WO2019176891A1 - 直流高電圧リレー及び直流高電圧リレー用の接点材料 - Google Patents
直流高電圧リレー及び直流高電圧リレー用の接点材料 Download PDFInfo
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- WO2019176891A1 WO2019176891A1 PCT/JP2019/009841 JP2019009841W WO2019176891A1 WO 2019176891 A1 WO2019176891 A1 WO 2019176891A1 JP 2019009841 W JP2019009841 W JP 2019009841W WO 2019176891 A1 WO2019176891 A1 WO 2019176891A1
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- voltage relay
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H1/00—Contacts
- H01H1/02—Contacts characterised by the material thereof
- H01H1/021—Composite material
- H01H1/023—Composite material having a noble metal as the basic material
- H01H1/0237—Composite material having a noble metal as the basic material and containing oxides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C5/00—Alloys based on noble metals
- C22C5/06—Alloys based on silver
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H1/00—Contacts
- H01H1/02—Contacts characterised by the material thereof
- H01H1/021—Composite material
- H01H1/023—Composite material having a noble metal as the basic material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/54—Contact arrangements
- H01H50/56—Contact spring sets
- H01H50/58—Driving arrangements structurally associated therewith; Mounting of driving arrangements on armature
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/14—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of noble metals or alloys based thereon
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H50/00—Details of electromagnetic relays
- H01H50/54—Contact arrangements
Definitions
- the present invention relates to a DC high voltage relay (contactor) that performs ON / OFF control of a DC high voltage circuit.
- the present invention relates to a DC high-voltage relay that realizes low heat generation characteristics during continuous energization and reliable circuit interruption performance when contacts are opened.
- this invention relates to the contact material applied to this direct current
- a direct current high voltage relay is used in the control of a high voltage circuit such as the above.
- a direct current high voltage relay called a system main relay (SMR) or a main contactor is used.
- SMR system main relay
- a direct current high voltage relay is similar in basic configuration and function to a direct current low voltage relay conventionally used in general automobile applications and the like.
- the DC high-voltage relay is a device corresponding to a relatively new application such as the above-described hybrid car, and has a difference related to the application and a specific problem caused by the difference.
- the conventional DC low voltage circuit will be described.
- the rated voltage and the rated current are clearly defined.
- the nominal voltage DC12V of the mounted battery is the rated voltage of a general vehicle-mounted general-purpose relay.
- Some trucks and buses are equipped with a DC 24V battery, so some relays have a rated voltage of DC 24V.
- DC low voltage relays tend to be required to be smaller and lighter for in-vehicle applications.
- the DC low voltage relay can be reduced in size and weight by reducing the size and weight of the components, this increases the burden on the contact material. Therefore, this requirement is also addressed by improving the durability (consumption resistance, welding resistance) of the contact material.
- the Ag-oxide-based contact material is a material in which particles of a metal oxide (SnO 2 , In 2 O 3, etc.) such as Sn and In are dispersed in an Ag matrix or an Ag alloy matrix.
- the Ag-oxide-based contact material improves the performance of the contact material by the dispersion strengthening action of the metal oxide particles to ensure required characteristics such as wear resistance and welding resistance.
- the present applicant has disclosed an Ag-oxide-based contact material described in Patent Document 1 as a contact material applied to a DC low voltage relay for vehicle use.
- the improvement of the conventional DC low-voltage relay is supported by increasing the amount of oxide of the applied Ag-oxide contact material.
- contact materials that utilize the oxide dispersion strengthening action increasing the concentration of metal components that form oxides to increase the amount of oxides improves welding resistance and wear resistance. is there.
- an Ag-oxide-based contact material in which a metal component other than Ag, such as Sn or In, is 10 mass% or more is often used. This is because if the metal component other than Ag of the contact material is less than 10% by mass, the amount of oxide is small, and there are cases where the required characteristics are not satisfied due to defects such as welding, transfer, and wear.
- improvements in Ag-oxide contact materials as described above can improve durability within the specified rated voltage range and ensure durability for miniaturization and weight reduction. Has been achieved.
- DC high-voltage relays are not currently clearly defined for rated voltage and rated current.
- the required specifications are greatly affected by future improvements in battery performance. That is, it is difficult to predict the upper limit of the load received by the contact in the DC high voltage relay, and there is a high possibility that it will increase in the future. This point is different from the conventional DC low voltage relay.
- the amount of heat generated at the contacts is proportional to the square of the current and the contact resistance value, so it is assumed that considerable heat will be generated when the current of the DC high-voltage relay increases in the future. In the worst case, abnormal heat generation in the relay causes a fatal problem such as ignition or burning.
- the welding of contacts becomes an important issue as well as the issue of heat generation.
- the welding is a phenomenon in which the contact surfaces of the contact pair are melted and fixed by Joule heat during energization and arc heat generated during arc opening and closing.
- Such contact welding becomes an obstacle when the contact pair is separated, and causes a return failure and a failure of the entire circuit.
- the failure can be a serious disaster. Therefore, the DC high voltage relay needs to realize a reliable circuit interruption. For example, when a system abnormality occurs in a DC high-voltage circuit such as a hybrid car, it is necessary to turn off the relay and shut off the circuit. In such a case, the cutoff current is larger than the current during normal switching. For this reason, the DC high-voltage relay needs to clear the problem of welding in order to ensure the interruption performance at the time of abnormality in the contact.
- Measures from the structure and mechanism of the DC high-voltage relay are taken as countermeasures against the problems of heat generation and welding at the contact of the DC high-voltage relay as described above.
- the contact pressure spring is strengthened to increase the contact force between the movable contact and the fixed contact to ensure a contact area, and the contact resistance between both contacts is reduced to suppress heat generation.
- the increase in contact force also contributes to prevention of relay ignition and rupture when the DC high-voltage circuit is short-circuited.
- DC high voltage relays often employ a structure for extinguishing arc discharge generated between contacts. Specifically, measures such as securing a sufficient gap between contacts, installing an arc extinguishing magnet, and strengthening the magnetic force thereof are considered.
- the relay is sealed so that hydrogen gas, nitrogen gas, or a mixed gas thereof is enclosed, and the arc is quickly extinguished by an arc cooling effect.
- a DC high voltage relay from the viewpoint of contact resistance, it is not preferable to increase the amount of oxide of the contact material.
- Ag which is a high conductivity metal
- metal oxides are resistors that reduce the overall conductivity of the contact material.
- An increase in the amount of oxide increases the resistance value of the entire contact material.
- an oxide aggregation layer is likely to be formed on the surface of the damaged portion that is generated when arc discharge occurs when the contact is opened and closed. This also increases the contact resistance value of the contact material.
- the amount of heat generated at the contact is proportional to the square of the current and the contact resistance.
- An increase in the amount of oxide that increases the contact resistance of the contact material of the DC high-voltage relay that is intended to increase the voltage and current is a measure that should be avoided from the viewpoint of suppressing heat generation and welding.
- the examination examples of various contact materials for DC high-voltage relays so far can be said to be just an extension of the study of materials for general switching contacts. And there are few reports for practical application to DC high-voltage relays.
- the present invention has been made based on the above background, and for DC high-voltage relays such as system main relays, it is possible to perform reliable ON / OFF control while dealing with the problems of contact heat generation and welding.
- the present invention provides a contact material suitable for a DC high voltage relay in consideration of the characteristics of the DC high voltage relay.
- the contact portion of the DC high-voltage relay Since the above-mentioned problem of the present invention is caused by the contact portion of the DC high-voltage relay, it is considered that the solution of the problem involves the optimization of the Ag-oxide-based contact material constituting the contact.
- the DC high-voltage relay cannot easily adopt the countermeasure that has been considered appropriate so far, which is an increase in oxides. This is because an increase in the amount of oxide leads to an increase in heat generation due to an increase in contact resistance.
- the inventors of the present invention focused on the characteristics of the DC high-voltage relay before examining the configuration of the contact material.
- the feature of this DC high voltage relay is the strength of the contact force and the separation force between the fixed contact and the movable contact.
- a relay including a contactor having an equivalent function / structure
- the contact / separation between a fixed contact and a movable contact is controlled by cooperation between an electromagnet or a coil and an appropriate biasing means.
- Energization / interruption (ON / OFF) is performed.
- Appropriate urging means include a contact pressure spring and a return spring in a plunger type relay, and a movable spring and a recovery spring in a hinge type relay.
- Such a control mechanism for the fixed contact and the movable contact is common to the entire relay regardless of the rated voltage.
- the contact force and the separation force between the fixed contact and the movable contact are often set high.
- the contact force and breaking force are often set at about 10 gf to 50 gf, whereas the DC high voltage relay has a contact force or breaking force of 100 gf or more. Often set.
