Switch device and manufacturing method of conductor thereof

Abstract

This disclosure provides a switching device comprising a device body, a triggering component, a first conductor, and a second conductor. The device body has a first pin and a second pin. The triggering component is disposed on the device body. The first conductor is disposed on the device body and electrically connected to the first pin, and the first conductor has a first contact portion. The second conductor is disposed on the triggering component and electrically connected to the second pin, and the second conductor has a second contact portion, and the second conductor is movable by the triggering component to contact the first contact portion of the first conductor with the second contact portion. The first and second contact portions are made of a graphene-copper alloy, and the graphene-copper alloy comprises at least graphene and copper.

Description

Technical Field

[0001] This disclosure relates to switching devices, and more particularly to a switching device with graphene copper contacts suitable for high current. Prior Technology

[0002] Existing switching devices, such as electronic component switches, semiconductor component switches, high-voltage high-current terminals, and relays, generate sparks with each switching contact. Copper contacts are prone to melting and sticking together after repeated switching. While silver contacts are more heat-resistant and have a longer lifespan for low-current applications, all-silver contacts are expensive, making their economic efficiency clearly poor. To save costs, current contact structures often consist of a base metal (e.g., copper) covered with a precious metal layer. When the precious metal layer is depleted, replacing the switching device only discards the base metal. However, limited by existing materials, contacts covered with a precious metal layer are still unsuitable for high-current applications and are difficult to improve.

[0003] In view of this, the inventor has devoted himself to researching and applying theoretical principles to address the aforementioned problems in the prior art, which is the goal of the inventor's improvement. Summary of the Invention

[0004] This disclosure provides a switching device with graphene copper alloy contacts.

[0005] This disclosure provides a switching device comprising a device body, a triggering component, a first conductor, and a second conductor. The device body has a first pin and a second pin. The triggering component is disposed on the device body. The first conductor is disposed on the device body and electrically connected to the first pin, and the first conductor has a first contact portion. The second conductor is disposed on the triggering component and electrically connected to the second pin, and the second conductor has a second contact portion, and the second conductor can be moved by the triggering component to contact the first contact portion of the first conductor with the second contact portion. The first and second contact portions are made of a graphene-copper alloy, and the graphene-copper alloy comprises at least graphene and copper.

[0006] In one embodiment of this disclosure, the first conductor has a first conductive body, and the first contact portion covers the first conductive body.

[0007] In one embodiment of this disclosure, the first conductive body is made of copper.

[0008] In one embodiment of this disclosure, the second conductor has a second conductive body, and the second contact portion covers the second conductive body.

[0009] In one embodiment of this disclosure, the second conductive body is made of copper.

[0010] In one embodiment of this disclosure, the first contact portion has a first convex surface.

[0011] In one embodiment of this disclosure, the second contact portion has a second convex surface.

[0012] This disclosure also provides a switching device comprising a device body, a triggering component, a pair of first conductors, and a second conductor. The device body has a pair of first pins and a second pin. The triggering component is disposed on the device body. The first conductors are disposed on the device body and electrically connected to each of the first pins, each of the first conductors having a first contact portion and the pair of first contacts being arranged facing each other. The second conductor is disposed on the triggering component and electrically connected to the second pin, the second conductor being disposed between the pair of first conductors, the second conductor having a pair of second contacts being arranged opposite to each of the first conductors, and the second conductor being movable by the triggering component so that one of its second contacts contacts the first contact portion of the corresponding first conductor. Each first contact portion and each second contact portion is made of a graphene-copper alloy, and the graphene-copper alloy comprises at least graphene and copper.

[0013] In one embodiment of this disclosure, in each first conductor, the first conductor has a first conductive body, and a first contact portion covers the first conductive body.

[0014] In one embodiment of this disclosure, the first conductive body is made of copper.

[0015] In one embodiment of this disclosure, in each second conductor, the second conductor has a second conductive body, and the second contact portion covers the second conductive body.

[0016] In one embodiment of this disclosure, the second conductive body is made of copper.

[0017] In one embodiment of this disclosure, at least one of the first contact portions has a first convex surface.

[0018] In one embodiment of this disclosure, at least one of the second contact portions has a second convex surface.

[0019] In one embodiment of this disclosure, the second conductor is pre-pressed against one of the first conductors by a triggering component and can be moved by the triggering component to contact the other first conductor.

