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  • 专利说明
  • 权利要求
  • 类似技术
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    • 专利摘要:
    ELECTRIC CONTACT COMPOSITES AND METHODS FOR PRODUCING ELECTRIC CONTACT COMPOSITES. It is an electrical contact composite, with a substrate and an electrically conductive coating applied to it, whose coating is connected to an electrode. A metallic contact element is connected to the electrode, where the contact element serves to connect the conductive coating to a current/voltage source. Additionally, at least one spray layer produced by means of a thermal spray method, in particular cold gas spray, and made of at least one metal and/or metallic alloy is provided, wherein the spray layer is disposed between the conductive coating and the contact element, the sprayed layer having a thermal expansion coefficient that is between the thermal expansion coefficients of the carrier and the contact element. In one variant, the sprayed layer serves as an electrode for the conductive coating.
    公开号:BR112014001043B1
    申请号:R112014001043-9
    申请日:2012-08-01
    公开日:2021-05-25
    发明作者:Mitja Rateiczak；Bernhard Reul
    申请人:Saint-Gobain Glass France；
    IPC主号:
    专利说明:

    Description
    [0001] The invention is in the technical area of the production of flat electrical structures with a substrate and an electrically conductive coating applied thereon and refers to the electrical contact composite of flat electrical structures, as well as methods for producing contact composites electric.
    [0002] Flat electrical structures with a substrate of an electrically insulating material and an electrically conductive coating applied on it are sufficiently known per se. These are often used as transparent or opaque panel heating elements, in particular in the form of heatable glazing. Examples of this include windshields, rear windows, glass roofs or heatable side windows in motor vehicles, or wall-mounted or free-standing heating elements in living spaces, which serve to heat the living spaces. However, these can also otherwise be used as heatable mirrors or transparent decorative elements. An alternative use of the conductive coating is a flat antenna to receive electromagnetic radiation. Flat electrical structures have been described numerous times in patent literature. Merely by way of example, reference is made in this respect to patent applications DE 102008018147 A1, DE 102008029986 A1, DE 10259110 B3 and DE 102004018109 B3.
    [0003] As a rule, the electrically conductive coating is electrically connected to at least one electrode. Thus, in general, a single electrode serves on flat antennas for coupling electrical signals outside the conductive coating. In panel heating elements, the conductive coating is typically electrically connected to at least one pair of strip or strip shaped electrodes (bus bars), which are intended to introduce the heating current as uniformly as possible. in the conductive coating and to distribute it widely.
    [0004] It is customary, in a flat electrical structure, to electrically connect the at least one electrode to a metallic contact element to form an electrical contact composite, for example, to connect the conductive coating to downstream antenna electronics (for example , amplifier circuit) or to the two terminals of a current/voltage source, making heating current available.
    [0005] It has been demonstrated, in practice, that such a contact composite is subjected to high wear and can break, which can even be accompanied by substrate breakage (eg, glass breakage). Since this results in a complete functional failure of the panel heating element, which always requires repair by service personnel, it is desirable to deploy the contact composite in as stable a way as possible. However, this undesirably increases production costs.
    [0006] In contrast, the purpose of the present invention is to make available an electrical contact composite of a flat electrical structure that has improved mechanical stability. This and other objects are realized in accordance with the purpose of the invention by electrical contact composites, as well as methods for producing electrical contact composites with the characteristics of the coordinated claims. Advantageous embodiments of the invention are indicated by the characteristics of the subclaims.
    [0007] According to the invention, a first electrical contact composite of a flat electrical structure, for example a panel heating element, in particular a heatable glazing, or a flat antenna, is presented. The contact composite comprises a flat substrate made, for example, of glass or plastic and an electrically conductive coating applied to it, which is electrically connected to an electrode.
    [0008] Additionally, a metallic contact element connected to the electrode is arranged, which contact element is provided for the electrical connection of the conductive coating with an electrical device, for example, an electronic circuit for processing antenna signals or a terminal of a current/voltage source. In particular, with a glass substrate, the metallic contact element material typically has a thermal expansion coefficient that is greater than the thermal expansion coefficient of glass. The contact composite further comprises at least one electrically conductive spray layer produced by a thermal spray method, preferably cold gas spray. Here and subsequently, the term "thermal spray method" means a coating method in which a particle stream, by which the sprayed layer is formed, is aimed with high energy at a target, whereby adhesion is between the particles and the target material. Especially in the case of spraying with cold gas, the particles are actually heated to generate the gas beam, but as a rule not to the melting point, so that the gas is relatively "cold". Such spraying methods, in particular cold gas spraying (cold spraying) are well known to those skilled in the art, such that it is unnecessary to make more detailed statements here. These are described in the patent literature, for example, in the German Offenlegungsschriften [ublished patent applications] DE 19747386 A1 and DE 10037212 A1.