- the reason why the contact force of the DC high voltage relay is high is to reduce the contact resistance of the contact and suppress the heat generation.
- the contact force affects the contact area between the contacts, and the larger the contact force is set, the smaller the contact resistance is, so that the generation of Joule heat can be suppressed and the effect of melting and welding the contact surface is reduced.
- the opening force means a restoring force for returning the contact point to the separated position. In the DC high voltage relay, the opening / closing operation of the contacts is performed smoothly, so that the opening force tends to increase with the increase of the contact force.
- DC high-voltage relay in which a high contact force and a separation force are set, even if the fixed contact and the movable contact can be welded, they can be separated with an increased separation force.
- the present inventors considered that the DC high-voltage relay that is the subject of the present invention can be set more flexibly than the conventional DC low-voltage relay with respect to the welding resistance of the contact material.
- Such an idea of allowing a certain degree of welding is unique in the field of switching contacts as well as DC high-voltage relays.
- DC high-voltage relays such as system main relays are devices that have begun to spread due to the recent development of high-voltage power supplies, and are expected to have many unknown setting items.
- One such tolerance is the tolerance of welding resistance to contacts.
- the characteristic that should be given priority as a contact material for DC high-voltage relays is a stable low contact resistance characteristic.
- it is effective to reduce the amount of oxide. Reduction of the amount of oxide for Ag-oxide-based contact materials leads to deterioration of the welding resistance, but as described above, the welding resistance can be flexibly handled, and when a high contact force or separation force can be set, A considerable degree of reduction in welding resistance is acceptable.
- the present inventors In order to find an Ag-oxide-based contact material applicable to a DC high-voltage relay having a predetermined contact force and opening force, the present inventors have proposed a suitable oxidation from the relationship between contact resistance reduction and welding resistance. A study was conducted to find the content of the product. Then, the present invention finds an Ag-oxide-based contact material in which the oxide content is reduced to a predetermined range compared to a conventional general Ag-oxide-based contact material for switching contacts, and applies the present invention I came up with it.
- the present invention that solves the above-described problem is provided with at least one contact pair composed of a movable contact and a fixed contact, and the contact force and / or breaking force of the contact pair is 100 gf or more, and a DC high voltage of a rated voltage of 48 V or more
- the movable contact and / or the fixed contact is made of an Ag-oxide-based contact material
- the metal component of the contact material includes at least one metal M that essentially contains Sn, and the balance Ag and Inevitable impurity metal, the content of the metal M is 0.2% by mass or more and 8% by mass or less with respect to the total mass of all metal components of the contact material, and the contact material is made of Ag or Ag alloy.
- a direct current high voltage relay having a material structure in which at least one metal M oxide is dispersed in a matrix.
- the direct current high voltage relay and the contact material for the direct current high voltage relay according to the present invention will be described in detail.
- content of an oxide is prescribed
- content of the metal M is prescribed
- the contact material applied in the present invention is an Ag-oxide-based contact material, its constituent elements are Ag, metal M, inevitable impurity metal, oxygen, and nonmetal inevitable impurity elements.
- elements called semimetals such as Te and Si are also handled as metals.
- A. DC high-voltage relay according to the present invention The DC high-voltage relay according to the present invention is required to have a rated voltage of 48 V or higher and a contact force or opening force of 100 gf or higher. Other configurations and characteristics are the same as those of a conventional DC high voltage relay such as a system main relay. In the following description, the two essential conditions will be described, and the configuration of a DC high voltage relay that can be optionally provided will be described.
- Relay-rated voltage rated voltage 48V for example, in the conventional DC low voltage relay to handle low voltage 24V from 12V, it can not satisfy the characteristics required for the high voltage DC relay in such system main relay.
- the significance of applying the present invention to such a conventional DC low voltage relay is small. Therefore, the DC high-voltage relay according to the present invention is targeted for a rated voltage of 48V or more.
- the upper limit of the rated voltage of the DC high voltage relay according to the present invention is 3000 V or less.
- the rated current of the DC high-voltage relay according to the present invention is assumed to be 10 A or more and 3000 A or less.
- the contact force and opening force of the DC high-voltage relay according to the present invention and the present invention are applied to a DC high-voltage relay having a contact force or opening force of 100 gf or more.
- the DC high-voltage relay of the present invention and the contact material mounted thereon have flexible welding resistance based on the relationship with the contact force or opening force of the applied DC high-voltage relay.
- the target DC high-voltage relay has a contact force or a separation force set to 100 gf or more between the movable contact and the fixed contact.
- the set value 100gf here assumes a lower limit value corresponding to the required characteristics for the DC high voltage relay, and in this case, the contact material to be applied has sufficient welding resistance. Is required.
- the upper limit value of the contact force or separation force is assumed to be 5000 gf.
- the contact force or separation force will be strengthened as the component parts and the relay body increase in size.
- a relay design having the lowest possible contact force and separation force is desired.
- by optimizing the contact material applied to the fixed contact and the movable contact it is possible to set a DC high voltage relay having a suitable contact force / breaking force while suppressing heat generation / welding.
- both the contact force and the opening force may be 100 gf or more. Further, the contact force and the separation force need not be the same value.
- the contact force or separation force can be adjusted by the capacity or size of an electromagnet or coil and appropriate biasing means, which are constituent members of a relay described later.
- Appropriate biasing means include contact pressure springs and return springs for plunger type relays, and movable springs and recovery springs for hinge type relays.
- the DC high voltage relay according to the present invention can be characterized by the above-described rated voltage, contact force, and opening force. Functions, configurations and mechanisms other than the rated voltage, contact force, and opening force can be the same as those of a conventional DC high voltage relay. The structure and the like of the DC high voltage relay according to the present invention will be described below.
- DC high-voltage relays can be broadly divided into a drive section that generates and transmits a driving force for moving a movable contact, and a contact section that opens and closes a DC high-voltage circuit. Composed.
- the drive section energizes the electromagnet or coil that generates the driving force, the transmission means (the plunger or armature described below) for transmitting the driving force to the contact section, and the transmission means to contact or separate the contact pair.
- Biasing means contact pressure spring, return spring, movable spring, recovery spring, etc.
- the contact section includes a contact pair composed of a movable contact and a fixed contact that are moved by the transmission means of the drive section, a movable terminal that joins the movable contact, and a fixed terminal that joins the fixed contact.
- DC high-voltage relays are generally divided into plunger type and hinge type based on the difference in the physical configuration of the contact pair.
- FIG. 1 is a diagram showing an example of the structure of a plunger type DC high voltage relay.
- the plunger-type relay is a relay that opens and closes a contact pair by driving a contact section with a plunger-type electromagnet.
- the contact section of the plunger type relay is constituted by members of a movable contact, a fixed contact, a movable terminal, and a fixed terminal.
- the drive section of the plunger type relay is constituted by an electromagnet, a movable iron core, a fixed iron core, a plunger as a transmission means, a contact pressure spring as a biasing means, and a return spring.
- the plunger which is a transmission means may be called a movable iron core, a shaft, etc.
- additional members such as an electromagnetic repulsion suppression yoke, an arc extinguishing magnet (permanent magnet), a terminal cover, an electrode, and a buffer spring (buffer rubber) may be provided.
- the DC high voltage relay includes wiring connected to the circuit and wiring for controlling the electromagnet.
- FIG. 2 is a diagram showing an example of the structure of a hinge type DC high voltage relay.
- the hinge-type relay is a relay that opens and closes a contact pair by directly or indirectly driving a movable contact by rotating an electromagnet armature around a fulcrum.
- the contact section of the hinge-type relay is configured by members of a movable contact, a fixed contact, a movable spring (movable terminal), and a fixed terminal (fixed spring).
- the drive section of the hinge-type relay includes a coil, an iron core, a yoke, an armature as a transmission means, and a return spring as an urging means.
- the springs such as the return spring, either a push spring or a tension spring is selected depending on the relay structure.
- the hinge type relay of FIG. 2 there is a type in which a contact driving card is provided as a transmission means, and the contact is driven by this.
- incidental members such as an arc extinguishing magnet (permanent magnet), a terminal cover, and an electrode may be provided.
- the DC high voltage relay includes wiring connected to the circuit, terminals for controlling the electromagnet, and wiring.
- an arc extinguishing magnet is installed in the vicinity of the contact pair in the contact section as necessary.
- the arc extinguishing magnet extends the arc discharge generated between the contacts when the movable contact and the fixed contact are separated by a Lorentz force and quickly extinguishes the arc.
- the arc extinguishing magnet is not an essential component because it does not participate in the opening / closing operation of the contact pair.