[0020] This disclosure also provides a method for manufacturing a conductor for a switching device, comprising: providing a first mold, a second mold, and a contact segment, wherein the contact segment is made of a graphene-copper alloy and the graphene-copper alloy includes at least graphene and copper; inserting the contact segment into the first mold; closing the first mold with the second mold to form a conductor, wherein the conductor has a contact portion made of the graphene-copper alloy; subjecting the conductor to heat treatment, the heat treatment comprising heating for 60-90 minutes to a temperature of 350-550 degrees Celsius, holding the temperature for 60-90 minutes, then allowing it to stand for annealing, and cleaning the heat-treated conductor.

[0021] In one embodiment of this disclosure, the method for manufacturing a conductor for a switching device further includes providing a conductive line segment, inserting the conductive line segment into a first mold before the contact line segment, and pressing the contact line segment to fit one end of the conductive line segment.

[0022] In one embodiment of this disclosure, the method for manufacturing a conductor for a switching device further includes closing a first mold with a second mold to shape a conductive line segment into a conductive body by the first mold and the second mold.

[0023] In one embodiment of this disclosure, the diameter of the contact segment is smaller than that of the conductive segment.

[0024] In one embodiment of this disclosure, the method for manufacturing a conductor for a switching device further includes providing another contact segment, placing the other contact segment into a first mold before the conductive segment, and pressing and fitting the other end of the conductive segment.

[0025] The disclosed switching device has its first and second contacts made of graphene-copper alloy. Graphene-copper alloy has excellent electrical conductivity and a melting point above 1000℃, allowing it to withstand high temperatures with low loss. Furthermore, the price of graphene-copper alloy is relatively low compared to precious metals such as silver. Compared to existing silver contact switching devices, the disclosed switching device has low resistance, excellent conductivity, high temperature resistance, and a long service life. It is not only inexpensive but also performs better than existing technologies. Simple Explanation of the Diagram

[0026] Figure 1 is a perspective view of the switching device according to the first embodiment disclosed herein.

[0027] Figure 2 is a partial enlarged view of the switching device of the first embodiment disclosed herein.

[0028] Figure 3 is a schematic diagram of one of the conductors of the switching device disclosed herein.

[0029] Figure 4 is a schematic diagram of another state of the conductor of the switching device disclosed herein.

[0030] Figure 5 is a schematic diagram of another state of the conductor of the switching device disclosed herein.

[0031] Figure 6 is a perspective view of the switching device according to the second embodiment disclosed herein.

[0032] Figure 7 is a partial enlarged view of the switching device of the second embodiment disclosed herein.

[0033] Figure 8 is a schematic diagram of one of the second conductors of the switching device of the second embodiment disclosed herein.

[0034] Figure 9 is a schematic diagram of another state of the second conductor of the switching device of the second embodiment disclosed herein.

[0035] Figure 10 is a schematic diagram of another state of the conductor of the switching device disclosed herein.

[0036] Figure 11 is a flowchart of the steps of the conductor manufacturing method of the switch assembly disclosed herein.

[0037] Figures 11A to 11D are schematic diagrams illustrating the steps of the conductor manufacturing method of the switch assembly according to the third embodiment of this disclosure.

[0038] Figures 12A to 12D are schematic diagrams illustrating the steps of the conductor manufacturing method of the switch assembly according to the fourth embodiment of this disclosure.

[0039] Figures 13A to 13D are schematic diagrams illustrating the steps of the conductor manufacturing method of the switch assembly according to the fifth embodiment of this disclosure. Implementation

[0040] In the description of this disclosure, it should be understood that the terms "front," "rear," "left," "right," "front end," "rear end," "end," "longitudinal," "lateral," "vertical," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting conditions of this disclosure.

[0041] Unless otherwise defined, terms such as "substantially" and "approximately" are used to describe and narrate small changes. When combined with an event or situation, the term may include the exact moment the event or situation occurred, or an approximate point in time. For example, when combined with a numerical value, the term may include a range of variation less than or equal to ±10% of the value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to ±0.05%.

[0042] The detailed description and technical content of this disclosure will be explained in conjunction with the following drawings. However, the accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0043] Figure 1 is a perspective view of the switching device according to the first embodiment of the present disclosure; Figure 2 is a partial enlarged view of the switching device according to the first embodiment of the present disclosure. Referring to Figures 1 and 2, the first embodiment of the present disclosure provides a switching device, which includes a device body 100, a trigger component 200, and a plurality of conductors. In this embodiment, the plurality of conductors includes a first conductor 410 and a second conductor 420.