    [0009] In the contact composite according to the invention, the sprayed layer comprises at least one metal and/or at least one metal alloy and is disposed between the conductive coating and the contact element. Here, it is essential that the sprayed layer material has a thermal expansion coefficient that is between the thermal expansion coefficient of the carrier materials and the contact element.
    [0010] In practice, flat electrical structures, such as panel heating elements and flat antennas, are often subjected to relatively large temperature fluctuations, which can, for example, be in the range of - 40°C to 120°C, so that materials used for compact composite undergo correspondingly large volume changes. As the applicant observes, an extremely large difference in thermally induced volume changes occurs, as a rule, between the substrate for the conductive coating and the metallic contact element. In this aspect, there is the possibility that large temperature changes cause thermal stresses that possibly favor the occurrence of a rupture in the contact composite.
    [0011] On the other hand, a reduction in the difference in the coefficients of thermal expansions of adjacent components of the contact composite can be advantageously achieved in the contact composite according to the invention by means of the sprayed layer that is disposed between the substrate and the contact element. The occurrence of thermal stresses can thus be countered very effectively, with the danger of rupture of the contact composite being significantly reduced.
    [0012] In principle, the sprayed layer can have any coefficient of thermal expansion provided that it is guaranteed to be between that of the substrate and the contact element in order to obtain the advantageous effect of a reduction in thermally induced stresses. In an embodiment of the contact composite according to the invention which is particularly advantageous from the point of view of reducing thermally induced stresses, the thermal expansion coefficient of the sprayed layer is in the range of a middle third of a value range of thermal expansion coefficients linked by the thermal expansion coefficients of the substrate and the contact element, through which a particularly effective reduction of thermal stresses can be obtained. In particular, the thermal expansion coefficient of the sprayed layer can correspond, at least approximately, to an average formed of the thermal expansion coefficients of the substrate and the contact element in order to obtain an optimum effect. In the case of a glass substrate and a metallic contact element, it may be advantageous for this purpose for the thermal expansion coefficient of the sprayed layer to lie in the range of 7 to 17 (x 10-6 K-1), preferably in the range of 12 to 13 (x 10-6 K-1).
    [0013] In an advantageous embodiment of the contact composite according to the invention, the sprayed layer is sprayed directly onto the electrode. As the applicant's experiments have shown, by means of bombardment with the particles, an oxide and/or corrosion layer possibly present on the electrode can be damaged, so that a particularly strong (direct) connection between the materials in the sprayed layer and the electrode can graduate. In particular, through relatively high particle velocities as well as high ductility of the bombardment material used, a roughness of the electrode surface can be performed, possibly even creating retentions. In connection with a reduction of the thermal stresses in the contact composite by means of a suitably selected thermal expansion coefficient of the sprayed layer, it is possible in this way to produce a particularly stable and low-wear contact composite.
    [0014] Alternatively, it is also possible to spray the sprayed layer directly onto the electrically conductive coating with, in that case, particularly good adhesion of the sprayed layer to the obtainable conductive coating. As the person skilled in the art knows, the electrically conductive coating has, due to the smooth surface of the substrate, a uniformly smooth surface. When the sprayed layer is applied to the electrically conductive coating, a stronger bond can be achieved between the (rougher or rougher) sprayed layer and the electrically conductive coating compared to applying the electrode to the electrically conductive coating, for example, in a printing method. In this way, stronger mechanical retention between the sprayed layer and the electrically conductive coating can be achieved than between the electrode and the electrically conductive coating. This is true, in particular, for an electrically conductive coating that is deployed as a multilayer system in which the sprayed layer allows a "tangle" (mechanical connection) with all layers, whereas the electrode is not applied in the spray method. it is mechanically connected only to the uppermost layer. Consequently, the sprayed layer is also electrically connected to all layers of the multilayer system, whereas the electrode not applied in the spraying method is electrically connected only to the uppermost layer.