- the arc extinguishing magnet is used in many products because it can exhibit a remarkable arc extinguishing effect in a DC high-voltage relay.
- the larger the magnetic flux density of the arc extinguishing magnet the shorter the time until arc extinguishing is completed.
- the type of arc extinguishing magnet either a ferrite magnet or a rare earth magnet is selected in consideration of the manufacturing cost and the balance of operation design.
- the various components described above are accommodated in a case, body, etc. for forming the entire device.
- the case and body have an airtight structure that protects the relay structure from external forces and prevents entry of dust, dust, etc., and meets the need to prevent intrusion of outside air and gas.
- Regarding the airtight structure of DC high-voltage relays there are known open air types that leave untreated gaps such as case terminals and fittings, and resin-sealed molds that seal gaps with a sealing material such as resin. Yes.
- a cooling gas sealing type is also known in which a cooling gas such as hydrogen gas or nitrogen gas is sealed in a case having a sealed structure in which a gap is sealed. Any of these hermetic structures can be employed in the DC high-voltage relay according to the present invention.
- the DC high-voltage relay of the present invention includes at least one contact pair composed of a movable contact and a fixed contact, like a general relay.
- the number of contact pairs may be one.
- DC high voltage relays such as system main relays often employ a double break structure having two contact pairs.
- the DC high voltage relay illustrated in FIG. 1 shows an example of the structure of a DC high voltage relay having a double break structure.
- the direct-current high-voltage relay according to the present invention uses a contact material described later for at least one of the movable contact and the fixed contact. At least one of the movable contact and the fixed contact is joined to the movable terminal and the fixed terminal.
- both the movable contact and the fixed contact are made of a contact material described later, and in addition to the case of joining to each terminal, either the movable contact or the fixed contact is made of a contact material described later.
- the other can be made of other contact materials and bonded to the respective terminals.
- the movable contact is a contact material described later
- the fixed terminal or movable terminal
- the contact acts as a movable contact or a fixed contact to constitute a contact pair.
- the movable and fixed contacts There are no particular restrictions on the shape and dimensions of the movable and fixed contacts. Examples of the shape of the movable contact or the fixed contact that are assumed include a rivet contact, a tip contact, a button contact, and a disk contact.
- the movable contact and the fixed contact may be a bulk material made of a contact material described later, but may be clad with another material.
- a contact material described later may be clad with a base material made of Cu, Cu alloy, Fe-based alloy, or the like to form a movable contact and a fixed contact.
- the shape of the clad material is not limited, and various shapes such as a tape contact (clad tape), a crossbar contact, a rivet contact, a chip contact, a button contact, and a disk contact can be applied.
- Cu a Cu alloy, or an Fe-based alloy is used as a constituent material of the movable terminal and the fixed terminal.
- surface treatment such as Sn plating, Ni plating, Ag plating, Cu plating, Cr plating, Zn plating, Pt plating, Au plating, Pd plating, Rh plating, Ru plating, Ir plating, etc., is performed on them. Is done.
- a method of joining the movable contact and the fixed contact to the respective terminals it can be performed by processing means such as caulking, brazing, and welding.
- processing means such as caulking, brazing, and welding.
- a part or all of the surface of the movable terminal and / or the fixed terminal may be covered with a contact material having a composition described later by a surface treatment such as sputtering to form a movable contact / fixed contact.
- the direct current high voltage relay according to the present invention is characterized by applying a predetermined contact material as a suitable constituent material of the movable contact and the fixed contact in consideration of having a high contact force and a separation force.
- the contact material of the present invention constitutes at least the surface of the movable contact and / or the fixed contact of the DC high-voltage relay having a rated voltage of 48 V or more and a contact force and / or opening force of the contact pair of 100 gf or more.
- a metal component of the contact material is composed of at least one metal M essentially containing Sn, the balance Ag and an unavoidable impurity metal, and the contact material.
- the content of the metal M is 0.2% by mass or more and 8% by mass or less with respect to the total mass of all metal components, and the contact material is an oxide of the metal M in a matrix made of Ag or an Ag alloy.
- the contact material applied to the DC high voltage relay of the present invention is an Ag-oxide based contact material in which the metal component is Ag, metal M, and inevitable impurity metal.
- Metal M which is a metal component, exists as a constituent element of an oxide dispersed in the matrix. This oxide is dispersed in order to improve the mechanical strength and adhesion resistance of the contact material.
- the welding resistance of the contact point is flexibly interpreted for the DC high-voltage relay that is the subject of the present invention. In other words, if the contact force and / or breaking force of the DC high-voltage relay can be set high, the contact material itself can be allowed to deteriorate in the welding resistance. However, this does not mean that welding resistance is not required. Also in the present invention, since welding resistance is required to some extent, an oxide is formed and dispersed. Therefore, in the contact material applied in the present invention, the metal M is an essential metal element.
- the content of the metal M is set to 0.2% by mass or more and 8% by mass or less based on the total mass of all metal components of the contact material. If the metal M is less than 0.2% by mass, the amount of oxide dispersion is too small, and there is a concern that the mechanical strength and the welding resistance are lowered, so that the material is substantially equivalent to pure Ag. Therefore, depending on the setting of the contact force or the separation force, there is a possibility that a blocking failure may occur. Further, when the amount of oxide is too small, the contact material melts and the contact shape collapses. If the contact shape collapses remarkably, normal contact between the movable contact and the fixed contact after return is not performed, resulting in contact failure.
- the contact material containing the metal M exceeding 8% by mass has high contact resistance and cannot solve the problem of heat generation in the DC high-voltage relay.
- the contents of Ag, metal M, and inevitable impurity metals are defined by mass concentration with respect to the total mass of all metal components.
- the total mass of all metal components is a mass obtained by dividing the mass of the contact material by the mass of components other than metal components such as oxygen and other gas components.
- the content of the metal M is preferably 0.2% by mass or more and 3% by mass or less from the viewpoint of contact resistance.
- the content of the metal M is preferably 3% by mass or more and 6% by mass or less.
- the content of the additive metal (metal M) in the contact material of the direct current high voltage relay of the present invention described above is intentionally higher than the content of the additive metal in the contact material of a conventional general vehicle relay. Has been reduced.
- contact materials Al-oxide-based contact materials
- the content of metal components other than Ag (metal M of the present invention) exceeds 10% by mass. is there.
- the Ag-oxide contact material applied in the present invention essentially contains Sn as the metal M.
- Sn is a metal that has been conventionally added as a constituent metal of the Ag-oxide-based contact material, and takes into consideration the material strengthening effect and the welding resistance improving effect of the oxide (SnO 2 ).
- Sn is essential, and the metal M may contain only Sn.
- the contact material of the present invention contains Sn in an amount of 0.2% by mass to 8% by mass.
- the Sn content is preferably 3% by mass or more and 6% by mass or less.
- the Ag-oxide contact material applied in the present invention can contain other metals as the metal M while requiring Sn. Specifically, In, Bi, Ni, and Te can be included. These metals tend to exert the effect of adjusting the hardness of the Ag-oxide-based contact material containing Sn and suppressing an increase in contact resistance. Hereinafter, the amount of these metals added will be described. If the addition amount of each of the following elements is less than the lower limit value, the above effect is not obtained.
- the contact material contains In as the metal M
- the content of In with respect to the total mass of all metal components of the contact material is preferably 0.1% by mass or more and 5% by mass or less.
- the Sn content is preferably 0.1% by mass or more and 7.9% by mass or less.
- the In content is 0.1% by mass or more and 3.1% by mass or less, and the Sn content is 2.8% by mass or more and 5.8% by mass or less.
- the content of the metal M is preferably 6% by mass or less.
- Bi is dispersed as an oxide (Bi 2 O 3 ) alone or a composite oxide with Sn (Bi 2 Sn 2 O 7 ).
- Bi is an additive element useful for a contact material in which the metal M is Sn or a contact material in which the metal M is Sn and In.
- the contact material contains Bi
- the content of Bi with respect to the total mass of all metal components of the contact material is preferably 0.05% by mass or more and 2% by mass or less.
- the Bi content is 0.05% by mass or more and 2% by mass or less
- the Sn content is 2.9% by mass or more and 5.95% by mass or less.
- the content of the metal M is preferably 6% by mass or less.
- it is preferable that the content of In arbitrarily contained is 0.1% by mass or more and 5% by mass or less.
- Te is dispersed as a single oxide (TeO 2 ).
- Te is an additive element useful for a contact material in which the metal M is Sn or a contact material in which the metal M is Sn and In.
- the Te content with respect to the total mass of all metal components of the contact material is preferably 0.05% by mass or more and 2% by mass or less.
