This application claims priority from Japanese Application JP2003-147803, filed on May 26, 2003.
1. Field of the Invention
The present invention relates to a contact construction for DC loads and a switching device having the contact construction for DC loads.
2. Description of the Related Art
In existing switching devices such as relays having a stationary contact and a movable contact which are opposite to each other, silver-tin oxide-indium oxide-based contacts (hereinafter referred to as the AgSnO2In2O3-based contacts), silver-tin oxide-based contacts (hereinafter referred to as the AgSnO2-based contacts), silver-nickel-based contacts (hereinafter referred to as the AgNi-based contacts), silver-zinc oxide-based contacts (hereinafter referred to as AgZnO-based contacts) have been used as contact materials. In general, each of the contact materials is individually used as a contact material common to a movable contact and a stationary contact. In such switching devices, attempts to cope with higher voltages have recently been made. In general, means such as enlarged contact-to-contact gaps are needed to realize switching devices capable of coping with higher voltages, but if switching devices having reduced sizes are to be realized, the contact-to-contact gaps are impossible to enlarge beyond approximately 1 mm. However, if the contact-to-contact gap of a switching device is simply set to approximately 1 mm, an arc remains for a comparatively long time, and if the arc continues to remain for a period of, for example, 100 ms or longer, the problem that cut-off failure occurs in the switching device arises.
Another problem occurring when an arc remains for a long period is that the surfaces of contacts of a switching device are heated to high temperatures so that locking or deposition occurs between the contacts or burning and destruction of the contacts occur to impair the life of the switching device. This problem is particularly remarkable in switching devices of the type which cut off high-capacitance loads. Locking is the phenomenon that a depression and a projection which are formed by the transfer of a contact material from one of the contacts to the other are caught to disable or delay the release of the movable contact from the stationary contact. Deposition is the phenomenon that owing to the melting of the contact surfaces, the movable contact and the stationary contact stick to each other, so that their release is disabled or delayed.
To achieve a long life of the switching device, there are various available methods such as a method of improving the heat resistance of the contacts as by enlarging the contacts and contact parts to which the contacts are secured and increasing the heat capacity of the switching device, a method of enlarging the contact-to-contact gaps to prevent abnormal continuation of an arc, and a method in which release force acting between the contacts is set to a large force so that even if the contacts adhere to each other by deposition, they can be peeled off each other. However, these methods cannot satisfactorily achieve a long life of the switching device, and incur an increase in the size and/or cost of the switching device.
To cope with this problem, it is known to use a method of producing a magnetic field between the contacts by means of a magnetic unit such as a permanent magnet. If a magnetic field is produced between the contacts, a Lorentz force acts on an arc, and the arc is significantly driven (travels) between the contacts in accordance with the Fleming's left hand rule. Accordingly, the concentration of the arc on the surfaces of the contacts is avoided and the arc is easily cut, so that a long life can be achieved.
However, even the above-mentioned method is incapable of achieving a sufficiently long life of a switching device such as a power relay which cuts off a high-capacitance load of, for example, approximately 42 V DC and 10 A. In addition, there occurs the new problem that the contact resistance increases with the repetition of switching. There is also the problem that the increase of the contact resistance causes Joule loss during energization. As the magnetic flux density of a magnetic field is increased, the life of the switching device is extended to some extent, but increases in the size and cost of the magnetic unit cannot be avoided. As a result, it has not yet been possible to achieve reductions in the size and cost of the switching device.
The invention has been made in view of the above-mentioned problems, and provides the switching device having a contact construction which, even in the case of a high-capacitance load, can be repeatedly cut off for a long term without causing any problems such as cut-off failure, locking and deposition due to an abnormal continuation of an arc between the contacts, burning and destruction of the contacts, and an increase in contact resistance, and whose reductions in size and cost can be achieved. The invention also provides a switching device having the above-mentioned contact construction.
The invention provides, therefore, a contact construction for DC loads which includes: a stationary contact and a movable contact that are opposite to each other; and a magnetic unit which applies a magnetic field acting in a direction orthogonal to a moving direction of the movable contact, to a space in which both contacts exist, and one of the stationary contact and the movable contact is used as an anode-side contact, and the other is used as a cathode-side contact. In the contact construction for DC loads, the anode-side contact is made of an AgSnO2-based alloy which contains at least Ag and SnO2, and the cathode-side contact is made of one of an AgNi-based alloy which contains at least Ag and Ni and an AgCuO-based alloy which contains Ag and CuO. The invention also provides a switching device having the above-mentioned contact construction.