[0044] The device body 100 includes an insulating base 110 and a housing 120. The insulating base 110 has a pin side 111 and a component side 112. A first pin 310 and a second pin 320 are provided on the insulating base 110. Specifically, the first pin 310 and the second pin 320 are snapped into the insulating base 110, but this disclosure is not limited to this. For example, the first pin 310 and the second pin 320 can also be embedded in the insulating base 110 by encapsulation injection molding. In this embodiment, the first pin 310 and the second pin 320 are both elongated metal strips, and the first pin 310 and the second pin 320 respectively penetrate the insulating base 110 and protrude from the pin side 111 and the component side 112 for insertion application.

[0045] A trigger assembly 200 is disposed on the device body 100. In this embodiment, the trigger assembly 200 is disposed on the insulating base 110 of the device body 100. Specifically, the trigger assembly 200 includes a spring arm 210 and an electromagnet 220. At least a portion of the spring arm 210 is made of a magnetically conductive material (e.g., iron). In this embodiment, the spring arm is an assembly of a phosphor bronze component riveted to an iron component, but this disclosure is not limited to this. The spring arm 210 is disposed on the component side 112, and the electromagnet 220 is disposed on the component side 112 corresponding to the spring arm 210 and disposed on the phosphor bronze component. When the electromagnet 220 is driven to generate a kinetic magnetic force, the electromagnet 220 can move (e.g., attract) the iron component of the spring arm 210 by its magnetic force, causing the spring arm 210 to deflect.

[0046] As shown in Figure 2, a first conductor 410 is disposed on the device body 100 and electrically connected to the first pin 310, while a second conductor 420 is disposed on the trigger assembly 200. In this embodiment, the first conductor 410 and the second conductor 420 can be components with the same structure. Figure 3 is a schematic diagram of one of the conductors of the switching device disclosed herein. As shown in Figure 3, in this embodiment, the first conductor 410 has a first conductive body 411 and a first contact portion 412. Specifically, the first conductive body 411 is nail-shaped, and the first contact portion 412 is disposed at one end of the first conductive body 411. In this embodiment, the first contact portion 412 covers the nail head of the first conductive body 411, but this disclosure is not limited to this example. For example, the first contact portion 412 can also be embedded in the first conductive body 411. Alternatively, the first conductor 410 can also be integrally formed with the same material to form the first contact portion 412 without having a first conductive body 411. In this embodiment, the second conductor 420 has a second conductive body 421 and a second contact portion 422. Specifically, the second conductive body 421 is nail-shaped, and the second contact portion 422 is disposed at one end of the second conductive body 421. In this embodiment, the second contact portion 422 covers the nail head of the second conductive body 421, but this disclosure is not limited thereto. For example, the second contact portion 422 can also be embedded in the second conductive body 421. As another example, the second conductor 420 can also be integrally formed with the same material to form the second contact portion 422 without having a second conductive body 421.

[0047] Referring to Figures 1 and 2, in this embodiment, the first conductive body 411 is riveted to the first pin 310 and disposed on the element side 112 of the insulating base 110 of the device body 100. The second conductor 420 is disposed in the trigger assembly 200 and electrically connected to the second pin 320. In this embodiment, the second conductive body 421 is riveted to the spring arm 210 of the trigger assembly 200 and disposed on the element side 112 of the insulating base 110 of the device body 100. The second contact portion 422 of the second conductor 420 is disposed facing the first contact portion 412 of the first conductor 410. In a preset state, the first conductor 410 and the second conductor 420 are disposed separately.

[0048] When the spring arm 210 of the trigger component 200 is deflected by its electromagnet 220, the second conductor 420 is moved by the deflection of the spring arm 210, and the second conductor 420 contacts the first contact portion 412 of the first conductor 410 with its second contact portion 422, thereby electrically connecting the first pin 310 to the second pin 320. Therefore, the switching device of this embodiment can switch the circuit connected to the first pin 310 and the second pin 320 between open and closed circuits.

[0049] Both the first conductive body 411 and the second conductive body 421 are made of copper, and both the first contact portion 412 and the second contact portion 422 are made of graphene-copper alloy. The graphene-copper alloy contains at least graphene (less than 5% by weight) and copper, and can be prepared according to the graphene modification method of metals in patent TWI710522. The graphene-copper alloy is sintered at an operating temperature above 1000°C, causing the graphene bonds to break and the copper atoms to connect. Therefore, the melting point of the graphene-copper alloy is above 1000°C and can withstand high temperatures, and graphene has good electrical conductivity. Taking the first conductive body 411 as an example, the copper in the graphene-copper alloy of the first contact portion 412 can be well bonded to the copper-made first conductive body 411, thus reducing the resistance between the first conductive body 411 and the first contact portion 412 and improving the conductivity of the first conductor 410.

