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WO2024233560A1 - Dispositifs électriques scellés - Google Patents

Dispositifs électriques scellés Download PDF

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Publication number
WO2024233560A1
WO2024233560A1 PCT/US2024/028174 US2024028174W WO2024233560A1 WO 2024233560 A1 WO2024233560 A1 WO 2024233560A1 US 2024028174 W US2024028174 W US 2024028174W WO 2024233560 A1 WO2024233560 A1 WO 2024233560A1
Authority
WO
WIPO (PCT)
Prior art keywords
housing
electrical device
cover
glass
electrical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/028174
Other languages
English (en)
Inventor
Samuel Naumowicz
Derek Hodge TURNER
Keith Singer
Kenny Chui
Jackson Robert BRIGHT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sensata Technologies Inc
Original Assignee
Sensata Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sensata Technologies Inc filed Critical Sensata Technologies Inc
Publication of WO2024233560A1 publication Critical patent/WO2024233560A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/023—Details concerning sealing, e.g. sealing casing with resin
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/023—Details concerning sealing, e.g. sealing casing with resin
    • H01H2050/025—Details concerning sealing, e.g. sealing casing with resin containing inert or dielectric gasses, e.g. SF6, for arc prevention or arc extinction
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/14—Terminal arrangements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/54—Contact arrangements
    • H01H50/546—Contact arrangements for contactors having bridging contacts

Definitions

  • the subject disclosure relates to electrical switching devices, such as contactor devices and electrical fuse devices, and more particularly to improved sealed electrical switching devices.
  • electrical contactors e.g., high-voltage DC contactors
  • fuses e.g., electrical fuses and/or pyrotechnic fuses
  • Contactors may be configured to interrupt or complete a circuit to control electrical power to and from a device.
  • Fuses may be used for overcurrent protection.
  • fuses may be used to prevent short circuits, overloading, and/or permanent damage to an electrical system or a connected electrical device.
  • the subject technology relates to improved electrical devices and methods of making those devices.
  • aspects of this disclosure relate to improved hermetically- sealed contactors and fuses that incorporate a header fabricated using glass-to-metal sealing techniques.
  • the present disclosure relates to improved hermetically-sealed contactors and fuses that include a header that is resistance welded to a can or housing.
  • contactors and fuses may be less expensive and/or more reliable than some existing contactors and fuses.
  • Additional aspects of this disclosure relate to methods of making improved hermetically-sealed contactors and fuses.
  • FIG. 1 includes a perspective view of an electrical device and an exploded perspective view of a portion of the electrical device, in accordance with aspects of this disclosure.
  • FIG. 2 is a cross-sectional view of the electrical device of FIG. 1, taken along section line 2-2 in FIG. 1, in accordance with aspects of this disclosure.
  • FIG. 3 is a cross-sectional view of the electrical device of FIG. 1, taken along section line 3-3 in FIG. 1, in accordance with aspects of this disclosure.
  • FIG. 4 is a side view of a portion of the electrical device of claim 1, in accordance with aspects of this disclosure.
  • FIG. 5 is a flow chart illustrating aspects of a method of manufacturing an electrical device, such as the electrical device illustrated in FIG. 1, in accordance with aspects of this disclosure.
  • FIG. 6 is a cross-sectional view of a portion of the electrical device of FIG. 3, generally corresponding to the section 6 — 6 shown in FIG. 3., in accordance with aspects of this disclosure.
  • FIG. 7 is a cross-sectional view showing aspects of a welding apparatus and an operation for assembling an electrical device, such as the electrical device illustrated in FIG. 1.
  • FIG. 8 is a flow chart illustrating aspects of a method of manufacturing an electrical device, such as the electrical device illustrated in FIG. 1, in accordance with aspects of this disclosure.
  • aspects of the subject technology may provide improved hermetically-sealed electrical devices.
  • Some aspects of this disclosure include an improved header for an electrical device that is, at least in part, formed using glass-to-metal sealing technologies.
  • Some aspects of this disclosure also describe methods of manufacturing the header.
  • Still further aspects of this disclosure relate to improvements to an electrical device housing, which may include a header attached to a can or lower housing. Additional aspects of this disclosure relate to methods of manufacturing the improved electrical device housing.
  • the devices and techniques described herein may provide hermetically-sealed devices that are cheaper to manufacture than similar conventional devices. Moreover, the devices and techniques described herein may provide superior thermal and electrical performance relative to similar conventional devices.
  • the devices and techniques described herein may also provide hermetically-sealed contactors and fuses that use lower-cost manufacturing methods, including but not limited to stamping, cold-forging, and wire-drawing. In some instances, these methods can be employed on less expensive raw materials In contrast, conventional techniques may employ more expensive subtractive machining in the manufacture of the raw components used in their ceramic and epoxy seals.
