Switch with an electrical contact material

Abstract

A switch in the form of a rocker switch, comprising: a first contact (A) which contacts a negative electrode, a third contact (C) which contacts a positive electrode, and a second contact (B) provided between the first contact (A) and the third contact (C), wherein the first contact (A), the second contact (B) and the third contact (C) are arranged on an electrical contact material, the second contact (B) is arranged in a portion corresponding to a center of the electrical contact material, and the second contact (B) is electrically connected to the first contact (A) and the third contact (C), and wherein different plating materials are respectively attached to the first contact (A), the second contact (B) and the third contact (C).

Description

BACKGROUND OF THE INVENTIONField of the InventionThe present invention relates to a switch having an electrical contact material (hereinafter referred to as electrical contact material for short).Description of the Related ArtAn opposing switch (e.g., a two-way switch, a rocker switch, etc., e.g., a switch having opposed contacts to each other) is formed of a pair of a fixed contact and a movable contact. The fixed contact and the movable contact come into contact with each other by a physical force to open, close, or switch a circuit. In contrast to a common switch for normal-open or normal-open / close having one or two pairs of contacts, a switch such as a cross rocker for two-direction electrical conductivity has four pairs of contacts. In this case, for the electric conductivity, a central bridge is used in a central portion thereof, and the bridge should maintain a continuous conducting state.Typically, the switch is operated with a structure in which the central position of the switch is provided in the manner of a wall, and therefore the switch is placed like a rocker on the wall. When a contact is operated by a physical force, a central portion of the moving contact and an upper end of the wall in the rocker structure continuously generate friction and are accordingly weakened due to wear. However, when a button contact becomes a contact state due to a vertical movement, unlike the center portion of the rocker, the contact may be damaged due to an arc. When a typical DC current is used, a transition of a metal atom which is an element of the contact when the contact assumes a contact state is generated, and thus a protrusion is formed at a contact (i.e., a negative (-) end) and a recess is formed at the opposite contact (i.e., a positive (+) end). When such a protrusion is continuously / progressively formed, a problem such as an abnormal contact may occur due to fusion of the contacts or locking between the protrusion and the recess, thereby causing a problem in continuous operation of the parts or an operation failure.When no protrusion is formed, fusion of the contacts may occur due to heat of arc or heat by conduction during a switching operation when a silver contact component has an inadequate content. Such a phenomenon is greatly influenced by a material of the switch and a current direction. In order to solve the fusion phenomenon, silver is plated on the switch, but silver plating may cause a reliability problem because it has a very low anti-fusion property.Such material transition or fusion due to arc is affected by a contact component and a contact shape. In order to solve such a problem, a contact material having excellent arc resistance, such as a silver oxide alloy, is processed in a form of a rivet in manufacturing a relay.However, such a rivet contact cannot be easily applied to the cross rocker type switch; a contact made of a silver plating material having a low anti-fusion property must be used.As described above, each contact of a cross rocker type switch requires different characteristics, so that it is difficult to ensure reliability thereof.For example, US 2005 / 0 045 461 A1 discloses an electrical contact material having a first contact, a third contact and a second contact, which is provided between the first contact and the third contact, wherein different plating materials are fastened respectively associated to the first contact, to the second contact and to the third contact.Further electrical contact materials are known from, for example, JP H04-259 712 A, JP S63-18 027 A, DE 28 24 117 A1 and JP 2012-198 999 A.EXPLANATION OF THE INVENTIONThe present invention is directed to providing a switch with an electrical contact material which is plated (hereinafter, briefly, plated) as a plating material (e.g., an electrically conductive coating), and which is different depending on a location of a corresponding contact (e.g., different contact regions are plated with different plating material).According to the invention, a switch in the manner of a rocker switch with an electrical contact material having the features of claim 1 is provided. Further embodiments of the switch are described in the dependent claims.That is, a switch according to an exemplary embodiment of the present invention includes a first contact region (hereinafter, first contact) contacting a negative electrode, a third contact region (hereinafter, third contact) contacting a positive electrode, and a second contact region (hereinafter, second contact) provided between the first contact and the third contact, wherein different plating materials respectively associated with the first contact, the second contact, and the third contact are fixed (e.g., coated) (e.g., the first, the second, and the third contact are plated with a different plating material), and wherein the first contact, the second contact, and the third contact are disposed on an electric contact material, the second contact is disposed in a portion, which corresponds to a center of the electrical contact material, and the second contact is electrically