The term “Ag-xM” used herein means an alloy which is made of Ag and M and in which the M content is x wt. % of the total weight of the alloy. For example, the term “Ag-12.2CuO” means an alloy which is made of Ag and CuO and in which the CuO content is 12.2 wt. % of the total weight of the alloy. The term “Ag-8.2SnO2-5.8In2O3” means an alloy which is made of Ag, SnO2 and In2O3 and in which the SnO 2 content and the In2O3 content are 8.2 wt. % and 5.8 wt. % of the total weight of the alloy, respectively.
The invention will become more readily appreciated and understood from the following detailed description of preferred embodiments of the invention when taken in conjunction with the accompanying drawings, in which:
A contact construction for DC loads according to the invention has a switching function capable of opening and closing an electrical circuit to which a direct current load is applied, and constitutes part of a switching device for DC loads such as a relay or a switch. The contact construction will be described below in detail with reference to the accompanying drawings.
The contact construction for DC loads according to the invention includes, as shown in
In the contact construction according to the invention, one of the stationary contact 1 and the movable contact 2 is used as an anode-side contact, while the other is used as a cathode-side contact, and generally, the stationary contact 1 is used as an anode-side contact and the movable contact 2 is used as a cathode-side contact. As shown in
When the stationary contact 1 and the movable contact 2 are to be used as the anode-side contact and the cathode-side contact, respectively, the contact construction may be connected in use so that the stationary contact 1 is coupled to the anode side of a DC power source and the movable contact 2 is coupled to the cathode side of the DC power source.
In either case where the stationary contact 1 or the movable contact 2 is used as the anode-side contact, in the invention, the anode-side contact is made of an AgSnO2-based alloy, and the cathode-side contact is made of an AgNi-based alloy or an AgCuO-based alloy. Namely, in the case where the stationary contact 1 is used as the anode-side contact and the movable contact 2 is used as the cathode-side contact, the stationary contact 1 is made of an AgSnO2-based alloy and the movable contact 2 is made of an AgNi-based alloy or an AgCuO-based alloy. In the case where the movable contact 2 is used as the anode-side contact and the stationary contact 1 is used as the cathode-side contact, the movable contact 2 is made of an AgSnO2-based alloy, and the stationary contact 1 is made of an AgNi-based alloy or an AgCuO-based alloy. In the invention, since the above-mentioned materials of the anode-side contact and the cathode-side contact are used in combination, an abnormal continuation of an arc generated between the contacts 1 and 2 can be prevented and, in addition, the contact resistance therebetween can be decreased, even if the load capacitance is comparatively large and the magnetic flux density of an applied magnetic field is comparatively small. Accordingly, it is possible to prevent, for a long time, various problems such as cut-off failure, locking and deposition between the contacts, burning and destruction of the contacts and an increase in the contact resistance, and it is also possible to easily achieve reductions in size and in cost of the contact construction.
The AgSnO2-based alloy which constitutes the anode-side contact is an alloy which contains at least Ag and SnO2, preferably an AgSnO2In2O3-based alloy which further contains In2O3. The AgSnO2-based alloy may contain other elements (metals or metal oxides) as long as the objects of the invention can be achieved.
The total content of the metal oxides (for example, SnO2 and In2O3) contained in the AgSnO2-based alloy, particularly, the AgSnO2In2O3-based alloy is 8–15 wt. %, preferably 12–15 wt. %, of the total weight of the AgSnO2-based alloy. If the total content of the metal oxides is excessively small, the transfer-resistance characteristics of the contacts decrease. For example, the amount of transfer when the contact construction is switched by 100,000 times under load conditions similar to those of examples to be described later averages 8.1 mg for contacts made of only Ag and 2.7 mg for contacts made of an Ag-8.2SnO2-5.8In2O3 alloy. On the other hand, if the total content of the metal oxides is excessively large, the alloy becomes difficult to form into contacts.