  • the devices and techniques may also or alternatively facilitate the use of different and/or more preferred materials to perform functions required of the electrical device.
  • the devices and techniques described herein may allow for the use of certain magnets, such as neodymium magnets, to increase arc suppression.
  • the devices and techniques described herein may accommodate the use of hydrogen to form the internal atmosphere of the electrical device, which may be preferred in some applications.
  • aspects of this disclosure may be particularly useful in electrical devices, such as contactors and fuses, the systems and techniques described herein may be useful with many hermetically-sealed applications.
  • FIG. 1 is a perspective view of an electrical device 100, which may be a contactor device, a fuse device, a pyrotechnic fuse, a pyrotechnic contactor, or the like.
  • the electrical device 100 generally includes a body or housing 102, and a header assembly 104 disposed to cover an opening of the housing 102.
  • the header assembly 104 is a hermetic glass-to-metal header assembly that is secured to the housing 102 to cover a top opening of the housing 102.
  • the assembly 104 includes a plate or cover 106 and two fixed contact structures 108 extending through the cover 106.
  • the housing 102 may be formed as a base body, a “can,” or a “cup,” e g., defining a substantially circular opening.
  • the assembly 104 may be a header sealed to the housing 102, e.g., at the circular opening to seal the interior of the housing 102.
  • the housing 102 is configured to contain a number of internal components.
  • the contact structures 108 are configured to electrically connect internal components of the electrical device 100 to external circuitry, for example, to an electrical system or device.
  • the contact structures 108 may be terminals configured to facilitate connection of electrical leads (not shown).
  • a power source may be coupled to one of the contact structures 108 and a load to be powered by the power source may be coupled to the other of the contact structures 108.
  • the housing 102 can generally include any suitable material that can support the structure and function of the electrical device 100. However, and as detailed further below, in some examples of this disclosure the housing 102 may be selected and/or configured to facilitate improved coupling to a header assembly, such as the header assembly 104. For example, the housing 102 may be configured for resistance welding to the header assembly 104. In these examples, the housing 102 may be made of a metal such as stainless steel. Also in examples, the housing 102 may be plated, e.g., by an electroless nickel plating.
  • the housing 102 can be configured such that an internal space of the housing 102, e g., which houses the various internal components of the electrical device 100, is hermetically sealed.
  • An electronegative gas may be disposed in the housing 102.
  • This hermetically sealed configuration can help mitigate or prevent electrical arcing between adjacent conductive elements, and in some embodiments, helps provide electrical isolation between spatially separated contacts.
  • the housing 102 can be under vacuum conditions and/or can be hermetically sealed using known means of generating hermetically sealed electrical devices. As also detailed herein, in some examples, the devices and techniques detailed herein may facilitate the use of hydrogen in the housing.
  • the header assembly 104 generally includes the cover 106 and a number of additional components.
  • the cover 106 includes a number of holes or apertures formed therein, including a pair of contact apertures 110.
  • Each of the contact apertures 110 is sized and positioned to receive one of the contact structures 108.
  • a glass seal 112 and a braze ring 114 also are disposed in each of the contact apertures 110.
  • each of the terminals 108 has an elongate body 116 configured to extend into a volume defined by the housing
  • the braze ring 114 is disposed to circumscribe the elongate body 116, and the glass seal 112 is disposed to circumscribe the braze ring 114.
  • the glass seal 112 has an outer circumference configured to be received in one of the contact apertures 110. Specifically, the contact apertures 110 have a diameter sized to receive the glass seal 112.
  • the braze ring 114 may be slid or otherwise placed on the elongate body 116 of the contact structure 108, the glass seal 112, which also has a ring-shape, may be slid, or otherwise placed on the braze ring 114, and the combination of the contact structure 108, the braze ring 114, and the glass seal 112 may be disposed in one of the contact apertures 110.
  • the braze ring 114 is provided to facilitate glass-to- metal sealing of the contact structure 108 to the cover 106.
  • the contact structure 108 may be made from a high-current capacity material, such as copper.
  • a high-current capacity material such as copper.
  • copper has thermal expansion properties that may make the material incompatible with glass, e.g., in conventional glass-to-metal sealing. That is, sealing glass to copper may be ineffective.
  • the braze ring 114 fixed, e.g., by brazing, to the (copper) contact structure 108, is selected to be compatible for glass-to-metal sealing.
  • the contact structure 108 may be hollowed out, e.g., to reduce a wall thickness of the contact structure 108 proximate the location of the braze ring 114.
  • the reduced wall thickness will allow the contact structure 108 to be relatively thin and flexible, e.g., so the braze ring can be fixed to the wall.
