von dem ersten Material unterscheidet. Beispielsweise, ist das erste Material Wolfram, ist das zweite Material ausgewählt aus der Gruppe umfassend Kohlenstoff.It should be noted that the second material is chemically different from the first material. For example, if the first material is tungsten, the second material is selected from the group comprising carbon.

In einer Ausführungsform der vorliegenden Erfindung umfasst das erste Material des Kontaktelements Silber und das zweite Material ist ausgewählt aus der Gruppe umfassend Kohlenstoff. Beispielsweise umfasst das erste Material des Kontaktelements Silber und das zweite Material umfasst Kohlenstoff. Vorzugsweise besteht das erste Material des Kontaktelements aus Silber und das zweite Material besteht aus Kohlenstoff.In one embodiment of the present invention, the first material of the contact element comprises silver and the second material is selected from the group comprising carbon. For example, the first material of the contact element comprises silver and the second material comprises carbon. Preferably, the first material of the contact element is made of silver and the second material consists of carbon.

Für das Kontaktelement ist es besonders vorteilhaft, wenn die Fremdphase homogen in der Matrix verteilt ist.For the contact element, it is particularly advantageous if the foreign phase is homogeneously distributed in the matrix.

Beispielsweise umfasst die in der Matrix verteilte Fremdphase Nanopartikel.For example, the foreign phase distributed in the matrix comprises nanoparticles.

Unter "Nanopartikel" sind gemäß der vorliegenden Erfindung Partikel mit Teilchengrößen im Nanometer- bis Mikrometerbereich zu verstehen. In einer Ausführungsform umfasst die in der Matrix verteilte Fremdphase Nanopartikel mit einem Durchmesser in einem Bereich von 100.0 bis 1000.0 nm. Beispielsweise umfasst die in der Matrix verteilte Fremdphase Nanopartikel mit einem Durchmesser in einem Bereich von 100.0 bis 750.0 nm oder in einem Bereich von 100.0 bis 500.0 nm. Die Verwendung von Nanopartikeln hat den Vorteil, dass dies zu einer homogeneren Verteilung der Fremdphase in der Matrix beiträgt.By "nanoparticles" according to the present invention are meant particles having particle sizes in the nanometer to micrometer range. In one embodiment, the extraneous phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 1000.0 nm. For example, the extraneous phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 750.0 nm or in a range of 100.0 to 500.0 nm. The use of nanoparticles has the advantage that this contributes to a more homogeneous distribution of the foreign phase in the matrix.

Gemäß der vorliegenden Erfindung weist das Kontaktelement eine Porosität von ≤ 1.0 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, auf. Eine geringe Porosität ist vorteilhaft, da dies zur Verringerung oder Vermeidung einer Lichtbogenbildung führt und das erhaltene Kontaktelement einen hohen Abbrandschutz aufweist und so ein geringeres Sicherheitsrisiko bietet. Des Weiteren kann durch Aufmahlen von Graphit auf den Matrixwerkstoff eine gleichmäßige Verteilung des Graphits in der Matrix erzielt werden.According to the present invention, the contact element has a porosity of ≦ 1.0 vol .-%, based on the total volume of the contact element on. A low porosity is advantageous, since this leads to the reduction or avoidance of arcing and the contact element obtained has a high erosion protection and thus offers a lower security risk. Furthermore, by grinding graphite on the matrix material, a uniform distribution of the graphite in the matrix can be achieved.

In einer Ausführungsform der vorliegenden Erfindung weist das Kontaktelement eine Porosität von ≤ 0.5 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, auf. Beispielsweise weist das Kontaktelement eine Porosität von ≤ 0.1 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, auf.In one embodiment of the present invention, the contact element has a porosity of ≦ 0.5 vol .-%, based on the total volume of the contact element on. For example, the contact element has a porosity of ≦ 0.1% by volume, based on the total volume of the contact element.

Eine Porosität von ≤ 1.0 Vol.-%, bevorzugt ≤ 0.5 Vol.-% und weiter bevorzugt ≤ 0.1 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, in dem Kontaktelement wird vorzugsweise erhalten, in dem dieses in einem thermischen Spritzverfahren hergestellt wird. Demnach ist das erfinderische Kontaktelement vorzugsweise ein thermisch gespritztes Kontaktelement.A porosity of ≦ 1.0% by volume, preferably ≦ 0.5% by volume and more preferably ≦ 0.1% by volume, based on the total volume of the contact element, in the contact element is preferably obtained by producing it in a thermal spraying process , Accordingly, the inventive contact element is preferably a thermally sprayed contact element.

Die Schichtdicke des Kontaktelements liegt in für diese Elemente typischen Bereichen. Beispielsweise weist das Kontaktelement eine Schichtdicke zwischen 100.0 µm und 5.0 mm auf. In einer weiteren Ausführungsform weist das Kontaktelement eine Schichtdicke zwischen 200.0 µm und 3.0 mm, weiter bevorzugt zwischen 250.0 µm und 2.0 mm und insbesondere zwischen 300.0 µm und 1.0 mm auf.The layer thickness of the contact element is in typical areas for these elements. For example, the contact element has a layer thickness of between 100.0 μm and 5.0 mm. In a further embodiment, the contact element has a layer thickness between 200.0 μm and 3.0 mm, more preferably between 250.0 μm and 2.0 mm and in particular between 300.0 μm and 1.0 mm.

