EP1433867B1 - Composite material for manufacturing electrical contacts and process for its preparation - Google Patents

Composite material for manufacturing electrical contacts and process for its preparation Download PDF

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Publication number
EP1433867B1
EP1433867B1 EP03025163A EP03025163A EP1433867B1 EP 1433867 B1 EP1433867 B1 EP 1433867B1 EP 03025163 A EP03025163 A EP 03025163A EP 03025163 A EP03025163 A EP 03025163A EP 1433867 B1 EP1433867 B1 EP 1433867B1
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EP
European Patent Office
Prior art keywords
composite material
metal strip
additive
diameter
atomised
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP03025163A
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German (de)
French (fr)
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EP1433867A2 (en
EP1433867A3 (en
Inventor
Isabell Dr. Buresch
Hermann Strum
Roland Binder
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Wieland Werke AG
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Wieland Werke AG
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Publication of EP1433867A3 publication Critical patent/EP1433867A3/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/10Alloys containing non-metals
    • C22C1/1036Alloys containing non-metals starting from a melt
    • C22C1/1042Alloys containing non-metals starting from a melt by atomising
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/021Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/023Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06Metallic material
    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/123Spraying molten metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0832Handling of atomising fluid, e.g. heating, cooling, cleaning, recirculating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0892Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid casting nozzle; controlling metal stream in or after the casting nozzle
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C2204/00End product comprising different layers, coatings or parts of cermet
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00Contacts
    • H01H1/02Contacts characterised by the material thereof
    • H01H1/021Composite material
    • H01H1/023Composite material having a noble metal as the basic material
    • H01H1/0237Composite material having a noble metal as the basic material and containing oxides
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00Contacts
    • H01H1/02Contacts characterised by the material thereof
    • H01H1/021Composite material
    • H01H1/027Composite material containing carbon particles or fibres
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01HELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H2300/00Orthogonal indexing scheme relating to electric switches, relays, selectors or emergency protective devices covered by H01H
    • H01H2300/036Application 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
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12014All metal or with adjacent metals having metal particles
    • Y10T428/12028Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063Nonparticulate metal component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12014All metal or with adjacent metals having metal particles
    • Y10T428/12028Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063Nonparticulate metal component
    • Y10T428/12069Plural nonparticulate metal components
    • Y10T428/12076Next to each other
    • Y10T428/12083Nonmetal in particulate component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12014All metal or with adjacent metals having metal particles
    • Y10T428/12028Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063Nonparticulate metal component
    • Y10T428/12104Particles discontinuous
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12014All metal or with adjacent metals having metal particles
    • Y10T428/12028Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063Nonparticulate metal component
    • Y10T428/12139Nonmetal particles in particulate component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12708Sn-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12861Group VIII or IB metal-base component
    • Y10T428/12896Ag-base component

Definitions

  • the invention relates to an electrically conductive composite material for producing electrical contact components, comprising a metal strip and a contact layer, applied at least on one side, of a silver or tin contact material.
  • a method for producing an electrically conductive composite material and its use is provided.
  • Such electrical contact components are used for example as plug-in contacts in connectors or in connector terminals in the automotive industry.
  • the design of the contact elements plays a crucial role.
  • the contact carrier material used together with the contact surface used determines the aging behavior and the service life.
  • the known electrical contacts for this purpose usually consist of a base body (metal strip), in particular of a Cu alloy, and a galvanically applied, by hot dip (eg Feuerverzinnung) or by roll-applied contact material.
  • a galvanically applied, by hot dip (eg Feuerverzinnung) or by roll-applied contact material In particular gold, silver or tin layers are used for this purpose.
  • a powder metallurgical production of the contact points, which are welded onto the contact area, is in the case of plug connectors - in particular the socket part - not possible because the contact area is reshaped and therefore not freely accessible.
  • the arc causes local heating of the material up to more than 1000 ° C, which causes the contact surfaces of the connector to burn off. Also, incomplete connections can cause such arcing due to the vibrations generated during driving, resulting in a creeping burn and ultimately the total failure of a connector.
  • EP 0 225 080 B1 discloses a device with a nebulizer, with which a jet of liquid metal with a gas jet is atomized into a droplet consisting of droplets.
  • the atomizer is mounted tiltable about a fixed axis so that the spray evenly distributed on a moving belt-shaped substrate or otherwise collecting device.
  • the device is used to make thin metal bands or to coat ribbons.
  • the production method pursues an areal uniform distribution of the applied metal layer, it primarily permits only a simple material selection with a fusible component. In addition, a relatively movable to the metal spray atomizer is an additional equipment expense.
  • a Cu or Ag-containing material is known, which is doped with at least one dispersoid.
  • the dispersoids are said to have a strongly negative value of enthalpy of formation be thermodynamically stable accordingly.
  • Suitable dispersoids are metals of Si, Al, Zr, Nb, Ti, Cr and Si and / or yttrium as well as oxides, nitrides and carbides of Si, W, Zr and / or pure carbon. In particular, it is a contact material for vacuum chambers with a Cr / Cu sintered structure.
  • An electrical contact of a connector is known, with a metallic substrate on which a contact layer is applied.
  • the contact layer is formed with a microstructure that has an optimized tribological behavior with reduced coefficients of friction and increased wear resistance.
  • the microstructure preferably lies in the range between 1 nm and 1 ⁇ m, ie in the area of nanostructuring, in which the particles are distributed in the matrix of the contact layer in the form of a solid-state dispersion or nanodispersion. It is proposed to produce such nanodispersions by a galvanic process.
  • the invention is therefore based on the object to provide a metallic composite material which is produced by means of a comparison with the prior art improved method and which also largely meets the above-mentioned increased requirements.
  • the composite material according to the invention is particularly suitable for connectors and connector terminals and switching contacts.
  • the electrically conductive composite material is provided with an addition of carbon.
  • the resulting arc when plugging and unplugging connectors and contacts generated carbon compounds released by the increase in the contact resistance by oxidation of the contact surfaces in the environment is largely prevented.
  • the main component of the contact layer is a metal with already good electrical Conductivity, which forms the matrix, in which the two additives are embedded particularly finely distributed according to their small diameter and form a homogeneous composite material.
  • This has a positive effect on other material properties.
  • the fine distribution of the alloy components of different hardness and the homogenization achieved thereby counteract the wear of a mechanically stressed surface.
  • the bands When making the plug, the bands must be reshaped. Good workability then means that the contact layer does not detach from the carrier during forming.
  • Carbon has a very low hardness in comparison to metallic materials. For this very reason, it is important that the small particle size of this addition in the nanometer range leads to a composite material having on its surface by the metallic constituents of sufficient hardness and thus abrasion resistance to mechanical stress.
  • the soft carbon powder is stored for this purpose in a harder metallic skeleton.
  • hard particles are also suitable as a second additive.
  • the adhesiveness of the contact layer on the support is also important for the adhesiveness of the contact layer on the support that, in addition to the electrical properties, it is also possible to transform it during the manufacture of the connector without detaching the contact layer.
  • the metal band consists of Cu or a Cu alloy, of Fe or a Fe alloy, of Al or an Al alloy, of Ni or a Ni alloy.
  • the advantages achieved with the invention with respect to the composite material in particular is that at high insertion and pulling speeds either the formation of an arc is prevented or if it comes to arc formation, this immediately extinguished and it does not lead to oxidation of the contact surface.
  • the intermediate layer ensures optimum adhesion of the contact layer to the carrier.
  • the inventive solution is used to optimize the properties of the composite material for use in electrical engineering.
  • the object is achieved with respect to the applied device for gas atomizing a jet of flowable or liquid material, for example a beam of liquid metal or a metal alloy, with an atomizer for applying atomizing gas to the jet for atomizing the jet into a droplet consisting of droplets the atomizer unit is annular or elongated and has a continuous outlet gap for the atomizer gas. Above the area of the atomizer unit, there is disposed a powder injector with a swirling chamber connected to a solids feed unit.
  • a powder injector with a swirling chamber connected to a solids feed unit.
  • the advantages achieved by the invention with respect to the applied device for gas atomization is that the powder components are introduced homogeneously into the spray mist in the swirling chamber.
  • the high gas velocity of the atomizing gas in the region of the swirling chamber generates a negative pressure which constantly discharges the powder particles from the chamber.
  • the particle movement in the vortex chamber triggers the agglomeration of fine powder particles and thus ensures a homogeneous distribution in the deposited layer.
  • wider belts can be coated without having to move the gas atomizer device or its parts.
  • the elongated part is aligned perpendicular to the direction of movement of the strip material.
  • the Feststoffzu classroom province classroom comprises a reservoir for dry powder or a container for powdered liquids with supply lines.
  • the agglomeration of the particles can be reduced.
  • the amount of material of the jet is controlled via a device with valve control and / or a device for pressurizing a melt reservoir.
  • a device with valve control and / or a device for pressurizing a melt reservoir With a corresponding pressurization targeted the material flow can be controlled without a valve, since a melt flow can be maintained only with a corresponding overpressure.
  • an additional valve allows even shorter switching times for switching on and off of the melt flow.
  • the object is achieved with regard to the method for producing a composite material with a device for gas atomization with the steps according to which a metal or a metal alloy is heated in a reservoir above the melting point, the melt exits with pressurization in the form of a melt jet and by means of a gas stream sprayed with a mist, mixed with non-melting additives in particulate form and then the atomized droplets are deposited on a support material or a collecting device.
  • As a catching device can serve a moving under the spray cooling belt from which can be detached the spray product.
  • the non-melting additives are fed to the melt stream from a fluidization chamber.
  • the tape to be coated is fed either continuously or from a stack of superposed band sections.
  • the system is housed in a nitrogen or nitrogen / hydrogen mixture flooded housing with inlet and outlet lock. Upstream of the inlet sluice is a belt cleaning and activating station which prepares the belt surface before coating for good adhesion of the deposited layer.
  • the atomization of the powder particles takes place using N 2 .
  • the additives are injected into the spray at a pressure of 0.15 to 1.5 MPa.
  • the nitrogen enters into a mixing chamber at very high speed via an outlet gap in order to fluidize the fine powder particles introduced into the mixing chamber and to obtain optimum mixing.
  • agglomeration of the nanopowder can be effectively prevented with a gas velocity, which may well be in the supersonic range.
  • the pressurization of the powder components is controlled accordingly for optimal mixing.
  • the metal strip is heated to a temperature of (0.6 to 0.9) x T s of the contact material Sn or Ag.
  • a uniform contact layer with finely dispersed additives is desired.
  • the metal strip is heated to a temperature of (0.6 to 0.9) x T s of the contact material Sn or Ag.
  • the metal ribbon is advantageously surface treated for flux activation prior to deposition of the layer.
  • the layer thickness is set again via other deposition parameters.
  • the thickness D 2 of the contact layer is controlled via the spray jet density and the passage speed of the metal strip to be coated.
  • the spray jet density is controlled via a needle valve or the like. If the needle valve is permanently open, then a full-surface one-sided coating can take place.
  • the metal strip can be pulled under the spray jet at a constant speed.
  • the material flow in the spray head can be controlled even without pressurization of the melt without a valve device.
  • the density or the porosity of the contact layer can also be adjusted in a targeted manner.
  • an open porosity of the contact layer of 70 to 85% is set via the selected spray parameters.
  • the porous contact layer is then infiltrated with oil for self-lubrication.
  • Porous layers are aftertreated in a further process step by rolling the sprayed metal strip at a temperature of at least 0.8 ⁇ T s of the layer matrix material in order to achieve a 100% density.
  • the metal strip is only partially coated. In this way, a partially resistive coating can be produced, for example, at the tip of a plug.
  • the metal strip is advantageously covered with a mask.
  • the metal strip can be shielded against the spray.
  • the mask is not placed on the carrier, but positioned at a certain distance in the beam.
  • On-site electronics means increased temperatures and increased vibration levels. This is especially true for the multi-valve technology.
  • current-carrying connections such as connectors, punched grid connections, relay connections as well as wear and vibration-resistant, high-temperature resistant coatings are required.
  • the electrically conductive composite material finds use for the automotive sector and in particular in electrical contact components such as connectors and connector terminals.
  • the advantages achieved with the invention are, in particular, that the contact coating of a metal strip as a carrier material can be partially applied in order to produce self-disconnecting contacts with low burn-off behavior.
  • a contact layer is produced on a carrier material in a process sequence via a suitable parameter selection, which can be further processed directly as strip material.
  • the coating process can thus easily be integrated into rational mass production.
  • the composite material 1 for producing electrical contact components according to FIG. 1 is composed of a metal strip 2 as a carrier made of metal and a contact layer 4 applied at least on one side of a silver or tin contact material.
  • an intermediate layer 6 made of Ag or Sn of thickness D 3 0.1 to 1 microns is arranged.
  • the metal strip 2 is surface treated for activation with flux.
  • gas atomizer 10 includes a arranged in a heated housing 40 melt container 12 with filler neck and feed channels 14 for the melt to a nozzle 28 with a needle valve 18, from which the jet of liquid metal or a metal alloy emerges.
  • the discharge quantity is controlled via a connection to the pressurization 16, which is attached to the melt container 12.
  • the filler neck on the melt container 12 is closed in a gas-tight manner for pressurizing with a stopper or a screw connection.
  • a container 20 is arranged with filler neck for liquids and mixtures of a liquid acted upon with powder. This is connected via supply channels 22 with the injector unit 32 arranged around the needle valve 18 with swirling chamber 26. Also from this container, the discharge amount is controlled by a container 20 mounted on the connection to the pressurization 24. Alternatively or additionally, there is the possibility to connect further Feststoffzu brieflytechniken with a powder container 44 for dry powder to the heated housing 40, which have a connection to the injector unit 32 via not shown in the schematic diagram channels. Further melting vessels, optionally with separate heating, can be docked to a connection unit 42.
  • the melt exiting through the needle valve 18 is mixed with the solids from the vortex chamber and treated with nebulizer gas with the N 2 atomizer unit 34 so that a spray consisting of droplets is formed from the jet, which is deposited on a belt 2.
  • An N 2 chamber 36, immediately in front of the N 2 exit gap 38, ensures a constant supply of gas.
  • an outlet funnel 30 with a predetermined exit cone To guide the spray is an outlet funnel 30 with a predetermined exit cone, which ensures a deposition over the entire bandwidth.
  • a mask 8 is positioned in the beam or applied to the substrate.
  • the atomizing unit 34 is annular or elongated in the image plane of Fig. 2 formed therein, which has a continuous exit gap 38 for the N 2 -Zerstäubergas.
  • the cleaning and activating unit 48 With the cleaning and activating unit 48, the metal strip 2 is pretreated for activation with flux on the surfaces.
  • the belt can be coated in continuous operation or in the form of a stacked layer in batch mode 46.