  • the braze ring 114 retained on the outer surface of the contact structure 108, restrains the contact structure, but allows for glass sealing at the braze ring 114.
  • the braze ring 114 may be formed of any conventional metal used for glass-to-metal sealing, such as a controlled-expansion metal.
  • the braze ring 114 may be formed of an alloy, such as an alloy of iron and nickel, including but not limited to alloy 52.
  • the braze ring 114 may prevent a thermal expansion mismatch between the (copper) contact structure 108 and the glass seal 112, which could cause seal failure.
  • aspects of this disclosure can facilitate creation of a glass-to-metal sealed hermetic housing that can still carry high currents, e.g., because the contact structure 108 is copper or another high-current capacity material.
  • the cover 106 can include a number of additional apertures, e.g., through which other or additional components can extend into the sealed space defined by the housing 102 and the header assembly 104.
  • FIG. 1 shows a number of feedthroughs 118 (four in FIG. 1) extending through corresponding feedthrough apertures 120 in the cover 106.
  • the feedthroughs 118 may be electrical leads or the like.
  • second glass seals 122 are disposed in the feedthrough apertures 120, with the feedthroughs 118 passing through the glass seals 122.
  • the second glass seals 122 facilitate sealing of the feedthroughs 118 to the cover 106, via glass-to-metal sealing, at the feedthrough apertures 120. Although four feedthroughs 118 are illustrated in FIG. 1, more or fewer may be provided.
  • the header assembly 104 also is illustrated as including a tube 124 that passes through the cover 106. More specifically, the cover 106 includes a tubing aperture 126 sized to receive the tube 124.
  • the tube 124 may be used to evacuate air in the housing 102, e.g., during the sealing process, to vent excess air in the housing, e.g., during a fault event, to supply a gas, such as an electronegative gas like hydrogen, to the housing 102, and/or the like.
  • a gas such as an electronegative gas like hydrogen
  • the header assembly 104 includes multiple seal types and sealing technologies.
  • braze joints 128 are formed between the braze rings
  • Braze joints 128 may also be formed between the tube 124 and the cover 106, e.g., at the tubing aperture 126.
  • the contact structures 108, the braze rings 114, the tubing 124, and/or the cover 106 are formed of materials that facilitate formation of the braze joints 128.
  • any of these components can include silver, copper, and/or alloys thereof.
  • the cover 106 may be made of steel, such as cold rolled steel, low carbon steel, and/or the like. Also in examples, the cover 106 may be treated, such as by plating or the like, to further facilitate formation of the braze joints 128 and/or glass-to-metal seals 130 described herein. In one non-limiting example, the cover 106 may be plated with sulfamate electrolytic nickel.
  • the header assembly 104 also includes the glass-to-metal seals 130.
  • the glass seals 112 and the second glass seals 122 may be glass preforms that bond or otherwise seal to the surrounding (e.g., metal) cover 106 at the interface of the metal and glass.
  • the glass seals 112, 122 may be formed of a low-lead glass, such as a barium-alkali low-lead glass.
  • the cover 106 may be made of any metallic material that cooperates with the glass seals 112, 122 to form the desired hermetic seal(s).
  • the cover 106 may be formed of a steel, such as low carbon steel or cold rolled steel.
  • the cover 106 may be surface treated, e.g., by plating or the like.
  • the cover 106 may have a sulfamate electrolytic nickel plating.
  • the cover 106 can include aluminum or an aluminum alloy.
  • the braze joints 128 and/or the glass-to-metal seals 130 may be leak free to 2.0 x 10' 9 cc/sec of helium at 1 atmosphere.
  • the braze joints 128 and/or the glass-to-metal seals 130 may also be configured to withstand an axial loading, e.g., a loading that would push the contact structures 108 into the contact apertures 110.
  • the braze joints 128 and/or the glass-to-metal seals 130 may withstand axial loads up to or exceeding 35 Ibf (155N) without leaking.
  • braze joints 128 and/or the glass-to-metal seals 130 may withstand side loads up to or exceeding 35 Ibf (155N) without leaking.
  • the braze joints 128 and/or the glass-to-metal seals 130 may also facilitate improved operation of the electrical device 100.
  • the electrical device 100 may facilitate the application of voltages up to or exceeding 4000 volts at 60 seconds at sea level between the contact structures 108 with a leakage current being below 1 milliampere.
  • the electrical device 100 will have no evidence of flashover, arcing, breakdown, or other damage at this electrical loading.
  • the electrical device 100 may also facilitate the application of voltages up to or exceeding 4000 volts at 60 seconds at sea level between the contact structures 108 and each of the feedthroughs 118 with a leakage current being below 1 milliampere.