Die vorliegende Erfindung betrifft auch ein Verfahren zur Herstellung eines Kontaktelements für Hochspannungs-Gleichstromschalter. Das erfindungsgemäße Verfahren zur Herstellung eines Kontaktelements für Hochspannungs-Gleichstromschalter wie vorstehend beschrieben, umfasst mindestens die Schritte:

  1. a) Bereitstellen eines ersten Materials ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen,
  2. b) Bereitstellen eines zweiten Materials, wobei das zweite Material Kohlenstoff ist und ausgewählt ist aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen,
  3. c) Inkontaktbringen des ersten Materials aus Schritt a) mit dem zweiten Material aus Schritt b) zur Herstellung einer Vorlegierung umfassend das erste Material und das zweite Material, und
  4. d) Thermisches Spritzen der in Schritt c) erhaltenen Vorlegierung zur Herstellung des Kontaktelements umfassend eine Matrix aus dem ersten Material und eine in der Matrix verteilte Fremdphase aus dem zweiten Material.
The present invention also relates to a method of manufacturing a contact element for high voltage DC switches. The method according to the invention for producing a contact element for high-voltage DC switches as described above comprises at least the steps:
  1. a) providing a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof,
  2. b) providing a second material, wherein the second material is carbon and is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these,
  3. c) contacting the first material from step a) with the second material from step b) to produce a master alloy comprising the first material and the second material, and
  4. d) thermal spraying of the master alloy obtained in step c) to produce the contact element comprising a matrix of the first material and a third phase of the second material distributed in the matrix.

In einer Ausführungsform der vorliegenden Erfindung besteht das Verfahren zur Herstellung eines Kontaktelements für Hochspannungs-Gleichstromschalter aus den Schritten:

  1. a) Bereitstellen eines ersten Materials ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen,
  2. b) Bereitstellen eines zweiten Materials, wobei das zweite Material Kohlenstoff ist und ausgewählt ist aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen,
  3. c) Inkontaktbringen des ersten Materials aus Schritt a) mit dem zweiten Material aus Schritt b) zur Herstellung einer Vorlegierung umfassend das erste Material und das zweite Material, und
  4. d) Thermisches Spritzen der in Schritt c) erhaltenen Vorlegierung zur Herstellung des Kontaktelements umfassend eine Matrix aus dem ersten Material und eine in der Matrix verteilte Fremdphase aus dem zweiten Material.
In one embodiment of the present invention, the method for producing a contact element for high-voltage DC switches consists of the steps:
  1. a) providing a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof,
  2. b) providing a second material, wherein the second material is carbon and is selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these,
  3. c) contacting the first material from step a) with the second material from step b) to produce a master alloy comprising the first material and the second material, and
  4. d) thermal spraying of the master alloy obtained in step c) to produce the contact element comprising a matrix of the first material and a third phase of the second material distributed in the matrix.

Dieses Verfahren bietet im Vergleich zu den bisher üblichen schmelzmetallurgischen und pulvermetallurgischen Verfahren den Vorteil, dass eine aufwendige Herstellung von Vorprodukten, wie z.B. Sinterblöcken, und deren aufwendige Weiterverarbeitung durch Walzen, Ziehen und/oder Strangpressen entfallen. Des Weiteren kann das Kontaktelement direkt auf dem verwendeten Träger aufgespritzt werden, so dass das Auflöten des Kontaktelements auf dem entsprechenden Träger bzw. das Stanzen und Prägen zur Herstellung von Einzelteilen entfällt. Das vorliegende Verfahren weist daher nur einen geringen Fertigungsaufwand auf. Weiterhin ist ein Vorteil von gespritzten Kontaktelementen im Vergleich zu stranggepressten Kontaktelementen, dass Zwischenglühschritte entfallen, um die Kaltverfestigungen, die durch hohe Verformungs- und Reckgrade entstehen, wieder aufzulösen, damit das Material wieder "fließfähig" wird. Beim Spritzverfahren entfallen diese Schritte, da das Kontaktelement generativ Lage für Lage aufgebaut wird und dies nicht durch Umformschritte mit Werkzeugen erfolgt.This process offers in comparison to the previously customary melt metallurgical and powder metallurgy process the advantage that a complex production of precursors, such as sintered blocks, and their complex further processing by rolling, drawing and / or extrusion omitted. Furthermore, the contact element can be sprayed directly onto the carrier used, so that the soldering of the contact element on the corresponding carrier or the stamping and embossing for the production of individual parts is eliminated. The present method therefore has only a low production cost. Furthermore, an advantage of sprayed contact elements compared to extruded contact elements is that intermediate annealing steps are eliminated to re-dissolve the strain hardening resulting from high levels of strain and strain to make the material "flowable" again. During the spraying process, these steps are eliminated because the contact element is constructed generatively layer by layer and this is not done by forming steps with tools.

