WO2014182174A1 - High performing aluminium component with a surface coating suitable for thermal radiation applications - Google Patents

High performing aluminium component with a surface coating suitable for thermal radiation applications Download PDF

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Publication number
WO2014182174A1
WO2014182174A1 PCT/NO2014/000028 NO2014000028W WO2014182174A1 WO 2014182174 A1 WO2014182174 A1 WO 2014182174A1 NO 2014000028 W NO2014000028 W NO 2014000028W WO 2014182174 A1 WO2014182174 A1 WO 2014182174A1
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WO
WIPO (PCT)
Prior art keywords
max
coating
aluminium component
aluminium
degreasing
Prior art date
Application number
PCT/NO2014/000028
Other languages
French (fr)
Inventor
Merete Hallenstvet
Svein Roger SKJERVOLD
Original Assignee
Norsk Hydro Asa
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Norsk Hydro Asa filed Critical Norsk Hydro Asa
Priority to EP14795185.9A priority Critical patent/EP2994552A4/en
Publication of WO2014182174A1 publication Critical patent/WO2014182174A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/023—Alloys based on aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment

Definitions

  • the present invention relates to a high performing aluminium component such as busbars and other electrical conductors and heat sinks with a surface coating suitable for thermal radiation, a method for preparation and application of the coating on the components.
  • the current rating of a busbar is limited by the maximum ambient temperature and the maximum permitted working temperature.
  • heat is generated in the bar due to the electrical resistance, and the heat is evacuated or tapped from the bar by convection and radiation.
  • an alloy with reduced electrical resistivity in combination with a high emissivity coating will improve the performance of electrical conductors.
  • performance may be increased by providing ribs, corrugations or other surface modifications which enhances convection and thereby increase heat transfer. The result should be the smallest possible bar size. As energy costs rise, it is worth considering the lifetime cost of a busbar system, including capital cost and the cost of waste energy.
  • Aluminium can substitute copper in many new application for electrical conductors.
  • the increased copper prize increase the market pull for aluminium conductors and busbars.
  • the temperature of the conductor is reduced and the conductivity is improved at the lower temperature. It is commonly known that black matt surfaces are better at radiating heat than bright and shiny metal surfaces, and that is why coating is sometimes suggested.
  • the efficiency of radiation is the emissivity of the surface and the total surface area per volume. Theoretically, for a perfect radiator (matt black), the emissivity is 1 and for a perfect reflector, emissivity is zero. Thus, the thermal radiation is governed by the emissivity of the surface of the conductor.
  • busbars thermal conductivity is very important due to the maximum limit on operational temperature.
  • General known requirements as regards he maximum temperature limits for bus bars are in the range of 140 and 105°C.
  • a high performing aluminium component suitable for thermal radiation applications such as aluminium busbars or heat sinks with high emissivity.
  • Fig. 1 shows a longitudinal view of part of a busbar according to the invention provided with a coating according to the invention
  • Fig. 2 shows a cross sections a) with a tape and b) with a copper deposition of the same busbar as is shown in Fig. 1 .
  • Fig. 3 shows an alternative bus bar design with serrated surface in the form of longitudinal ribs.
  • Standard black powder coating typically has an emissivity from 0.84 to 0.88.
  • the emissivity is influenced by the binder system, pigmentation and the surface roughness. As is indicated above, black matt coatings have higher emissivity then black and glossy surfaces.
  • the pigmentation of a black powder coating for interior applications can apply all types of pigments and binder systems since it is not affected by solar radiation or corrosive environment.
  • the coating may be a dry powder coating type or wet type coating containing black pigments.
  • the coating may be a thermosetting or thermoplastic polymer such as polyester or polyurethane, polyester epoxy, straight epoxy or acrylics.
  • the coating may be any polymer based type such as an acrylic polymer coating, polyester resin type or polyurethane type.
  • Figs. 1 and 2 shows respectively in perspective view and cross section, a busbar 1 of aluminium with a coating 2 according to the invention.
  • the aluminium busbar is preferably made by extrusion of an age hardening 6000 aluminium alloy with high electrical conductivity and yield strength in the range from 100 to 180MPa.
  • EC 6000 and EC 1000 each containing by weight %:
  • the electrical conductivity can be increased by reducing the content of elements like Fe, Cu, Mn, Cr, Zn, Ti and V in a standard 6101 aluminium alloy and the above selected alloy lies within the desired electrical conductivity level.
  • part of the bus bar is un-coated in the longitudinal direction to obtain good connectivity with electrical components and connections.
  • the extruded profile 1 is preferably subjected to mild degreasing before being provided with a masking tape 3 (see Fig 2 a) in its longitudinal direction.
  • the tape may be applied without degreasing, but mild degreasing is preferred to obtain improved adhesion.
  • the purpose of the tape which should be chemical and temperature resistant, is to keep the masked part of the busbar surface free from further treatment and coating, thereby obtaining good connectivity with electrical components and connections.
  • Such process may include the following process steps:
  • the un-masked surface of the busbar is provided with the high emissivity coating according to the invention.
  • the coating may be applied to the busbar surface by spray, dip or rolling with a wet lacquer or by electrostatic or tribiostatic application using powder coating, as stated above.
  • the busbar will be held or stored at required temperature for some time to cure (dry or harden etc.) the coating.
  • the tape will then finally removed after the coating has been cured / dried. .
  • a temperature rise test has documented that the total effect of the selected alloy and use of the high emissivity black powder according to the invention was -10°K, or 7% performance improvement.
  • Fig. 3 shows an alternative bus bar 5 where performance is increased by providing ribs 6, which enhances convection and thereby increase heat transfer.
  • Other designs may also be provided such as corrugations, dents or other surface modifications.
  • the bus bar may as well, as in the former example shown in Figs. 1 and 2 be provided with an uncoated part 7 in the longitudinal or transversal direction.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Conductive Materials (AREA)