[0050] In this embodiment, the surfaces of the first contact portion 412 and the second contact portion 422 are both flat, and when the first contact portion 412 contacts the second contact portion 422, the surfaces of the first contact portion 412 and the second contact portion 422 adhere to each other, but this disclosure is not limited thereto.

[0051] Figure 4 is a schematic diagram of another configuration of the conductor of the switching device according to the first embodiment of this disclosure. Specifically, the first contact portion 412 has a first convex surface 413, and the second contact portion 422 has a second convex surface 423. In this configuration, both the first convex surface 413 and the second convex surface 423 are arc-shaped. After several uses, the convex surface wears down and deforms, allowing its shape to fit against the surface of the mating second contact portion 422, thereby reducing the resistance between them.

[0052] Figure 5 is a schematic diagram of another state of the conductor of the switching device of the first embodiment disclosed herein. Specifically, the first contact portion 412 has a first convex surface 413, the second contact portion 422 has a second convex surface 423, and in this state, both the first convex surface 413 and the second convex surface 423 are conical surfaces.

[0053] In this embodiment, the first conductor 410 and the second conductor 420 are structurally identical components. However, depending on different usage requirements, the first conductor 410 and the second conductor 420 can also be structurally different components, such as two of the structures shown in Figures 3 to 5 combined together.

[0054] Figure 6 is a perspective view of the switching device according to the second embodiment of the present disclosure; Figure 7 is a partial enlarged view of the switching device according to the second embodiment of the present disclosure. Referring to Figures 6 and 7, the second embodiment of the present disclosure provides a switching device, which includes a device body 100, a trigger component 200, and a plurality of conductors. In this embodiment, the plurality of conductors includes a pair of first conductors 410 / 410a and a second conductor 420.

[0055] The device body 100 includes an insulating base 110 and a housing 120. The insulating base 110 has a pin side 111 and a component side 112, and a pair of first pins 310 / 310a and a second pin 320 are provided on the insulating base 110. In this embodiment, the first pins 310 / 310a and the second pin 320 are both elongated metal strips, and the first pins 310 / 310a and the second pin 320 respectively penetrate the insulating base 110 and protrude from the pin side 111 and the component side 112 respectively.

[0056] A trigger assembly 200 is disposed on the device body 100. In this embodiment, the trigger assembly 200 is disposed on the insulating base 110 of the device body 100. Specifically, the trigger assembly 200 includes a spring arm 210 and an electromagnet 220. At least a portion of the spring arm 210 is made of a magnetically conductive material (e.g., iron). In this embodiment, the spring arm is an assembly of a phosphor bronze component riveted to an iron component, but this disclosure is not limited to this. The spring arm 210 is disposed on the component side 112, and the electromagnet 220 is disposed on the component side 112 corresponding to the spring arm 210 and disposed on the phosphor bronze component. When the electromagnet 220 is driven to generate a kinetic magnetic force, the electromagnet 220 can move (e.g., attract) the iron component of the spring arm 210 by its magnetic force, causing the spring arm 210 to deflect.

[0057] As shown in Figures 6 and 7, the pair of first conductors 410 / 410a are disposed on the device body 100 and electrically connected to each of the first pins 310 / 310a, respectively, and the second conductor 420 is disposed on the trigger assembly 200. In this embodiment, the pair of first conductors can be components with the same structure, as shown in Figure 3, but this disclosure is not limited to this, and can also be the structure shown in Figures 4 to 5, where the first contact portion 412 has a first convex surface 413 and the second contact portion 422 has a second convex surface 423. Moreover, in this embodiment, the first convex surface 413 and the second convex surface 423 can be an arc surface as shown in Figure 4 or a conical surface as shown in Figure 5.

[0058] Depending on the specific application requirements, the first conductor (410, 410a) and the second conductor 420 can also be components with different structures, such as two of the structures shown in Figures 3 to 5, which can be combined together.