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  • Metallurgy (AREA)
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  • Manufacturing & Machinery (AREA)
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  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
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  • Manufacturing Of Electrical Connectors (AREA)

Abstract

Electrically conducting composite material comprises a metal strip and a contact layer formed on one side. The contact layer is made from a silver or tin material additionally containing 0.5-60 wt.% carbon powder in the form of fine particles having a diameter of 5-200 nm and 0.5-60 wt.% of a further additive in the form of particles for improving the electrical conductivity, hardness and abrasion resistance and having a diameter of 5-200 nm. Independent claims are also included for the following: (1) Device for the gas sputtering of a liquid material; and (2) Process for the production of a composite material.

Description

Die Erfindung betrifft ein elektrisch leitfähiges Verbundmaterial zur Herstellung elektrischer Kontaktbauteile, bestehend aus einem Metallband und einer zumindest einseitig aufgebrachten Kontaktschicht aus einem Silber- oder Zinn-Kontaktwerkstoff. Darüber hinaus ist ein Verfahren zur Herstellung eines elektrisch leitfähigen Verbundmaterials sowie dessen Verwendung vorgesehen.The invention relates to an electrically conductive composite material for producing electrical contact components, comprising a metal strip and a contact layer, applied at least on one side, of a silver or tin contact material. In addition, a method for producing an electrically conductive composite material and its use is provided.

Derartige elektrische Kontaktbauteile werden beispielsweise als Steckkontakte in Steckverbindern oder in Steckverbinder-Anschlüssen in der Automobilindustrie eingesetzt.Such electrical contact components are used for example as plug-in contacts in connectors or in connector terminals in the automotive industry.

Für die Zuverlässigkeit von Steckverbindern spielt die Ausführung der Kontaktelemente eine entscheidende Rolle. Im Betrieb bestimmt das verwendete Kontaktträgermaterial zusammen mit der verwendeten Kontaktoberfläche das Alterungsverhalten und die Lebensdauer.For the reliability of connectors, the design of the contact elements plays a crucial role. During operation, the contact carrier material used together with the contact surface used determines the aging behavior and the service life.

Die bekannten elektrischen Kontakte für diesen Verwendungszweck bestehen üblicherweise aus einem Grundkörper (Metallband), insbesondere aus einer Cu-Legierung, und einem auf galvanischem Wege, durch Schmelztauchverfahren (z.B. Feuerverzinnung) oder durch Walzplattieren aufgebrachten Kontaktwerkstoff. Hierzu werden insbesondere Gold-, Silber- oder Zinnschichten verwendet. Eine pulvermetallurgische Herstellung der Kontaktpunkte, welche auf den Kontaktbereich aufgeschweißt werden, ist bei Steckverbindern - insbesondere dem Buchsenteil - nicht möglich, da der Kontaktbereich umgeformt wird und damit nicht frei zugänglich ist.The known electrical contacts for this purpose usually consist of a base body (metal strip), in particular of a Cu alloy, and a galvanically applied, by hot dip (eg Feuerverzinnung) or by roll-applied contact material. In particular gold, silver or tin layers are used for this purpose. A powder metallurgical production of the contact points, which are welded onto the contact area, is in the case of plug connectors - in particular the socket part - not possible because the contact area is reshaped and therefore not freely accessible.