    [0015] On the other hand, the electrode also has a somewhat rough or coarse surface, so that through the electrode applied to the layer (also somewhat rough or thick) sprayed, a particularly satisfactory "tangle" (mechanical and electrical connection) can be achieved. Thus, with a contact composite in which the sprayed layer is applied to the electrically conductive coating and the electrode is applied to the sprayed layer, a particularly satisfactory mechanical and electrical connection of both the sprayed layer and the electrode can be obtained, so that the contact composite is particularly stable and has good electrical conductivity.
    [0016] In another advantageous embodiment of the contact composite according to the invention, the sprayed layer has a layer thickness, so that the electrode is mechanically reinforced. For this purpose, the layer thickness of the sprayed layer can be, for example, 2 to 50 times as thick as the layer thickness of the electrode. Through this measure, the mechanical strength of the contact composite can be further improved, and, in particular, the breakage of the contact composite through the detachment of the electrode from the substrate can be effectively counteracted.
    [0017] In one embodiment of the contact composite, the contact element is not produced by a spray method and thus not deployed as a sprayed layer, but rather deployed in the form of a pre-contact element. -manufactured (eg a piece) or contact part and is electrically connected to the electrode as a prefabricated contact element.
    [0018] In the contact composite according to the invention, the contact element is not a weld, so that the contact element itself is solder-free. However, the contact element can, for example, be fixed to the contact composite by a lead-containing or lead-free solder. In practice, it has been shown that, in fact, lead-containing solders have high ductility, which, however, is not true for lead-free solders. In the contact composite according to the invention, the sprayed layer can be used particularly advantageously for improving the mechanical stability (ductility) of the contact composite even with the use of lead-free solders, where the contact element is fixed to the electrode or the sprayed layer by means of lead-free solder.
    [0019] In the contact composite according to the invention, the sprayed (electrically conductive) layer comprises at least one metal and/or at least one metal alloy to achieve that coefficient of thermal expansion of the sprayed layer that is among those among the substrate and the contact element. Advantageously, the sprayed layer comprises one or a plurality of metals and/or one or a plurality of metal alloys, selected from silver, copper, gold, aluminum, sodium, tungsten, brass, iron, chromium, lead, bismuth , titanium, tin, zinc, molybdenum, indium, nickel, platinum, vanadium, cobalt, thallium and niobium. The selection of a suitable metal or metal alloy substantially results from the desired coefficient of thermal expansion, which can be easily and safely set in this mode.
    [0020] It may also be advantageous for the sprayed layer to contain at least one additional component made of an electrically insulating material, for example glass particles, to selectively influence the mechanical properties of the contact composite, as well as the thermal expansion coefficient of the sprayed layer.
    [0021] According to the invention, another second contact composite is presented, which differs from the previous contact composite in that the electrode for contacting the electrically conductive coating is replaced by the sprayed layer. Consequently, the contact composite comprises a flat substrate made, for example, of glass or plastic and an electrically conductive coating applied thereto, as well as a sprayed layer sprayed onto the conductive coating by a thermal spray method, in particular, spraying with cold gas. The contact composite additionally comprises a metallic contact element electrically connected to the sprayed layer, which serves to connect the conductive coating with an electrical component, for example a current/voltage source. The sprayed layer material has a thermal expansion coefficient that is between the thermal expansion coefficients of the substrate materials and the contact element. The contact composite can, in principle, be configured in the same way as the contact composite described above. To avoid unnecessary repetition, reference is made to the declarations made in it.
    [0022] In such a contact composite, the danger of thermal stresses can be considerably reduced in a particularly advantageous way by means of the sprayed layer applied to the conductive coating. Additionally, the sprayed layer can be connected to the conductive coating with a particularly strong adhesive force.
    [0023] The invention further extends to a flat electrical structure, in particular a panel heating element, for example a heatable opaque or transparent glazing or a flat antenna comprising a flat substrate with an electrically conductive coating, wherein the flat electrical structure has at least one contact composite as described above.
