阅读说明：本技术 接触开关涂层 (Contact switch coating ) 是由 菲利普·沃纳·利斯 约书亚·詹姆斯·科佩尔 J·安东尼·斯皮斯 埃里克·詹姆斯·哈芬斯蒂恩 于 2020-01-06 设计创作，主要内容包括：公开了开关组件和切换方法。在一些实施方案中,一种开关组件可包括在封闭腔内具有第一触点的第一刀片和在封闭腔内具有第二触点的第二刀片。该第一触点和该第二触点可操作以响应于磁场而彼此接触或断开接触。该开关组件还可包括在该第一触点和该第二触点中的每一者上形成的涂层,该涂层包括钛层、在该钛层上形成的第二层,以及在该第二层上形成的钨铜层。在一些实施方案中,该第二层为铜或钼。(Switch assemblies and switching methods are disclosed. In some embodiments, a switch assembly may include a first blade having a first contact within a closed cavity and a second blade having a second contact within the closed cavity. The first contact and the second contact are operable to contact or break contact with each other in response to a magnetic field. The switch assembly may also include a coating formed on each of the first contact and the second contact, the coating including a titanium layer, a second layer formed on the titanium layer, and a tungsten copper layer formed on the second layer. In some embodiments, the second layer is copper or molybdenum.)

1. A switch assembly, the switch assembly comprising:

a first blade having a first contact within an enclosed cavity; and

a second blade having a second contact within the enclosed cavity, the first and second contacts operable to contact or break contact with each other in response to a magnetic field; and

a coating formed on each of the first and second contacts, the coating comprising:

a base conductive layer;

a second conductive layer formed on the base conductive layer; and

a tungsten copper layer formed on the second conductive layer.

2. The switch assembly of claim 1, wherein the second conductive layer is one of: copper and molybdenum.

3. The switch assembly of claim 1, wherein the base conductive layer, the second conductive layer, and the tungsten copper layer are each sputtered layers.

4. The switch assembly of claim 1, wherein the tungsten copper layer of the first contact is operable to contact the tungsten copper layer of the second contact.

5. A handover method, the handover method comprising:

providing a first contact operable with a second contact, wherein the first contact and the second contact form an open circuit in a first configuration and a closed circuit in a second configuration;

providing a coating on each of the first and second contacts, the coating comprising:

a base conductive layer;

a second conductive layer formed on the base conductive layer; and

a tungsten copper layer formed on the second conductive layer; and

biasing the first contact and the second contact relative to each other using a magnetic field.

6. The switching method of claim 5, wherein providing the coating on each of the first and second contacts comprises:

sputtering the base conductive layer on the first contact and the second contact;

sputtering the second conductive layer on the base conductive layer; and

sputtering the tungsten copper layer on the second conductive layer.

7. The switching method of claim 5, wherein sputtering the second conductive layer comprises sputtering a copper layer on the base conductive layer.

8. The switching method of claim 5, wherein sputtering the second conductive layer comprises sputtering a molybdenum layer on the base conductive layer.

9. The switching method of claim 5, further comprising providing a magnet adjacent to the first contact and the second contact.

10. The switching method of claim 9, further comprising changing the first and second contacts between the first and second configurations in response to movement of the magnet.

11. The handover method of claim 5, further comprising providing an indication of the open circuit or the closed circuit.

12. A reed switch, the reed switch comprising:

a first blade having a first contact within an enclosed cavity; and

a second blade having a second contact within the enclosed cavity, the first and second contacts operable to contact or break contact with each other in response to a magnetic field; and

a coating formed on each of the first and second contacts, the coating comprising:

a base conductive layer;

a second conductive layer formed on the base conductive layer; and

a tungsten copper layer formed on the second conductive layer.

13. The reed switch of claim 12, wherein the second conductive layer is one of: copper and molybdenum.

14. The reed switch of claim 12, wherein the base conductive layer, the second conductive layer, and the tungsten copper layer are each sputtered layers.