- the Sn content is preferably 0.1% by mass or more and 7.95% by mass or less.
- the content of In optionally contained is preferably 0.1% by mass or more and 5% by mass or less.
- the Te content is set to 0.05% by mass to 2% by mass and the Sn content is set to 2.8% by mass to 5.8% by mass.
- the content of the metal M is preferably 6% by mass or less. In this case, the content of In optionally included is preferably 0.1% by mass or more and 3.1% by mass or less.
- Ni is dispersed as a single oxide (NiO).
- Ni is an additive element useful for a contact material in which the metal M is Sn and In, or a contact material in which the metal M is Sn and Te.
- the Ni content is preferably 0.05% by mass or more and 1% by mass or less.
- the Sn content is preferably 0.1% by mass or more and 7.85% by mass or less.
- the In content should be 0.1 mass% or more and 5 mass% or less, and the Te content should be 0.05 mass% or more and 2 mass% or less. preferable.
- the content of these three metals M (Sn + In + Ni or Sn + Te + Ni) is preferably 8% by mass or less.
- the Ni content is 0.05 mass% or more and 1 mass% or less, and the Sn content is 2.8 mass% or more and 5.7 mass% or less.
- the content of the metal M is preferably 6% by mass or less.
- the In content is 0.1 mass% or more and 3.1 mass% or less, and the Te content is 0.05 mass% or more and 2 mass% or less. It is preferable to do this.
- the metal component of the contact material according to the present invention is composed of the metal M, the balance Ag and the inevitable impurity metal described above.
- Inevitable impurity metals include Ca, Cu, Fe, Pb, Pd, Zn, Al, Mo, Fe, Mg, La, Li, Ge, W, Na, Zr, Nb, Y, Ta, Mn, Ti, Co, Cr, Cd, K, Si, etc. are mentioned.
- the content of these inevitable impurity metals is preferably 0% by mass to 1% by mass with respect to the total mass of all metal components of the contact material.
- the contact material applied in the present invention is an Ag-oxide contact material, and contains oxygen and a non-metallic inevitable impurity element in addition to the metal component.
- the oxygen content in the contact material of the present invention is 0.025% by mass or more and 2% by mass or less based on the mass of the entire contact material.
- C, S, P, etc. are mentioned as a nonmetallic inevitable impurity element.
- the content of these inevitable impurity elements is preferably 0% by mass or more and 0.1% by mass or less with respect to the mass of the entire contact material.
- the above-described inevitable impurity metals and non-metallic inevitable impurity elements may form intermetallic compounds. For example, WC, TiC, etc. are assumed. About such an intermetallic compound, it is preferable that they are 0 mass% or more and 1 mass% or less, respectively with respect to the mass of the whole contact material.
- the contact material applied in the DC high voltage relay of the present invention is an Ag-oxide based contact material.
- the material structure is basically the same as that of a conventional Ag-oxide-based contact material. That is, it has a material structure in which at least one oxide of the metal M is dispersed in a matrix made of Ag and / or an Ag alloy. This matrix is made of Ag (pure Ag) or an Ag alloy, or Ag and an Ag alloy.
- An Ag alloy is an alloy of Ag and an additive element M or an inevitable impurity metal, but is not limited to a single-phase Ag alloy of one composition, and is a plurality of Ag alloys having different solid solution amounts of the metal M and the like. May be configured.
- the composition and structure of the Ag alloy can vary depending on the degree of oxidation.
- the matrix may contain the metal M in some cases.
- the concentration (average concentration) of the metal M in the matrix is preferably 4% by mass or less, but an upper limit of less than 8% by mass, for example, 7% by mass or less can be used as the contact material.
- the composition of the oxide particles dispersed in the matrix is based on the metal M, and is at least one of oxides such as SnO 2 , Bi 2 O 3 , Bi 2 Sn 2 O 7 , In 2 O 3 , NiO, TeO 2. The seeds are dispersed.
- the content of the dispersed oxide (the content of the metal M) is intentionally reduced as compared with the conventional Ag-oxide-based contact material to obtain a stable low contact resistance.
- the present invention it is not intended to ignore the welding resistance and the mechanical strength of the material. Therefore, in the present invention, while reducing the amount of oxide, by reducing the size of the oxide particles, the number of oxides is increased and the interparticle distance is shortened to enhance the dispersion effect. This ensures the minimum material strength, welding resistance, and material strength required for the DC high-voltage relay.
- the material strength of the contact material applied in the present invention is preferably 50 Vv or more and 150 Hv or less in terms of Vickers hardness. If it is less than 50 Hv, the strength is too low and there is a risk of deformation due to opening and closing of the contact pair. Further, a hard material exceeding 150 Hv may have a high contact resistance.
- the contact material applied in the present invention preferably has an average particle size of the oxide dispersed in the matrix of 0.01 ⁇ m or more and 0.3 ⁇ m or less.
- the average particle size of the oxide is preferably small, but it is difficult to make it less than 0.01 ⁇ m.
- the particle diameter of the oxide particles is a circle equivalent diameter (area equivalent circle diameter), which is a diameter of a perfect circle having an area corresponding to the area of the particles.
- distribute is equal.
- the particle diameter (D 90 ) when the cumulative number when observing an arbitrary cross section and measuring the particle size distribution of all oxide particles is 90% is 0.5 ⁇ m or less.
- the area of the oxide in the cross section is 0.1% or more and 15% or less.
- This area ratio can be measured by observing a cross section obtained by cutting the contact material in an arbitrary direction with a microscope (preferably an electron microscope) at 1000 to 10000 times. What is necessary is just to calculate the ratio which the total area of the oxide particle in a visual field occupies by making the observation visual field area at this time into the whole area of a contact material. The above average particle diameter can also be calculated in this observation.
- image processing software can be used as appropriate.
- the contact material of the present invention can be manufactured by an internal oxidation method, a powder metallurgy method, or a combination of an internal oxidation method and a powder metallurgy method.
- an alloy of Ag and metal M (Ag-M alloy) is manufactured and subjected to internal oxidation treatment to obtain a contact material.
- the alloy produced here is an Ag—Sn alloy (Sn: 0.2 to 8 mass%, balance Ag), an Ag—Sn—In alloy (Sn: 0.1 to 7.9 mass%).
- an alloy of Ag and metal M is internally oxidized, and metal M is converted into an oxide to form a contact material.
- the conditions for internal oxidation of the Ag-M alloy are preferably an oxygen partial pressure of 0.9 MPa or less (above atmospheric pressure) and a temperature of 300 ° C. or more and 900 ° C. or less. Under conditions of less than atmospheric pressure or less than 300 ° C., internal oxidation cannot proceed and oxide particles cannot be dispersed inside the alloy. On the other hand, if the oxygen partial pressure is greater than 0.9 MPa, the aggregated oxide may be precipitated. Moreover, when temperature is higher than 900 degreeC, there exists a possibility that a part and all of an alloy may fuse
- the treatment time for the internal oxidation treatment is preferably 24 hours or longer.
- the alloy ingot can be appropriately formed and processed, and the internal ingot can be appropriately formed to obtain a contact material.
- the alloy ingot may be pulverized, cut, or the like into solid pieces (small pieces, chips), and the solid pieces may be collected by internal oxidation treatment under the above conditions, and compression molded to form billets for processing.
- the manufactured billet can be subjected to appropriate processing such as extrusion processing and drawing processing, whereby a contact material having a predetermined shape and size can be obtained.
- a contact material is manufactured by mixing and compressing Ag powder and metal M oxide powder (SnO 2 powder, In 2 O 3 powder, etc.) and then sintering.
- the Ag powder and the oxide powder preferably have an average particle size of 0.5 ⁇ m or more and 100 ⁇ m or less.
- sintering temperature when sintering powder 700 to 900 degreeC is preferable.
- the contact material can be manufactured by combining the internal oxidation method and the powder metallurgy method.
- a powder made of an alloy of Ag and metal M (Ag-M alloy powder) is manufactured, and the alloy powder is internally oxidized and then compressed and sintered to manufacture a contact material.
- the Ag-M alloy powder is composed of an Ag alloy (Ag—Sn alloy, Ag—Sn—In alloy, Ag—Sn—Bi alloy, Ag—Sn—In—Bi alloy, Ag— Sn—Te alloy, Ag—Sn—In—Te alloy, Ag—Sn—In—Ni alloy, and Ag—Sn—In—Te—Ni alloy).
- the alloy powder is preferably a powder having an average particle size of 100 ⁇ m or more and 3.0 mm or less.
- the conditions for internal oxidation of the Ag alloy powder are preferably the same as described above.