  • the electrical device 100 will have no evidence of flashover, arcing, breakdown, or other damage at this electrical loading.
  • the electrical device 100 may also facilitate insulation resistance between the contact structures 108 and/or between the contact structures 108 and each of the feedthroughs 118 of up to or greater than 100 megohms at 1000 volts DC.
  • FIG. 2 is a cross-sectional view of the electrical device 100 taken along the section line 2-2 in FIG. 1.
  • FIG. 2 shows the contact structures 108 extending through cover 106 and into an interior 202 of the housing 102.
  • the interior 202 of the housing 102 may be hermetically sealed.
  • at least a portion of the interior 202 may be an arc chamber.
  • the arc chamber may be filled with a gas, such as hydrogen, that facilitates arc suppression.
  • a number of internal components also are shown in the interior 202. For example,
  • FIG. 2 shows a movable contact 204 disposed on a distal end of a movable shaft 206.
  • the shaft 206 may be selectively movable to configure the movable contact 204 in a first position contacting the contact structures 108, e.g., to allow for current flow between the contact structures 108, and a second position (illustrated) in which the movable contact 204 is spaced from the contact structures 108.
  • an end of the shaft 206 opposite the movable contact 204 includes a plunger 208.
  • the plunger 208 extends into an opening defined by a coil 210, e.g., an electromagnetic coil.
  • the electromagnetic coil 210 may be selectively energized to cause the plunger 208 (and thus the shaft 206 and the movable contact 204) to move relative to the contact structures 108.
  • FIG. 2 also shows an interrupt mechanism 212, e.g., proximate an inner surface of the cover 106 and between the contact structures 108.
  • the interrupt mechanism can include a triggering device 214, which may be a pyrotechnic trigger, for example, and a projectile 216.
  • the triggering device 214 may detonate in response to an overcurrent, a power surge, arcing, or some other event. The detonation applies a force that causes the projectile 216 to strike the shaft 206, driving the shaft 206 (and thus the movable contact 204) away from the contact structures 108, thereby inhibiting current flow through the electrical device 100.
  • FIG. 2 also shows that the electrical device 100 can include one or more additional components exterior to the housing 102.
  • FIG. 2 shows two magnets 218 coupled to the electrical device 100.
  • the magnets 218 are disposed proximate the housing 102 generally at positions radially spaced from the contact structures 108.
  • the magnets 218 may be provided to assist with current interruption.
  • certain types of magnets such as neodymium magnets may be desirable to provide a high current interruption capability.
  • Example implementations of devices described herein may facilitate the use of neodymium magnets, in particular when a stainless steel is used for the housing 102, according to examples described herein.
  • this disclosure is not limited to neodymium magnets, and in some examples, magnets may not be provided, e.g., as in FIG. 1.
  • the magnets 218 are coupled to the electrical device via a magnet mounts 220.
  • the magnet mounts 220 are generally illustrated as L-shaped members, having a first leg 222 on top of the cover 106 and a second leg 224 extending generally along, but spaced from, an outer surface of the housing 102.
  • the magnets 218 may be secured to the second leg 224, e.g.., between the second leg 224 and the housing 102.
  • the magnet mounts 220 are for example only. Any structure, configuration and/or the like that retains the magnets 218 in a desired position may be used.
  • the magnet mounts 220 may not be included. For instance, the magnets 218 may be secured directly to the housing 102.
  • FIG. 2 shows the electrical device 100 as including various internal and external components
  • FIG. 2 is for example only. Aspects of this disclosure can be used with any number or types of electrical devices that include a header assembly and a housing, like the header assemblyl04 and the housing 102.
  • FIG. 3 is a cross-sectional view of the electrical device 100 taken along the section line 3-3 in FIG. 1.
  • FIG. 3 shows electrical components 302 disposed in the interior 202 of the housing.
  • the electrical components 302 may be connected to one of the feedthroughs 118.
  • the electrical components 302 may be coupled to the coil 210, to the interrupt mechanism 212, and/or to any other of the components associated with the electrical device.
  • the electrical components 302 can be coupled to one or more electronic components outside the electrical device 100, e.g., to send and/or receive signals to/from outside the housing 102.
  • FIG. 3 also shows the tubing 124 in cross-section.
  • the tubing 124 may be provided to exchange air in the interior 202 of the housing 102 and/or to evacuate the interior 202 of the housing 102.
  • the interior 202 may be filled with hydrogen or another inert gas.
  • particular implementations of this disclosure can incorporate a stainless steel housing as the housing 102, which may facilitate use of the magnets 218 and/or a hydrogen or other inert atmosphere in the interior 202.