Damit lassen sich nur für Betriebsspannungen bis 14 Volt, unter den bisher geforderten Randbedingungen, eine hinreichende Verschleißbeständigkeit und ein geringer Kontaktwiderstand des Steckverbinder-Systems während der geplanten Lebensdauer erreichen.Thus, only for operating voltages up to 14 volts, under the previously required boundary conditions, a sufficient wear resistance and a low contact resistance of the connector system can be achieved during the planned life.

Dies trifft jedoch nicht mehr zu, wenn erhöhte Anforderungen an die Steckkontakte gestellt werden, beispielsweise hinsichtlich der möglichen Gefahr der Lichtbogenbildung bei einem 42 V-Bordnetzes in der Automobilindustrie oder hinsichtlich der Platzierung der Steckkontakte in unmittelbarer Motornähe aufgrund hoher Temperaturen. Die Problematik einer Lichtbogenentstehung ist bei schaltenden Kontakten, beispielsweise bei Relais, bereits bekannt. Bei schaltenden Kontakten werden die speziellen Kontaktbeschichtungen durch einen zusätzlichen Arbeitsgang auf das Trägermaterial durch Auflöten oder Aufschweißen aufgebracht. Das Kontaktmaterial selbst wird in einem vorangehenden Arbeitsschritt durch Sintern oder Strangpressen hergestellt.
Bei gebräuchlichen Steckverbindungen im Automotive Bereich tritt dieses Phänomen erst ab einer Spannung von über 16 Volt in Erscheinung. Bei einem 42 V-Bordnetz besteht die Gefahr der Lichtbogenbildung und des Kontaktprellens beim Stecken bzw. Ziehen der Steckverbinderanschlüsse. Durch den Lichtbogen kommt es lokal zu einer Erwärmung des Materials bis über 1000°C, dies führt zum Abbrennen der Kontaktflächen des Steckverbinders. Auch können unvollständig gesteckte Verbindungen durch die im Fahrbetrieb entstehenden Vibrationen derartige Lichtbögen hervorrufen, die zu einem schleichenden Abbrand und letztendlich zum Totalausfall einer Steckverbindung führen.
However, this is no longer true when increased demands are placed on the plug contacts, for example, in terms of the potential risk of arcing in a 42 V electrical system in the automotive industry or with regard to the placement of the plug contacts in the immediate vicinity of the engine due to high temperatures. The problem of arcing is already known in the case of switching contacts, for example in the case of relays. In switching contacts, the special contact coatings are applied by an additional operation on the substrate by soldering or welding. The contact material itself is produced in a preceding step by sintering or extrusion.
For conventional connectors in the automotive sector, this phenomenon occurs only from a voltage of over 16 volts in appearance. With a 42 V electrical system there is a risk of arcing and contact bounce when plugging or unplugging the connector connections. The arc causes local heating of the material up to more than 1000 ° C, which causes the contact surfaces of the connector to burn off. Also, incomplete connections can cause such arcing due to the vibrations generated during driving, resulting in a creeping burn and ultimately the total failure of a connector.

Aus der Druckschrift DE 195 03 184 C1 ist ein Werkstoff für elektrische Kontakte aus Silber- und Kohlenstoff bekannt. Es handelt sich dabei um einen Sinterwerkstoff, der durch einen gewissen Rußanteil eine verbesserte Abbrandeigenschaft aufweist. Zu dessen Herstellung wird der Kohlenstoff in Form von Ruß mit einer Primärteilchengröße von weniger als 150 nm Silber zugesetzt, das Gemisch kaltisostatisch verpresst und anschließend gesintert. Mit gleicher Zielsetzung, die Abbrandeigenschaften und die Verschweißresistenz zu verbessern, ist aus der Druckschrift DE 41 11 683 C2 ein Verbundwerkstoff für elektrische Kontakte bekannt. Der Verbundwerkstoff besteht aus Silber oder einer Silberlegierung mit einem Kohlenstoffanteil, der in Form einer Kombination aus Kohlenstoffpulver und Kohlenstofffasern in einem Massenverhältnis von 10:1 bis 1:10 mit der Metallkomponente verarbeitet wird.From the publication DE 195 03 184 C1 is a material known for electrical contacts made of silver and carbon. It is a sintered material which has an improved burn-off property due to a certain amount of carbon black. To For its production, the carbon in the form of carbon black with a primary particle size of less than 150 nm silver is added, the mixture cold isostatically pressed and then sintered. With the same objective to improve the Abbrandeigenschaften and the Verschweißresistenz is from the document DE 41 11 683 C2 a composite material for electrical contacts known. The composite material is made of silver or a silver alloy having a carbon content, which is processed in the form of a combination of carbon powder and carbon fibers in a mass ratio of 10: 1 to 1:10 with the metal component.

Nachteil derartiger Werkstoffe ist, dass deren Herstellung und Weiterverarbeitung nicht mit der Herstellung elektrischer Kontaktbauteile in Verbindung mit einer Verformung der Metallbänder geeignet ist.Disadvantage of such materials is that their production and further processing is not suitable for the production of electrical contact components in conjunction with a deformation of the metal strips.

Des Weiteren ist aus der Druckschrift EP 0 225 080 B1 eine Vorrichtung mit einem Zerstäuber bekannt, mit der ein Strahl aus flüssigem Metall mit einem Gasstrahl in einen aus Tröpfchen bestehenden Sprühnebel zerstäubt wird. Der Zerstäuber ist dabei um eine feststehende Achse kippbar so gelagert, dass sich der Sprühnebel auf einem bewegten bandförmigen Substrat oder einer anderweitigen Auffangvorrichtung gleichmäßig verteilt. Die Vorrichtung wird zur Herstellung von dünnen Metallbändern oder zum Beschichten von Bändern verwendet.Furthermore, from the document EP 0 225 080 B1 discloses a device with a nebulizer, with which a jet of liquid metal with a gas jet is atomized into a droplet consisting of droplets. The atomizer is mounted tiltable about a fixed axis so that the spray evenly distributed on a moving belt-shaped substrate or otherwise collecting device. The device is used to make thin metal bands or to coat ribbons.

Mit dem Herstellungsverfahren wird zwar eine flächenmäßig gleichförmige Verteilung der aufgebrachten Metallschicht verfolgt, es gestattet jedoch in erster Linie nur eine einfache Materialauswahl mit einer Schmelzkomponente. Außerdem stellt ein relativ zum Metallstrahl beweglicher Zerstäuber einen zusätzlichen apparativen Aufwand dar.Although the production method pursues an areal uniform distribution of the applied metal layer, it primarily permits only a simple material selection with a fusible component. In addition, a relatively movable to the metal spray atomizer is an additional equipment expense.

Auch ist aus der DE 199 32 867 A1 ein Cu- oder Ag-haltiger Werkstoff bekannt, der mit wenigstens einem Dispersoid dotiert ist. Bei der Auswahl der Dispersoide ist besonders auf eine geringe Löslichkeit innerhalb der Werkstoffkombination zu achten. Die Dispersoide sollen aufgrund eines stark negativen Wertes der Bildungsenthalpie thermodynamisch entsprechend stabil sein. Als Dispersoide kommen Metalle von Si, Al, Zr, Nb, Ti, Cr und Si und/oder Yttrium sowie Oxide, Nitride und Karbide von Si, W, Zr und/oder reiner Kohlenstoff in Frage. Insbesondere handelt es sich um einen Kontaktwerkstoff für Vakuumkammern mit einer Cr/Cu-Sinterstruktur.Also is from the DE 199 32 867 A1 a Cu or Ag-containing material is known, which is doped with at least one dispersoid. When selecting the dispersoids, particular attention should be paid to a low solubility within the material combination. The dispersoids are said to have a strongly negative value of enthalpy of formation be thermodynamically stable accordingly. Suitable dispersoids are metals of Si, Al, Zr, Nb, Ti, Cr and Si and / or yttrium as well as oxides, nitrides and carbides of Si, W, Zr and / or pure carbon. In particular, it is a contact material for vacuum chambers with a Cr / Cu sintered structure.

Aus der nachveröffentlichten Schrift WO 2004/032166 A1 ist ein elektrischer Kontakt eines Steckverbinders bekannt, mit einem metallischen Substrat, auf dem eine Kontaktschicht aufgebracht ist. Die Kontaktschicht ist mit einer Gefügestrukturierung ausgebildet, die ein optimiertes tribologisches Verhalten mit reduzierten Reibwerten und einem erhöhten Verschleißwiderstand zum Ziel hat. Die Gefügestrukturierung liegt bevorzugt im Bereich zwischen 1 nm und 1 µm, also im Bereich der Nanostrukturierung, bei der in der Matrix der Kontaktschicht die Teilchen in Form einer Festkörperdispersion oder Nanodispersion verteilt sind. Dabei wird vorgeschlagen, derartige Nanodispersionen nach einem galvanischen Verfahren herzustellen.From the post-published font WO 2004/032166 A1 An electrical contact of a connector is known, with a metallic substrate on which a contact layer is applied. The contact layer is formed with a microstructure that has an optimized tribological behavior with reduced coefficients of friction and increased wear resistance. The microstructure preferably lies in the range between 1 nm and 1 μm, ie in the area of nanostructuring, in which the particles are distributed in the matrix of the contact layer in the form of a solid-state dispersion or nanodispersion. It is proposed to produce such nanodispersions by a galvanic process.