In einer Ausführungsform des erfindungsgemäßen Verfahrens umfasst Schritt a) das Bereitstellen eines ersten Materials wie oben beschrieben.In one embodiment of the method according to the invention, step a) comprises providing a first material as described above.

Ein Erfordernis der vorliegenden Erfindung ist demnach, dass ein erstes Material ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel, Gold und Legierungen von diesen bereitgestellt wird.Accordingly, a requirement of the present invention is that a first material selected from the group consisting of copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold, and alloys thereof is provided therefrom.

In einer Ausführungsform der vorliegenden Erfindung umfasst, vorzugsweise besteht, das erste Material aus Molybdän oder Kupfer.In one embodiment of the present invention, preferably, the first material comprises molybdenum or copper.

In einer weiteren Ausführungsform der vorliegenden Erfindung umfasst das erste Material Silber oder Gold oder Palladium. Beispielsweise umfasst das erste Material Silber oder Gold, vorzugsweise Silber.In a further embodiment of the present invention, the first material comprises silver or gold or palladium. For example, the first material comprises silver or gold, preferably silver.

In einer Ausführungsform der vorliegenden Erfindung besteht das erste Material aus Silber oder Gold oder Palladium. Beispielsweise besteht das erste Material aus Silber oder Gold, vorzugsweise Silber.In one embodiment of the present invention, the first material is silver or gold or palladium. For example, the first material is silver or gold, preferably silver.

In einer Ausführungsform der vorliegenden Erfindung umfasst das erste Material eine Legierung, wobei das Basismetall ausgewählt ist aus einem der oben genannten Elemente. Dementsprechend umfasst die Legierung vorzugsweise ein erstes Element ausgewählt aus der Gruppe umfassend Kupfer, Silber, Palladium, Platin, Wolfram, Molybdän, Rhenium, Nickel und Gold als Basismetall. Weiterhin umfasst die Legierung mindestens ein zweites Element oder eine zweite Verbindung ausgewählt aus der Gruppe umfassend Palladium, Wolfram, Wolframcarbid, Carbid, Nickel, Cobalt, Kupfer, Kohlenstoff, Silber und Gemische von diesen. Hierbei ist festzuhalten, dass sich das erste Element chemisch von dem zweiten Element oder der zweiten Verbindung unterscheidet. Beispielsweise, ist das erste Element der Legierung, d.h. das Basismetall, Silber, ist das zweite Element oder die zweite Verbindung der Legierung ausgewählt aus der Gruppe umfassend Palladium, Wolfram, Wolframcarbid, Carbid, Nickel, Nickelcarbid, Ruthenium, Iridium, SilberKupfer, SilberNickel, Cobalt, Kupfer, Kohlenstoff und Gemische von diesen.In one embodiment of the present invention, the first material comprises an alloy, wherein the base metal is selected from one of the above-mentioned elements. Accordingly, the alloy preferably comprises a first element selected from the group consisting of copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel and gold as the base metal. Farther For example, the alloy comprises at least one second element or a second compound selected from the group consisting of palladium, tungsten, tungsten carbide, carbide, nickel, cobalt, copper, carbon, silver, and mixtures of these. It should be noted that the first element is chemically different from the second element or the second compound. For example, the first element of the alloy, ie, the base metal, silver, is the second element or compound of the alloy selected from the group comprising palladium, tungsten, tungsten carbide, carbide, nickel, nickel carbide, ruthenium, iridium, silver copper, silver nickel, Cobalt, copper, carbon and mixtures of these.

Ist das zweite Element der Legierung Kohlenstoff, ist der Kohlenstoff vorzugsweise ausgewählt aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen.When the second element of the alloy is carbon, the carbon is preferably selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.

In einer Ausführungsform der vorliegenden Erfindung umfasst die Legierung beispielsweise Ag-Pd, Ag-Cd, AgC, Ag-WC, Ag-WC-C, Ag-Ni, AgNiC, AgCu, Ag-W, Au-Ni, Au-Co, AuAg, AuAgCu, AuAgNi, Pd-Ag, PdCu, PdRu, Ptlr, PtRu, PtW, W-Cu, Cu-W, Cu-Ag etc.In one embodiment of the present invention, the alloy comprises, for example, Ag-Pd, Ag-Cd, AgC, Ag-WC, Ag-WC-C, Ag-Ni, AgNiC, AgCu, Ag-W, Au-Ni, Au-Co, AuAg, AuAgCu, AuAgNi, Pd-Ag, PdCu, PdRu, Ptlr, PtRu, PtW, W-Cu, Cu-W, Cu-Ag, etc.