Abstract

High performing aluminium component with a surface coating suitable for thermal radiation applications such as aluminium busbars, other electrical conductors and heat sinks. The coating is a polymer based coating with carbon pigments having an emissivity higher than 0,90. Further the aluminium component is manufactured on the basis of an alloy with one of the following two compositions: Type: EC 6000 EC 1000 Si 0,3 - 0,6 0,15 max Fe 0,1- 0,3 0,30 max Cu 0,01 max 0,01 max Mn 0,005 max 0,010 max Mg 0,3 - 0,6 0,02 max Cr 0,005 max 0,005 max Zn 0,02 max 0,02 max Ti 0,01 max 0003 max V 0,005 max 0,01 Omax B 0,010 max Others each 0,02 max 0,02 max Others total 0,10 max 0,01 Omax

Description

High performing aluminium component with a surface coating suitable for thermal radiation applications
The present invention relates to a high performing aluminium component such as busbars and other electrical conductors and heat sinks with a surface coating suitable for thermal radiation, a method for preparation and application of the coating on the components.
The current rating of a busbar is limited by the maximum ambient temperature and the maximum permitted working temperature. In use, heat is generated in the bar due to the electrical resistance, and the heat is evacuated or tapped from the bar by convection and radiation. Hence, an alloy with reduced electrical resistivity in combination with a high emissivity coating will improve the performance of electrical conductors. In addition performance may be increased by providing ribs, corrugations or other surface modifications which enhances convection and thereby increase heat transfer. The result should be the smallest possible bar size. As energy costs rise, it is worth considering the lifetime cost of a busbar system, including capital cost and the cost of waste energy.
Aluminium can substitute copper in many new application for electrical conductors. The increased copper prize increase the market pull for aluminium conductors and busbars.
With high thermal radiation from a conductor the temperature of the conductor is reduced and the conductivity is improved at the lower temperature. It is commonly known that black matt surfaces are better at radiating heat than bright and shiny metal surfaces, and that is why coating is sometimes suggested. The efficiency of radiation is the emissivity of the surface and the total surface area per volume. Theoretically, for a perfect radiator (matt black), the emissivity is 1 and for a perfect reflector, emissivity is zero. Thus, the thermal radiation is governed by the emissivity of the surface of the conductor.
Aluminium metal has a very low emissivity, typical ε = 0.06 for untreated aluminium. But the emissivity changes very rapidly by surface treatment of aluminium (see table below). High emissivity will give high radiation heat loss.
Figure imgf000003_0001
As to busbars, thermal conductivity is very important due to the maximum limit on operational temperature. General known requirements as regards he maximum temperature limits for bus bars are in the range of 140 and 105°C.
With the present invention is provided a high performing aluminium component suitable for thermal radiation applications such as aluminium busbars or heat sinks with high emissivity. Further is provided an aluminium component with improved electrical and thermal conductivity based on the combination of selected alloy quality and improved thermal radiation by surface treatment including the inventive coating and serrated profile design.
The invention will be further described in the following by way of example and with reference to the attached figures where: Fig. 1 shows a longitudinal view of part of a busbar according to the invention provided with a coating according to the invention,
Fig. 2 shows a cross sections a) with a tape and b) with a copper deposition of the same busbar as is shown in Fig. 1 .
Fig. 3 shows an alternative bus bar design with serrated surface in the form of longitudinal ribs.
Standard black powder coating typically has an emissivity from 0.84 to 0.88. The emissivity is influenced by the binder system, pigmentation and the surface roughness. As is indicated above, black matt coatings have higher emissivity then black and glossy surfaces.