- the DC high-voltage relay according to the present invention can perform reliable ON / OFF control while dealing with the problems of heat generation and welding in the contact pair. This effect is due to the cooperation between the high contact force and the separation force set for the DC high-voltage relay and the characteristics of the contact materials constituting the movable contact and the fixed contact.
- the contact material applied to the direct current high voltage relay of the present invention dares to reduce the content of dispersed oxide. This realizes stable low contact resistance characteristics and eliminates the problem of heat generation of the DC high-voltage relay.
- the minimum oxide amount is set, thereby forming a contact pair that does not have a failure due to welding.
- flow high voltage relay double break structure
- flow high voltage relay The SEM image of the cross section of the contact material of Example 4, 6, 8 of the 1st Embodiment, and the comparative example 2.
- FIG. The figure which shows the particle size distribution of the oxide of the contact material of Example 4 of 1st Embodiment.
- the contact material by the internal oxidation method In the production of the contact material by the internal oxidation method, an ingot was cast by melting an Ag alloy of each composition in a high-frequency melting furnace. Then, the ingot was made into a solid piece of 3 mm or less and internally oxidized under the above-mentioned conditions. The solid pieces after internal oxidation were collected and compression molded to form a billet with a diameter of 50 mm. This billet was hot-extruded and subsequently drawn into a wire having a diameter of 2.3 mm, and a rivet-type contact material was produced by a header machine.
- the contact materials of Examples 15 and 27 were subjected to internal oxidation after the contact material was processed. In Examples 15 and 27, each processing step was performed without internal oxidation of the alloy ingot, and after processing into a rivet shape, internal oxidation treatment was performed, and molding was appropriately performed to obtain a rivet-type contact material.
- the dimension of the head of the movable contact was 3.15 mm in diameter ⁇ 0.75 mm in height
- the dimension of the head of the fixed contact was 3.3 mm in diameter ⁇ 1.0 mm in height.
- Table 1 shows the compositions and hardness values of the contact materials of the examples manufactured in this embodiment (Examples 1 to 32).
- Table 2 shows the composition and hardness value of the contact materials of the comparative examples (Comparative Examples 1 to 10).
- a contact material made of pure Ag without oxide particles was also manufactured and evaluated (Comparative Example 10). This Ag contact was manufactured by hot extruding a melted and cast billet.
- the hardness measurement of the Ag contact after the Ag wire was annealed (temperature 700 ° C.), the sample was cut out and measured after wire drawing with a processing rate of 4.2%.
- FIG. 3 is SEM images of contact materials of Examples 4, 6, and 8 and Comparative Example 2.
- Table 3 also relates to contact materials of Examples 1 to 4, 6, 8, 9, 12 to 14, 16, 18 to 20, 23 to 26, 28, 29, and 32, and Comparative Examples 2, 3, and 8. It shows the state of the measured oxide particles. From FIG. 3 and Table 3, it can be seen that in the contact material of each example, fine oxide particles are dispersed in the Ag matrix. On the other hand, in the contact material of the comparative example, relatively coarse oxide particles are dispersed.
- FIG. 4 is a particle size distribution of the oxide particles in the contact material of Example 4. From FIG. 4, it can be seen that the oxide particles dispersed in the contact material of this example are fine and uniform in particle size. From the particle size distribution of the oxide particles of Example 4, the particle size (D 90 ) at which the cumulative number becomes 90% is 0.2 ⁇ m or less. The results of measurement similarly the particle size distribution in other embodiments, D 90 is was 0.5 ⁇ m or less with respect to any of the examples.
- the dimensions of the contact are as follows: the movable contact has a diameter of 3.15 mm ⁇ thickness of 0.75 mm (the contact surface area is 7.79 mm 2 when the head is observed from above), and the fixed contact has a diameter of 3 .3 mm ⁇ thickness 1.0 mm (area of contact surface 8.55 mm 2 when the head is observed from above).
- arc extinguishing magnets using two neodymium magnets having a magnetic flux density of 200 mT were arranged around the movable contact and the fixed contact. From the measurement with a gauss meter, the magnetic flux density at the center position at the time of contact was 26 mT.
- the interruption operation simulating the interruption operation at the time of occurrence of abnormality was repeated, and the number of times until the interruption failure due to the welding of the contacts (the number of interruptions) was measured.
- the number of interruptions is a standard indicating the interruption durability of the contact material, which is characterized by the relationship between the contact force / breaking force of the relay and the welding resistance. That is, the number of interruptions measured in this test is not a simple evaluation of welding resistance, but an indicator of the availability of a relay that is an actual machine.
- the test conditions of the interruption endurance test in this embodiment were as follows: voltage / current: DC360V / 400A, movable contact contact force / separation force: 75 gf / 125 gf.
- the setting of the contact force was adjusted by the strength of the contact pressure spring, and the setting of the opening force was adjusted by the strength of the return spring. Since the DC high voltage relay used for the evaluation test has a double break structure, the force applied to each contact pair is 1 ⁇ 2 of the force applied by the contact pressure spring and the return spring. The force applied to each contact pair was defined as contact force and opening force.
- the number of interruptions 100 was set as the upper limit, and the measurement of samples that reached 100 was terminated at that time.
- the melting area of the contact material after the above-described interruption durability test was measured.
- the melted area is measured by observing the contact surface after the interruption endurance test from above with a digital microscope, surrounding the melted part with area selection, and using the measurement function of the digital microscope as the area of the contact surface. It was measured.
- required was calculated
- the melted area is an index indicating the ease of contact shape deformation that may be caused by a load at the time of interruption. Since there are two contact pairs in the double break structure DC relay used in this embodiment, a total of four contact materials are used. The molten area was measured for four contact materials, and the total value was evaluated.
- the temperature rise due to the heat generated at the contacts was also measured.
- the temperature rise of the terminal portion for connecting the relay incorporating the contact material and the resistance measuring circuit was measured.
- the temperatures of the two terminals, the anode side terminal and the cathode side terminal were measured, and the average value of the temperature difference from the room temperature was measured. Elevated (° C.).
- Table 4 shows the results of the above interruption durability test, melting area measurement, contact resistance / heat generation measurement, and failure probability evaluation under conventional relay use conditions.
- the contact materials of Examples 1 to 32 have a smaller amount of oxide to be dispersed than that of the comparative example, but have good welding resistance when applied to a DC high voltage relay. It can be confirmed that problems of contact resistance and heat generation are unlikely to occur.
- the contact materials of each example of the present embodiment cleared the criterion of 50 times or more in the breaking durability test at a high voltage, and the breaking durability was good.
- the contact material of each example had a lower contact resistance than the comparative example.
- the contact materials of Examples 1 to 27 had a particularly low contact resistance of 2.5 m ⁇ or less.
- the contact materials of Examples 28 to 32 all have a breakage number of 80 or more according to high voltage evaluation, and exhibit particularly good breakage resistance.
- the contact materials of Examples 28 to 32 had a slightly higher contact resistance, but were lower than the comparative examples.
- the superiority of the contact material of each example can be grasped from the measurement result when actually incorporated in the relay.
- the temperature rise value is lower than that of the comparative example.
- the amount of heat generated at the contact is proportional to the square of the current and the contact resistance value.
- the energization current in the measurement test in the present embodiment is relatively low at 30 A, but if the energization current is increased by application to an actual DC high voltage relay, the temperature rise is further increased.
- the melted area in the present embodiment described in Table 4 is the total area change amount of the four contact surfaces after the breaking test, the number of breaking at the contact ( It is a numerical value divided by a maximum of 100 times. That is, the melted area here means the melted area per block.
- the main interruption of the relay occurs only once in the event of an abnormality, but five interruptions are necessary in consideration of the margin. Assuming that, for example, in Example 1 to Example 32 where the melted area was maximized, the melted area was 0.22 mm 2 . It is estimated to change by 10 mm 2 (0.22 mm 2 ⁇ 5 times).
- the contact material of each Example can suppress the area change at the time of interruption
- the metal M of the contact material applied in the present invention allows Sn to be contained, but also includes metals other than Sn (Bi, In, Ni, Te).
- the contact material containing only Sn as the metal M for example, Example 24
- the contact material containing Bi or the like with Sn for example, Example 9 (Sn + Bi), Example 19 (Sn + In),
- Example 23 (Sn + In + Ni + Te)) is compared, there is a tendency that the contact resistance tends to be low while showing good results for the breaking durability and the melted area. Therefore, it is confirmed that the metal M other than Sn (Bi, In, Ni, Te) is also effective.
- the contact materials of Examples 1 to 26, 30, and 31 are suitable for DC low voltage relays in terms of failure probability. It can be said that it is not. This is because the failure probability tends to increase as compared with the comparative example. That is, it can be seen that the contact materials of Examples 1 to 26, 30, and 31 exhibit their usefulness when used in an appropriate place as a DC high voltage relay.