[0059] In each of the first conductors 410 / 410a shown in this embodiment, the first conductor 410 / 410a has a first conductive body 411 / 411a and a first contact portion 412 / 412a. Specifically, the first conductive body 411 / 411a is nail-shaped, and the first contact portion 412 / 412a is disposed at one end of the first conductive body 411 / 411a. In this embodiment, the first contact portion 412 / 412a covers the nail head of the first conductive body 411 / 411a, but this disclosure is not limited thereto. For example, the first contact portion 412 / 412a may also be embedded in the first conductive body 411 / 411a. Alternatively, the first conductor 410 / 410a may also be integrally formed of the first contact portion 412 / 412a from the same material without having a first conductive body 411 / 411a.

[0060] Figure 8 is a schematic diagram of one of the second conductors 420 of the switching device according to the second embodiment of this disclosure. Referring to Figure 8, in this embodiment, the second conductor 420 has a second conductive body 421 and a pair of second contacts 422 / 422a. Specifically, the second conductive body 421 is nail-shaped, and the pair of second contacts 422 / 422a are respectively disposed at both ends of the second conductive body 421. In this embodiment, the second contacts 422 / 422a cover both ends of the second conductive body 421, but this disclosure is not limited thereto. For example, the second contacts 422 / 422a can also be embedded in the second conductive body 421. Alternatively, the second conductor 420 can also be integrally formed of the second contacts 422 / 422a from the same material without having a second conductive body 421.

[0061] Referring to Figures 6 and 7, each first conductive body 411 / 411a is riveted to its corresponding first pin 310 / 310a and disposed on the element side 112 of the insulating base 110 of the device body 100. The pair of first contacts 412 / 412a of the pair of first conductors 410 / 410a are arranged facing each other. The second conductor 420 is disposed in the trigger assembly 200 and electrically connected to the second pin 320. In this embodiment, the second conductive body 421 is riveted to the spring arm 210 of the trigger assembly 200 and disposed on the element side 112 of the insulating base 110 of the device body 100. The second conductor 420 is disposed between the pair of first conductors 410 / 410a. The pair of second contacts 422 / 422a of the second conductor 420 are disposed opposite to each of the first conductors 410 / 410a. The second conductor 420 can be moved by the trigger component 200 so that one of the second contacts 422 (422a) contacts the first contact 412 (412a) of the corresponding first conductor 410 (410a).

[0062] In a preset state, the second conductor 420 is pre-pressed by the trigger component 200 onto one of the first conductors 410a. The second conductor 420 contacts the first contact 412a of the pre-pressed first conductor 410a with one of its second contact portions 422a, thereby electrically connecting the first pin 310a connected to this first conductor 410a to the second pin 320. When the spring arm 210 of the trigger component 200 is moved and deflected by its electromagnet 220, the second conductor 420 is moved by the deflection of the spring arm 210, and the second conductor 420 contacts the first contact 412 of another first conductor 410 with its other second contact portion 422, thereby electrically connecting the other first pin 310 to the second pin 320. Therefore, the switching device of this embodiment can switch between two circuits respectively connected to each of the first pins 310 / 310a.

[0063] Referring to Figures 7 and 8, in this embodiment, the surfaces of the first contact portion 412 / 412a and the second contact portion 422 / 422a are both flat, and when the first contact portion 412 (412a) contacts the second contact portion 422 (422a), the surfaces of the first contact portion 412 (412a) and the second contact portion 422 (422a) are attached to each other, but this disclosure is not limited thereto. Figure 9 is a schematic diagram of another state of the second conductor 420 of the switching device of the second embodiment of this disclosure. Referring to Figure 9, specifically, each second contact portion 422 / 422a has a second convex surface 423 / 423a, and in this state, the second convex surface 423 / 423a is curved.

[0064] Referring to Figure 10, the switching device disclosed herein also includes a conductor 400 integrally made of graphene copper alloy. At least one contact portion 401 / 401a is formed at an appropriate position on the conductor 400. This conductor 400 can be used as the first conductor 410 / 410a or the second conductor 420, / 420a in the embodiments shown in the foregoing figures, depending on the configuration position. When any of its contact portions 401 / 401a is configured in the corresponding position, it can also be used as the first contact portion 412 / 412a or the second contact portion 422 / 422a in the embodiments shown in the foregoing figures.

[0065] The disclosed switching device has its first contact portion 412 / 412a and second contact portion 422 / 422a made of graphene copper alloy. Graphene copper alloy has excellent electrical conductivity and a melting point above 1000℃, allowing it to withstand high temperatures with low loss. Furthermore, the price of graphene copper alloy is relatively low compared to precious metals such as silver. Compared to existing silver contact switching devices, the disclosed switching device has low resistance, excellent conductivity, high temperature resistance, and a long service life. It is not only inexpensive but also performs better than existing technologies.