Umfasst das erste Material eine Legierung, umfasst die Legierung das erste Element vorzugsweise in einer Menge von 50.0 bis 97.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung. Beispielsweise umfasst die Legierung das erste Element in einer Menge von 60.0 bis 95.0 Gew.-% oder in einer Menge von 70.0 bis 90.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung. Zusätzlich oder alternativ umfasst die Legierung das zweite Element oder die zweite Verbindung in einer Menge von 3.0 bis 50.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung. Beispielsweise umfasst die Legierung das zweite Element oder die zweite Verbindung in einer Menge von 5.0 bis 40.0 Gew.-% oder in einer Menge von 10.0 bis 30.0 Gew.-%, bezogen auf das Gesamtgewicht der Legierung.If the first material comprises an alloy, the alloy preferably comprises the first element in an amount of 50.0 to 97.0% by weight, based on the total weight of the alloy. For example, the alloy comprises the first element in an amount of 60.0 to 95.0 wt% or in an amount of 70.0 to 90.0 wt%, based on the total weight of the alloy. Additionally or alternatively, the alloy comprises the second element or compound in an amount of from 3.0 to 50.0 weight percent, based on the total weight of the alloy. For example, the alloy comprises the second element or the second compound in an amount of 5.0 to 40.0 wt% or in an amount of 10.0 to 30.0 wt% based on the total weight of the alloy.

In einer Ausführungsform der vorliegenden Erfindung umfasst die Matrix eine Legierung wie beispielsweise AgNi10, AgNi15, AgNi40, AgCu3, AgCu10, AgCu20, AgCu28, AgPd30, AgPd50, PdCu15 oder PdCu40.In one embodiment of the present invention, the matrix comprises an alloy such as AgNi10, AgNi15, AgNi40, AgCu3, AgCu10, AgCu20, AgCu28, AgPd30, AgPd50, PdCu15 or PdCu40.

Zusätzlich oder alternativ, weist das erste Material eine bestimmte Partikelgröße auf. Gemäß dieser Ausführungsform umfasst das erste Material in Schritt a) Partikel mit einem Durchmesser in einem Bereich von 5.0 bis 100.0 µm. Beispielsweise umfasst das erste Material in Schritt a) Partikel mit einem Durchmesser in einem Bereich von 5.0 bis 50.0 µm oder von 5.0 bis 25.0 µm.Additionally or alternatively, the first material has a certain particle size. According to this embodiment, the first material in step a) comprises particles with a diameter in a range of 5.0 to 100.0 μm. For example, the first material in step a) comprises particles with a diameter in the range of 5.0 to 50.0 μm or of 5.0 to 25.0 μm.

In einer Ausführungsform der vorliegenden Erfindung besteht das erste Material in Schritt a) aus Partikel mit einem Durchmesser in einem Bereich von 5.0 bis 100.0 µm. Beispielsweise besteht das erste Material in Schritt a) aus Partikel mit einem Durchmesser in einem Bereich von 5.0 bis 50.0 µm oder von 5.0 bis 25.0 µm.In one embodiment of the present invention, the first material in step a) consists of particles with a diameter in the range of 5.0 to 100.0 μm. For example, the first material in step a) consists of particles with a diameter in the range of 5.0 to 50.0 μm or of 5.0 to 25.0 μm.

In einer Ausführungsform der vorliegenden Erfindung wird das erste Material als Pulver bereitgestellt.In one embodiment of the present invention, the first material is provided as a powder.

Das erste Material wird vorzugsweise in einer Menge von 75.0 bis 99.9 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt. Beispielsweise wird das erste Material in einer Menge von 75.0 bis 90.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt. In einer Ausführungsform der vorliegenden Erfindung wird das erste Material in einer Menge von 80.0 bis 90.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt.The first material is preferably provided in an amount of from 75.0 to 99.9% by weight, based on the total weight of the contact element. For example, the first material is provided in an amount of 75.0 to 90.0% by weight, based on the total weight of the contact element. In one embodiment of the present invention, the first material is provided in an amount of from 80.0 to 90.0 weight percent, based on the total weight of the contact element.

In einer Ausführungsform der vorliegenden Erfindung besteht das zweite Material aus Kohlenstoff.In one embodiment of the present invention, the second material is carbon.

Das zweite Material ist Kohlenstoff, und der Kohlenstoff ist vorzugsweise ausgewählt aus der Gruppe umfassend Fullerene, Kohlenstoff-Nanotubes, Graphen, Graphit und Gemische von diesen.The second material is carbon, and the carbon is preferably selected from the group comprising fullerenes, carbon nanotubes, graphene, graphite, and mixtures of these.

Zusätzlich oder alternativ, weist das zweite Material eine bestimmte Partikelgröße auf. Gemäß dieser Ausführungsform umfasst das zweite Material in Schritt b) Nanopartikel. Beispielsweise umfasst das zweite Material in Schritt b) Partikel mit einem Durchmesser in einem Bereich von 100.0 bis 1000.0 nm. Beispielsweise umfasst das zweite Material in Schritt b) Partikel mit einem Durchmesser in einem Bereich von 100.0 bis 750.0 nm oder von 100.0 bis 500.0 nm.Additionally or alternatively, the second material has a certain particle size. According to this embodiment, the second material in step b) comprises nanoparticles. For example, the second material in step b) comprises particles having a diameter in the range from 100.0 to 1000.0 nm. For example, the second material in step b) comprises particles having a diameter in a range from 100.0 to 750.0 nm or from 100.0 to 500.0 nm.