Der Erfindung liegt daher die Aufgabe zugrunde, ein metallisches Verbundmaterial anzugeben, das mittels eines gegenüber dem Stand der Technik verbesserten Verfahrens hergestellt wird und das auch den eingangs genannten erhöhten Anforderungen weitestgehend genügt.The invention is therefore based on the object to provide a metallic composite material which is produced by means of a comparison with the prior art improved method and which also largely meets the above-mentioned increased requirements.

Die Aufgabe wird hinsichtlich des Erzeugnisses nach Anspruch 1 gelöst. Insbesondere besteht das elektrisch leitfähige Verbundmaterial zur Herstellung elektrischer Kontaktbauteile, aus einem Metallband und einer zumindest einseitig aufgebrachten Kontaktschicht aus einem Silber- oder Zinn-Kontaktwerkstoff, wobei der Kontaktwerkstoff als ersten Zusatz 0,5 bis 60 Gew.-% Kohlenstoff-Pulver in Form feiner Teilchen mit einem Durchmesser Ø1 = 5 bis 200 nm und 0,5 bis 60 Gew.-% eines zweiten pulverförmigen Zusatzes in Form feiner Teilchen mit einem Durchmesser Ø2 = 5 bis 200 nm enthält.The object is achieved in terms of the product according to claim 1. In particular, the electrically conductive composite material for producing electrical contact components, consisting of a metal strip and a contact layer applied at least on one side of a silver or tin contact material, wherein the contact material as a first additive 0.5 to 60 wt .-% carbon powder in the form of fine Contains particles with a diameter Ø 1 = 5 to 200 nm and 0.5 to 60 wt .-% of a second powdery additive in the form of fine particles with a diameter Ø 2 = 5 to 200 nm.

Das erfindungsgemäße Verbundmaterial eignet sich insbesondere für Steckverbindern und Steckverbinder-Anschlüsse und auch schaltende Kontakte.The composite material according to the invention is particularly suitable for connectors and connector terminals and switching contacts.

Die Erfindung geht dabei von der Überlegung aus, dass das Verbundmaterial eine Vielzahl optimal aufeinander abgestimmte Eigenschaften ausweisen sollte. Für die Auswahl eines geeigneten Kontaktwerkstoffe auf einem Trägermaterial sollten u. a. folgende Kriterien bzw. Eigenschaften optimiert sein:

  • Bogenerosionsbeständigkeit
  • hohe elektrische / thermische Leitfähigkeit
  • niedrige erforderliche Kontaktkraft
  • Abrieb- / Abnutzungsbeständigkeit
  • gute Verarbeitbarkeit: lötbar.
Insbesondere sollten dabei die Bogenerosionsbeständigkeit für den Einsatz bei 42V Bordnetzen in der Automobilbranche im Vordergrund stehen, um ein Abbrennen der Kontakte zu verhindern.The invention is based on the consideration that the composite material should identify a variety of optimally matched properties. The following criteria or properties should be optimized for the selection of a suitable contact material on a carrier material:
  • Arc erosion resistance
  • high electrical / thermal conductivity
  • low required contact force
  • Abrasion / wear resistance
  • good processability: solderable.
In particular, the Bogenerosionsbeständigkeit should be for the use of 42V on-board networks in the automotive industry in the foreground to prevent burning of the contacts.

Das elektrisch leitfähige Verbundmaterial ist dazu mit einem Zusatz von Kohlenstoff versehen. Der beim Stecken und Ziehen von Steckverbindern und Kontakten entstehende Lichtbogen erzeugt frei werdende Kohlenstoffverbindungen, durch die eine Erhöhung des Kontaktwiderstandes durch Oxidation der Kontaktflächen in der Umgebung weitgehend verhindert wird.The electrically conductive composite material is provided with an addition of carbon. The resulting arc when plugging and unplugging connectors and contacts generated carbon compounds released by the increase in the contact resistance by oxidation of the contact surfaces in the environment is largely prevented.

So ist der Hauptbestandteil der Kontaktschicht ein Metall mit bereits guter elektrischer Leitfähigkeit, das die Matrix bildet, in welche die beiden Zusätze entsprechend ihrer geringen Durchmesser besonders fein verteilt eingelagert sind und ein homogenes Verbundmaterial bilden. Dies wirkt sich unmittelbar auch auf weitere Werkstoffeigenschaften positiv aus. Insbesondere steht die Feinverteilung der Legierungsbestandteile unterschiedlicher Härte und die damit erzielte Homogenisierung dem Verschleiß einer mechanischen beanspruchten der Oberfläche entgegen.Thus, the main component of the contact layer is a metal with already good electrical Conductivity, which forms the matrix, in which the two additives are embedded particularly finely distributed according to their small diameter and form a homogeneous composite material. This has a positive effect on other material properties. In particular, the fine distribution of the alloy components of different hardness and the homogenization achieved thereby counteract the wear of a mechanically stressed surface.

Bei der Steckerfertigung müssen die Bänder umgeformt werden. Zu einer guten Bearbeitbarkeit zählt dann, dass sich bei der Umformung die Kontaktschicht nicht vom Träger löst. In bevorzugter Ausführungsform wird ein Optimum dadurch erzielt, indem zwischen Metallband und Kontaktschicht eine Zwischenschicht aus Ag bzw. Sn der Dicke D3 = 0,1 bis 1 µm angeordnet ist. Die Zwischenschicht ist dabei auf eine gereinigte und aktivierte Bandoberfläche abgeschieden.When making the plug, the bands must be reshaped. Good workability then means that the contact layer does not detach from the carrier during forming. In a preferred embodiment, an optimum is achieved by an intermediate layer of Ag or Sn of thickness D 3 = 0.1 to 1 microns is arranged between the metal strip and contact layer. The intermediate layer is deposited on a cleaned and activated strip surface.

In einer bevorzugten Ausführungsform enthält der Kontaktwerkstoff als ersten Zusatz 3 bis 40 Gew.-% Kohlenstoff-Pulver plättchenförmig und/oder globular und/oder geperlt in Form feiner Teilchen mit einem Durchmesser Ø1 = 20 bis 150 nm. Kohlenstoff hat eine ausgesprochen geringe Härte im Vergleich zu metallischen Werkstoffen. Gerade aus diesem Grund ist es von Bedeutung, dass die geringe Teilchengröße dieses Zusatzes im Nanometerbereich zu einem Verbundmaterial führt, das an seiner Oberfläche durch die metallischen Bestandteile eine ausreichende Härte und damit Abriebbeständigkeit gegen mechanische Beanspruchung aufweist. Das weiche Kohlenstoffpulver wird hierzu in ein härteres metallisches Grundgerüst eingelagert.In a preferred embodiment, the contact material contains as a first additive 3 to 40 wt .-% carbon powder platy and / or globular and / or beads in the form of fine particles with a diameter Ø 1 = 20 to 150 nm. Carbon has a very low hardness in comparison to metallic materials. For this very reason, it is important that the small particle size of this addition in the nanometer range leads to a composite material having on its surface by the metallic constituents of sufficient hardness and thus abrasion resistance to mechanical stress. The soft carbon powder is stored for this purpose in a harder metallic skeleton.

Zusätzlich zum ersten Zusatz kommen mit dem zweiten Zusatz Stoffe in Betracht, die die elektrische Leitfähigkeit, Bogenerosionsbeständigkeit, Härte und Abriebfestigkeit verbessern. So können auch metallische Teilchen eingebracht werden. In einer bevorzugten Ausführungsform handelt es sich bei dem zweiten Zusatz um 2 bis 50 Gew.-% eines Metalls aus der Gruppe Co, Cu, Mo, Ni, Ti, W in Form feiner Teilchen mit einem Durchmesser Ø2 = 10 bis 200 nm.In addition to the first additive, substances which improve the electrical conductivity, corrosion resistance, hardness and abrasion resistance come into consideration with the second additive. So also metallic particles can be introduced. In a preferred embodiment, the second additive is from 2 to 50% by weight of a metal from the group Co, Cu, Mo, Ni, Ti, W in the form of fine particles with a diameter of Ø 2 = 10 to 200 nm.

Alternativ kommen auch Hartteilchen als zweiter Zusatz in Betracht. Vorteilhafterweise handelt es sich hierbei um 2 bis 40 Gew.-% eines Karbids, bevorzugt aus der Gruppe SiC, WC, in Form feiner Teilchen mit einem Durchmesser Ø2 = 10 bis 200 nm.Alternatively, hard particles are also suitable as a second additive. Advantageously, these are 2 to 40 wt .-% of a carbide, preferably from the group SiC, WC, in the form of fine particles with a diameter Ø 2 = 10 to 200 nm.

Alternativ handelt es sich vorteilhafterweise beim zweiten Zusatz um 0,5 bis 40 Gew.-% eines Disulfids, bevorzugt aus der Gruppe MoS2, WS2, in Form feiner Teilchen mit einem Durchmesser Ø2 = 50 bis 200 nm.Alternatively, it is advantageous in the second addition to 0.5 to 40 wt .-% of a disulfide, preferably from the group MoS 2 , WS 2 , in the form of fine particles with a diameter Ø 2 = 50 to 200 nm.

