阅读说明：本技术 一种高耐磨电磁导电触头的制造方法 (Manufacturing method of high-wear-resistance electromagnetic conductive contact ) 是由 张敬敏 于 2019-12-14 设计创作，主要内容包括：本发明公开了一种高耐磨电磁导电触头的制造方法,该导电触头的磁芯基体是具有甲基聚硅氧烷典型结构的压敏胶体,具有软磁性能的填料是通过粉末冶金的形式将软磁性金属材料与10wt％左右的二硼化钛混合,采用特殊方式烧结获得,芯体中还添加石墨粉；本发明的线圈材料与苯胺改性碳纤维铝芯复合导线,除了具有良好导电性外,其结构强度、与芯体的结合稳定性都优于常规技术。本发明自润滑、高耐磨、磁导率高。(The invention discloses a method for manufacturing a high-wear-resistance electromagnetic conductive contact, wherein a magnetic core matrix of the conductive contact is a pressure-sensitive colloid with a typical structure of methyl polysiloxane, a filler with soft magnetic property is obtained by mixing a soft magnetic metal material and about 10 wt% of titanium diboride in a powder metallurgy manner and sintering in a special manner, and graphite powder is also added into a core body; the coil material and aniline modified carbon fiber aluminum core composite wire has good conductivity, and the structural strength and the combination stability with the core body are superior to those of the conventional technology. The invention has the advantages of self-lubricating property, high wear resistance and high magnetic conductivity.)

1. The manufacturing method of the high-wear-resistance electromagnetic conductive contact is characterized by comprising the following steps of:

1) raw material preparation

① raw material preparation, 10 to 12 parts of pure iron powder, 40 to 45 parts of pure nickel powder, 5 to 6 parts of nano titanium diboride powder, 5 to 8 parts of graphite powder, 50 to 55 parts of methyl vinyl silicone resin with the relative molecular mass of 22000-24000 and the M/Q of 0.75 to 0.9, and the viscosity of 1.7 multiplied by 10⁶mPa·s-1.9×10⁶α parts of mPa & s, 20-25 parts of omega-dihydroxy polysiloxane, 0.5-0.8 part of dibutyl dilaurate, sufficient carbon fiber and aluminum core composite wires, sufficient aniline, and 0.2-0.5 part of ammonium persulfate initiator;

② preparing auxiliary materials, namely preparing sufficient 20% nitric acid aqueous solution, sufficient ethylene glycol, sufficient 3-hydroxy-1, 3, 5-pentanedioic acid, sufficient toluene, sufficient mixed solution of concentrated sulfuric acid and concentrated nitric acid according to the volume ratio of 3: 1, and sufficient 10% hydrochloric acid aqueous solution with solute mass fraction;

2) liquid fraction preparation

①, soaking the methyl vinyl silicone resin prepared in step ① in the stage 1) and α, omega-dihydroxy polysiloxane into toluene with the same total mass as the mixture, and uniformly stirring to obtain mixed organic liquid;

②, heating the mixed organic liquid obtained in the step ① to 105-110 ℃, then gradually dripping the dibutyl dilaurate prepared in the step 1) and the step ① in the mixed organic liquid for reaction for 3-3.5 h to obtain colorless transparent liquid, wherein the colorless transparent liquid is a liquid part;

3) core preparation

①, adopting a magnesium oxide crucible as a container, and filling the pure iron powder and the pure nickel powder prepared in the step ① in the stage 1) into the crucible after completely mixing the pure iron powder and the pure nickel powder uniformly to obtain a material to be smelted;

② melting the material to be melted obtained in step ① by vacuum induction melting method, and vacuumizing to 1 × 10 before heating^-2Pa-1×10^-3Pa, timing when the raw materials begin to melt after the raw materials are heated to the temperature, keeping the temperature for 20-23 min, stopping heating, rapidly cooling by adopting nitrogen, discharging from the furnace, and demolding to obtain a rough magnetic core;

③ grinding the rough magnetic core obtained in step ② into micropowder with particle size of 3000-5000 meshes to obtain soft magnetic micropowder;

④ uniformly mixing the soft magnetic micro powder and the graphite powder prepared in step ① in the stage 1), putting the mixture into the liquid part obtained in the stage 2), dispersing the mixture for 40-45 min by ultrasonic waves to obtain turbid liquid, standing the turbid liquid until the viscosity of the turbid liquid is 25000-28000 mPa.s, performing injection molding according to the designed core body size, and demolding and drying to obtain the required magnetic conductive core;

4) wire preparation

① completely immersing the carbon fiber aluminum core composite wire prepared in the step ① in the mixed solution of concentrated sulfuric acid and concentrated nitric acid prepared in the step ② in the step 1) for 3.5-4 h by using 200-250W ultrasonic wave to obtain a carboxylated passivated composite wire, and then rinsing the composite wire by using clean water;