15. The reed switch of claim 12, wherein the tungsten copper layer of the first contact is operable to contact the tungsten copper layer of the second contact.

16. The reed switch of claim 12, wherein the tungsten copper layer of the first contact is operable to contact the tungsten copper layer of the second contact in response to movement of a magnet.

17. The reed switch of claim 12, wherein the tungsten copper layer of the first contact is operable to break contact with the tungsten copper layer of the second contact.

Technical Field

The present disclosure relates generally to the field of switches, and more particularly, to a coating for a contact switch.

Discussion of related Art

A reed switch is an electromechanical switch having two reed blades formed of an electrically conductive ferromagnetic material, typically a ferrous nickel alloy. In the presence of a magnetic field, the overlapping reed blades will attract, causing the blades to bend toward and contact each other, closing the circuit. The two reed blades can be positioned within a glass capsule that hermetically seals the reed blades. The capsule typically contains vacuum, air or nitrogen at atmospheric or superatmospheric pressure. The reed switch can switch significant power, for example in the range of 10 watts to 100 watts. Reed switches also have a long lifetime in millions or even more than 1 million operations without failure or significant increase in contact resistance. Over many cycles, the reed contact may wear, dent or corrode due to mechanical wear or arcing as the switch opens and closes. Such dishing or erosion results in an increase in resistance across the closed switch. To prevent or at least minimize such erosion, the contact surfaces of the reed blades can be coated with various materials having a relatively low resistivity of hard, high melting temperature metals. Recently, the cost of certain plating materials such as gold, rhodium, and ruthenium has increased significantly. Accordingly, there is a need for a reed switch contact arrangement that minimizes the amount of these types of materials present on the contact face of the reed blade without reducing reed switch life.

Background

Disclosure of Invention

In one or more embodiments, a switch assembly can include a switch assembly including a first blade having a first contact within a closed cavity and a second blade having a second contact within the closed cavity. The first and second contacts are operable to contact or break contact with each other in response to a magnetic field. The switch assembly may also include a coating formed on each of the first and second contacts. The coating may include a titanium layer, a second layer formed on the titanium layer, and a tungsten copper layer formed on the second layer.

In one or more embodiments, a switching method can include providing a first contact operable with a second contact, wherein the first contact and the second contact form an open circuit in a first configuration and a closed circuit in a second configuration. The switching method can also include providing a coating on each of the first contact and the second contact, the coating including a titanium layer, a second layer formed on the titanium layer, and a tungsten copper layer formed on the second layer. The switching method may further include biasing the first contact and the second contact relative to each other using a magnetic field, wherein the magnetic field.

In one or more embodiments, a reed switch can include a first blade having a first contact within a closed cavity, a second blade having a second contact within the closed cavity, the first and second contacts operable to contact or break contact with each other in response to a magnetic field. The reed switch can further include a coating formed on each of the first contact and the second contact, the coating including a titanium layer, a second layer formed on the titanium layer, and a tungsten copper layer formed on the second layer.

Drawings

The drawings illustrate an exemplary method, designed for practical application of the principles disclosed thus far for a switching assembly, and in which:

fig. 1 is a top cross-sectional view of a reed switch employing a contact coating according to an embodiment of the present disclosure;

fig. 2 is a cross-sectional view of the reed switch of fig. 1 taken along section line 2-2, according to an embodiment of the present disclosure;

figure 3 is a side cross-sectional view of one contact of the reed switch of figure 1 taken along section line 3-3, according to an embodiment of the present disclosure; and is

Fig. 4 is a flow diagram of a handover method according to an embodiment of the present disclosure.

The figures are not necessarily to scale. The drawings are merely representations, not intended to portray specific parameters of the disclosure. Furthermore, the drawings are intended to depict exemplary embodiments of the disclosure, and therefore should not be considered as limiting the scope.