The pigmentation of a black powder coating for interior applications can apply all types of pigments and binder systems since it is not affected by solar radiation or corrosive environment.
By selecting and applying carbon pigments with high emissivity it has, according to the invention, proved possible to develop powder coatings with emissivity larger than the current 0.90.
The coating may be a dry powder coating type or wet type coating containing black pigments. In turn if the coating is dry, it may be a thermosetting or thermoplastic polymer such as polyester or polyurethane, polyester epoxy, straight epoxy or acrylics. On the other hand, if wet, the, coating may be any polymer based type such as an acrylic polymer coating, polyester resin type or polyurethane type.
Figs. 1 and 2 shows respectively in perspective view and cross section, a busbar 1 of aluminium with a coating 2 according to the invention. The aluminium busbar is preferably made by extrusion of an age hardening 6000 aluminium alloy with high electrical conductivity and yield strength in the range from 100 to 180MPa. For electrical conductors with lower requirements on mechanical strength it is an alternative to use a high purity 1000 aluminium alloy. (EC 6000 and EC 1000 each containing by weight %:
Type: EC 6000 EC 1000
Si 0,3 - 0,6 0,15 max
Fe 0,1 - 0,3 0,30 max
Cu 0,01 max 0,01 max
Mn 0,005 max 0,010 max
Mg 0,3 - 0,6 0,02 max
Cr 0,005 max 0,005 max
Zn 0,02 max 0,02 max
Ti 0,01 max 0003 max
V 0,005 max 0,010max
B 0,010 max
Others each 0,02 max 0,02 max
Others total 0,10 max 0,010max
It has been documented that the electrical conductivity can be increased by reducing the content of elements like Fe, Cu, Mn, Cr, Zn, Ti and V in a standard 6101 aluminium alloy and the above selected alloy lies within the desired electrical conductivity level.
As can be seen in the example shown in Figs. 1 and 2, part of the bus bar is un-coated in the longitudinal direction to obtain good connectivity with electrical components and connections.
This is done as follows:
After extrusion, the extruded profile 1 is preferably subjected to mild degreasing before being provided with a masking tape 3 (see Fig 2 a) in its longitudinal direction. The tape may be applied without degreasing, but mild degreasing is preferred to obtain improved adhesion. The purpose of the tape, which should be chemical and temperature resistant, is to keep the masked part of the busbar surface free from further treatment and coating, thereby obtaining good connectivity with electrical components and connections.
After masking the un-masked part of the busbar is subjected to further degreasing and surface treatment. Such process may include the following process steps:
1. Degreasing , preferred alkaline degreasing
2. Rinsing.
3. Etching / neutralisation / desmutting, an acid process step if the degreasing is alkaline
4. Rinsing.
5. Passivation preferred in no-chromate processes for improved adhesion and corrosion protection.
6. Rinsing.
7. Drying with hot air typical in a small furnace.
After surface treatment, the un-masked surface of the busbar is provided with the high emissivity coating according to the invention. The coating may be applied to the busbar surface by spray, dip or rolling with a wet lacquer or by electrostatic or tribiostatic application using powder coating, as stated above.
Depending on type of coating, the busbar will be held or stored at required temperature for some time to cure (dry or harden etc.) the coating. The tape will then finally removed after the coating has been cured / dried. .
Masking of the busbar with tape before coating represents a cheap alternative to the costly machining process used today.
A temperature rise test has documented that the total effect of the selected alloy and use of the high emissivity black powder according to the invention was -10°K, or 7% performance improvement.
Fig. 3 shows an alternative bus bar 5 where performance is increased by providing ribs 6, which enhances convection and thereby increase heat transfer. Other designs may also be provided such as corrugations, dents or other surface modifications. The bus bar may as well, as in the former example shown in Figs. 1 and 2 be provided with an uncoated part 7 in the longitudinal or transversal direction.