The content of SnO2 in the AgSnO2-based alloy, in particular the AgSnO2In2O3-based alloy, is 6–10 wt. %, preferably 7–10 wt. %, of the total weight of the AgSnO2-based alloy. If the Sn2O3 content is excessively small, the transfer-resistance characteristics of the contacts decrease. On the other hand, if the Sn2O3 content is excessively large, the contact resistance becomes unstable and the alloy becomes difficult to form into contacts.
The content of In2O3 in the AgSnO2In2O3-based alloy in particular is 2–8 wt. %, preferably 5–7 wt. %, of the total weight of the AgSnO2In2O3-based alloy. If the In2O3 content is excessively small, the contact resistance becomes unstable. On the other hand, if the In2O3 content is excessively large, the transfer-resistance characteristics of the contacts decrease. For example, the amount of transfer when the contact construction is switched by 100,000 times under load conditions similar to those of the examples to be described later averages 2.7 mg for contacts made of an Ag-8.2SnO2-5.8In2O3 alloy and 5.6 mg for contacts made of an Ag-3.8SnO2-10.2In2O3 alloy.
The AgNi-based alloy which constitutes the cathode-side contact is an alloy containing at least Ag and Ni, preferably an AgNiC-based alloy further containing C from the point of view of deposition resistance of the contacts. The AgNi-based alloy may contain other elements (metals or metal oxides) as long as the objects of the invention can be achieved.
The content of Ni in the AgNi alloy, particularly in the AgNiC-based alloy, is 8–12 wt. %, preferably 9–11 wt. %, of the total weight of the AgNi-based alloy. If the Ni content is excessively small, the transfer resistance characteristics of the contacts decrease. For example, the amount of transfer when the contact construction is switched by 100,000 times under load conditions similar to those of the examples to be described later averages 8.1 mg for contacts made of only Ag and 7.2 mg for contacts made of an Ag-10Ni-0.5C alloy. On the other hand, if the Ni content is excessively large, Ni easily condenses, and easily precipitates on the surfaces of the contacts. When this Ni undergoes a chemical change such as oxidation, the contact resistance increases (electrical resistivity—Ag: 1.63×10−8 Ωm and NiO: 1011 Ωm).
The content of C in the AgNiC-based alloy in particular is not greater than 2 wt. %, preferably not greater than 1 wt. %, of the total weight of the AgNiC-based alloy. On the other hand, if the C content is excessively large, manufacturing becomes difficult.
Another AgCuO-based alloy which can constitute the cathode-side contact is an alloy containing at least Ag and CuO, and may also contain other elements (metals or metal oxides) as long as the objects of the invention can be achieved.
The content of CuO in the AgCuO-based alloy is 10–14 wt. %, preferably 11–13 wt. %, of the total weight of the AgCuO-based alloy. If the CuO content is excessively small, the transfer resistance characteristics of the contacts decrease. For example, the amount of transfer when the contact construction is switched by 100,000 times under load conditions similar to those of the examples to be described later averages 8.1 mg for contacts made of only Ag and 6.5 mg for contacts made of an Ag-12.2CuO alloy. On the other hand, if the CuO content is excessively large, the alloy becomes difficult to form into contacts.
The AgSnO2-based alloy and the AgCuO-based alloy may be manufactured by any known method that ensures that they can contain their individual components in the respective predetermined amounts, and can be manufactured by, for example, a powder metallurgy method or an internal oxidation method.
The AgNi-based alloy can be manufactured by the powder metallurgy method.
Materials which constitute the stationary contact part 11 and the movable contact part 12 are not particularly limitative, and it is preferable to use materials comparatively high in electrical conductivity, for example, electrolytic copper as the stationary contact part 11 and beryllium copper as the movable contact part 12.
The contact construction according to the invention further includes the magnetic unit 3. As shown in
The magnetic unit 3 is not particularly limitative, and may use any material that can produce a comparatively weak magnetic field in the central portion between both contacts 1 and 2 when the contacts 1 and 2 are released from each other, for example, a comparatively weak magnetic field with a magnetic flux density of not lower than approximately 5 mT. Specific usable examples are a permanent magnet and an electromagnet. In the invention, since the magnetic unit 3 is only capable of producing a comparatively weak magnetic field as described above, the permanent magnet which is easy to miniaturize is the most useful. A preferable magnetic flux density in the central portion between the contacts 1 and 2 when both contacts 1 and 2 are released from each other is not lower than 10 mT.