Es ist festzuhalten, dass sich das zweite Material chemisch von dem ersten Material unterscheidet. Beispielsweise, wird Wolfram als erstes Material bereitgestellt, wird als zweites Material ein Material ausgewählt aus der Gruppe umfassend Kohlenstoff bereitgestellt.It should be noted that the second material is chemically different from the first material. For example, when tungsten is provided as the first material, a material selected from the group consisting of carbon is provided as the second material.

Zusätzlich oder alternativ, wird das zweite Material in einer Menge von 0.1 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt. Beispielsweise wird das zweite Material in einer Menge von 10.0 bis 25.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements bereitgestellt. In einer Ausführungsform der vorliegenden Erfindung wird das zweite Material in einer Menge von 10.0 bis 20.0 Gew.-%, bezogen auf das Gesamtgewicht des Kontaktelements, bereitgestellt.Additionally or alternatively, the second material is provided in an amount of from 0.1% to 25.0% by weight, based on the total weight of the contact element. For example, the second material is provided in an amount of 10.0 to 25.0 wt%, based on the total weight of the contact element. In one embodiment of the present invention, the second material is provided in an amount of from 10.0 to 20.0% by weight, based on the total weight of the contact element.

In einer Ausführungsform der vorliegenden Erfindung wird das zweite Material als Pulver bereitgestellt. Vorzugsweise wird das erste Material und das zweite Material als Pulver bereitgestellt.In one embodiment of the present invention, the second material is provided as a powder. Preferably, the first material and the second material are provided as a powder.

Wie bereits oben erwähnt, ist es besonders vorteilhaft, wenn die Fremdphase aus dem zweiten Material, vorzugsweise homogen, in der Matrix, d.h. dem ersten Material, verteilt ist. Dies wird insbesondere dadurch erzielt, dass das erste Material mit dem zweiten Material zur Herstellung einer Vorlegierung umfassend das erste Material und das zweite Material, vorzugsweise bestehend aus dem ersten Material und dem zweiten Material, in Kontakt gebracht wird.As already mentioned above, it is particularly advantageous if the foreign phase of the second material, preferably homogeneous, in the matrix, ie the first material, is distributed. This is achieved, in particular, by bringing the first material into contact with the second material for producing a master alloy comprising the first material and the second material, preferably consisting of the first material and the second material.

Eine Verteilung, vorzugsweise eine homogene Verteilung, der Fremdphase, d.h. dem zweiten Material, in der Matrix, d.h. dem ersten Material, wird vorzugsweise dadurch erzielt, dass das Inkontaktbringen des ersten Materials mit dem zweiten Material in Schritt c) durch Vermahlen des ersten Materials mit dem zweiten Material erfolgt.A distribution, preferably a homogeneous distribution, of the foreign phase, i. the second material, in the matrix, i. The first material is preferably achieved by bringing the first material into contact with the second material in step c) by grinding the first material with the second material.

Verfahren zum Vermahlen von Materialien sind im Stand der Technik bekannt. Beispielsweise kann das Vermahlen des ersten Materials mit dem zweiten Material in einer dafür geeigneten Mühle, wie z.B. Attritormühle, Kugelmühle etc., erfolgen. Mit Hilfe dieses Schrittes kann das zweite Material auf die Partikel des ersten Materials aufgerieben werden und so zu einer homogenen Verteilung Fremdphase in der Matrix führen. Dies geschieht üblicherweise bei Temperaturen von vorzugsweise nicht mehr als 100 °C für vorzugsweise weniger als 10 Minuten. Beispielsweise erfolgt dies bei Raumtemperatur, d.h. ca. 18 bis 24 °C, für vorzugsweise weniger als 10 Minuten.Methods of milling materials are known in the art. For example, milling the first material with the second material may be carried out in a mill suitable therefor, e.g. Attritormühle, ball mill, etc., take place. With the help of this step, the second material can be rubbed onto the particles of the first material and thus lead to a homogeneous distribution of foreign phase in the matrix. This is usually done at temperatures of preferably not more than 100 ° C for preferably less than 10 minutes. For example, this occurs at room temperature, i. about 18 to 24 ° C, for preferably less than 10 minutes.

Alternativ kann das Inkontaktbringen des ersten Materials mit dem zweiten Material in Schritt c) durch chemische Anbindung des zweiten Materials an das erste Material über übliche Hilfsstoffe erfolgen. Solche sogenannten "Cladding-Verfahren" sind im Stand der Technik bekannt.Alternatively, the contacting of the first material with the second material in step c) can be carried out by chemical attachment of the second material to the first material via conventional auxiliaries. Such so-called "cladding processes" are known in the art.