②, immersing the carboxylated passivated composite wire obtained in the step ① into the hydrochloric acid aqueous solution prepared in the step ② in the stage 1), immersing the hydrochloric acid aqueous solution into an ice bath at minus 5 ℃ to minus 10 ℃, starting stirring at the speed of 120rpm/min to 150rpm/min, then putting aniline prepared in the step ① in the stage 1), finally putting ammonium persulfate initiator prepared in the step ① in the stage 1) in the reaction solution at the mass speed of 10%/min, stirring for 40min to 50min, taking out the reaction solution, standing the reaction solution in a refrigerator at the temperature of minus 5 ℃ to minus 10 ℃ for 0.5 day to 1 day, filtering out a cured substance, and respectively rinsing with ethanol and water until the cured substance is rinsed to obtain the modified composite wire;

5) high-wear-resistance electromagnetic conductive contact forming

① winding the modified composite wire obtained in the stage 4) on the surface of the conductive magnetic core obtained in the stage 3), namely obtaining the required high-abrasion-resistance electromagnetic conductive contact.

Technical Field

The invention relates to the technical field of electrical devices, in particular to a manufacturing method of a high-abrasion-resistance electromagnetic conductive contact.

Background

Three-phase short circuit and two-phase short circuit ground faults of the power system have an important influence on the electrical life of the contacts of the circuit breaker. According to research of professionals, mathematical models and simulation models of all elements are established by applying a Power System Analysis Software Package (PSASP), and dynamic states of the circuit breaker after different short-circuit faults are simulated. Simulation results show that the contact abrasion loss can directly cause short-circuit faults in different areas and degrees, and the magnitude of the short-circuit current directly influences the electrical abrasion loss and the electrical service life of the contacts of the circuit breaker in turn.

The conventional technology does not have the existing research aiming at the improvement and the upgrade of the wear resistance of the existing contact at present, and can confirm that the improvement needs to be carried out in the following directions for improving the contact performance, namely 1, increasing the self-lubricating performance; 2. the wear resistance is improved; 3, the magnetic permeability is improved.

Therefore, a self-lubricating, high-wear-resistance and high-magnetic-permeability electromagnetic conductive contact and a manufacturing method thereof are urgently needed in the market.

Disclosure of Invention

The invention aims to provide a method for manufacturing a high-wear-resistance electromagnetic conductive contact with self-lubrication, high wear resistance and high magnetic conductivity.

In order to achieve the purpose, the invention adopts the following technical scheme: a manufacturing method of a high-abrasion-resistance electromagnetic conductive contact comprises the following steps:

1) raw material preparation

① raw material preparation, 10 to 12 parts of pure iron powder, 40 to 45 parts of pure nickel powder, 5 to 6 parts of nano titanium diboride powder, 5 to 8 parts of graphite powder, 50 to 55 parts of methyl vinyl silicone resin with the relative molecular mass of 22000-24000 and the M/Q of 0.75 to 0.9, and the viscosity of 1.7 multiplied by 10⁶mPa·s-1.9×10⁶α parts of mPa & s, 20-25 parts of omega-dihydroxy polysiloxane, 0.5-0.8 part of dibutyl dilaurate, sufficient carbon fiber and aluminum core composite wires, sufficient aniline, and 0.2-0.5 part of ammonium persulfate initiator;

② preparing auxiliary materials, namely preparing sufficient 20% nitric acid aqueous solution, sufficient ethylene glycol, sufficient 3-hydroxy-1, 3, 5-pentanedioic acid, sufficient toluene, sufficient mixed solution of concentrated sulfuric acid and concentrated nitric acid according to the volume ratio of 3: 1, and sufficient 10% hydrochloric acid aqueous solution with solute mass fraction;

2) liquid fraction preparation

①, soaking the methyl vinyl silicone resin prepared in step ① in the stage 1) and α, omega-dihydroxy polysiloxane into toluene with the same total mass as the mixture, and uniformly stirring to obtain mixed organic liquid;

②, heating the mixed organic liquid obtained in the step ① to 105-110 ℃, then gradually dripping the dibutyl dilaurate prepared in the step 1) and the step ① in the mixed organic liquid for reaction for 3-3.5 h to obtain colorless transparent liquid, wherein the colorless transparent liquid is a liquid part;

3) core preparation

①, adopting a magnesium oxide crucible as a container, and filling the pure iron powder and the pure nickel powder prepared in the step ① in the stage 1) into the crucible after completely mixing the pure iron powder and the pure nickel powder uniformly to obtain a material to be smelted;