In addition, for clarity of illustration, certain elements in some of the figures may be omitted, or may not be shown to scale. For clarity of illustration, the cross-sectional views may be in the form of "slices" or "near-sighted" cross-sectional views, omitting certain background lines that would otherwise be visible in a "real" cross-sectional view. Moreover, for clarity, some of the reference numerals may be omitted in certain drawings.

Detailed Description

The disclosure will now be made with reference to the accompanying drawings, in which various methods are shown. It should be understood, however, that the switch and switch assembly may be embodied in many different forms and should not be construed as limited to the methods described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout.

As used herein, an element or operation recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural elements or operations, unless such exclusion is explicitly recited. Furthermore, references to "a method" or "one embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional methods and embodiments that also incorporate the recited features.

Furthermore, as shown in the figures, spatially relative terms, such as "lower," "below," "lower," "central," "above," "upper," "proximal," "distal," and the like, may be used herein to facilitate describing the relationship of one element to another. It will be understood that the spatially relative terms may encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures.

As disclosed, embodiments herein provide switch assemblies and switching methods. The embodiments disclosed herein are designed as an improvement over existing electroplated contact systems in which the reed blade is coated with continuous layers of titanium, copper, titanium, molybdenum, and ruthenium. To ameliorate the performance and cost deficiencies of the prior art, embodiments herein provide a sputtered material contact apparatus that includes continuous titanium, copper, and tungsten copper layers. In some non-limiting examples, the concentration of copper in the tungsten copper material may be in a range of 0 wt% to 30 wt%.

It has been found that embodiments herein provide at least the following technical advantages/improvements over the prior art. First, sputtered tungsten copper, titanium (W-Cu/Ti) contact materials layered on reed switches exhibit superior electrical performance compared to sputtered ruthenium, molybdenum, titanium, copper, and titanium contact materials. Second, sputtered W-Cu/Cu/Ti contact materials on reed switches exhibit superior electrical performance at, for example, 33V-3A, 120V-1A, and 400V-0.002A, as compared to ruthenium, rhodium, and gold plated contact materials. Again, where a heat treatment is performed, it has been found that the post-sputter heat treatment can significantly increase the electrical performance at, for example, 400V-0.002A.

Referring now to fig. 1-2, a switch assembly (hereinafter "assembly") 10 according to an embodiment of the present disclosure will be described. As shown, the assembly 10 may include a reed switch 20. While not limiting, the reed switch 20 is of the so-called "a-mode" type having an axially extending cylindrical glass capsule 22. Two reed blades 24 extend into the hermetically sealed volume defined by the glass capsule 22. Each reed blade 24 has leads 26 extending through opposite axial ends 28 of the glass capsule 22. The opposite end 28 of the glass capsule can be heated and fused to the leads 26 of each reed blade 24, thereby positioning the reed blades relative to each other and forming an airtight seal and enclosing the capsule volume. The capsule volume typically contains a vacuum or an inert gas such as nitrogen or argon, sometimes above atmospheric pressure.

Although not limiting, a portion 30 of each reed blade 24 can be flattened, thereby creating a controlled spring constant that controls the force required to close the reed switch 20. Each reed blade 24 terminates in a contact 32. The contacts 32 of the reed blades 24 overlap, defining a contact space or gap 34 therebetween. Each contact 32 may have a contact surface 36. The contact surfaces 36 face each other over the contact gap 34.

The reed switch blade 24 may be formed of a ferromagnetic alloy (typically an alloy of nickel and iron) having a composition of, for example, 51% -52% nickel. In the presence of a magnetic field, such as that generated by an electrical coil or permanent magnet, the magnetic field penetrates the reed blades 24 causing the reed blades to attract one another. The attractive force causes the flexible portion 30 of the reed switch blade 24 to bend such that the contact 32 closes the contact gap 34, thereby engaging the contact surface 36 and completing the electrical circuit between the leads 26. When the magnetic field is removed, the magnetic field no longer penetrates the reed blade 24 and the contacts 32 separate, thereby reestablishing the contact gap 34 and breaking the electrical circuit between the leads 26.