[0066] Figure 11 is a flowchart of the conductor manufacturing method of the switch device disclosed herein. Referring to Figure 11, the conductor manufacturing method of the switch device disclosed herein includes at least the following steps: providing a first mold, a second mold, and a contact segment; inserting the contact segment into the first mold, closing the first mold with the second mold to form a conductor, and the contact segment being formed into a contact portion by the second mold; subjecting the conductor to heat treatment (heating time 60-90 minutes, holding temperature 350-550 degrees Celsius, holding time 60-90 minutes followed by static annealing); and cleaning the heat-treated conductor.

[0067] Figures 11A to 11D are schematic diagrams illustrating the steps of a method for manufacturing a conductor in a switch assembly according to the third embodiment of this disclosure. Referring to Figures 11A to 11D, this embodiment manufactures a conductor 400 for use in the embodiment shown in Figure 10. The steps of this embodiment are as follows.

[0068] Referring to Figures 11 and 11A, in step a, a first mold 11, a second mold 12, and a contact line segment 41 are provided.

[0069] Referring to Figures 11 and 11B, continuing from step a, in step b, the contact segment 41 is inserted into the first mold 11. Referring to Figures 11 and 11C, continuing from step b, in step c, the first mold 11 is closed with the second mold 12 to form a conductor 400, and the contact segment 41 is formed by the second mold 12 into a contact portion 401 and by the first mold 11 into another contact portion 401a. In this embodiment, to produce a nail-shaped conductor, the inner contour of the first mold 11 is tubular and the inner contour of the second mold 12 is a concave arc surface, but this disclosure is not limited to this. Specifically, the first mold 11 is closed by the second mold 12 so that the contact line segment 41 is shaped by the first mold 11 and the second mold 12 to form a conductor 400. The inner contour of the first mold 11 and the second mold 12 corresponds to the predetermined shape of the contact portion 401 (401a) so that either end of the contact line segment can be shaped by the first mold 11 and the second mold 12 to form the contact portion 401 (401a).

[0070] After annealing, the hardness of the graphene copper alloy ranges from 80HV to 150HV (HV, Vickers hardness), which is better than that of copper. This hardness range allows the contact part 401 (401a) to undergo a permissible degree of deformation after repeated collisions. Therefore, it can disperse the contact points to avoid the wear of the contact part 401 (401a) from being concentrated in a local area.

[0071] Referring to Figures 11 and 11D, following step c, in step d, the conductor 400 is subjected to heat treatment (heating time 60-90 minutes, holding temperature 350-550 degrees Celsius, holding time 60-90 minutes followed by static annealing). Following step d, in step e, the heat-treated conductor 400 is cleaned.

[0072] Figures 12A to 12D are schematic diagrams illustrating the steps of a conductor manufacturing method for a switch assembly according to the fourth embodiment of this disclosure. Referring to Figures 12A to 12D, this embodiment manufactures a conductor 400 for use as the first conductor 410 or the second conductor 420 in the embodiment shown in Figure 3. The steps of this embodiment are as follows.

[0073] Referring to Figures 11 and 12A, in step a, a first mold 11, a second mold 12, and a contact segment 41 are provided. In this embodiment, the contact segment 41 is made of the aforementioned graphene-copper alloy. Further, in this embodiment, a conductive segment 42 is provided. In this embodiment, the conductive segment 42 is made of copper, which is softer than the contact segment 41 made of graphene-copper alloy.

[0074] Referring to Figures 11 and 12B, following step a, in step b1, the conductive segment 42 is first inserted into the first mold 11 before the contact segment 41. Following step b1, in step b, the contact segment 41 is then inserted into the first mold 11, and the contact segment 41 is pressed and embedded into one end of the conductive segment 42. Specifically, the conductive segment 42 can be pushed into the first mold 11 by the contact segment 41 against that end of the conductive segment 42, and the conductive segment 42 can be pressed simultaneously to embed the contact segment 41 into that end of the conductive segment 42. In this embodiment, the wire diameter of the contact segment 41 is smaller than that of the conductive segment 42, and the hardness of the contact segment 41 is greater than that of the conductive segment 42, which facilitates the embedding of the contact segment 41 into the conductive segment 42.