② melting the material to be melted obtained in step ① by vacuum induction melting method, and vacuumizing to 1 × 10 before heating^{- 2}Pa-1×10^-3Pa, timing when the raw materials begin to melt after the temperature is reached, keeping the temperature for 20-23 min, stopping heating, rapidly cooling by adopting nitrogen, discharging from the furnace, and demolding to obtain the productA coarse magnetic core;

③ grinding the rough magnetic core obtained in step ② into micropowder with particle size of 3000-5000 meshes to obtain soft magnetic micropowder;

④ uniformly mixing the soft magnetic micro powder and the graphite powder prepared in step ① in the stage 1), putting the mixture into the liquid part obtained in the stage 2), dispersing the mixture for 40-45 min by ultrasonic waves to obtain turbid liquid, standing the turbid liquid until the viscosity of the turbid liquid is 25000-28000 mPa.s, performing injection molding according to the designed core body size, and demolding and drying to obtain the required magnetic conductive core;

4) wire preparation

① completely immersing the carbon fiber aluminum core composite wire prepared in the step ① in the mixed solution of concentrated sulfuric acid and concentrated nitric acid prepared in the step ② in the step 1) for 3.5-4 h by using 200-250W ultrasonic wave to obtain a carboxylated passivated composite wire, and then rinsing the composite wire by using clean water;

②, immersing the carboxylated passivated composite wire obtained in the step ① into the hydrochloric acid aqueous solution prepared in the step ② in the stage 1), immersing the hydrochloric acid aqueous solution into an ice bath at minus 5 ℃ to minus 10 ℃, starting stirring at the speed of 120rpm/min to 150rpm/min, then putting aniline prepared in the step ① in the stage 1), finally putting ammonium persulfate initiator prepared in the step ① in the stage 1) in the reaction solution at the mass speed of 10%/min, stirring for 40min to 50min, taking out the reaction solution, standing the reaction solution in a refrigerator at the temperature of minus 5 ℃ to minus 10 ℃ for 0.5 day to 1 day, filtering out a cured substance, and respectively rinsing with ethanol and water until the cured substance is rinsed to obtain the modified composite wire;

5) high-wear-resistance electromagnetic conductive contact forming

① winding the modified composite wire obtained in the stage 4) on the surface of the conductive magnetic core obtained in the stage 3), namely obtaining the required high-abrasion-resistance electromagnetic conductive contact.

Compared with the prior art, the invention has the following advantages: (1) the magnetic core matrix of the invention is a pressure-sensitive colloid with a typical structure of methyl polysiloxane, other functional fillers are uniformly distributed and mutually promoted under the action of the pressure-sensitive adhesive body, 180-degree peel strength of 1.1kN/m and shear strength of about 0.85MPa are integrally obtained, and the aniline modified carbon fiber aluminum core composite wire serving as a coil material has good binding force with the matrix and is not easy to move and deform in frequent switches. (2) The core body matrix is made of pressure-sensitive material, and along with deformation after attraction, the path of good conductors (silver powder and the like) in the core body matrix can be shortened, the conceptual diameter of the core body matrix can be increased, and the conductivity can be obviously improved. (3) The magnetic core is different from the traditional magnetic core in an integral hard structure, the soft magnetic material is ground into powder and then mixed with the functional assistant titanium diboride to be used as the functional filler to be filled into the matrix to obtain the resin-based soft conductive soft magnetic core body, the advantages of large magnetic conductivity and small coercive force of the iron-nickel alloy are obtained, the defect that the iron-nickel alloy is sensitive to stress is avoided, the service performance is good, and meanwhile, the powder metallurgical functional filler is mixed with graphite, so that the intrinsic arc extinguishing capability is strong, and the self-lubricating capability is certain. (4) The specially made soft magnetic material is prepared by mixing a soft magnetic metal material with about 10 wt% of titanium diboride in a powder metallurgy mode, and sintering in a special mode, wherein the functional part of the obtained contact material is higher in hardness and electric conductivity due to the action of a titanium diboride phase, so that the functional part exists in a resin matrix as hard particles, and is matched with graphite powder with good lubricating property and a flexible matrix, so that the invention obtains good surface wear resistance. (5) The invention adopts the structure which is not adopted by the conventional electromagnetic contact, namely, the soft magnetic functional material is mixed into the flexible matrix to obtain the overall soft collision core body, and the soft collision surface is adaptive to the target end, so that the poor contact caused by the reduction of the mechanical property or the deformation of the contact after the aging of the traditional contact can not exist, the service life is long, and the bonding property is good. (6) The invention is different from the conventional technology that the metal is repeatedly bent, and is completed by the elastic deformation of the flexible core, so the invention is anti-fatigue in nature. (7) The core body of the invention is a flexible collision body, and meanwhile, the core body has light weight, low impact kinetic energy and flexible buffering, so the invention has good impact resistance. Therefore, the invention has the characteristics of self-lubrication, high wear resistance and high magnetic conductivity.

Detailed Description