In einer weiteren alternativen Ausführungsform besteht der zweite Zusatz aus 2 bis 40 Gew.-% SnO2 in Form feiner Teilchen mit einem Durchmesser Ø2 = 5 bis 100 nm.In a further alternative embodiment, the second additive consists of 2 to 40 wt .-% SnO 2 in the form of fine particles with a diameter Ø 2 = 5 to 100 nm.

Bei einer ebenso alternativen Ausführungsform handelt es sich bei dem zweiten Zusatz um 2 bis 40 Gew.-% oxidische Keramikteilchen, bevorzugt aus der Gruppe Al2O3, ZrO2, mit einem Durchmesser Ø2 = 50 bis 150 nm.In a likewise alternative embodiment, the second additive is from 2 to 40% by weight of oxidic ceramic particles, preferably from the group Al 2 O 3 , ZrO 2 , with a diameter of Ø 2 = 50 to 150 nm.

Des Weiteren vorteilhaft als zweiter Zusatz ist 2 bis 20 Gew.-% PTFE (Polytetrafluoräthylen) in Form feiner Teilchen mit einem Durchmesser Ø2 = 50 bis 200 nm.Further advantageous as a second additive is 2 to 20 wt .-% PTFE (polytetrafluoroethylene) in the form of fine particles with a diameter Ø 2 = 50 to 200 nm.

Für die Haftfähigkeit der Kontaktschicht auf dem Träger ist auch von Bedeutung, dass außer der elektrischen Eigenschaften auch eine Umformung bei der Steckerherstellung gelingt, ohne die Kontaktschicht abzulösen. In bevorzugter Ausführungsform beträgt hierzu die Dicke des Metallbandes D1 = 0,06 bis 1,2 mm und der Kontaktschicht D2 = 0,5 bis 10 µm. Daraus resultieren auch für das Umformen geeignete Dickenverhältnisse, die ein abplatzen der Schichten verhindert.It is also important for the adhesiveness of the contact layer on the support that, in addition to the electrical properties, it is also possible to transform it during the manufacture of the connector without detaching the contact layer. In a preferred embodiment, this is the thickness of the metal strip D 1 = 0.06 to 1.2 mm and the contact layer D 2 = 0.5 to 10 microns. This results in suitable for the forming thickness ratios, which prevents spalling of the layers.

Für ein geeignetes Verbundmaterial müssen auch die Träger entsprechend ausgewählt werden. Bevorzugt sind dabei Werkstoffe, die zumindest eine gute bis sehr gute elektrische Leitfähigkeit aufweisen. Vorteilhafterweise besteht das Metallband aus Cu oder einer Cu-Legierung, aus Fe oder einer Fe-Legierung, aus Al oder einer Al-Legierung, aus Ni oder einer Ni-Legierung.For a suitable composite material and the carrier must be selected accordingly. Preference is given to materials which have at least a good to very good electrical conductivity. Advantageously, the metal band consists of Cu or a Cu alloy, of Fe or a Fe alloy, of Al or an Al alloy, of Ni or a Ni alloy.

Die mit der Erfindung erzielten Vorteile bestehen bezüglich des Verbundmaterials insbesondere darin, dass bei hohen Steck- und Ziehgeschwindigkeiten entweder die Entstehung eines Lichtbogens verhindert wird oder sofern es zur Lichtbogenausbildung kommt, dieser sofort verlöscht und es nicht zur Oxidation der Kontaktoberfläche führt. Insbesondere wird durch die Zwischenschicht eine optimale Haftfestigkeit der Kontaktschicht auf dem Träger gewährleistet. Über bereits bestehende Verbundmaterialien hinaus werden mit der erfinderischen Lösung die Eigenschaften des Verbundmaterials für den Einsatz in der Elektrotechnik optimiert.The advantages achieved with the invention with respect to the composite material in particular is that at high insertion and pulling speeds either the formation of an arc is prevented or if it comes to arc formation, this immediately extinguished and it does not lead to oxidation of the contact surface. In particular, the intermediate layer ensures optimum adhesion of the contact layer to the carrier. Beyond already existing composite materials, the inventive solution is used to optimize the properties of the composite material for use in electrical engineering.

Die Aufgabe wird hinsichtlich der angewandten Vorrichtung zur Gaszerstäubung eines Strahls aus fließfähigem oder flüssigem Material, beispielsweise eines Strahls aus flüssigem Metall oder einer Metalllegierung, mit einer Zerstäubereinheit zum Beaufschlagen von Zerstäubergas auf den Strahl zum Zerstäuben des Strahls in einen aus Tröpfchen bestehenden Sprühnebel gelöst, wobei die Zerstäubereinheit ringförmig oder lang gestreckt ausgebildet ist und diese einen durchgehenden Austrittsspalt für das Zerstäubergas aufweist. Oberhalb des Bereiches der Zerstäubereinheit ist ein Injektor für Pulver mit einer Verwirbelungskammer angeordnet, der mit einer Feststoffzuführeinheit verbunden ist.The object is achieved with respect to the applied device for gas atomizing a jet of flowable or liquid material, for example a beam of liquid metal or a metal alloy, with an atomizer for applying atomizing gas to the jet for atomizing the jet into a droplet consisting of droplets the atomizer unit is annular or elongated and has a continuous outlet gap for the atomizer gas. Above the area of the atomizer unit, there is disposed a powder injector with a swirling chamber connected to a solids feed unit.

Die mit der Erfindung erzielten Vorteile bestehen bezüglich der angewandten Vorrichtung zur Gaszerstäubung darin, dass die Pulverbestandteile in der Verwirbelungskammer homogen in den Sprühnebel eingebracht werden. Hierzu erzeugt die hohe Gasgeschwindigkeit des Zerstäubergases im Bereich der Verwirbelungskammer einen Unterdruck, der die Pulverteilchen konstant aus der Kammer abführt. Die Teilchenbewegung in der Wirbelkammer löst die Agglomeration feiner Pulverteilchen auf und sorgt so für eine homogene Verteilung in der abgeschiedenen Schicht. Insbesondere mit einer lang gestreckten Form der Zerstäubereinheit können breitere Bänder beschichtet werden, ohne dass die Gaszerstäubervorrichtung oder deren Teile bewegt werden müssen. Hierzu ist der längliche Teil senkrecht zur Bewegungsrichtung des Bandmaterials ausgerichtet.The advantages achieved by the invention with respect to the applied device for gas atomization is that the powder components are introduced homogeneously into the spray mist in the swirling chamber. For this purpose, the high gas velocity of the atomizing gas in the region of the swirling chamber generates a negative pressure which constantly discharges the powder particles from the chamber. The particle movement in the vortex chamber triggers the agglomeration of fine powder particles and thus ensures a homogeneous distribution in the deposited layer. In particular, with an elongate shape of the atomizer unit, wider belts can be coated without having to move the gas atomizer device or its parts. For this purpose, the elongated part is aligned perpendicular to the direction of movement of the strip material.

Eine Beaufschlagung des Sprühnebels mit Pulverteilchen stellt je nach Pulverbeschaffenheit unterschiedliche Anforderungen an die Art der Beimengung. In bevorzugter Ausführungsform umfasst die Feststoffzuführeinheit einen Vorratsbehälter für trockenes Pulver oder einen Behälter für mit Pulver beaufschlagte Flüssigkeiten mit Zuleitungen. So kann bereits durch die Pulveraufbereitung, insbesondere durch ein Aufschlämmen in einer geeigneten Flüssigkeit, die Agglomeration der Teilchen herabgesetzt werden.Depending on the nature of the powder, an application of the powder with powder particles places different demands on the type of admixture. In a preferred embodiment, the Feststoffzuführeinheit comprises a reservoir for dry powder or a container for powdered liquids with supply lines. Thus, already by the powder preparation, in particular by slurrying in a suitable liquid, the agglomeration of the particles can be reduced.

Vorteilhafterweise ist die Materialmenge des Strahls über eine Vorrichtung mit Ventilsteuerung und/oder einer Vorrichtung zur Druckbeaufschlagung eines Schmelzevorratbehälters gesteuert. Mit einer entsprechenden Druckbeaufschlagung kann gezielt der Materialstrom auch ohne ein Ventil gesteuert werden, da ein Schmelzefluss nur mit einem entsprechenden Überdruck aufrecht erhalten werden kann. Ein zusätzliches Ventil gestattet jedoch noch kürzere Schaltzeiten zum An- und Abschalten des Schmelzeflusses.Advantageously, the amount of material of the jet is controlled via a device with valve control and / or a device for pressurizing a melt reservoir. With a corresponding pressurization targeted the material flow can be controlled without a valve, since a melt flow can be maintained only with a corresponding overpressure. However, an additional valve allows even shorter switching times for switching on and off of the melt flow.