    [0024] The invention further extends to a method for producing an electrical contact composite of a flat electrical structure, in particular, to produce the first contact composite described above, which comprises the following steps: - Provide a flat substrate, made, for example, of glass or plastic, with an electrically conductive coating applied thereto; - Produce an electrode electrically connected to the conductive coating; - Produce a metallic contact element electrically connected to the electrode, whose contact element serves to connect the electrode with an electrical component, for example, an electrical circuit or a current/voltage source, current/voltage source; - Producing, by means of the thermal spray method, in particular cold gas spraying, at least one sprayed layer comprising at least one metal and/or at least one metal alloy and is disposed between the conductive coating and the contact element , wherein the sprayed layer material has a thermal expansion coefficient that is between the thermal expansion coefficients of the substrate materials and the contact element.
    [0025] In one embodiment of the method, the sprayed layer is sprayed on the electrode or the conductive coating, where it may be advantageous from the point of view of the mechanical properties of the contact composite that the sprayed layer is sprayed directly on the electrode.
    [0026] The invention further extends to a method for producing an electrical contact composite of a flat electrical structure, in particular, to produce the second contact composite described above, with the following steps: - Provide a substrate with a coating electrically conductive applied to it; - Spray a sprayed layer, by means of a thermal spray method, in particular cold gas spraying, on the conductive coating, the sprayed layer comprising at least one metal and/or at least one metal alloy and the sprayed layer material has a thermal expansion coefficient that is between the thermal expansion coefficients of the substrate materials and the contact element; - Produce a metallic contact element electrically connected to the sprayed layer for connecting the conductive coating to an electrical component, eg an electrical circuit or a current/voltage source.
    [0027] Furthermore, the invention extends to the use of an electrically conductive sprayed layer produced by a thermal spray method, in particular cold gas spray, for the reduction of thermal stresses in a contact composite as described above.
    [0028] Consequently, the invention extends to the use of an electrically conductive spray layer produced by a thermal spray method, in particular cold gas spray, for the reduction of thermal stresses between a substrate made, for example, of glass or plastic and an electrically conductive coating contacted by an electrode applied to it, and a metallic contact element electrically connected to the electrode, the spray layer material having a thermal expansion coefficient that is between the thermal expansion coefficients of the substrate materials and the contact element.
    [0029] Likewise, it extends to the use of an electrically conductive sprayed layer produced by means of a thermal spray method, in particular cold gas spray, for the reduction of thermal stresses between a substrate made, for example, of glass or plastic and an electrically conductive coating applied thereto contacted by the sprayed layer, and a metallic contact element electrically connected to the sprayed layer, the material of the sprayed layer having a thermal expansion coefficient that is between the thermal expansion coefficients of the substrate materials and the contact element. It is understood that the different embodiments of the invention can be carried out individually or in any combinations. In particular, the features mentioned above and those to be explained below can be used not only in the indicated combinations, but also in other combinations or alone, without departing from the scope of the present invention. Brief Description of Drawings
    [0030] The invention is now explained in detail using exemplary embodiments, with reference to the accompanying figures. Identical or identically acting components are referenced with the same reference characters. These describe the simplified non-scale representation: Figure 1 is a schematic cross-sectional view of an exemplary embodiment for an electrical contact composite according to the invention; Figure 2 is a schematic cross-sectional view of a variant of the electrical contact composite of Figure 1; Figure 3 is a schematic cross-sectional view of another variant of the electrical contact composite of Figure 1. Detailed Description of the Drawings
    [0031] Figure 1 illustrates a contact composite referenced as a whole with reference number 1, which is part of a flat electrical structure (not shown further). The flat electrical structure can, for example, be a panel heating element, in particular a heatable glazing or a flat antenna. The heatable glazing can be implemented, for example, in the form of a composite glazing, in which two individual glazings are connected together by a thermoplastic adhesive layer. Similarly, the heatable glazing may be a so-called single-glazed safety glass which comprises only a single glazing.
    [0032] The contact composite 1 comprises at least one flat substrate 2 with an electrically conductive coating 6 applied thereto, which is not shown in detail in Figure 1. As used herein, the term "substrate" refers to, for example, to a single glazing (carrier) of a composite glazing or a single glazing glass or to the carrier of a flat antenna.