connected to the first contact and the third contact.For example, a plating material selected from a group consisting of an AgCu alloy having a Cu content of 20 wt % to 50 wt %, an AgNi alloy having a Ni content of 10 wt % to 30 wt %, and an AgPd alloy having a Pd content of 10 wt % to 70 wt % may be attached (e.g., coated) to the first contact.For example, a plating material selected from a group consisting of an AgNi alloy having a Ni content of 10 wt % to 30 wt %, an AgPd alloy having a Pd content of 10 wt % to 40 wt %, an AuCo alloy having a Co content of 1 wt % to 5 wt %, an AuNi alloy having a Ni content of 1 wt % to 10 wt %, and a PdNi alloy having a Ni content of 10 wt % to 30 wt % may be attached (e.g., coated) to the second contact.For example, a plating material may be attached (e.g., coated) to the third contact, which is a composite material of silver and an oxide, wherein the oxide is one selected from a group consisting of AgMnlnO x, AgMnO 2 and AgMnO, and wherein the content of the oxide is 5 wt % to 20 wt %.For example, the first contact plating material, the second contact plating material, and the third contact plating material may be attached to (e.g., coated on) a phosphor bronze plate.According to the exemplary embodiment of the present invention, a plating material that differs depending on a location of a contact of a switch in the manner of a cross rocker is fixed (e.g., plated, applied, coated, etc.) to the corresponding contact using a plating, application, etc.), so that a contact characteristic that satisfies a requirement for the corresponding location of the contact can be provided and a life of the product can be improved.The devices of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.Brief Description of the DrawingsFIG. 1 illustrates an electrical contact material according to an example embodiment. FIG. 2 is an illustration of a cross rocker switch to which the electrical contact material of FIG. 1 is applied.Detailed DescriptionIn the figures, the thicknesses of layers, films, panels, regions, etc. are exaggerated for clarity. Like reference numerals designate like elements throughout the specification. It will be understood that when an element includes a layer, film, region or substrate, or a substrate is referred to as being "on another element", it may be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on another element", there are no intervening elements present.Hereinafter, a switch including an electric contact material according to an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.FIG. 1 illustrates an electrical contact material according to an exemplary embodiment of the present invention. FIG. 2 is a diagram of a cross rocker switch to which the electrical contact material of FIG. 1 is applied.Referring to FIG. 1, the electric contact material according to the present exemplary embodiment includes a first contact A contacting a negative electrode, a third contact C contacting a positive electrode, and a second contact B provided between the first contact A and the third contact C, different plating materials respectively corresponding to the first contact A, the second contact B, and the third contact C being fixed (e.g., coated).Referring to FIG. 1, the plating material of the first contact A, the plating material of the second contact B, and the plating material of the third contact C may be mounted on a copper plating material (or a plate for switches including phosphor bronze, brass, pure copper, etc.). The first contact A plating material, the second contact B plating material, and the third contact C plating material are / are provided / supplied in the manner of bands on the phosphor bronze plating material provided as an entire plate, and then are rolled, so that a plate having a complex shape as in FIG. 1 can be manufactured.The plating material fixed to the first contact A will now be described. The first contact A is a portion contacting a negative electrode and requires that a low contact resistance be maintained. Moreover, the first contact A requires a high conductivity, a high hardness, and a high corrosion resistance.Therefore, the plating material of the first contact A may be any one selected from a group consisting of an AgCu alloy having a Cu content of 20 wt % to 50 wt %, an AgNi alloy having a Ni content of 10 wt % to 30 wt %, and an AgPd alloy having a Pd content of 10 wt % to 70 wt %.When the plating material of the first contact A is an AgCu alloy, a content of Cu is preferably 20 wt % to 50 wt %. When the Cu content is less than 20 wt %, sufficient strengthening effect cannot be obtained, and when the Cu content exceeds 50 wt %, corrosion may occur.When the plating material of the first contact A is an AgNi alloy, a content of Ni may be 10 wt % to 30 wt %. When the Ni content is less than 10 wt %, a sufficient strengthening effect cannot be obtained, and when the Ni content exceeds 30 wt %, a contact resistance may be significantly increased.Moreover, when the plating material of the first contact A is an AgPd alloy, a content of Pd may be 10 wt % to 70 wt %. If the Pd content is less than 10 wt %, a sufficient strengthening effect cannot be obtained, and if the Pd content exceeds 70 wt %, it may be difficult to perform the plating process.Next, the plating material fixed to the second contact B will be described. The second contact B is a portion corresponding to a center of a rocker when used in the cross rocker type switch, and requires a large wear resistance and a small contact resistance. That is, the second contact B requires a high hardness, a high wear resistance, and a high corrosion resistance.In the present case, the plating material of the second contact B may be one selected from a group consisting of an AgNi alloy having a Ni content of 10 wt % to 30 wt %, an AgPd alloy having a Pd content of 10 wt % to 40 wt %, an