Die Aufgabe wird hinsichtlich des Verfahrens zur Herstellung eines Verbundmaterials mit einer Vorrichtung zur Gaszerstäubung mit den Schritten gelöst, nach denen ein Metall oder eine Metalllegierung in einem Vorratsbehälter über den Schmelzpunkt erwärmt wird, die Schmelze mit Druckbeaufschlagung in Form eines Schmelzestrahls austritt und mittels eines Gasstroms zu einem Sprühnebel zerstäubt, mit nicht schmelzenden Zusätzen in Partikelform vermengt wird und anschließend die zerstäubten Tröpfchen auf ein Trägermaterial oder eine Auffangvorrichtung abgeschieden werden.The object is achieved with regard to the method for producing a composite material with a device for gas atomization with the steps according to which a metal or a metal alloy is heated in a reservoir above the melting point, the melt exits with pressurization in the form of a melt jet and by means of a gas stream sprayed with a mist, mixed with non-melting additives in particulate form and then the atomized droplets are deposited on a support material or a collecting device.

Als Auffangvorrichtung kann ein sich unter dem Sprühstrahl bewegendes Kühlband dienen, von dem sich das Sprühprodukt ablösen läßt.As a catching device can serve a moving under the spray cooling belt from which can be detached the spray product.

In einer bevorzugten Ausführungsform werden die nicht schmelzenden Zusätze dem Schmelzestrom aus einer Verwirbelungskammer zugeführt.In a preferred embodiment, the non-melting additives are fed to the melt stream from a fluidization chamber.

Bei diesem Herstellungsverfahren kann entweder im Durchlaufbetrieb oder im Batchbetrieb gearbeitet werden, bei dem das zu beschichtende Band entweder kontinuierlich oder von einem Stapel übereinanderliegender Bandabschnitte zugeführt wird. Die Anlage ist in ein mit Stickstoff oder Stickstoff/Wasserstoff-Gemisch geflutetem Gehäuse mit Ein- und Auslaufschleuse untergebracht. Der Einlaufschleuse vorgeschaltet ist eine Bandreinigungs und -aktivierungsstation, mit der die Bandoberfläche vor der Beschichtung für eine gute Haftfestigkeit der abgeschiedenen Schicht entsprechend vorbereitet wird.In this manufacturing process, either in continuous operation or in batch mode be worked, in which the tape to be coated is fed either continuously or from a stack of superposed band sections. The system is housed in a nitrogen or nitrogen / hydrogen mixture flooded housing with inlet and outlet lock. Upstream of the inlet sluice is a belt cleaning and activating station which prepares the belt surface before coating for good adhesion of the deposited layer.

In bevorzugter Ausführungsform erfolgt das Verdüsen der Pulverteilchen unter Einsatz von N2. Hierzu werden die Zusätze in den Sprühstrahl bei einem Druck von 0,15 bis 1,5 MPa eingeblasen. Durch den Überdruck tritt der Stickstoff über einen Austrittsspalt in eine Mischkammer mit sehr hoher Geschwindigkeit ein, um die in der Mischkammer eingebrachten feinen Pulverteilchen zu verwirbeln und eine optimale Durchmischung zu erhalten. Zudem kann mit einer Gasgeschwindigkeit, die durchaus auch im Überschallbereich liegen kann, eine Agglomeration des Nanopulvers effektiv verhindert werden. Hierzu wird für eine optimale Vermischung die Druckbeaufschlagung der Pulverkomponenten entsprechend gesteuert.In a preferred embodiment, the atomization of the powder particles takes place using N 2 . For this purpose, the additives are injected into the spray at a pressure of 0.15 to 1.5 MPa. As a result of the overpressure, the nitrogen enters into a mixing chamber at very high speed via an outlet gap in order to fluidize the fine powder particles introduced into the mixing chamber and to obtain optimum mixing. In addition, agglomeration of the nanopowder can be effectively prevented with a gas velocity, which may well be in the supersonic range. For this purpose, the pressurization of the powder components is controlled accordingly for optimal mixing.

Um im Fertigungsprozess die Zusätze in variabler Zusammensetzung abscheiden zu können erfolgt vorteilhafterweise das Einblasen der Zusätze unabhängig voneinander.In order to be able to deposit the additives in a variable composition during the production process, it is advantageous to inject the additives independently of one another.

Bei der Wahl der Abscheidebedingungen wird eine gleichförmige Kontaktschicht mit fein dispergierten Zusätzen angestrebt. Vorteilhafterweise wird hierzu das Metallband auf eine Temperatur von (0,6 bis 0,9) x Ts des Kontaktwerkstoffes Sn oder Ag erwärmt. Damit können derartige Schichten zugleich mit geringer Porosität und hoher Haftung abgeschieden werden.When choosing the deposition conditions, a uniform contact layer with finely dispersed additives is desired. Advantageously, for this purpose, the metal strip is heated to a temperature of (0.6 to 0.9) x T s of the contact material Sn or Ag. Thus, such layers can be deposited at the same time with low porosity and high adhesion.

Um die Haftfestigkeit der Schicht auf dem Trägermaterial zu verbessern wird vor der Abscheidung der Schicht vorteilhafterweise das Metallband zur Aktivierung mit Flußmittel oberflächenbehandelt.In order to improve the adhesive strength of the layer on the carrier material, the metal ribbon is advantageously surface treated for flux activation prior to deposition of the layer.

Über wiederum andere Abscheideparameter wird die Schichtdicke eingestellt. Hierzu wird in bevorzugter Ausführungsform die Dicke D2 der Kontaktschicht über die Sprühstrahldichte und die Durchlaufgeschwindigkeit des zu beschichtenden Metallbandes gesteuert. Bevorzugt wird die Sprühstrahldichte über ein Nadelventil oder dergleichen gesteuert. Ist dabei das Nadelventil permanent geöffnet, so kann auch eine vollflächige einseitige Beschichtung erfolgen. Zur Herstellung einer gleichförmigen Schicht kann das Metallband mit konstanter Geschwindigkeit unter dem Sprühstrahl hindurch gezogen werden. Alternativ kann auch ohne Ventilvorrichtung allein durch eine Druckbeaufschlagung der Schmelze der Materialfluss im Sprühkopf gesteuert werden.The layer thickness is set again via other deposition parameters. For this purpose, in a preferred embodiment, the thickness D 2 of the contact layer is controlled via the spray jet density and the passage speed of the metal strip to be coated. Preferably, the spray jet density is controlled via a needle valve or the like. If the needle valve is permanently open, then a full-surface one-sided coating can take place. To make a uniform layer, the metal strip can be pulled under the spray jet at a constant speed. Alternatively, the material flow in the spray head can be controlled even without pressurization of the melt without a valve device.

Unter geeigneter Wahl der Abscheidebedingungen lassen sich die Dichte bzw. die Porosität der Kontaktschicht auch gezielt einstellen. In einer besonders vorteilhaften Ausführungsform wird über die gewählten Sprühparameter eine offene Porosität der Kontaktschicht von 70 bis 85 % eingestellt. Die poröse Kontaktschicht wird anschließend zur Selbstschmierung mit Öl infiltriert.By suitable choice of the deposition conditions, the density or the porosity of the contact layer can also be adjusted in a targeted manner. In a particularly advantageous embodiment, an open porosity of the contact layer of 70 to 85% is set via the selected spray parameters. The porous contact layer is then infiltrated with oil for self-lubrication.

Poröse Schichten werden in einem weiteren Verfahrensschritt nachbehandelt, indem das besprühte Metallband bei einer Temperatur von mindestens 0,8 x Ts des Schichtmatrixwerkstoffs nachgewalzt wird, um eine 100 %ige Dichte zu erzielen.Porous layers are aftertreated in a further process step by rolling the sprayed metal strip at a temperature of at least 0.8 × T s of the layer matrix material in order to achieve a 100% density.

In besonders bevorzugter Ausführungsform wird das Metallband nur teilweise beschichtet. Damit kann eine partiell resistive Beschichtung beispielsweise an der Spitze eines Steckers erzeugt werden.In a particularly preferred embodiment, the metal strip is only partially coated. In this way, a partially resistive coating can be produced, for example, at the tip of a plug.

Bei partiell resistiven Beschichtungen wird während des Ziehvorganges der Strom kontinuierlich herabgesetzt, so dass sich in Abhängigkeit vom Material und der Spannung ab einem gewissen Grenzwiderstand kein Lichtbogen mehr ausbilden kann. Bei derartigen selbstabschaltenden Kontakten wird auf diese Weise der Abbrand minimiert.In the case of partially resistive coatings, the current is continuously reduced during the drawing process so that, depending on the material and the voltage, starting from a certain limiting resistance, it is no longer possible to form an arc. In such Selbstabschaltenden contacts the burnup is minimized in this way.

Zur Herstellung partiell resistiver Beschichtungen wird vorteilhafterweise das Metallband mit einer Maske bedeckt. Alternativ kann das Metallband gegen den Sprühstrahl abgeschirmt werden. Hierzu wird die Maske nicht auf den Träger aufgelegt, sondern in einem gewissen Abstand im Strahl positioniert.To produce partially resistive coatings, the metal strip is advantageously covered with a mask. Alternatively, the metal strip can be shielded against the spray. For this purpose, the mask is not placed on the carrier, but positioned at a certain distance in the beam.