  • FIG. 4 is a partial cross-section of the header assembly 104 particularly showing aspects of the braze joints 128 at one of the contact structures 108 and at the tubing 124 and showing aspects of the glass-to-metal seal 130 associated with one of the contact structures 108.
  • the braze joints 128 and/or the glass-to-metal seals 130 may also facilitate improved operation of the electrical device 100.
  • the electrical device 100 may facilitate the application of voltages up to or exceeding 4000 volts at 60 seconds at sea level between the contact structures 108 with a leakage current being below 1 milliampere.
  • the electrical device 100 will have no evidence of flashover, arcing, breakdown, or other damage at this electrical loading.
  • the electrical device 100 may also facilitate the application of voltages up to or exceeding 4000 volts at 60 seconds at sea level between the contact structures 108 and each of the feedthroughs 118 with a leakage current being below 1 milliampere. Moreover, the electrical device 100 will have no evidence of flashover, arcing, breakdown, or other damage at this electrical loading. The electrical device 100 may also facilitate insulation resistance between the contact structures 108 and/or between the contact structures 108 and each of the feedthroughs 118 of up to or greater than 100 megohms at 1000 volts DC.
  • FIG. 5 is a flowchart showings aspects of a process 500, which may be a manufacturing process to form a hermetically-sealed electrical device, like the electrical device 100.
  • the process 500 includes providing a head plate.
  • the head plate may be the cover 106 discussed above.
  • the cover 106 has a plurality of apertures, including the contact apertures 110, the feedthrough apertures 120, and/or the tube aperture 126.
  • the cover 106 may be made of a metal, such as aluminum or an aluminum alloy.
  • the process 500 includes providing a glass seal in an opening in the head plate.
  • the cover 106 can include the contact aperture 110, and the glass seal 112 may be placed in the contact aperture 110.
  • the glass seal 112 can be a glass preform, e g., of a predetermined size and configuration.
  • the process 500 includes providing a terminal proximate the glass seal.
  • the contact structure 108 may be a terminal disposed in the contact aperture 110.
  • the glass seal 112 may be a ring that circumscribes an outer surface of the contact structure 108.
  • the process 500 includes providing a braze ring proximate the terminal.
  • the braze ring 114 illustrated in FIG. 1 is a sleeve disposed on an outer surface of the contact structure 108.
  • the braze ring 114 may contact both the contact structure 108 and the glass seal.
  • the process 500 includes creating an assembly including a braze joint at the braze ring and a glass-to-metal seal at the glass seal.
  • the operation 510 can include performing a brazing operation, such as vacuum brazing or the like, to form the braze j oint 128 at an interface of the braze ring 114 and the contact structure 108.
  • the glass-to-metal seal 130 can be formed at the glass seal 112, e.g., between the glass seal 112 and the cover 106 and/or between the glass seal 112 and the braze ring 114.
  • the operation 510 can include performing a glass-to-metal sealing process to form the desired seal(s) at the glass seal 112.
  • the result of the operation 510 may be the assembly 104 discussed above.
  • the operation 510 is illustrated and described as a single process, as will be appreciated, the operation 510 may be performed in multiple steps.
  • the braze joint 128 may be formed prior to forming the glass-to-metal seals 130.
  • the braze ring 114 may be brazed to the contact structure 108 prior to insertion into to the cover 106.
  • the operations 506 and 508 may include a single operation of providing the contact structure 108 with the braze ring 114 joined thereto.
  • the assembly may be pre-assembled as in the operations 502-508, but the glass-to-metal sealing may be performed prior to the brazing process.
  • brazing and glass-to- metal sealing may both include the application of heat
  • aspects of the brazing and glass-to-metal sealing may be done contemporaneously, e.g., via the same application of heat, such as in a furnace or the like.
  • the process 500 includes securing the assembly to a housing.
  • the assembly 104 may be secured to the housing using known methods, including epoxy sealing or the like.
  • the process 500 can include evacuating the housing.
  • ambient air in the housing after sealing may be removed and/or replaced with an electronegative gas, such as hydrogen, to provide a hermetically-sealed electrical device, like the electrical device 100.
  • an electronegative gas such as hydrogen
  • the process 500 can also include providing the brazedjoints 128 at the tube 124 and/or providing the glass-to-metal seals 130 at the feedthroughs 118.
  • all of the brazedjoints 128 may be formed in a single process, e.g., the entire assembly 104 may be exposed to a brazing process, such as a vacuum brazing process, a furnace brazing process, or the like to create the brazing j oints at the braze rings 114 and at the tube 124.
  • the brazing joints can be formed individually.
  • the glass-to-metal seals 130 associated with the contact structures 108 and associated with the feedthroughs 118 may similarly all be formed via a single process, e.g., a process applied to the entire header assembly 104.