- the contact materials of Examples 28, 29, and 32 have the same level of failure probability in the low voltage evaluation as that of the comparative example. However, it can be said that the contact materials of these examples are suitable for DC high voltage relays because of their low contact resistance values in high voltage evaluation.
- the contact materials of the comparative examples had a large amount of oxides, and hence the interruption durability and the fusion area in high voltage evaluation were excellent.
- the values of contact resistance and heat generation were high. Therefore, it can be said that there is a concern about the problem of heat generation at the contact in the DC high voltage relay including the contact material having a large amount of oxide.
- Second embodiment Also in this embodiment, it manufactured by the internal oxidation method and the powder metallurgy method. After observation of the structure and hardness of each material, a DC high voltage relay (contact force / separation force: 500 gf / 250 gf) was manufactured, and durability evaluation and contact resistance were measured and evaluated. Table 5 shows the contact materials manufactured in this embodiment. Table 5 also shows the measurement results of hardness measured in the same manner as in the first embodiment. In addition, each contact material manufactured by the internal oxidation method was manufactured by the process similar to 1st Embodiment.
- FIG. 5 is a diagram showing an SEM image of the cross-sectional structure of the contact material of Example 36 (contact material manufactured by powder metallurgy) and the particle size distribution of dispersed oxide particles. Also in the contact material of Example 36, a material structure in which fine oxide particles were dispersed in the Ag matrix was observed. It can be seen from the particle size distribution chart that oxide particles having a uniform particle size are dispersed. In Example 36, the average particle size was 0.113 ⁇ m (standard deviation ⁇ : 0.101 ⁇ m), and the particle area ratio was 8.58%. The particle diameter (D 90 ) at which the cumulative number was 90% was 0.2 ⁇ m or less. Table 6 shows the state of oxide particles measured for the contact materials of Examples 36, 39, 40, 43, 44, 47, and 49. From this table, it can be seen that fine oxide particles are dispersed in the contact materials of other examples.
- the contact endurance test in the DC high voltage relay was done about the contact material of each Example.
- This test basically has the same contents as in the first embodiment, and a DC high voltage relay having the same double break structure is used.
- the test conditions were the same as in the first embodiment.
- the contact force / separation force of the movable contact was set to 500 gf / 250 gf, and the contact force and the separation force were increased compared to the first embodiment.
- a direct current high voltage relay in which a sufficient contact force and separation force are set is manufactured.
- the number of interruptions was measured with the number of interruptions 100 being the upper limit.
- the melting area of the contact material after the interruption durability test was measured. Furthermore, the contact resistance value and heat generation of each contact material were also measured. These measurement methods are the same as those in the first embodiment.
- the same breaking durability test was performed and evaluated for the contact materials of Comparative Examples 3 and 10 of the first embodiment for comparison. Furthermore, the interruption durability test was done also about the contact material whose content of the metal M is less than the lower limit (0.2 mass%) prescribed
- the DC high-voltage relay including the contact materials of Examples 33 to 50 in this embodiment also has good breaking durability. Further, it can be confirmed that the contact of the DC high voltage relay has a low contact resistance and no problem of heat generation. These relays cleared the criterion of 50 or more interruptions, the contact resistance was as low as 2.5 m ⁇ or less, and the calorific value was also low. Also, in the evaluation regarding the melting area, it was assumed that when the contacts of Examples 46 and 47 having the largest melting area (0.63 mm 2 ) were evaluated in the same manner as in the first embodiment, five interruptions occurred. The change rate of the area of the contact surface is 9.6% and is suppressed to 10% or less.
- the contact material of Comparative Example 3 is excellent in the breaking durability and the melting area, as in the result in the first embodiment.
- the value of the contact resistance is high and the temperature rise value due to heat generation is clearly large, it is considered that it becomes an obstacle to the application when mounted on a DC high voltage relay.
- the contact material of Comparative Example 11 is a contact material having a metal M content less than the lower limit (0.2% by mass) defined in the present invention.
- This contact material has a low contact resistance and a low calorific value.
- the melting area of the contact is excessive. With respect to the melted area (1.48 mm 2 ) of Comparative Example 11, the rate of change of the contact surface area, assuming that five interruptions, which employ the evaluation method of the first embodiment, is 22.6%. There is extremely large. Thus, when the melting area increases, the contact shape collapses significantly. If the contact shape collapses, normal contact is not performed at the contact pair after the relay is restored, resulting in poor contact. As a result, the contact material (pure Ag) of Comparative Example 10 is also seen, and it can be said that the Ag-oxide contact material of Comparative Example 11 is substantially equivalent to pure Ag.
- the number of interruptions in the interruption endurance test cleared the standard, but this is considered to be caused by a larger contact force and separation force than in the first embodiment. If the contact force and the separation force are set to be approximately the same as those in the first embodiment, it is considered that a failure in blocking due to welding occurs at an early stage as in Comparative Example 10. That is, it can be seen that there is a limit even if it is acceptable to reduce the amount of oxide of the contact material applied to the DC high voltage relay.
- the DC high-voltage relay is set with sufficient contact force or separation force, and the content of oxide in the contact material of the contact pair (content of metal M) It has been confirmed that by making the material suitable, it is possible to exhibit excellent breaking durability and to solve the problems of contact resistance and heat generation.
- a break-through endurance test that simulates a shut-off operation when an abnormality occurs is manufactured by manufacturing a DC high voltage relay (FIG. 1) having a double break structure incorporating various contact materials. Went.
- this DC high-voltage relay is mounted as a system main relay such as a hybrid car, durability that simulates an opening / closing operation during normal use was evaluated.
- the normal use is a use condition that receives a load due to the ON / OFF operation of the power supply of a normal circuit.
- a precharge relay suitable for the inrush current is installed in order to prevent the contact of the system main relay from being damaged by a high inrush current when the power is turned on.
- the system main relay is turned on after the precharge relay absorbs a high inrush current.
- the same DC high-voltage relay as in the first and second embodiments is incorporated in the test circuit as shown in FIG. 6, and the capacitor load that simulates the opening / closing operation of the contact due to the inrush current relaxed as described above.
- a durability test was conducted.
- the test conditions of the capacitor load endurance test of the present embodiment are as follows: voltage: DC 20 V, load current: 80 A (when entering), 1 A (when shutting off), and switching cycle: 1 second (ON) / 9 seconds (OFF). .
- the contact force / breaking force of the movable contact was set to 75 gf / 125 gf or 500 gf / 250 gf. In this capacitor load endurance test, the number of operations was 100,000 times, and this was used as a pass criterion for endurance life.
- the contact resistance and the temperature rise were measured as in the first and second embodiments.
- the contact resistance was implemented by switching the relay connection to a resistance measurement circuit (DC5V30A) different from the circuit for the capacitor load endurance test after the capacitor load endurance test.
- the measurement method is the same as in the first embodiment.
- Table 8 shows the measurement results of durability life evaluation, contact resistance, and temperature rise in the capacitor load endurance test of this embodiment.
- the DC high-voltage relay of each example also passed the endurance life (operating 100,000 times) in the load during normal use. Further, the contact resistance was low, and there was no problem with the amount of heat generated. In contrast, the DC high voltage relay of Comparative Example 3 having a large amount of oxide of the contact material had high contact resistance and heat generation.
- the DC high-voltage relay according to the present invention preferably operates as a DC high-voltage relay by making the configuration of the contact material of the movable contact and the fixed contact suitable.
- the DC high-voltage relay according to the present invention can be effectively operated against interruption due to abnormal operation of the circuit, and can be stably operated even in normal use.
- the Ag-oxide contact material applied in the DC high-voltage relay according to the present invention exhibits excellent breaking durability, and in addition, is a contact material with low contact resistance and low heat generation.
- the DC high-voltage relay according to the present invention can solve the problem of heat generation and welding in the contact pair and perform reliable ON / OFF control.
- the present invention is suitably applied to a system main relay in a power supply circuit of a high voltage battery such as a hybrid car, a power conditioner in a power supply system such as a solar power generation facility, and the like.