[0075] Referring to Figures 11 and 12C, continuing from step b, in step c, the first mold 11 is closed with the second mold 12 to form a conductor 400, and the contact segment 41 is formed into a contact portion 401 by the second mold 12. When the first mold 11 is closed with the second mold 12, the contact segment 41 and the conductive segment 42 are pressed together by the first mold 11 and the second mold 12. In this embodiment, in order to make a nail-shaped conductor, the inner contour of the first mold 11 is tubular and the inner contour of the second mold 12 is a concave arc surface, but this disclosure is not limited to this. Specifically, the first mold 11 is closed with the second mold 12 to form a conductive body 402 by the first mold 11 and the second mold 12, and the inner contour of the second mold 12 corresponds to the predetermined shape of the contact portion 401, so that the contact segment 41 can be formed into the contact portion 401 by the second mold 12.

[0076] After annealing, the hardness of the graphene copper alloy ranges from 80HV to 150HV (HV, Vickers hardness). Its hardness is better than that of copper, and this range allows the contact part 401 to undergo a permissible degree of deformation after repeated impacts. Therefore, it can disperse the contact points to avoid the wear of the contact part 401 being concentrated in a local area.

[0077] Referring to Figures 11 and 12D, following step c, in step d, the conductor 400 is heat-treated (heating time 60-90 minutes, holding temperature 350-550 degrees Celsius, holding time 60-90 minutes followed by static annealing). Following step d, in step e, the heat-treated conductor 400 is cleaned.

[0078] Figures 13A to 13D are schematic diagrams illustrating the steps of a conductor manufacturing method for a switch assembly according to the fifth embodiment of this disclosure. Referring to 13A to 13D, this embodiment manufactures a conductor 400 for use as the second conductor 420 / 420a in the embodiment shown in FIG8. The steps of this embodiment are as follows.

[0079] Referring to Figures 11 and 13A, in step a of this embodiment, a first mold 11, a second mold 12, contact segments 41 as described above, and another contact segment 41a of the same material are provided. The contact segments 41 and 41a shown in this embodiment are made of the aforementioned graphene-copper alloy. The conductive segment 42 shown in this embodiment is made of copper, which is softer than the contact segments 41 and 41a made of graphene-copper alloy.

[0080] Referring to Figures 11 and 13B, following step a, in step b2, one of the aforementioned contact segments 41a is first inserted into the first mold 11. Following step b2, in step b1, the conductive segment 42 is then inserted into the first mold 11. Following step b1, in step b, the other contact segment 41a is then inserted into the first mold 11. Specifically, the two contact segments 41 and 41a can be pre-pressed and embedded into the two ends of the conductive segment 42 before being inserted into the first mold 11, or the conductive segment 42 and the preceding contact segment 41a can be pushed into the first mold 11 by the subsequent contact segment 41 and simultaneously pressed and fitted together. In this embodiment, the wire diameter of each contact segment 41 and 41a is smaller than that of the conductive segment 42, and the hardness of the contact segments 41 and 41a is greater than that of the conductive segment 42, which facilitates the embedding of the contact segments 41 and 41a into the conductive segment 42.

[0081] Referring to Figures 11 and 12C, continuing from step b, in step c, when the second mold 12 closes the first mold 11, each contact segment 41, 41a is pressed and connected to the conductive segment 42 to form a conductor 400. One contact segment 41 forms a contact portion 401, the conductive segment 42 forms a conductive body 402, and the other contact segment 41a forms another contact portion 401a. In this embodiment, to produce the nail-shaped conductor 400, the inner contour of the first mold 11 is tubular and the inner contour of the second mold 12 is a concave arc surface, but this disclosure is not limited to this. Specifically, the first mold 11 is closed by the second mold 12, so that the conductive line segment 42 is shaped by the first mold 11 and the second mold 12 to form a conductive body 402. The inner contour of the second mold 12 corresponds to the predetermined shape of the contact portion 401, so that each contact line segment 41, 41a can be shaped by the first mold 11 and the second mold 12 to form the contact portion 401, 401a.

[0082] Referring to Figures 11 and 13D, following step c, in step d, the conductor 400 is heat-treated (heating time 60-90 minutes, holding temperature 350-550 degrees Celsius, holding time 60-90 minutes followed by static annealing). Following step d, in step e, the heat-treated conductor 400 is cleaned.

