CN1123053C - 烧结电极及其制造方法 - Google Patents

烧结电极及其制造方法 Download PDF

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CN1123053C
CN1123053C CN97192363.9A CN97192363A CN1123053C CN 1123053 C CN1123053 C CN 1123053C CN 97192363 A CN97192363 A CN 97192363A CN 1123053 C CN1123053 C CN 1123053C
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metal
electrode
powder
sintered electrode
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CN1211341A (zh
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D·弗罗姆
B·阿尔特曼
W·格拉瑟尔
P·沙德
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PATRA Patent Treuhand Munich
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Abstract

本文涉及由高熔点金属(例如钨)形成的烧结电极，该电极由一定颗粒度的球状金属粉末制成。其平均粒度为5-70μm。其粒度分布围绕平均值的最大波动为20%。

Description

烧结电极及其制造方法
相互参照
本申请与平行申请97P5568有关联。
技术领域
本发明涉及权利要求1总概念中的烧结电极。而且涉及高压放电灯的烧结电极，例如金属卤化物灯或钠高压放电灯的烧结电极。
技术状况
从DE-OS 4206909获知一种真空电子管用热离子发射阴极元件，该元件由平均粒变为1μm以下的球形颗粒制成。烧结电极总体积的5-90％由未充填的开放孔组成。相邻颗粒之间的距离小于1μm。
从US-A 3 244 929获知一种烧结电极，其发射材料的成分除钨以外还含有如铝、钡、钙或钍的氧化物。该烧结体安置在由实心材料制成的固定棒上。
从US-A 5 418 070获知一种阴极，该阴极由一种多孔钨-基体组成，在其孔中嵌入发射材料。这些孔是通过用液态铜充满基体的坯体，然后重新将铜溶出而形成的。此方法的缺点在于孔的形状是不规则的，其特性亦不是确定的。制造过程既复杂又费时。
从DD-PS 292 764获知一种由钨和钍的氧化物或碱土金属氧化物的混合物组成的金属陶瓷烧结体。其中烧结体的孔隙率通过在制造过程中应用一种粘合剂调节。金属陶瓷粉末的粒度为80-550μm。
已知的烧结电极存在的大问题是，其孔隙率在使用期内不能保持恒定，因为由于电极运行期间的高温度负荷使烧结过程重新发生。因此，这类灯在使用期内不易维护。
由于这种严重的缺点，烧结电极迄今未得到广泛的应用。相反地，迄今依赖于利用带一个由敷钍的钨制固定棒的螺旋丝电极或敷钍的钨制棒形电极。现今总是由致密的实心材料进行制造。
发明描述
本发明的任务在于制造一种用于高压放电灯的烧结电极(1)，其由高熔点金属钨，钽，锇，铱，钼或铼或这些金属的合金的烧结体(2)组成，其特征在于，该烧结体(2)主要由球状，特别是单晶的金属或合金粉末制成，其平均颗粒度为2-100μm，而且其粒度分布围绕平均值的最大波动为20％，烧结电极总体积的10-40％由开放孔组成。该电极不用钍，使用期长，并且电弧扰动小。
根据本发明的高压放电灯的烧结电极由高熔点的金属钨、钽、锇、铱、钼或铼或这些金属的合金组成。此外，还可向该金属或该合金添加氧化性掺杂物(至5％(重量))，例如镧或钇的氧化物。
烧结体主要由金属或合金的球状粉末制造，其平均粒度为2-100μm，其中颗粒度分布围绕平均值最大波动约为20％，并且烧结电极总体积中的10-40％由开放孔组成。
这些孔可不被充填或者含有发射体添加物。典型的发射体添加物为碱土金属的氧化物，例如钡，钙，锶的氧化物和这些氧化物的混合物。适宜的氧化物亦可被铝酸盐以及铪或锆或稀土金属(特别是Sc，Y，La，Ce，Nb，Gd，Dy和Yb)的氧化物。
球状粉末的平均粒度优选为5-70μm。
在一个特别优选的实施方案中，颗粒度分布围绕平均值的最大波动约为10％。
特别之处在于烧结体按已知方式固定在实心材料的固定棒上。其特别的优点在于可不用焊接或钎焊一类连接技术。仅通过热压配合或烧结即可实现机械连接。
优选的烧结体材料和固定棒的材料基本相同，例如纯钨。其中烧结体可未充填或者含有发射体添加物(例如镧的氧化物)。适宜作固定棒的有纯钨、钾掺杂的钨或铼-钨合金。
特别是该电极不用钍，从而不带放射性。
根据本发明的电极具有一系列优点：
装备该电极的高压放电灯的使用期延长，灯点火电压的增加减少，光电流的稳定性明显改善。此外，放电容器壁变黑亦将减少。此外，在灯的运行中电弧扰动和闪烁减小。电极的制造亦大大简化。与普通电极相比可节省电极螺旋丝。
制造本发明的烧结体的一种特别有利的方法由下列步骤组成：
a)由高熔点金属钨、钽、钼、铱、锇或铼或其合金制备基本呈球
形的金属粉末，其中该粉末具有下列性质：
金属粉末的平均粒度为2-100μm；
颗粒度分布围绕平均值的最大波动为20％(典型的为10％)；尤其采用晶粒作球状金属粉末颗粒；