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Abstract
Description
本発明における直流高電圧リレーは、定格電圧48V以上であることと、接触力又は開離力が100gf以上であることを必須の条件とする。他の構成や特性に関しては、従来のシステムメインリレー等の直流高電圧リレーと同様である。以下の説明では、上記2つの必須条件の説明と行うと共に、任意的に具備することができる直流高電圧リレーの構成について説明する。
定格電圧が48V未満のリレー、例えば、12Vから24Vの低電圧を扱う従来の直流低電圧リレーでは、システムメインリレー等の直流高電圧リレーに要求される特性を満足することができない。そして、そのような従来の直流低電圧リレーに本発明を適用する意義は少ない。よって、本発明に係る直流高電圧リレーは、定格電圧48V以上を対象とした。尚、本発明に係る直流高電圧リレーの定格電圧の上限は3000V以下とするのが好ましい。また、本発明に係る直流高電圧リレーの定格電流は、10A以上3000A以下が想定される。
そして、本発明は、接触力又は開離力が100gf以上の直流高電圧リレーに適用される。上述のとおり、本発明の直流高電圧リレー及びそれに搭載される接点材料は、適用される直流高電圧リレーの接触力又は開離力との関係に基づき、耐溶着性を柔軟に設定している。対象となる直流高電圧リレーは、可動接点と固定接点との間において、接触力又は開離力が100gf以上に設定されているものである。ここでの設定値100gfは、直流高電圧リレーへの要求特性に対応するための下限値を想定しており、この場合、適用される接点材料には充分な耐溶着性を有している事が求められる。一方、接触力又は開離力の上限値は5000gfが想定される。接触力又は開離力は、構成部品及びリレー本体のサイズアップに伴い、強化される事になる。但し、リレーの小型化や軽量化の観点からは、できるだけ低い接触力・開離力を有するリレー設計が望まれる。本発明によれば、固定接点及び可動接点に適用する接点材料の好適化により、発熱・溶着を抑制しつつ、好適な接触力・開離力の直流高電圧リレーを設定することができる。尚、接触力及び開離力は、双方が100gf以上であっても良い。また、接触力と開離力は同じ値である必要はない。
本発明に係る直流高電圧リレーは、上記した定格電圧と接触力及び開離力によって特徴づけることができる。そして、定格電圧と接触力及び開離力以外の機能や構成・機構は、従来の直流高電圧リレー同様とすることができる。以下、本発明に係る直流高電圧リレーの構造等について説明する。
直流高電圧リレーは、大別すると、可動接点を移動させるための駆動力を発生及び伝達する駆動セクションと、直流高電圧回路の開閉を行う接点セクションとで構成される。駆動セクションは、駆動力を発生する電磁石又はコイルと、駆動力を接点セクションに伝達する伝達手段(後述のプランジャー又は接極子)と、接点対を接触又は開離するために伝達手段を付勢する付勢手段(接圧ばね、復帰ばね、可動ばね、復旧ばね等のばね)を備える。接点セクションは、駆動セクションの伝達手段によって移動する可動接点と固定接点とからなる接点対と、可動接点を接合する可動端子及び固定接点を接合する固定端子を備える。直流高電圧リレーは、接点対の物理的な構成の相違に基づき、プランジャー型とヒンジ型に概ね区分される
本発明の直流高電圧リレーは、一般的なリレーと同様、可動接点と固定接点とからなる接点対を少なくとも一対備える。接点対の数は一つでも良い。但し、システムメインリレー等の直流高電圧リレーにおいては、二つの接点対を有するダブルブレーク構造が採用されたものが多い。図1で例示した直流高電圧リレーは、ダブルブレーク構造の直流高電圧リレーの構造の一例を示すものである。ダブルブレーク構造を採用する事で二対の接点対で電圧が分圧され、速やかなアーク消弧が達成される。よって、接点対が多くなれば、アーク消弧の効果が大きくなる。但し、接点対が多すぎると、制御が困難となる。また、接点対を多数設定すると、多くのスペースが必要となる。そのため、小型化等の要請に対応することを考慮すると、ダブルブレーク構造の直流高電圧リレーが好ましい。
本発明に係る直流高電圧リレーは、その可動接点及び固定接点の少なくともいずれかについて、後述する接点材料を適用する。可動接点及び固定接点の少なくともいずれかが、可動端子及び固定端子に接合される。具体的な態様としては、可動接点及び固定接点の双方を後述する接点材料で構成し、それぞれの端子に接合する場合の他、可動接点又は固定接点のいずれか一方を後述する接点材料で構成し、他方を他の接点材料で構成し、それぞれの端子に接合することもできる。更に、可動接点(又は固定接点)を後述する接点材料とする一方で、他方の固定接点(又は可動接点)には、接点材料を接合することなく固定端子(又は可動端子)をそのまま使用することもできる。この一方の接点を端子のみで構成する態様において、当該接点が可動接点又は固定接点として作用し、接点対を構成する。
本発明に係る直流高電圧リレーは、高い接触力及び開離力を有することを考慮し、可動接点と固定接点の好適な構成材料として所定の接点材料を適用することを特徴とする。
本発明の直流高電圧リレーに適用される接点材料は、金属成分がAg、金属M、不可避的不純物金属であるAg-酸化物系の接点材料である。金属成分である金属Mは、マトリックス中に分散する酸化物の構成元素として存在する。この酸化物は、接点材料の機械的強度の向上や耐溶着性の向上のため分散している。上記のとおり、本発明の対象である直流高電圧リレーについては、接点の耐溶着性を柔軟に解釈している。即ち、直流高電圧リレーの接触力及び/又は開離力を高く設定できるのであれば、接点材料自体の耐溶着性の低下を許容している。但し、これは耐溶着性が不要であることを意味する訳ではない。本発明においても、耐溶着性はある程度必要であるので、酸化物を形成・分散させている。よって、本発明で適用する接点材料において、金属Mは必須の金属元素である。
本発明の直流高電圧リレーで適用される接点材料は、Ag-酸化物系接点材料である。その材料組織は、基本的に、従来のAg-酸化物系接点材料と同様である。即ち、Ag及び/又はAg合金からなるマトリックス中に、少なくとも1種の前記金属Mの酸化物が分散する材料組織を有する。このマトリックスは、Ag(純Ag)又はAg合金、若しくは、AgとAg合金とからなる。Ag合金とは、Agと添加元素M又は不可避不純物金属との合金であるが、一組成の単一相のAg合金に限定されず、金属M等の固溶量が相違する複数のAg合金で構成される場合もある。これは、その接点材料がAgと金属Mとの合金の内部酸化によって製造される場合、その酸化の程度によってAg合金の組成と構造は変化し得る事を示す。以上から、マトリックスは、金属Mを含む場合がある。マトリックス中の金属Mの濃度(平均濃度)は4質量%以下が好ましいが、上限8質量%未満、例えば7質量%以下でも接点材料として使用可能である。一方、マトリックス中に分散する酸化物粒子の構成は、金属Mに基づき、SnO2、Bi2O3、Bi2Sn2O7、In2O3、NiO、TeO2等の酸化物の少なくとも1種が分散する。
次に、本発明の直流高電圧リレーで適用されるAg-酸化物系接点材料の製造方法について説明する。本発明の接点材料は、内部酸化法又は粉末冶金法若しくは内部酸化法と粉末冶金法との組み合わせによって製造可能である。
上記の接点材料の製造工程において、線引き加工し焼鈍(温度700℃)した線材からワイヤサンプルを切り出して硬度測定を行った。硬度測定は、サンプルを樹脂に埋め込み、横断面(短手方向断面)が露出するように面出し研磨を行い、ビッカース硬度計で測定した。測定条件は、荷重200gfとして、5箇所測定して平均値を硬度値とした。
次に、各接点材料の組織観察を行った。硬度測定のときと同様にして樹脂埋めしたサンプルの横断面を電子顕微鏡(SEM)で観察した(倍率5000倍)。そして、撮像したSEM画像について、粒子解析ソフトウェアを用いた画像処理を行った。画像処理では、接点材料中の酸化物の分散状態として、酸化物の合計面積(視野面積に対する面積率)、平均粒子径、粒径分布を測定・分析した。この解析には、オックスフォード・インストゥルメンツ株式会社製の粒子解析システムAZtecFeatureを使用した。また、粒径は円相当径(面積円相当径)を求めた。個々の酸化物粒子の面積fに基づき、円相当径の算出式((4f/π)1/2)により酸化物粒子の粒径を算出し、その平均と標準偏差σを計算した。
次に、各実施例、比較例の接点材料を組み込んだ直流高電圧リレーを製造し、その諸特性の評価試験を行った。ここでは、図1と同型のダブルブレーク構造のリレーを用意し、その可動端子及び固定端子に、各接点材料からなるリベット型接点を接合した(合計4箇所の接点で2組の接点対を形成した)。接点の寸法(リベットの頭部寸法)は、可動接点が直径3.15mm×厚さ0.75mm(頭部を上面から観察したときの接点表面の面積7.79mm2)、固定接点が直径3.3mm×厚さ1.0mm(頭部を上面から観察したときの接点表面の面積8.55mm2)である。また、可動接点及び固定接点の周辺に消弧用磁石(磁束密度が200mTのネオジム磁石を2個使用)を配置した。ガウスメータでの測定から接点接触時の中心位置における磁束密度は26mTであった。
各実施例、比較例の接点材料について、接触抵抗を測定した。接触抵抗は、各接点材料を上記の遮断耐久試験と同様のリレーに組み込み、遮断耐久試験と同条件の遮断操作を5回行った後の状態の値を測定した。接触抵抗の測定は、5回の遮断操作後、遮断試験回路とは別に用意した抵抗測定用回路(DC5V30A)にリレーの接続を切替て実施した。この接触抵抗測定では、回路に30分の連続通電(30A)を行った時点の端子間の電圧降下を測定した。そして、測定した電圧降下値(mV)を通電電流(30A)で除算した値を接触抵抗(mΩ)とした。