Claims

Claims
High performing aluminium component with a surface coating suitable for thermal radiation applications such as aluminium busbars, other electrical conductors and heat sinks,
characterised in that
the coating is a polymer based coating with carbon pigments having an emissivity higher than 0,90 and that the aluminium component is manufactured on the basis of an alloy with one of the following two compositions:
Type: EC 6000 EC 1000
Si 0,3-0,6 0,15 max
Fe 0,1-0,3 0,30 max
Cu 0,01 max 0,01 max
Mn 0,005 max 0,010 max
Mg 0,3-0,6 0,02 max
Cr 0,005 max 0,005 max
Zn 0,02 max 0,02 max
Ti 0,01 max 0003 max
V 0,005 max 0,010max
B 0,010 max
Others each 0,02 max 0,02 max
Others total 0,10 max 0,01 Omax
2. Aluminium component according to claim 1 ,
characterised in that
the coating is a dry powder type based on a thermoplastic or thermoset type polymer.
3. Aluminium component according to claim 1 ,
characterised in that the coating is a lacquer is a wet type polymer. Aluminium component according to claims 1-3,
characterised in that
part of the bus bar is un-coated in the longitudinal direction to obtain good connectivity with electrical components and connections.
5 Aluminium component according to claims 1-4,
characterised in that
part of the bus bar is provided with ribs, corrugations or other surface
modifications which enhances convection, thereby increasing heat transfer.
6. Method of manufacturing an aluminium component according to the previous claims where the component is a busbar made from an extruded profile, characterised in that
the extruded profile (1) preferably is subjected to mild degreasing before being provided with a masking tape (3) in its longitudinal direction.
7. Method according to claim 6,
characterised in that
after masking the un-masked part of the busbar is subjected to further pre- treatment steps as follows:
a. degreasing , preferably based on alkaline degreasing
b. rinsing
c. etching / neutralisation / desmutting, and including an acid process step if the degreasing according to step a. is alkaline
d. rinsing
e. passivation preferred is no-chromate processes for improved
adhesion and corrosion protection rinsing
drying with hot air typical in a small furnace
8. Method according to claim 6,
characterised in that
the coating is a polymer based coating with carbon pigments having an emissivity higher than 0,90 9. Method according to claim 6,
characterised in that
the coating is a dry powder type based on a thermoplastic or thermoset type polymer.
PCT/NO2014/000028 2013-05-06 2014-04-08 High performing aluminium component with a surface coating suitable for thermal radiation applications WO2014182174A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP14795185.9A EP2994552A4 (en) 2013-05-06 2014-04-08 High performing aluminium component with a surface coating suitable for thermal radiation applications