[0083] After annealing, the hardness of the graphene copper alloy ranges from 80HV to 150HV (HV, Vickers hardness), which is better than that of copper. This hardness range allows the contact part 401 (401a) to undergo a permissible degree of deformation after repeated collisions. Therefore, it can disperse the contact points to avoid the wear of the contact part 401 (401a) from being concentrated in a local area.

[0084] The above description is merely a preferred embodiment of this invention and is not intended to limit the patent scope of this invention. Other equivalent variations that utilize the patent spirit of this invention should also fall within the patent scope of this invention.

[0085] 11: First mold 12: Second mold 41, 41a: Contact segment 42: Conductive line segment 100:Device body 110: Insulating base 111: Foot side 112: Component side 120: Outer shell 200: Triggering Component 210: Spread Arm 220: Electromagnet 310, 310a: First pin 320: Second pin 400: Conductor 401, 401a: Contact parts 402: Conductive body 410, 410a: First conductor 411, 411a: First conductive body 412, 412a: First contact part 413, 413a: First convex surface 420, 420a: Second conductor 421: Second conductive body 422, 422a: Second contact portion 423, 423a: Second convex surface

Claims

1. A switching device, comprising: a device body having a first pin and a second pin; a triggering component disposed on the device body; a first conductor disposed on the device body and electrically connected to the first pin, the first conductor having a first conductive body and a first contact portion covering the first conductive body; and a second conductor disposed on the triggering component and electrically connected to the second pin, the second conductor having a second conductive body and a second contact portion covering the second conductive body, and the second conductor being movable by the triggering component to contact the first contact portion of the first conductor with the second contact portion; wherein the first contact portion and the second contact portion are made of a graphene-copper alloy and the graphene-copper alloy comprises at least graphene and copper; wherein the first contact portion has a first convex surface and the second contact portion has a second convex surface.

2. The switching device as claimed in claim 1, wherein the first conductive body is made of copper.

3. The switching device as claimed in claim 1, wherein the second conductive body is made of copper.

4. A switching device, comprising: a device body having a pair of first pins and a second pin; a triggering component disposed on the device body; a pair of first conductors disposed on the device body and electrically connected to each of the first pins, each of the first conductors having a first conductive body and a first contact portion covering the first conductive body, and the pair of first contacts being arranged facing each other; and a second conductor disposed on the triggering component and electrically connected to the second pin, the second conductor being disposed between the pair of first conductors, the second conductor having a pair of second conductive bodies and a pair of second contacts respectively covering the pair of first conductive bodies, and the pair of second contacts being arranged opposite to each of the first conductors, and the second conductor being movable by the triggering component to contact the first contact portion of the corresponding first conductor with one of its second contacts; wherein each of the first contacts and each of the second contacts is made of a graphene-copper alloy, and the graphene-copper alloy comprises at least graphene and copper; At least one of the first contact portions has a first convex surface, and at least one of the second contact portions has a second convex surface.

5. The switching device as claimed in claim 4, wherein the first conductive body is made of copper.

6. The switching device as claimed in claim 4, wherein the second conductive body is made of copper.

7. The switching device as claimed in claim 4, wherein the second conductor is pre-pressed against one of the first conductors by the triggering component and is movable by the triggering component to contact the other of the first conductors.

8. A method for manufacturing a conductor for a switching device, comprising: providing a first mold, a second mold, and a contact segment, wherein the contact segment is made of a graphene-copper alloy and the graphene-copper alloy comprises at least graphene and copper; inserting the contact segment into the first mold; closing the first mold with the second mold to form a conductor, wherein the conductor has a contact portion made of the graphene-copper alloy; subjecting the conductor to heat treatment, the heat treatment comprising heating for 60-90 minutes to a temperature of 350-550 degrees Celsius, holding the temperature for 60-90 minutes, then allowing it to stand for annealing, and cleaning the heat-treated conductor.

9. The method of manufacturing a conductor for a switching device as claimed in claim 8 further comprises providing a conductive segment, inserting the conductive segment into the first mold before the contact segment, and pressing the contact segment to fit one end of the conductive segment.

10. The method for manufacturing a conductor of a switching device as claimed in claim 9 further comprises closing the first mold with the second mold to mold the conductive line segment into a conductive body by the first mold and the second mold.

11. A method for manufacturing a conductor for a switching device as claimed in claim 9, wherein the diameter of the contact segment is smaller than that of the conductive segment.

12. The method of manufacturing a conductor for a switching device as claimed in claim 9 further comprises providing another contact segment, placing the other contact segment into the first mold and pressing and fitting the other end of the conductive segment before the conductive segment.

Images