  • aspects of this disclosure relate to providing electrical devices incorporating a header assembly that incorporates glass-to-metal sealing techniques.
  • the header assembly using the glass-to-metal sealing can provide a number of benefits over conventional header assemblies.
  • a hermetically-sealed and electrically-insulative assembly for use in high-voltage DC contactors, fuses, and pyrotechnic fuses may make use of glass-to-metal sealing technology along with a unique combination of materials and geometry to reduce cost and improve performance in comparison to conventional sealed assemblies.
  • Hermetic glass-to-metal assemblies according to this disclosure may be assembled using manufacturing methods that are less expensive than existing ceramic-to-metal or epoxy sealing, including in electrical devices like contactors and fuses.
  • the hermetic glass-to-metal assemblies described herein also may utilize lower cost manufacturing methods in its raw materials, further reducing cost in comparison to existing ceramic-to-metal and epoxy sealing applications.
  • hermetic glass-to-metal assemblies described herein may utilize unique combinations of materials and geometries to provide thermal and electrical performance that may be superior to existing glass-to-metal seals used in unrelated products (e.g., motor protectors), thus allowing the use of this technology in electrical devices including but not limited to, contactors and fuses.
  • FIG. 6 is a partial, cross-sectional view 600 of the electrical device 100, taken along the sectioning line 6-6 in FIG. 3. More specifically, FIG. 6 shows an interface of the header assembly 104, e.g., the cover 106, with the housing 102.
  • the header assembly 104 e.g., the cover 106
  • the housing 102 can be embodied as a can or cup.
  • FIG. 6 shows the housing 102 as including a generally cylindrical sidewall 602 and an outtumed rim 604.
  • the rim 604 may be bent relative to the sidewall 602 by an angle of between about 30- degrees and about 55-degrees, although other angles may be used.
  • the rim 604 may be in-turned, e.g., to define an opening narrower than an opening defined by the sidewall 602.
  • the housing 102 may be substantially cylindrical, e.g., the rim 604 may not be provided and/or the rim 604 may refer to the area proximate the termination of the sidewall 602 where the housing 102 meets the cover 106.
  • the sidewall 602 terminates at an edge 606.
  • the edge 606 is provided at the termination of the rim 604.
  • the edge 606 is a pinch trim edge, e.g., formed via pinch trimming.
  • Pinch trimming generally describes a process in which metal is cut by pinching the metal between two die sections. As a result of pinch trimming, the edge 606 is sharp, forming a generally circular edge.
  • the edge 606 is formed at a junction between an inner surface 608 of the housing 102 and an end surface 610 of the housing 102.
  • the housing may be fabricated by first pinch trimming the sidewall 602 of the housing 102, and then bending the sidewall 602 to form the rim 604.
  • pinch trimming is described herein for making the edge 606, the edge 606 is not limited to being formed using this process. Any process that forms the edge 606 as a sharp edge can be used.
  • a bottom surface 612 of the cover 106 contacts the edge 606 of the sidewall 602.
  • the bottom surface 612 is substantially planar, such that the cover 106 contacts the housing 102 about the entirety of the edge 606.
  • the cover 106 is secured to the housing 102 at the junction of the bottom surface 612 and the edge 606.
  • the bottom surface 612 and the edge 606 are welded together.
  • the bottom surface 612 and the edge 606 may be resistance welded.
  • the cover 106 and the housing 102 may be selected and/or fabricated to facilitate welding or other joining processes.
  • the cover 106 may be a low carbon steel, such as a cold-rolled steel.
  • the cover 106 may comprise an AISI 1006-1024 steel, which may be cold rolled, cold drawn, or otherwise manufactured.
  • the material of the cover 106 may be selected for its use in glass-to-metal sealing, as discussed above. The material may also be selected for its ability to be welded, e.g., using a resistance weld.
  • the cover 106 may also or alternatively be treated, e.g., to facilitate glass-to-metal sealing and/or welding, as described herein.
  • the cover 106 may be plated.
  • the cover 106 may have a nickel plating.
  • the plating can be a sulfamate electrolytic nickel plating.
  • the plating may be on the order of from about .0001 to about .0005 inches thick. However, other types of plating and/or other thicknesses of plating may also be used.
  • any surface treatment that is compatible with glass-to-metal sealing and/or techniques for joining the cover 106 to the housing 102 may be used.
  • the material for the housing 102 may also be selected for its compatibility with the cover 106 to facilitate joining, e.g., by resistance welding, as described herein.
  • the housing 102 may be a stainless steel can.
  • the housing 102 can have a thickness on the order of from about 0.015 to about 0.045 inches.
  • the housing 102 can also include a surface treatment, such as a plating or the like.