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NO20130651 2013-05-06
NO20130651 2013-05-06

Publications (1)

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WO2014182174A1 true WO2014182174A1 (en) 2014-11-13

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WO (1) WO2014182174A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2545446A (en) * 2015-12-16 2017-06-21 Ge Aviation Systems Group Ltd Power distribution connector
WO2017124428A1 (en) * 2016-01-22 2017-07-27 Abb 瑞士股份有限公司 Metal coating copper bar and electrical equipment
CN107274955A (en) * 2017-06-12 2017-10-20 合肥铭佑高温技术有限公司 A kind of wire conductor and its production technology for Equipment for Heating Processing

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2382871A (en) * 2001-12-08 2003-06-11 Seco Aluminium Ltd Heating and cooling in railway carriages
US20040186201A1 (en) * 2003-03-07 2004-09-23 James Stoffer Corrosion resistant coatings containing carbon
JP2006240243A (en) * 2005-03-07 2006-09-14 Sumitomo Light Metal Ind Ltd Precoated aluminium alloy plate excellent in heat release nature
DE102007023672A1 (en) * 2007-05-22 2008-11-27 Institut für Luft- und Kältetechnik gGmbH Compact condenser for e.g. house-hold refrigerator, has band-like extruded section pipe having breadth that is double thickness of pipe, and two channels that are separated from each other and run parallel to each other
KR101055657B1 (en) * 2011-06-03 2011-08-09 (주)시그너스시스템 High polymer application aluminium busbar and switchgear having thereof

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US3383188A (en) * 1965-09-27 1968-05-14 Olin Mathieson Aluminum conductors
FR2313748A1 (en) * 1975-06-06 1976-12-31 Trefimetaux Electric conductors made of aluminium contg. magnesium and silicon - and possessing optimum combination of strength, ductility and conductivity
JP5105483B2 (en) * 2008-09-19 2012-12-26 古河スカイ株式会社 Resin coated aluminum plate

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2382871A (en) * 2001-12-08 2003-06-11 Seco Aluminium Ltd Heating and cooling in railway carriages
US20040186201A1 (en) * 2003-03-07 2004-09-23 James Stoffer Corrosion resistant coatings containing carbon
JP2006240243A (en) * 2005-03-07 2006-09-14 Sumitomo Light Metal Ind Ltd Precoated aluminium alloy plate excellent in heat release nature
DE102007023672A1 (en) * 2007-05-22 2008-11-27 Institut für Luft- und Kältetechnik gGmbH Compact condenser for e.g. house-hold refrigerator, has band-like extruded section pipe having breadth that is double thickness of pipe, and two channels that are separated from each other and run parallel to each other
KR101055657B1 (en) * 2011-06-03 2011-08-09 (주)시그너스시스템 High polymer application aluminium busbar and switchgear having thereof

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP2994552A4 *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2545446A (en) * 2015-12-16 2017-06-21 Ge Aviation Systems Group Ltd Power distribution connector
GB2545446B (en) * 2015-12-16 2018-08-22 Ge Aviat Systems Ltd Power distribution connector
US10494119B2 (en) 2015-12-16 2019-12-03 Ge Aviation Systems Limited Power distribution connector with thermally conductive polymer heat sink
WO2017124428A1 (en) * 2016-01-22 2017-07-27 Abb 瑞士股份有限公司 Metal coating copper bar and electrical equipment
CN107274955A (en) * 2017-06-12 2017-10-20 合肥铭佑高温技术有限公司 A kind of wire conductor and its production technology for Equipment for Heating Processing

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EP2994552A1 (en) 2016-03-16

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