In some embodiments, the reed switch 20 can switch loads between 10 watts and 100 watts or more at voltages up to or exceeding 500 volts DC. When the reed switch 20 is under load, an arc may form between the contact surfaces 36 when the reed switch 20 is opened or closed. In addition, mechanical wear may occur between the contact surfaces 36 during repeated opening and closing of the reed switch 20. Since reed switches are typically designed to have 100 to 1 million operational lifetimes or longer over the lifetime of the reed switch, it is desirable that the contact resistance does not increase significantly, e.g., by more than 50%.

As shown in fig. 3, to prevent an increase in contact resistance, the contact 32 of each reed blade 24 can be coated with multiple layers, for example by sputtering. For example, the first layer 50 may be made of a titanium layer, the second layer 52 may be made of copper, and the third layer 54 may be made of tungsten copper. In some embodiments, the second layer 52 may be made of molybdenum. During formation, first layer 50 may be sputtered on outer surface 56 of contact 32, and second layer 52 may be sputtered on first layer 50. Next, a third layer 54 may be sputtered on the second layer 52.

After forming the first layer 50, the second layer 52, and the third layer 54, the reed blade 24 can be heat treated. The heat treatment after sputtering the first, second, and third layers 50, 52, 54 may extend the number of cycles before failing. For example, at 400V, 0.002A, the average life of prior art plated switches before failure is about 650 ten thousand cycles. For the sputtered prior art device comprising a Ru/Mo/Ti/Cu/Ti coating, the average life before failure was about 550 million cycles. However, when the sputtered layer of W-Cu/Ti of the present disclosure is heat treated after formation, failure may not occur until at least 1.64 million cycles are exceeded.

Although not limiting, the thickness of the three layers may range, for example, from about 15 to about 150 microinches for each of the titanium and copper/molybdenum layers, and between about 5 and 75 microinches for tungsten copper. When replacing the contact coating arrangement in existing reed switch designs, the total thickness of the first, second and third layers 50, 52, 54 can be selected to have the same total thickness as the initial contact coating. In this way, the design of the reed switch itself need not be modified.

Referring now to fig. 4, a method 100 for operating the assembly 10 in accordance with an embodiment of the present disclosure will be described in more detail. At block 101, the method 100 may include providing a first contact operable with a second contact, wherein the first contact and the second contact form an open circuit in a first configuration and a closed circuit in a second configuration. In non-limiting embodiments, the first and second contacts may be normally open or normally closed. In other embodiments, the switch assembly may have three leads that combine a normally closed circuit and a normally open circuit.

At block 103, the method 100 may include sputtering a titanium layer on the first contact and the second contact. At block 105, the method 100 may include sputtering a second layer on the titanium layer. In some embodiments, the second layer may be a copper or molybdenum layer. At block 107, the method 100 may include sputtering a tungsten copper layer on the second layer. In some embodiments, the first contact and the second contact may then be heat treated. At block 109, the method 100 may optionally include providing a magnet adjacent to the first contact and the second contact. The magnet causes the first and second contacts to change between the first and second configurations in response to movement of the magnet. In some embodiments, the method 100 may then include providing an indication of an open circuit or a closed circuit between the first contact and the second contact.

Although the present disclosure has been described with reference to certain methods, numerous modifications, alterations and changes to the described methods are possible without departing from the spirit and scope of the present disclosure, as defined in the appended claims. Accordingly, it is intended that the disclosure not be limited to the described methods, but that it have the full scope defined by the language of the following claims, and equivalents thereof. Although the present disclosure has been described with reference to certain methods, numerous modifications, alterations and changes to the described methods are possible without departing from the spirit and scope of the present disclosure, as defined in the appended claims. Accordingly, it is intended that the disclosure not be limited to the described methods, but that it have the full scope defined by the language of the following claims, and equivalents thereof.