  • the housing 102 can include an electroless nickel plating.
  • the plating can be on the order of from about .0001 to about .0005 inches thick.
  • the plating may also be a high phosphorous plating, e.g., containing phosphorous in an amount of between about 8% and about 20%.
  • an activator such as woods nickel strike may be applied to the housing 102 prior to plating.
  • the housing 102 is not limited to the materials and/or finishes given herein as examples. Any materials that facilitate joining of the housing 102 to the cover 106 may be used.
  • the combination of the stainless steel housing 102 and the gas-to-metal sealed header assembly 104 including a steel cover 106 may provide certain benefits.
  • this combination can allow for use of neodymium magnets, e.g., as the magnets 218.
  • this combination may facilitate the use of a hydrogen atmosphere in the arc chamber volume 202.
  • a hydrogen gas backfill is optimal to extinguish heavy arcing events.
  • hydrogen will permeate through epoxy-filled contactors. Conventionally, then, such atmosphere has required the use of a ceramic header and a metallic housing.
  • neodymium magnets which are conventionally used inside hermetic contactors, are susceptible to hydrogen embrittlement if kept in a hydrogen environment.
  • the present disclosure may be less expensive than conventional devices, while still providing higher current interruption performance by providing both neodymium magnets and a hydrogen-enriched arcing chamber.
  • a header assembly which may be the header assembly 104, may be secured to the housing 102 to create a hermetically sealed inner volume.
  • the bottom surface 612 of the cover 106 may be sealed to the edge 606 of the housing 102.
  • FIG. 7 shows an example schematic of aspects of a welding operation for welding the cover 106 to the housing 102.
  • FIG. 7 is a cross-sectional representation of a welding apparatus 700 used to resistance weld the header assembly 104 to the housing 102.
  • the illustrated example shows the header assembly 104, which may be the glass-to-metal sealed header assembly discussed above, aspects of this disclosure may be used with other types of header assemblies.
  • the housing 102 is shown, this is merely for ease of reference. Aspects of this disclosure may be used with other types of housings.
  • the welding apparatus 700 includes a lower electrode holder 702.
  • the lower electrode holder 702 defines a bore 704 configured to receive the housing 102.
  • the lower electrode holder 702 also is configured to retain a lower electrode 706, e.g., proximate a top or open end of the bore 704.
  • the lower electrode 706 may be a ring-shaped electrode that is arranged such that when the housing 102 is disposed in the bore 704, the lower electrode 706 contacts the rim 604 of the housing 102, e.g., proximate the edge 606.
  • the edge 606 may be a sharp edge, which may be formed using a pinch trimming operation. However, other configurations for the edge 606 also may be used.
  • the header assembly 104 is placed on the housing 102.
  • the welding apparatus 700 can optionally include a positioning device 708 to maintain a position of the header assembly 104 relative to the housing 102 retained in the bore 704.
  • the positioning device 708 may axially align the cover 106 and the housing 102.
  • the positioning device 708 is embodied as a ring having a central opening that has a diameter that is slightly larger than an outer diameter of the cover 106.
  • the illustrated positioning device is for example only; other structures or arrangements also may be contemplated by those having ordinary skill in the art with the benefit of this disclosure.
  • the welding apparatus 700 also includes an upper electrode holder 710, which is configured to carry or retain an upper electrode 712. As illustrated in FIG. 7, the upper electrode
  • the welding apparatus 700 positions the cover 106 on the housing 102 and places a first electrode (the lower electrode 706) proximate the edge 606 of the housing 102 and the bottom surface 612 of the cover 106.
  • the welding apparatus 700 also positions a second electrode (the upper electrode 712) on the top surface of the cover 106.
  • the lower electrode holder 702 and the upper electrode holder 710 may be movable relative to each other, e g. in an axial direction.
  • the holders 702, 710 may be movable away from each other to facilitate insertion of the header assembly 104 and/or the housing 102.
  • the holders 702, 710 also may be movable toward each other, e.g., to apply a pressure to the housing 102 and/or to the cover 106 using the electrodes 706, 712. When this pressure is applied, a current may be passed through one or both of the electrodes 706, 712 to create a resistance weld at the edge 606/bottom surface 612 interface.
  • the resistance weld created by the welding apparatus 700 creates a hermetic seal between the header assembly 104 and the housing 102.
  • the resistance weld may allow for a hydrogen gas backfill, which may result in greater contactor break performance.
  • neodymium magnets may be placed outside of the hermetic assembly to prevent hydrogen embrittlement while still providing a magnetic field benefit that aids in contactor break performance.