    [0033] Substrate 2 is made, for example, of a glass material such as float glass, quartz glass, borosilicate glass, soda-lime glass, molten glass or ceramic glass or made of a non-glass material, for example , plastic, such as polystyrene (PS), polyamide (PA), polyester (PE), polyvinyl chloride (PVC), polycarbonate (PC), polymethyl methacrylate (PMA) or polyethylene terephthalate (PET) and/or mixtures thereof. Examples of suitable glasses can be found, in particular, in European patent EP 0847965 B1. In general, any material with adequate chemical resistance, adequate shape and size stability, as well as, as the case may be, adequate optical transparency, can be used.
    [0034] Depending on the application, the thickness of substrate 2 can vary widely. For a heatable transparent glazing, the thickness of substrate 2 is, for example, in the range of 1 to 25 mm, while typically for transparent glazing, a thickness of 1.4 to 2.1 mm is used. Substrate 2 is flat or inclined in one or one of a plurality of spatial directions.
    [0035] The substrate 2 can, for example, be coated substantially over the entire surface with the conductive coating 6 (coating extension, for example, 90%). The conductive coating 6 can in particular be a transparent coating which is transparent to electromagnetic radiation, preferably electromagnetic radiation of a wavelength of 300 to 1300 nm, in particular to visible light. The term "transparent" here refers to a total transmittance of the flat electrical structure which is, in particular for visible light, for example, >70% and, in particular, >80%. Transparent conductive coatings 6 are known, for example, from printed publications DE 202008017611 U1 and EP 0847965 B1.
    [0036] The conductive coating 6 includes an electrically conductive material, typically a metal or metal oxide. Examples of this are metals with a high electrical conductivity such as silver (Ag), copper (Cu), gold (Au), aluminum (AI) or molybdenum (Mo), metal alloys such as silver (Ag) in alloy with palladium (Pa), as well as transparent conductive oxides (TCOs). TCOs are preferably indium tin oxide, fluorine-doped tin dioxide, aluminum-doped tin dioxide, gallium-doped tin dioxide, boron-doped tin dioxide, tin-zinc oxide or aluminum-doped tin oxide antimony. For example, the conductive coating 6 consists of a metallic layer such as a layer of silver or a metallic alloy containing silver which is embedded between at least two coatings made of dielectric material of the metal oxide type. Metal oxide includes, for example, zinc oxide, tin oxide, indium oxide, titanium oxide, silicon oxide, aluminum oxide, or the like, as well as combinations of one or a plurality thereof. The dielectric material may also contain silicon nitride, silicon carbide, or aluminum nitride. For example, metallic layer systems with a plurality of metallic layers are used, with the individual metallic layers separated by at least one layer made of a dielectric material. Very thin metallic layers containing, in particular, titanium or niobium can also be provided on both sides of a silver layer. The metal bottom layer serves as an adhesion and crystallization layer. The metal top layer serves as a protective and absorbent layer to prevent silver modification during additional process steps. Advantageously, the sequence of layers has high thermal stability, so that it withstands the temperatures typically greater than 600°C necessary for the slope of glass panes without damage; however, even layer sequences with poor thermal stability can be provided. In general, the conductive coating 6 is not restricted to a specific material as long as the desired effect, for example, extensive electrical heating of substrate 2 can be obtained with that material.
    [0037] Such layer construction is typically obtained by a succession of deposition procedures. The conductive coating 6 is, for example, deposited out of the gas phase directly onto the substrate 2, for which purpose a method known per se, such as chemical vapor deposition (CVD) or physical vapor deposition (PVD), can be used . Preferably, the conductive coating 6 is deposited on the substrate 2 by sputtering (magnetron cathode spraying). However, it is also conceivable to apply the conductive coating 6 first to a plastic film, in particular PET film (PET = polyethylene terephthalate), which is then adhesively bonded to substrate 2.
    The conductive coating 6 has, for example, a film resistance in the range of 1 ohm/square to 10 ohms/square, in particular in the range of 1 ohm/square to 5 ohms/square.
    [0039] The thickness of the conductive coating 6 can vary widely and be adapted to the requirements of the individual case. It is essential that in a transparent flat electrical structure, the thickness of the conductive coating 6 is not so great that it becomes impermeable to electromagnetic radiation, preferably electromagnetic radiation of a wavelength of 300 to 1300 nm and, in particular, light visible. For example, the thickness of conductive coating 6 is anywhere in the range from 30 nm to 100 µm. In the case of TCOs, the layer thickness is, for example, in the range 100 nm to 1.5 µm, preferably in the range 150 nm to 1 µm and more preferably in the range 200 nm to 500 nm .