Elektronik vor Ort bedeutet zum einen erhöhte Temperaturen, zum anderen eine erhöhte Schwingungsbelastung. Dies gilt insbesondere für die Mehrventiltechnik. Für eine Anwendung im Automotiv Bereich werden stromleitende Anschlüsse wie Steckverbinder, Stanzgitteranschlüsse, Relaisanschlüsse sowie verschleiß- und schwingungsbeständige, hochtemperaturfeste Beschichtungen benötigt. Auf diese Weise findet das elektrisch leitfähigen Verbundmaterial Verwendung für den Automotiv Bereich und insbesondere in elektrischen Kontaktbauteilen wie Steckverbinder und Steckverbinderanschlüsse.On-site electronics means increased temperatures and increased vibration levels. This is especially true for the multi-valve technology. For an application in the automotive sector, current-carrying connections such as connectors, punched grid connections, relay connections as well as wear and vibration-resistant, high-temperature resistant coatings are required. In this way, the electrically conductive composite material finds use for the automotive sector and in particular in electrical contact components such as connectors and connector terminals.

Die mit der Erfindung erzielten Vorteile bestehen bezüglich des Verfahrens insbesondere darin, dass die Kontaktbeschichtung eines Metallbandes als Trägermaterial partiell aufgebracht werden kann, um selbstabschaltende Kontakte mit geringen Abbrandverhalten zu erzeugen. Insbesondere wird in einem Prozessablauf über eine geeignete Parameterwahl eine Kontaktschicht auf einem Trägermaterial erzeugt, die unmittelbar als Bandmaterial weiterverarbeitet werden kann. Über bereits bestehende Fertigungsverfahren hinaus kann der Beschichtungsprozess damit ohne Weiteres in eine rationelle Serienfertigung eingebunden werden.With regard to the method, the advantages achieved with the invention are, in particular, that the contact coating of a metal strip as a carrier material can be partially applied in order to produce self-disconnecting contacts with low burn-off behavior. In particular, a contact layer is produced on a carrier material in a process sequence via a suitable parameter selection, which can be further processed directly as strip material. In addition to already existing manufacturing processes, the coating process can thus easily be integrated into rational mass production.

Ausführungsbeispiele der Erfindung werden anhand einer Zeichnung näher erläutert. Darin zeigen:

  • Fig. 1 ein Verbundmaterial mit Träger und Kontaktschicht,
    und
  • Fig. 2 eine schematische Darstellung der Gaszerstäubervorrichtung.
Embodiments of the invention will be explained in more detail with reference to a drawing. Show:
  • Fig. 1 a composite material with carrier and contact layer,
    and
  • Fig. 2 a schematic representation of the gas atomizing device.

Einander entsprechende Teile sind in allen Figuren mit denselben Bezugszeichen versehen.Corresponding parts are provided in all figures with the same reference numerals.

Das Verbundmaterial 1 zur Herstellung elektrischer Kontaktbauteile nach Figur 1 ist aus einem Metallband 2 als Träger aus Metall und einer zumindest einseitig aufgebrachten Kontaktschicht 4 aus einem Silber- oder Zinn-Kontaktwerkstoff aufgebaut. Der Kontaktwerkstoff enthält als ersten Zusatz 0,5 bis 60 Gew.-% Kohlenstoff-Pulver in Form feiner Teilchen mit einem Durchmesser Ø1 = 5 bis 200 nm und 0,5 bis 60 Gew.-% eines zweiten pulverförmigen Zusatzes unterschiedlicher Materialien in Form feiner Teilchen mit einem Durchmesser Ø2 = 5 bis 200 nm.
Zwischen Metallband 2 und Kontaktschicht 4 ist eine Zwischenschicht 6 aus Ag bzw. Sn der Dicke D3 = 0,1 bis 1 µm angeordnet.
Die Dicke des Metallbandes 2 beträgt bevorzugt D1 = 0,06 bis 1,2 mm und der Kontaktschicht 4 D2 = 0,5 bis 10 µm. Das Metallband 2 wird zur Aktivierung mit Flußmittel oberflächenbehandelt.
The composite material 1 for producing electrical contact components according to FIG. 1 is composed of a metal strip 2 as a carrier made of metal and a contact layer 4 applied at least on one side of a silver or tin contact material. The contact material contains as the first additive 0.5 to 60 wt .-% carbon powder in the form of fine particles with a diameter Ø 1 = 5 to 200 nm and 0.5 to 60 wt .-% of a second powdered additive of different materials in the form fine particles with a diameter Ø 2 = 5 to 200 nm.
Between metal strip 2 and contact layer 4, an intermediate layer 6 made of Ag or Sn of thickness D 3 = 0.1 to 1 microns is arranged.
The thickness of the metal strip 2 is preferably D 1 = 0.06 to 1.2 mm and the contact layer 4 D 2 = 0.5 to 10 microns. The metal strip 2 is surface treated for activation with flux.

Die in Fig. 2 schematisch dargestellte Gaszerstäubervorrichtung 10 beinhaltet einen in einem beheizten Gehäuse 40 angeordneten Schmelzebehälter 12 mit Einfüllstutzen und Zuführkanälen 14 für die Schmelze zu einer Düse 28 mit einem Nadelventil 18, aus dem der Strahl aus flüssigem Metall oder einer Metalllegierung austritt. Die Austrittsmenge wird über einen am Schmelzebehälter 12 angebrachten Anschluss zur Druckbeaufschlagung 16 gesteuert. Der Einfüllstutzen am Schmelzebehälter 12 ist zur Druckbeaufschlagung mit einem Stopfen oder einer Schraubverbindung gasdicht verschlossen.In the Fig. 2 schematically illustrated gas atomizer 10 includes a arranged in a heated housing 40 melt container 12 with filler neck and feed channels 14 for the melt to a nozzle 28 with a needle valve 18, from which the jet of liquid metal or a metal alloy emerges. The discharge quantity is controlled via a connection to the pressurization 16, which is attached to the melt container 12. The filler neck on the melt container 12 is closed in a gas-tight manner for pressurizing with a stopper or a screw connection.

Zudem ist im beheizten Gehäuse 40 ein Behälter 20 mit Einfüllstutzen für Flüssigkeiten und Gemische aus einer mit Pulver beaufschlagten Flüssigkeit angeordnet. Dieser ist über Zuführkanäle 22 mit der um das Nadelventil 18 angeordneten Injektoreinheit 32 mit Verwirbelungskammer 26 verbunden. Auch aus diesem Behälter wird die Austrittsmenge über einen am Behälter 20 angebrachten Anschluss zur Druckbeaufschlagung 24 gesteuert. Alternativ oder zusätzlich besteht die Möglichkeit weitere Feststoffzuführeinheiten mit einem Pulvergefäß 44 für trockenes Pulver an das beheizte Gehäuse 40 anzuschließen, die über nicht in der schematischen Darstellung abgebildete Kanäle eine Verbindung zur Injektoreinheit 32 besitzen. Weitere Schmelzgefäße, gegebenenfalls mit getrennter Heizung, können an einer Anschlusseinheit 42 angedockt werden.In addition, in the heated housing 40, a container 20 is arranged with filler neck for liquids and mixtures of a liquid acted upon with powder. This is connected via supply channels 22 with the injector unit 32 arranged around the needle valve 18 with swirling chamber 26. Also from this container, the discharge amount is controlled by a container 20 mounted on the connection to the pressurization 24. Alternatively or additionally, there is the possibility to connect further Feststoffzuführeinheiten with a powder container 44 for dry powder to the heated housing 40, which have a connection to the injector unit 32 via not shown in the schematic diagram channels. Further melting vessels, optionally with separate heating, can be docked to a connection unit 42.

Die durch das Nadelventil 18 austretende Schmelze wird mit den Feststoffen aus der Wirbelkammer vermengt und mit der N2-Zerstäubereinheit 34 mit Zerstäubergas so beaufschlagt, dass aus dem Strahl ein aus Tröpfchen bestehender Sprühnebel entsteht, der auf ein Band 2 abgeschieden wird. Eine N2-Kammer 36, unmittelbar vor den N2-Austrittsspalt 38, sorgt für eine konstante Gaszufuhr.The melt exiting through the needle valve 18 is mixed with the solids from the vortex chamber and treated with nebulizer gas with the N 2 atomizer unit 34 so that a spray consisting of droplets is formed from the jet, which is deposited on a belt 2. An N 2 chamber 36, immediately in front of the N 2 exit gap 38, ensures a constant supply of gas.

Zur Führung des Sprühstrahls dient ein Austrittstrichter 30 mit einem vorgegebenen Austrittskegel, der eine Abscheidung über die gesamte Bandbreite gewährleistet. Zur selektiven Abscheidung wird eine Maske 8 im Strahl positioniert oder auf dem Substrat aufgebracht.To guide the spray is an outlet funnel 30 with a predetermined exit cone, which ensures a deposition over the entire bandwidth. For selective deposition, a mask 8 is positioned in the beam or applied to the substrate.