AuCo alloy having a Co content of 1 wt % to 5 wt %, an AuNi alloy having a Ni content of 1 wt % to 10 wt %, and a PdNi alloy having a Ni content of 10 wt % to 30 wt %.When the plating material of the second contact B is an AgNi alloy, a content of Ni may be 10 wt % to 30 wt %. When the Ni content is less than 10 wt %, a sufficient strengthening effect cannot be obtained, and when the Ni content exceeds 30 wt %, a contact resistance may be significantly increased.When the plating material of the second contact B is an AgPd alloy, a Pd content may be 10 wt % to 40 wt %. If the Pd content is less than 10 wt% or exceeds 40 wt%, a sufficient strengthening effect cannot be obtained.When the plating material of the second contact B is an AuCo alloy, a Co content may be 1 wt % to 5 wt %. If the Co content is less than 1% by weight, a sufficient strengthening effect cannot be obtained, and if the Co content exceeds 5% by weight, corrosion may occur.When the plating material of the second contact B is an AuNi alloy, a Ni content may be 1 wt % to 10 wt %. If the Ni content is less than 1 wt%, a sufficient strengthening effect cannot be obtained, and if the Ni content exceeds 10 wt%, corrosion may occur.When the plating material of the second contact B is a PdNi alloy, a Ni content may be 10 wt % to 30 wt %. If the Ni content is less than 10 wt%, a sufficient strengthening effect cannot be obtained, and if the Ni content exceeds 30 wt%, the contact resistance may be significantly increased.Next, the plating material attached to (e.g., coated on) the third contact C will be described. The third contact C is a portion contacting the positive electrode, and the contact is consumed mainly due to a DC current. Therefore, the third contact C requires arc resistance and anti-fusion property. The plating material fixed to the third contact C may be made of a composite material of silver and an oxide.The oxide is one selected from a group consisting of: AgMnlnO x, AgMnO 2 and AgMnO, and a content of the oxide may be 5 wt % to 20 wt %. When the content of the oxide is less than 5 wt %, sufficient arc resistance cannot be obtained, and when the content of the oxide exceeds 20 wt %, electrical conductivity may be deteriorated.As described above, according to the exemplary embodiment of the present invention, plating materials attached to each contact are different from each other to optimize the characteristics of each contact. Accordingly, various characteristics required for the respective contacts of the switch such as the cross rocker can be satisfied while securing reliability of the switch.Next, an effect of the electric contact material according to the exemplary embodiment of the present invention and an effect of an electric contact material according to a comparative example are compared by detailed experimental examples.Experimental Example 1As shown in FIG. 1, a switch for operating a seat reclining motor was prepared, and the switch was then operated in a forward direction, off, reverse direction. A motor voltage was 12 V and a current was 10 A.The following Table 1 shows materials of the first, second and third contacts in Comparative Examples and exemplary embodiments of the present invention, and shows a number of durability tests (e.g., switching operations) of Experimental Example 1. "Clad X" ("Clad X") used below in the Comparative Examples is, for example, a sandwich material in which aluminum is compressed between two or more layers of stainless steel under application of heat. Table 1 Table 1Comparative Example 1Coating XCoating XCoating X12.400Comparative Example 2Silver coating (5 μm)Silver coating (5 μm)Silver coating (5 μm)27.400Comparative Example 3Gold coating (1 μm)Gold coating (1 μm)Gold coating (1 μm)26.800Comparative Example 4AgMnO x rivet, 10 μmCoating XAgMnO x rivet, 10 μm14.800Comparative Example 5AgMnO x rivet, 10 μmNickel, 3 μm - silver coating, 1 μmAgMnO x rivet, 10 μm28.700Comparative Example 6AgMnO x ( oxide, 15%)AgNi20AgCu4047.800Exemplary Embodiment 1AgCu40AgNi20AgMnO x ( oxide, 15%)143.000Exemplary Embodiment 2AgCu40PdNi20AgMnO x ( oxide, 15%)173.000Exemplary Embodiment 3AgNi20AgNi20AgMnO x ( oxide, 15%)132.000Exemplary Embodiment 4AgNi20PdNi20AgMnO x ( oxide, 15%)148.000Exemplary Embodiment 5AgPd30PdNi20AgMnO x ( oxide, 15%)182.000As shown in Table 1, the number of durability tests (e.g., switching operations) in Exemplary Embodiments 1 to 5 in which different plating materials respectively associated with the first contact A, the second contact B, and the third contact B were improved as compared with Comparative Examples 1 to 6.Experimental Example 2A switch which is the same as that of Experimental Example 1 was prepared, and then a test was carried out under the same conditions as in Experimental Example 1 to measure a number of merges produced, and Table 2 shows the results of the test. Table 2 Table 2Comparative Example 1Coating XCoating XCoating X0Comparative Example 2Silver coating (5 μm)Silver coating (5 μm)Silver coating (5 μm)480Comparative Example 3Gold coating (1 μm)Gold coating (1 μm)Gold coating (1 μm)11Comparative Example 4AgMnO x rivet, 10 μmCoating XAgMnO x rivet, 10 μm17Comparative Example 5AgMnO x rivet, 10 μmNickel, 3 μm - silver coating, 1 μmAgMnO x rivet, 10 μm12Comparative Example 6AgMnO x ( oxide, 15%)AgNi20AgCu40182Exemplary Embodiment 1AgCu40AgNi20AgMnO x ( oxide, 15%)0Exemplary Embodiment 2AgCu40PdNi20AgMnO x ( oxide, 15%)0Exemplary Embodiment 3AgNi20AgNi20AgMnO x ( oxide, 15%)2Exemplary Embodiment 4AgNi20PdNi20AgMnO x ( oxide, 15%)7Exemplary Embodiment 5AgPd30PdNi20AgMnO x ( oxide, 15%)0As shown in Table 2, in Exemplary Embodiments 1 to 5 in which different plating materials respectively associated with the first contact A, the second contact B, and the third contact C were fixed, a number of merges were significantly reduced compared with Comparative Examples 1 to 6.