更に、各実施例、比較例の接点材料について、従来の車載用の直流低電圧リレーにおける使用条件を適用した場合の耐久性を評価した。この評価試験では、各接点材料を直流低電圧リレーの模擬試験機に組み込み、アクチュエータで接点開閉を行わせ、接点閉成時に投入電流を0.1秒間発生させて接点を溶着させ、開離させる際にその溶着を引き離す力を歪ゲ-ジで読み取った。この条件は下記のとおりである。
・試験電圧:DC14V
・投入電流:115A
・負荷:ハロゲンランプ4灯(240W)
・接触力:20gf
・試験温度:20℃
・開閉回数:10000回
本実施形態でも、内部酸化法と粉末冶金法で製造した。そして、各材料の組織観察及び硬度測定後、直流高電圧リレー(接触力/開離力:500gf/250gf)を製造して耐久性評価と接触抵抗を測定・評価した。本実施形態で製造した接点材料を表5に示す。表5には、第1実施形態と同様にして測定した硬度の測定結果も示している。尚、内部酸化法及びで製造した各接点材料は、第1実施形態と同様の工程で製造した。
Claims (15)
- 可動接点と固定接点とからなる接点対を少なくとも一対備え、前記接点対の接触力及び/又は開離力が100gf以上である、定格電圧48V以上の直流高電圧リレーにおいて、
前記可動接点及び/又は前記固定接点は、Ag-酸化物系の接点材料からなり、
前記接点材料の金属成分は、Snを必須的に含む少なくとも1種の金属Mと、残部Ag及び不可避的不純物金属とからなり、
前記接点材料の全金属成分の合計質量に対する、前記金属Mの含有量が0.2質量%以上8質量%以下であり、
前記接点材料は、Ag又はAg合金からなるマトリックス中に、前記金属Mの酸化物が1種以上分散する材料組織を有する、直流高電圧リレー。 - 接点材料は、金属MとしてInを含み、
前記接点材料の全金属成分の合計質量に対する、Inの含有量が0.1質量%以上5質量%以下であり、
前記接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.9質量%以下である請求項1記載の直流高電圧リレー。 - 接点材料は、金属MとしてBiを含み、
全金属成分の合計質量に対する、Biの含有量が0.05質量%以上2質量%以下であり、
前記接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.95質量%以下である請求項1又は請求項2記載の直流高電圧リレー。 - 接点材料は、金属MとしてTeを含み、
前記接点材料の全金属成分の合計質量に対する、Teの含有量が0.05質量%以上2質量%以下であり、
前記接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.95質量%以下である請求項1又は請求項2に記載の直流高電圧リレー。 - 接点材料は、金属Mとして、更にNiを含み、
前記接点材料の全金属成分の合計質量に対する、Niの含有量が0.05質量%以上1質量%以下であり、
前記接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.85質量%以下である請求項2又は請求項4記載の直流高電圧リレー。 - 請求項1~請求項5のいずれかに記載の直流高電圧リレーであって、
可動接点を移動させるための駆動力を発生及び伝達する駆動セクションと、直流高電圧回路の開閉を行う接点セクションとを含み、
前記駆動セクションは、駆動力を発生する電磁石又はコイルと、前記駆動力を接点セクションに伝達する伝達手段と、接点対を接触又は開離するために伝達手段を付勢する付勢手段と、を備え、
前記接点セクションは、前記駆動セクションの前記伝達手段によって移動する可動接点と固定接点とからなる接点対を少なくとも一つと、前記可動接点を接合する少なくとも一つの可動端子及び前記固定接点を接合する少なくとも一つの固定端子とを備える、直流高電圧リレー。 - 接点材料のマトリックス中に分散する酸化物の平均粒径が、0.01μm以上0.3μm以下である請求項1~請求項6のいずれかに記載の直流高電圧リレー。
- 接点材料の任意断面における酸化物の面積率が0.1%以上15%以下である請求項1~請求項7のいずれかに記載の直流高電圧リレー。
- 定格電圧48V以上であり、接点対の接触力及び/又は開離力が100gf以上である直流高電圧リレーの可動接点及び/又は固定接点の少なくとも表面を構成するためのAg-酸化物系の接点材料であって、
前記接点材料の金属成分は、Snを必須的に含む少なくとも1種の金属Mと、残部Ag及び不可避的不純物金属とからなり、
前記接点材料の全金属成分の合計質量に対する、前記金属Mの含有量が0.2質量%以上8質量%以下であり、
前記接点材料は、Ag又はAg合金からなるマトリックス中に、前記金属Mの酸化物が1種以上分散する材料組織を有する、直流高電圧リレー用の接点材料。 - 金属MとしてInを含み、
接点材料の全金属成分の合計質量に対する、Inの含有量が0.1質量%以上5質量%以下であり、
接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.9質量%以下である請求項9記載の直流高電圧リレー用の接点材料。 - 金属MとしてBiを含み、
接点材料の全金属成分の合計質量に対する、Biの含有量が0.05質量%以上2質量%以下であり、
接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.95質量%以下である請求項9又は請求項10記載の直流高電圧リレー用の接点材料。 - 金属MとしてTeを含み、
接点材料の全金属成分の合計質量に対する、Teの含有量が0.05質量%以上2質量%以下であり、
接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.95質量%以下である請求項9又は請求項10のいずれかに記載の直流高電圧リレー用の接点材料。 - 金属Mとして、更にNiを含み、
接点材料の全金属成分の合計質量に対する、Niの含有量が0.05質量%以上1質量%以下であり、
接点材料の全金属成分の合計質量に対する、Snの含有量が0.1質量%以上7.85質量%以下である請求項10又は請求項12記載の直流高電圧リレー用の接点材料。 - マトリックス中に分散する酸化物の平均粒径が、0.01μm以上0.3μm以下である請求項9~請求項13のいずれかに記載の直流高電圧リレー用の接点材料。
- 任意断面における酸化物の面積率が0.1%以上15%以下である請求項9~請求項14のいずれかに記載の直流高電圧リレー用の接点材料。
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WO2021049469A1 (ja) * | 2019-09-13 | 2021-03-18 | 田中貴金属工業株式会社 | 直流高電圧リレー及び直流高電圧リレー用の接点材料 |
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KR102497462B1 (ko) * | 2020-10-28 | 2023-02-08 | 엘에스일렉트릭(주) | 아크 경로 형성부 및 이를 포함하는 직류 릴레이 |
CN114203486A (zh) * | 2021-10-18 | 2022-03-18 | 深圳市酷客智能科技有限公司 | 一种具有过流保护功能的继电器及插座 |
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- 2019-03-12 KR KR1020207022385A patent/KR102475806B1/ko active IP Right Grant
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WO2021049469A1 (ja) * | 2019-09-13 | 2021-03-18 | 田中貴金属工業株式会社 | 直流高電圧リレー及び直流高電圧リレー用の接点材料 |
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JP7230001B2 (ja) | 2023-02-28 |
CN111868864B (zh) | 2023-02-28 |
US11309141B2 (en) | 2022-04-19 |
TWI817239B (zh) | 2023-10-01 |
PH12020551424A1 (en) | 2021-09-06 |
KR20230003260A (ko) | 2023-01-05 |
KR102638007B1 (ko) | 2024-02-20 |
KR20200103099A (ko) | 2020-09-01 |
JPWO2019176891A1 (ja) | 2021-04-15 |
KR102475806B1 (ko) | 2022-12-09 |
EP3767656A1 (en) | 2021-01-20 |
CN111868864A (zh) | 2020-10-30 |
TW202208642A (zh) | 2022-03-01 |
US20210012977A1 (en) | 2021-01-14 |
TWI748168B (zh) | 2021-12-01 |
TW201938806A (zh) | 2019-10-01 |
EP3767656A4 (en) | 2021-04-28 |
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