Das Inkontaktbringen des ersten Materials mit dem zweiten Material in Schritt c) dient insbesondere zur Herstellung einer Vorlegierung umfassend das erste Material und das zweite Material, vorzugsweise bestehend aus dem ersten Material und dem zweiten Material. Dabei ist festzuhalten, dass die in diesem Schritt erhaltene Vorlegierung eine vorzugsweise homogene Verteilung des zweiten Materials in dem ersten Material aufweist.The contacting of the first material with the second material in step c) is used in particular for producing a master alloy comprising the first material and the second material, preferably consisting of the first material and the second material. It should be noted that the received in this step Pre-alloy has a preferably homogeneous distribution of the second material in the first material.

Gemäß Schritt d) der vorliegenden Erfindung wird die Vorlegierung zur Herstellung des Kontaktelements thermisch gespritzt. Beispielsweise erfolgt das thermische Spritzen durch Kaltgasspritzen oder Plasmaspritzen oder Flammspritzen.According to step d) of the present invention, the master alloy for the production of the contact element is thermally sprayed. For example, the thermal spraying takes place by cold gas spraying or plasma spraying or flame spraying.

Beispielsweise erfolgt das thermische Spritzen in Schritt d) durch Flammspritzen. In einer Ausführungsform der vorliegenden Erfindung erfolgt das Flammspritzen durch Hochgeschwindigkeits-Flammspritzen. Flammspritzverfahren und Hochgeschwindigkeits-Flammspritzverfahren sind im Stand der Technik bekannt. Insbesondere geschieht dies bei Temperaturen von vorzugsweise mehr als 800°C. In einer Ausführungsform der vorliegenden Erfindung, ist die Prozesstemperatur ≥ der Schmelztemperatur des zu verarbeitenden Pulverwerkstoffes.For example, the thermal spraying in step d) takes place by flame spraying. In one embodiment of the present invention, flame spraying is by high velocity flame spraying. Flame spraying and high speed flame spraying processes are known in the art. In particular, this occurs at temperatures of preferably more than 800 ° C. In one embodiment of the present invention, the process temperature ≥ the melting temperature of the powder material to be processed.

Alternativ erfolgt das thermische Spritzen in Schritt d) durch Plasmaspritzen. Plasmaspritzverfahren sind im Stand der Technik bekannt. Insbesondere geschieht dies im Normal- oder Niederdruckbereich. Das thermische Spritzen im Niederdruckbereich hat den Vorteil, dass eine homogenere Verteilung der Fremdphase, d.h. des zweiten Materials, in der Matrix, d.h. dem ersten Material, erzielt werden kann. Wird das Plasmaspritzverfahren im Niederdruckbereich ausgeführt, erfolgt dies vorzugsweise in einem Bereich von 0.01 bis 1 bar. Das Plasma wird vorzugsweise dadurch erzeugt, dass durch einen innerhalb des Plasmabrenners kontinuierlich brennenden Lichtbogen ein Prozessgas geführt wird. Als Prozessgas wird vorzugsweise ein Gas ausgewählt aus der Gruppe umfassend Argon, Stickstoff, Helium, Wasserstoff oder Gemische von diesen eingesetzt. Beispielsweise wird als Prozessgas eine Mischung aus Argon und Helium und optional Stickstoff verwendet. Alternativ wird als Prozessgas eine Mischung aus Argon und Wasserstoff und optional Stickstoff verwendet. Das Plasmaspritzverfahren erfolgt bei Temperaturen von vorzugsweise mehr als 800 °C.Alternatively, the thermal spraying in step d) is carried out by plasma spraying. Plasma spray techniques are known in the art. In particular, this happens in the normal or low pressure range. The thermal spraying in the low-pressure region has the advantage that a more homogeneous distribution of the foreign phase, ie of the second material, in the matrix, ie the first material, can be achieved. If the plasma spraying process is carried out in the low-pressure range, this is preferably carried out in a range from 0.01 to 1 bar. The plasma is preferably generated by passing a process gas through an arc burning continuously within the plasma torch. The process gas used is preferably a gas selected from the group comprising argon, nitrogen, helium, hydrogen or mixtures of these. For example, a mixture of argon and helium and optionally nitrogen is used as the process gas. Alternatively, a mixture of argon and hydrogen and optionally nitrogen is used as the process gas. The plasma spraying process is carried out at temperatures of preferably more than 800 ° C.