b)将粉末压制成型；其中所用压力的典型值为100-400MPa；
c)将压块烧结，其温度约为所采用的金属的熔点的0.6-0.8倍(以绝对温度计)。
该粉末优选为单晶，在工序b)中该粉末尤适于围绕固定棒压制。
工序c)例如在钨的情况下可优选在2500-2800K的温度下进行。在合金的情况下其熔点意为最低熔点组分的熔点。
由于金属粉末呈球状，其流动性质最适宜填充压模，从而有利于在不添加粘接剂的条件进行压制。这就节省了准备工序并排队了可能带入的杂质。
另一具有很多优点的方法是金属压力铸造法。此种技术在平行申请97P 5568中有详细的叙述。经稍加改变即可在本发明中应用。该方法之流程可简述如下：将一种合适的金属粉末与同样多的塑料(亦称粘接剂)混合，致使这种呈粒状的原料，获得塑料的流动性，并可用类似于塑料的压力铸造法继续进行处理，即使其进入呈预期部件轮廓的压铸模中。为了得到金属部件，将发坯从压铸模中取出；接着用加热或溶剂将粘接剂从所谓的生坯中去除。这个过程称为脱蜡(dewaxing)。然后将此部件按照经典的粉末冶金技术烧结成很高密度的部件。
基本呈球状的金属粉末的制造按已知的方式进行，其中能形成圆的或者近于精确球状的颗粒。碳酰工艺(新型金属粉，Ed.H.Hausner，Gordonand Breach Science Publishers，New York 1963，金属协会系列会议论文集，23卷)是一个例子。采用单晶金属粉末可获得特好的结果。
粒度均匀的类球状粉末颗粒在烧结过程中形成多面体形状的平衡面。例如涉及〔110〕-或〔111〕-面。意外地发现，这种多面体面不继续烧结，致使这种新型烧结体的孔隙率在使用期内实际上保持恒定。这涉及一种所谓具有开孔的海绵体。
该烧结体的工作方式将在下面用例子详细说明，其中烧结体由纯钨(不含ThO2)制成。
原料为直径尽可能一致的W-粉，其粒度分布宽度较小。粉末的这种均匀度最后导致烧结体在高温下的优良稳定性，并在灯的使用期内导致其相应的稳定性。特别是该粉末可直接围绕不含ThO2的固定棒压制。然后在约2350(±100)℃的较低温度下烧结。这种较低的温度约相当于钨熔点的0.7倍，与通常实心钨材的烧结温度2800-3000℃相比，意味着能显著节能。
另外一些发射体添加物在多种应用中不是必需的，但需要时可添加到空腔或孔中。
烧结完成的海绵电极的剩余孔隙率可有目的地经过原料的小球粒度来调节。在海绵电极的情况下，小球粒度优选采用5-70μm，从而可使剩余孔隙率达到15-30％(体积)。
下面列举海绵电极在灯中的具体优点：
根据本发明的电极，放电在大面积上进行。这可避免传统电极经常产生的点状沉积物，后者经常在沉积地点引起局部高温和燃烧点移动。在整个海绵体上的温度分布相当均匀。相反，传统的电极具有高的温度梯度。这种电极特别之处是在尖端的温度比电极后面部分一般高500K。
灯点火之后，从辉光放电到电弧放电的过渡在应用烧结电极的情况下进行得比传统的实心电极块，因为从电极尖端向压缩变形方向的导热由于在烧结体的烧结颗粒之间的接触面小而急剧下降。
在海绵电极的情况下，特别是垂直使用状况，可使放电管的压缩变形区附近的预热得到改善，其原因在于具有较大的发射光的电极表面。因此，灯泡端头上可能的反射层的尺寸可以缩小或者完全去掉，从而达到较大的光流。
示意图
本发明将在下面用一种实施例子详细说明：
图1表示烧结电极的剖面。
图2表示具有烧结电极的金属卤化物灯。
图的描述
图1所示的150W灯用的烧结电极1由圆柱形烧结体2组成，在与放电相对的另一半烧结体中按轴向压入实心的钨固定棒5。烧结体2由钨组成，后者由平均粒度为10μm的球状金属粉制成。粒度分布围绕平均值有10％的波动，剩余孔隙率约为15％(体积)。
固定棒的直径约为0.5mm，烧结体的外径约为1.5mm。
图2表示功率为150W的金属卤化物灯9的应用实例。它由石英泡10组成，其内充金属卤化物。在其两端13置入外接电流导线11和钼箔12。在钼箔12上固定电极1的固定棒5。后者伸入放电泡10。在放电泡的两端各装一氧化锆热反射层14。
在另一实施例子中，电极由烧结体组成，其放电面作成圆形或逐渐变成尖状。该烧结体由钨组成，而压入的固定棒则由铼，镀铼的钨或钼组成。
根据本发明制造烧结电极的特别有利的方法基于已知的金属压力铸造方法。其原理在平行申请(内部文件登号码97P5568)已有详细叙述。本发明明确地涉及此平行申请。在P.J Vervoort等发表于“新性能材料”(Advanced Performance Materials)第3卷P121-151页(1996)的文章“粉末注入成型概论”(Overview of Power Injection Molding)中可找到简要的说明。
本发明的烧结电极将分别采用下列步骤：
-由高熔点金属，如钨、钽、钼、锇、铱或铼或这些金属的合金制备基本呈球状，特别是单晶的金属粉末，该粉末具有下列物质：
金属粉末的平均粒度为2-100μm；
粒度分布围绕平均值的最大波动为20％；
-由粉末和粘接剂(通常亦称为“蜡”)和可能还有聚合物制备混合物(亦称“原料”)；
-将混合物注入压铸模中；
-用化学法或热法去除粘接剂(亦称脱蜡)；
-在温度约为所用金属熔点的0.6-0.8倍的温度下烧结。
在特别优选的实施方案中将该混合物围绕固定棒注入压铸模中，并在烧结过程中与固定棒结合。
这类电极具有较长的使用期。对功率为150W的金属卤化物灯的研究表明，采用粒度为5-20μm的金属粉末，1000小时之后的光流保持为起始光流的95％。与现有技术(传统的由掺杂过的钨材料作成的棒形电极)相比，在1000小时之后其光流降低到83-90％。