Claims

A switch of the toggle type, comprising: a first contact (A) contacting a negative electrode; a third contact (C) contacting a positive electrode; and a second contact (B) provided between the first contact (A) and the third contact (C), wherein the first contact (A), the second contact (B), and the third contact (C) are disposed on an electric contact material, the second contact (B) is disposed in a portion corresponding to a center of the electric contact material, and the second contact (B) is electrically connected to the first contact (A) and the third contact (C), and wherein different plating materials respectively corresponding to the first contact (A), the second contact (B) and the third contact (C).The switch according to claim 1, wherein the first contact (A) has fixed thereto a plating material selected from a group consisting of an AgCu alloy having a Cu content of 20 wt% to 50 wt%, an AgNi alloy having a Ni content of 10 wt% to 30 wt%, and an AgPd alloy having a Pd content of 10 wt% to 70 wt%.The switch according to claim 1 or 2, wherein the second contact (B) has fixed thereto a plating material selected from a group consisting of an AgNi alloy having a Ni content of 10 wt% to 30 wt%, an AgPd alloy having a Pd content of 10 wt% to 40 wt%, an AuCo alloy having a Co content of 1 wt% to 5 wt%, an AuNi alloy having a Ni content of 1 wt% to 10 wt%, and a PdNi alloy having a Ni content of 10 wt% to 30 wt%.The switch according to any one of the preceding claims, wherein a plating material which is a composite material of silver and an oxide is attached to the third contact (C), wherein the oxide is one selected from a group consisting of AgMnlnO x, AgMnO 2 and AgMnO, and wherein the content of the oxide is 5 wt% to 20 wt%.The switch according to any one of the preceding claims, wherein the plating material of the first contact (A), the plating material of the second contact (B), and the plating material of the third contact (C) are fixed to a phosphor bronze plate.

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