Alternativ erfolgt das thermische Spritzen in Schritt d) durch Kaltgasspritzen. Kaltgasspritzverfahren sind im Stand der Technik bekannt. Dabei wird ein Schutzgas auf Überschallgeschwindigkeit beschleunigt und die Vorlegierung umfassend das erste Material und das zweite Material in den Gasstrahl injiziert. Dies führt dazu, dass die in den Gasstrahl injizierte Vorlegierung auf eine so hohe Geschwindigkeit beschleunigt wird, dass ein vorangehendes An- oder Aufschmelzen der Vorlegierung nicht erforderlich ist. Als Schutzgas wird vorzugsweise ein Gas ausgewählt aus der Gruppe umfassend Stickstoff, Helium, Druckluft oder Gemische von diesen eingesetzt. Beispielsweise wird als Schutzgas Druckluft verwendet. Die Verwendung von Druckluft erfolgt vorzugsweise in einem Druckbereich von 30 bis 70 bar, beispielsweise in einem Druckbereich von 30 bis 60 bar. Alternativ wird als Schutzgas eine Mischung aus Stickstoff und Helium verwendet. Das Kaltgasspritzen bietet mehrere Vorteile. Zum einen werden Kontaktelemente mit einer sehr geringen Porosität erhalten, vorzugsweise mit einer Porosität von ≤ 0.5 Vol.-% und weiter bevorzugt ≤ 0.1 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements. Zum anderen weisen die so hergestellten Kontaktelemente eine sehr dichte Schicht mit einer hohen Härte auf, mit denen zusätzlich eine hohe Haftung auf Trägerwerkstoffen erzielt werden kann. Des Weiteren wird durch das Kaltgasspritzen eine Oxidation des ersten und/oder zweiten Materials in der Vorlegierung vermieden. Ein weiterer Vorteil des Kaltgasspritzens ist, dass ein Kontaktelement mit einem graduellen Anteil des zweiten Materials in dem ersten Material hergestellt werden kann.Alternatively, the thermal spraying in step d) by cold gas spraying. Cold gas spraying processes are known in the art. In this case, a protective gas is accelerated to supersonic speed and the master alloy comprising the first material and the second material is injected into the gas jet. As a result, the master alloy injected into the gas jet is accelerated to such a high speed that it is not necessary to premelt or reflow the master alloy. The inert gas used is preferably a gas selected from the group comprising nitrogen, helium, compressed air or mixtures of these. For example, compressed air is used as protective gas. The use of compressed air is preferably carried out in a pressure range of 30 to 70 bar, for example in a pressure range of 30 to 60 bar. Alternatively, a mixture of nitrogen and helium is used as protective gas. Cold gas spraying offers several advantages. On the one hand, contact elements with a very low porosity are obtained, preferably with a porosity of ≦ 0.5 vol.% And more preferably ≦ 0.1 vol.%, Based on the total volume of the contact element. On the other hand, the contact elements produced in this way have a very dense layer with a high hardness, with which a high adhesion to carrier materials can additionally be achieved. Furthermore, the cold gas spraying avoids oxidation of the first and / or second material in the master alloy. Another advantage of cold gas spraying is that a contact element can be made with a gradual fraction of the second material in the first material.

Aufgrund der Vorteile, die das erfindungsgemäße Kontaktelement bietet, betrifft die vorliegende Erfindung auch die Verwendung des Kontaktelements in einem Hochspannungs-Gleichstromschalter. In einer Ausführungsform der vorliegenden Erfindung wird das Kontaktelement in einem elektrischen Leistungsantrieb verwendet. Beispielsweise wird das Kontaktelement in einem elektrischen Leistungsantrieb eines Luftfahrzeugs verwendet. Wie vorstehend ausgeführt kann durch das erfindungsgemäße Kontaktelement die Ausbildung von Plasmaüberschlägen stark reduziert werden bzw. das erfindungsgemäße Kontaktelement weist keine Plasmaüberschläge auf. Dadurch wird das Sicherheitsrisiko bei Verwendung des Kontaktelements reduziert.Due to the advantages offered by the contact element according to the invention, the present invention also relates to the use of the contact element in a high-voltage DC switch. In one embodiment of the present invention, the contact element is used in an electric power drive. For example, the contact element is used in an electric power drive of an aircraft. As stated above the formation of plasma flashovers are greatly reduced by the contact element according to the invention or the contact element according to the invention has no plasma flashovers. This reduces the security risk when using the contact element.

BeispieleExamples

Ein Kontaktelement nicht gemäß der Erfindung umfassend eine Matrix aus Silber und eine in der Matrix verteilte Fremdphase aus Zinn(II)-oxid wurde wie nachfolgend erläutert hergestellt.A contact element not according to the invention comprising a matrix of silver and a foreign phase of stannous oxide distributed in the matrix was prepared as explained below.

80 Vol.-% Silberpulver und 20 Vol.-% Zinn(II)-oxidpulver, bezogen auf das Gesamtvolumen der Mischung, wurden trocken durch Vermahlen gemischt. Die Mischung wurde mit Hilfe einer Kaltgas-Spritzanlage mit 40 bar und Stickstoff als Prozessgas auf ein Kontaktträgerband aus Kupfer aufgespritzt. Das Kupferträgerband wurde vor dem Aufspritzen der Silber/Zinn(II)-oxid-Mischung zunächst geschliffen und dann gebürstet. Das Aufspritzen der Silber/Zinn(II)-oxid-Mischung als Kontaktelement erfolgte zur homogeneren Verteilung der Fremdphase, d.h. Zinn(II)-oxid, in der Silbermatrix unter Vakuum. Das erhaltene Kontaktelement wurde anschließend ausgestanzt oder geprägt.80% by volume of silver powder and 20% by volume of tin (II) oxide powder, based on the total volume of the mixture, were mixed dry by grinding. The mixture was sprayed onto a contact carrier strip made of copper using a cold gas injection system with 40 bar and nitrogen as the process gas. The copper carrier tape was first ground and then brushed before spraying the silver / tin (II) oxide mixture. The spraying of the silver / tin (II) oxide mixture as a contact element was carried out for more homogeneous distribution of the foreign phase, i. Tin (II) oxide, in the silver matrix under vacuum. The contact element obtained was then punched out or embossed.