Claims (17)

1.一种用于高压放电灯的烧结电极(1)，由高熔点金属钨、钽、锇、铱、钼或铼或这些金属的合金的烧结体(2)组成，其特征在于，该烧结体(2)由球状的金属或合金粉末制成，其平均颗粒度为2-100μm，而且其粒度分布围绕平均值的最大波动为20％，烧结电极总体积的10-40％由开放孔组成。
2.根据权利要求1的烧结电极，其特征在于，所述金属或合金粉末是单晶。
3.根据权利要求1的烧结电极，其特征在于，其孔是未充填的或者含有发射体添加物。
4.根据权利要求1的烧结电极，其特征在于，平均粒度为5-70μm。
5.根据上述权利要求之一的烧结电极，其特征在于，其粒度分布围绕平均值的最大波动为10％。
6.根据权利要求1的烧结电极，其特征在于，烧结体(2)固定在实心的金属固定棒(5)上。
7.根据权利要求6的烧结电极，其特征在于，烧结体(2)和固定棒(5)的材料基本相同。
8.根据权利要求1的烧结电极，其特征在于，该金属含掺杂物质可达5％(重量)。
9.根据权利要求1的烧结电极的制造方法，该方法由下列步骤组成：
-由高熔点金属或这些金属的合金制备球状的金属粉末，该粉末具有下列性质：
金属粉末的平均粒度为2-100μm；
粒度分布围绕平均值的最大波动为20％；
-将该粉末压制成型；
-在温度为所用金属或合金熔点的0.6-0.8倍的温度下烧结。
10.根据权利要求9的方法，其特征在于，所述高熔点金属是钨、钽、钼、锇、铱或铼。
11.根据权利要求9的方法，其特征在于，所述金属粉末是单晶。
12.根据权利要求9的方法，其特征在于，该粉末围绕固定棒(5)压制成型，并在烧结过程中与固定棒结合。
13.根据权利要求9的方法，其特征在于，压制是在未加添加粘接剂下进行。
14.根据权利要求1的烧结电极的制造方法，该方法由下列步骤组成：
-由高熔点金属或这些金属的合金制备球状的金属粉末，该粉末具有下列性质；
金属粉末的平均粒度为2-100μm；
粒度分布围绕平均值的最大波动为20％；
-由粉末和粘结剂制备混合物，即“原料”；
-将该混合物注入压铸模中；
-用化学方法或热方法去除粘结剂；
-在温度为所用金属熔点的0.6-0.8倍的温度下烧结。
15.根据权利要求14的方法，其特征在于，所述高熔点金属是钨、钽、钼、锇、铱或铼。
16.根据权利要求14的方法，其特征在于，所述金属粉末是单晶
17.根据权利要求14的方法，其特征在于，将该混合物围绕固定棒注入压铸模中，并在烧结过程中与固定棒结合。
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