An operating mechanism for releasing the contacts 1 and 2 from each other in the above-mentioned contact construction according to the invention will be described below in brief with reference to
First, when the stationary contact 1 and movable contact 2 start releasing from each other (
In order to improve the efficiency of driving of the arc 4 by the magnetic field, it is preferable to enlarge the gap between the contacts 1 and 2 in the direction in which to magnetically drive the arc 4, as by making the periphery of each of the stationary contact 1 and the movable contact 2 thinner than the central portion of the same.
The invention also relates to a switching device. The switching device according to the invention is intended for DC loads, and may have any construction that is similar to the above-described contact construction for DC loads. The switching device may be, for examples, a relay and a switch.
In the contact construction and the switching device according to the invention, even if the release force between the movable contact and the stationary contact is set to 0.1–0.5 N and the contact force therebetween is set to a comparatively low value of 0.1–1 N, the objects of the invention can be achieved. The release force is the driving force required for the movable contact to be released from the stationary contact, and is one of initial settings which are set in advance. The contact force is the driving force required for the movable contact to be held in contact with the stationary contact, and is one of the initial settings which are set in advance.
The contact construction and the switching device according to the invention can be applied to any direct current electrical circuits for electrical and electronic devices from controls for electronic equipment of vehicles such as automobiles to heavy electrical equipment for factories, and for example it is effective in switching direct current electrical circuits under a high load condition such as of a current value of 5 to 50A, in particular 10A or more.
As each of embodiments 1 and 2 as well as comparative examples 1 to 9, a stationary contact and a movable contact which were made of the contact materials listed in the following table were respectively fixed to a stationary contact part and a movable contact part, and the obtained component was incorporated into a magnetic driving relay. Electrolytic copper (sectional area: 1.32 mm2) and beryllium copper (sectional area: 0.45 mm2) were used as the materials of the stationary contact part and the movable contact part, respectively. The dimensions of the stationary contact, the movable contact, the stationary contact part and the movable contact part and other structures of the relay were similar to those of a small-sized relay made by OMRON corporation.
(Electrical Life Test)
Each of the relays was connected so that the stationary contact and the movable contact assumed the predetermined polarities noted in the table, and was evaluated under the following conditions:
Test conditions: 42 V DC, 10 A, resistance load
Magnetic flux density applied at the center of contact portion: 5 mT
Contact-to-contact gap: 1 mm
Contact force: 0.29 N
Release force: 0.15 N
In the evaluation, each of the relays was switched by 100,000 times, and the relays which did not suffer problems such as an abnormal continuation of arc between the contacts for 100 ms or more, locking and deposition as well as burning and destruction of the contacts are marked “o”. In each of the relays marked “x”, there occurred a problem such as cut-off failure due to abnormal continuation of an arc or a problem such as locking or deposition, or burning or destruction of the contacts.
(Contact Resistance)
The maximum values of the contact resistances of the respective relays obtained during the electrical life test are listed in the table. The contact resistances of not higher than 25 mΩ are marked “o”, the contact resistances of not higher than 30 mΩ are marked “Δ”, and the contact resistances of higher than 30 mΩ are marked “x”. The contact resistances of not lower than “Δ” are within a range having no practical problem, and the values marked “o” are preferable.
In the table, Ag-8.2SnO2-5.8In2O3 was used as AgSnO2In2O3, Ag-8ZnO was used as AgZnO, Ag-10Ni-0.5C was used as AgNiC, and Ag-12.2CuO was used as AgCuO. None of the contact materials contains any metals and metal oxides other than the listed metals and metal oxides.
The contact construction and the switching device according to the invention, even if a load capacitance is comparatively large and the magnetic flux density of an applied magnetic field is comparatively small, can be repeatedly cut off for a long term without causing any problems such as cut-off failure, locking and deposition due to an abnormal continuation of an arc between the contacts, burning and destruction of the contacts, and an increase in contact resistance. In addition, it is possible to easily achieve reductions in the size and cost of contact constructions and switching devices.
Number | Date | Country | Kind |
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2003-147803 | May 2003 | JP | national |
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Number | Date | Country | |
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20040239457 A1 | Dec 2004 | US |