  • FIG. 8 is a flowchart showings aspects of a process 800, which may be a manufacturing process to form a hermetically-sealed electrical device, like the electrical device
  • the process 800 can correspond to aspects of operations 512 and 514 of the process 500 described above.
  • the process 800 includes providing a housing.
  • the housing may be the housing 102 discussed above.
  • the housing may be a can or cup.
  • the housing may be formed, at least in part, using pinch trimming, such that the housing includes a pinch trim edge circumscribing an opening.
  • the housing may be formed of a stainless steel and/or may be plated, e.g., using electroless nickel plating.
  • the process 800 includes providing a header.
  • the header may be the header assembly 104 described above.
  • the header may be a glass-to-metal sealed header assembly.
  • the header may be otherwise formed and/or include features and/or components different from those described herein.
  • the process 800 includes resistance welding the header to the housing.
  • the header may be resistance welded using a resistance welding apparatus like the welding apparatus 700 discussed above.
  • the process 500 includes, optionally, securing magnets relative to the housing.
  • magnets such as neodymium magnets
  • FIG. 2 shows the magnets 218 positioned along an outer surface of the housing 102.
  • the magnets may be aligned with ends of a movable contact and may assist in arc suppression and/or resistance.
  • the process 500 includes evacuating/backfilling the housing.
  • ambient air in the housing after sealing may be removed and/or replaced with an electronegative gas, such as hydrogen, to provide a hermetically-sealed electrical device, like the electrical device 100.
  • an electronegative gas such as hydrogen
  • a hydrogen-rich environment may be particularly useful for suppressing arcs, but other gases and/or environmental conditions may also be of use and may be used with aspects of this disclosure.

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  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Casings For Electric Apparatus (AREA)

Abstract

L'invention concerne un dispositif électrique hermétiquement scellé comprenant un boîtier et un ensemble collecteur. L'ensemble collecteur comprend des bornes de contact, des traversées et/ou un tube s'étendant à travers une plaque de recouvrement. Des joints verre-métal et/ou des joints de brasage sont utilisés pour sceller les bornes de contact, les traversées et/ou le tube sur la plaque de recouvrement, ce qui peut éviter le besoin d'un collecteur en céramique. La plaque de recouvrement peut être soudée par résistance à un boîtier ou une boîte inférieur.
PCT/US2024/028174 2023-05-08 2024-05-07 Dispositifs électriques scellés Pending WO2024233560A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363500734P 2023-05-08 2023-05-08
US63/500,734 2023-05-08

Publications (1)

Publication Number Publication Date
WO2024233560A1 true WO2024233560A1 (fr) 2024-11-14

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WO (1) WO2024233560A1 (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102592890A (zh) * 2012-02-20 2012-07-18 北京航空航天大学 用于直流接触器的无极性氢气混合气体直流灭弧系统
US20130214884A1 (en) * 2010-11-01 2013-08-22 Ngk Spark Plug Co., Ltd. Relay
US20150187518A1 (en) * 2013-12-27 2015-07-02 Gigavac, Llc Sectionalized contact contactor
US20180286614A1 (en) * 2015-10-02 2018-10-04 Schott Japan Corporation Hermetic Terminal for High-Capacity Relay and Contact Device for High-Capacity Relay Including the Hermetic Terminal
CN111128605A (zh) * 2020-02-21 2020-05-08 上海瑞垒电子科技有限公司 一种玻璃封装型高压直流继电器
EP4033511A2 (fr) * 2021-01-21 2022-07-27 Gigavac, LLC Dispositif de commutation avec oeillets en céramique/verre
JP7191144B2 (ja) * 2020-03-18 2022-12-16 ショット日本株式会社 気密端子およびその気密端子を用いた接点装置

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130214884A1 (en) * 2010-11-01 2013-08-22 Ngk Spark Plug Co., Ltd. Relay
CN102592890A (zh) * 2012-02-20 2012-07-18 北京航空航天大学 用于直流接触器的无极性氢气混合气体直流灭弧系统
US20150187518A1 (en) * 2013-12-27 2015-07-02 Gigavac, Llc Sectionalized contact contactor
US20180286614A1 (en) * 2015-10-02 2018-10-04 Schott Japan Corporation Hermetic Terminal for High-Capacity Relay and Contact Device for High-Capacity Relay Including the Hermetic Terminal
CN111128605A (zh) * 2020-02-21 2020-05-08 上海瑞垒电子科技有限公司 一种玻璃封装型高压直流继电器
JP7191144B2 (ja) * 2020-03-18 2022-12-16 ショット日本株式会社 気密端子およびその気密端子を用いた接点装置
EP4033511A2 (fr) * 2021-01-21 2022-07-27 Gigavac, LLC Dispositif de commutation avec oeillets en céramique/verre

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