Die visuelle Überprüfung des Kontaktelementes mittels Schliffbildanalyse ergab, dass das Kontaktelement eine Porosität von ≤ 1.0 Vol.-%, bezogen auf das Gesamtvolumen des Kontaktelements, aufwies; siehe auch Fig. 1. Die Partikel der Fremdphase haben einen Durchmesser von 5-35 µm. Ferner wurde für das Kontaktelement eine Haftung von ca. 80 MPa auf dem Trägerband ermittelt, so dass eine sehr hohe Haftung auf dem Trägerwerkstoff gegeben ist. Die Haftung wurde mittels der AQL-Methode (statistische Kontrolle) gemäß Din 50014 bestimmt.The visual inspection of the contact element by means of micrograph analysis showed that the contact element had a porosity of ≦ 1.0% by volume, based on the total volume of the contact element; see also Fig. 1 , The particles of the foreign phase have a diameter of 5-35 microns. Furthermore, an adhesion of about 80 MPa was determined on the carrier tape for the contact element, so that a very high adhesion to the carrier material is given. The adhesion was determined by the AQL method (statistical control) according to Din 50014.

Claims (14)

  1. Contact element for a high-voltage direct-current switches, the contact element comprising
    a) a matrix of a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof, and
    b) a foreign phase, distributed in the matrix, of a second material, the second material being carbon and being selected from the group comprising fullerene, carbon nanotubes, graphene, graphite and mixtures thereof,
    wherein the contact element has a porosity of ≤ 1.0 % by volume based on the total volume of the contact element.
  2. Contact element according to claim 1, wherein the contact element comprises the matrix in an amount of 75.0 to 99.9 % by weight based on the total weight of the contact element, and/or the contact element comprises the foreign phase in an amount of 0.1 to 25.0 % by weight based on the total weight of the contact element.
  3. Contact element according to either claim 1 or claim 2, wherein the foreign phase is homogeneously distributed in the matrix.
  4. Contact element according to any of the preceding claims, wherein the foreign phase distributed in the matrix comprises nanoparticles having a diameter in a range of 100.0 to 1000.0 nm, preferably in a range of 100.0 to 750.0 nm and more preferably in a range of 100.0 to 500.0 nm.
  5. Contact element according to any of the preceding claims, wherein the contact element has a porosity of ≤ 0.5 % by volume and preferably ≤ 0.1 % by volume based on the total volume of the contact element.
  6. Contact element according to any of the preceding claims, wherein the contact element is a thermally sprayed contact element.
  7. Contact element according to any of the preceding claims, wherein the contact element has a layer thickness between 100.0 µm and 5.0 mm, preferably between 200.0 µm and 3.0 mm, more preferably between 250.0 µm and 2.0 mm and in particular between 300.0 µm and 1.0 mm.
  8. Method producing a contact element for a high-voltage direct-current switch, the method comprising
    a) providing a first material selected from the group comprising copper, silver, palladium, platinum, tungsten, molybdenum, rhenium, nickel, gold and alloys thereof,
    b) providing a second material, the second material being carbon and being selected from the group comprising fullerene, carbon nanotubes, graphene, graphite and mixtures thereof,
    c) bringing the first material from step a) into contact with the second material from step b) to produce a master alloy comprising the first material and the second material, and
    d) thermally spraying the master alloy obtained in step c) to produce the contact element comprising a matrix of the first material and a foreign phase, distributed in the matrix, of the second material.
  9. Method according to claim 8, wherein the first material in step a) comprises particles having a diameter in a range of 5.0 to 100.0 µm, preferably in a range of 5.0 to 50.0 µm and more preferably in a range of 5.0 to 25.0 µm, and/or the second material in step b) comprises nanoparticles having a diameter in a range of 100.0 to 1000.0 nm, preferably in a range of 100.0 to 750.0 nm and more preferably in arrange of 100.0 to 500.0 nm.
  10. Method according to either of the preceding claims 8 or 9, wherein the first material is provided in an amount of 75.0 to 99.9 % by weight based on the total weight of the contact element, and/or the second material is provided in an amount of 0.1 to 25.0 % by weight based on the total weight of the contact element.
  11. Method according to any of the preceding claims 8 to 10, wherein the materials are brought into contact in step c) by grinding the first material together with the second material.
  12. Method according to any of claims 8 to 11, wherein the thermal spraying in step d) is provided by cold-gas spraying or plasma spraying.
  13. Use of a contact element according to any of claims 1 to 7 in a high-voltage direct-current switch.
  14. Use according to claim 13 in an electrical power drive.
EP14002972.9A 2013-09-11 2014-08-28 Contact materials for use in on-board high-voltage direct-current systems Active EP2849185B1 (en)

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