Die Zerstäubereinheit 34 ist ringförmig oder lang gestreckt in die Bildebene der Fig. 2 hinein ausgebildet, wobei diese einen durchgehenden Austrittsspalt 38 für das N2-Zerstäubergas aufweist. Mit der Reinigungs- und Aktiviereinheit 48 wird das Metallband 2 zur Aktivierung mit Flussmittel an der Oberflächen vorbehandelt. Das Band kann im Durchlaufbetrieb kontinuierlich oder in Form einer Stapellage im Batchbetrieb 46 beschichtet werden.The atomizing unit 34 is annular or elongated in the image plane of Fig. 2 formed therein, which has a continuous exit gap 38 for the N 2 -Zerstäubergas. With the cleaning and activating unit 48, the metal strip 2 is pretreated for activation with flux on the surfaces. The belt can be coated in continuous operation or in the form of a stacked layer in batch mode 46.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Verbundmaterialcomposite material
22
Metallbandmetal band
44
Kontaktschichtcontact layer
66
Zwischenschichtinterlayer
88th
Maskemask
1010
GaszerstäubervorrichtungGaszerstäubervorrichtung
1212
Schmelzebehältermelt container
1414
Zuführkanäle für SchmelzeFeed channels for melt
1616
Anschluss zur DruckbeaufschlagungConnection for pressurization
1818
Nadelventilneedle valve
2020
Behälter für Flüssigkeiten und GemischeContainers for liquids and mixtures
2222
Zuführkanälesupply channels
2424
Anschluss zur DruckbeaufschlagungConnection for pressurization
2626
Verwirbelungskammerswirl
2828
Düsejet
3030
Austrittstrichter/SprühstrahlführungOutlet funnel / Sprühstrahlführung
3232
Injektoreinheit mit WirbelkammerInjector unit with vortex chamber
3434
N2-ZerstäubereinheitN 2 atomizer unit
3636
N2-KammerN 2 chamber
3838
N2-AustrittsspaltN 2 exit slit
4040
beheiztes Gehäuseheated housing
4242
Anschluss für weiteres SchmelzegefäßConnection for another melt vessel
4444
Pulvergefäßpowder vessel
4646
Stapellage für BatchbetriebStacking layer for batch operation
4848
Reinigungs- und AktiviereinheitCleaning and activating unit

Claims (28)

  1. Electrically conductive composite material (1) for producing electrical contact components, in particular plug type connectors, plug type connector terminals, comprising a metal strip (2) and a contact layer (4) which is applied at least to one side and which comprises a silver or tin contact material,
    characterised in that
    - the contact material contains, as the first additive, from 0.5 to 60% by weight of carbon powder in the form of fine particles having a diameter ∅1 = from 5 to 200 nm and from 0.5 to 60% by weight of a second powder-like additive in the form of fine particles which improve the electrical conductivity, hardness and abrasion resistance, having a diameter ∅2 = from 5 to 200 nm and in that
    - the production of the composite material is carried out in such a manner that a metal or a metal alloy of the contact layer (4) in the form of a molten stream becomes atomised by means of a gas stream to form an atomised mist, is mixed in particle form with non-molten additives and subsequently the atomised droplets are deposited onto the metal strip (2).
  2. Composite material according to claim 1, characterised in that an intermediate layer (6) comprising Ag or Sn having a thickness D3 = from 0.1 to 1 µm is arranged between the metal strip (2) and the contact layer (4).
  3. Composite material according to claim 1 or claim 2, characterised in that the contact material contains, as the first additive, from 3 to 40% by weight of carbon powder of plate-like and/or globular and/or pelletised form in the form of fine particles having a diameter ∅1 = from 20 to 150 nm.
  4. Composite material according to any one of claims 1 to 3, characterised in that the second additive is from 2 to 50% by weight of a metal from the group comprising Co, Cu, Mo, Ni, Ti, W in the form of fine particles having a diameter ∅2 = from 10 to 200 nm.
  5. Composite material according to any one of claims 1 to 3, characterised in that the second additive is from 2 to 40% by weight of a carbide in the form of fine particles having a diameter ∅2 = from 10 to 200 nm.
  6. Composite material according to any one of claims 1 to 3, characterised in that the second additive is from 0.5 to 40% by weight of a disulphide from the group comprising MoS2, WS2, in the form of fine particles having a diameter ∅2 = from 50 to 200 nm.
  7. Composite material according to any one of claims 1 to 3, characterised in that the second additive is from 2 to 40% by weight of SnO2 in the form of fine particles having a diameter ∅2 = from 5 to 100 nm.
  8. Composite material according to any one of claims 1 to 3, characterised in that the second additive is from 2 to 40% by weight of oxidic ceramic particles from the group comprising Al2O3, ZrO2, having a diameter ∅2 = from 50 to 150 nm.
  9. Composite material according to any one of claims 1 to 3, characterised in that the second additive is from 2 to 20% by weight of PTFE in the form of fine particles having a diameter ∅2 = from 50 to 200 nm.
  10. Composite material according to one or more of claims 1 to 9, characterised in that the thickness of the metal strip (2) is D1 = from 0.06 to 1.2 mm and the contact layer (4) is D2 = from 0.5 to 10 µm.
  11. Composite material according to one or more of claims 1 to 10, characterised in that the metal strip (2) comprises Cu or a Cu alloy, Fe or an Fe alloy, Al or an Al alloy, Ni or an Ni alloy.
  12. Method for producing a composite material according to any one of claims 1 to 11, having a device for gas atomisation, characterised by the steps according to which a metal or a metal alloy in a storage container is heated above the melting point, the fluid melt is discharged with the application of pressure in the form of a molten stream and becomes atomised to form an atomised mist by means of a gas stream, is mixed with non-molten additives in particle form and subsequently the atomised droplets are deposited onto a metal strip (2) as a carrier material or a collection device.
  13. Method for producing a composite material according to claim 12, characterised in that the non-molten additives are supplied to the molten stream from a vortex chamber (26).
  14. Method according to claim 12, characterised in that the atomisation is carried out using N2 or an N2/H2 admixture.
  15. Method according to claims 12 to 14, characterised in that the additives are introduced into the atomised stream at a pressure of from 0.15 to 1.5 MPa.
  16. Method according to any one of claims 12 to 15, characterised in that the additives are introduced independently of each other.
  17. Method according to one or more of claims 12 to 16, characterised in that the metal strip (2) is heated to a temperature of (0.6 to 0.9) x Ts of the contact material.
  18. Method according to one or more of claims 12 to 17, characterised in that the metal strip (2) is surface-treated with a fluxing agent in order to be activated.
  19. Method according to one or more of claims 12 to 18, characterised in that the thickness D2 of the contact layer (4) is controlled by means of the density of the atomised stream and the passage speed of the metal strip (2) to be coated.
  20. Method according to claim 19, characterised in that the density of the atomised stream is controlled by means of a needle valve, or the like.
  21. Method according to any one of claims 12 to 20, characterised in that the metal strip (2) is drawn under the atomised stream at a constant speed.
  22. Method according to any one of claims 12 to 21, characterised in that an open porosity of the contact layer (4) of from 70 to 85% is adjusted by means of the atomisation parameters selected.
  23. Method according to claim 22, characterised in that oil is introduced into the porous contact layer (4).
  24. Method according to one or more of claims 12 to 23, characterised in that the sprayed metal strip (2) is subsequently rolled at a temperature of at least 0.8 x Ts of the metal strip material in order to obtain 100% density.
  25. Method according to one or more of claims 12 to 24, characterised in that the metal strip (2) is only partially coated.
  26. Method according to claim 25, characterised in that the metal strip (2) is covered with a mask (8).
  27. Method according to claim 25, characterised in that the metal strip (2) is screened against the atomised stream.
  28. Use of an electrically conductive composite material according to any one of claims 1 to 11 in the automotive sector as electrical contact components such as plug type connectors and plug type connector terminals.
EP03025163A 2002-12-27 2003-11-04 Composite material for manufacturing electrical contacts and process for its preparation Expired - Lifetime EP1433867B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10261303 2002-12-27
DE10261303A DE10261303B3 (en) 2002-12-27 2002-12-27 Electrically conducting composite material used in automotive applications as electrical contact components, such as connectors or connections, comprises a metal strip and a contact layer containing carbon powder and a further additive

Publications (3)

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EP1433867A2 EP1433867A2 (en) 2004-06-30
EP1433867A3 EP1433867A3 (en) 2006-05-17
EP1433867B1 true EP1433867B1 (en) 2009-10-14

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US (1) US7132172B2 (en)
EP (1) EP1433867B1 (en)
JP (1) JP4571397B2 (en)
KR (1) KR101090190B1 (en)
CN (1) CN1519991B (en)
AT (1) ATE445719T1 (en)
DE (2) DE10261303B3 (en)

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Publication number Publication date
US7132172B2 (en) 2006-11-07
EP1433867A2 (en) 2004-06-30
CN1519991A (en) 2004-08-11
ATE445719T1 (en) 2009-10-15
DE10261303B3 (en) 2004-06-24
JP4571397B2 (en) 2010-10-27
CN1519991B (en) 2011-05-18
EP1433867A3 (en) 2006-05-17
JP2004214183A (en) 2004-07-29
KR101090190B1 (en) 2011-12-06
KR20040060753A (en) 2004-07-06
US20040202884A1 (en) 2004-10-14
DE50312017D1 (en) 2009-11-26

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