    [0040] In the contact composite 1, the electrode 3 is, for example, implanted in the form of a busbar shaped into a strip or strip, which is produced by printing, for example, screen printing, on the conductive coating 6 Alternatively, it would also be possible to prefabricate the electrode 3 as a metallic element, for example as a metallic strip or metallic wire which is then electrically connected by a solder or an electrically conductive plastic to the conductive coating 6. A metal such as silver (Ag), in particular, in the form of a printing paste for use in the printing method, copper (Cu), aluminum (Al), tungsten (W) and zinc (Zn) or a metallic alloy can, for example, be used as an electrode material, and this list is not exhaustive. For example, printing paste includes silver particles and glass frits.
    [0041] For an electrode 3 made, for example, of silver (Ag), which is produced in the printing method, the layer thickness is, for example, in the range of 2 to 25 microns (μm), in particular, in the range from 10 to 15 µm. The specific electrical resistance of electrode 3 depends, in general, on the material used, being in particular for a printed electrode 3 in the range of 2 to 4 micro-ohms-cm (μohm-cm). For example, the specific electrical resistance of an 80% silver content printing paste for the screen printing method is 2.8 µohm-cm. Compared to the high-impedance conductive coating 6, electrode 3 has relatively low impedance, with electrical resistance, for example, in the range of 0.15 to 4 ohms/meter (Q/m). By this measure, it can be achieved that the applied heating voltage falls substantially on the conductive coating 6, so that electrode 3 heats up only slightly during operation and a very small share of the heating output available on electrode 3 is emitted as energy dissipation.
    [0042] As already stated, electrode 3 can be produced by printing a metallic printing paste on the conductive coating 6.
    [0043] Alternatively, it is also possible for a thin sheet metal strip containing, for example, copper and/or aluminum to be used as electrode 3. For example, an electrical contact between the sheet metal strip and the conductive coating 6 can be obtained by an autoclave process through the action of heat and pressure. Electrical contact can, however, also be produced by soldering or gluing with an electrically conductive adhesive.
    [0044] The contact composite 1 further comprises a cold spray layer 4 sprayed directly onto the electrode 3 in the cold gas spray method. The cold spray layer 4 is made here of a metallic material, in particular an elemental metal or a metallic alloy, for example, selected from silver (Ag), copper (Cu), gold (Au), aluminum (AI) , sodium (Na), tungsten (W), brass, iron (Fe), chromium (Cr), lead (Pb), bismuth (Bi), titanium (Ti), tin (Sn), zinc (Zn), molybdenum ( Mo), indium (In), nickel (Ni), platinum (Pt), vanadium (Va), cobalt (Co), thallium (Th) and niobium (Ni).
    [0045] The layer thickness of the cold sprayed layer 4 can vary widely and is, for example, in the range of 10 to 500 µm, in particular in the range of 20 to 100 µm. Advantageously, the layer thickness of the cold sprayed layer 4 is at least twice the layer thickness of the electrode 3, in order to obtain a good mechanical reinforcement of the electrode 3, in particular, if it is implanted relatively thin.
    [0046] In the contact composite 1, a metallic contact element 5 is applied on the cold spray layer 4, which contact element serves for connecting the conductive coating 6 with an electrical component, for example, a current/voltage source (not shown). Here, the contact element 5 is deployed, for example, in the form of a prefabricated metal element, for example a metal strip which is fixedly connected to the cold spray layer 4 by means of a lead-free or lead-containing or a conductive adhesive (not described in detail). The metallic strip 4 is made, for example, of aluminum (AI) or copper (Cu) and has a thickness that is, for example, in the range of 50 to 200 µm. Alternatively, the contact element 5 could also be connected to the cold spray layer 4 through pressure or ultrasonic welding. It would also be conceivable to deploy the contact element 5 as a spring contact which leans on the cold spray layer 4 with a certain spring preload.
    [0047] In contact composite 1, the thermal expansion coefficient of the contact element material 5 is typically greater than the thermal expansion coefficient of the substrate material 2. For example, the thermal expansion coefficient of a substrate of glass 2 is in the range of about 7 to 7.5 (x 10-6 K-1), while the coefficient of thermal expansion for a contact element 5 made of aluminum or copper is in the range of about 16 to 17 (x 10-6 K-1).
    [0048] The cold spray layer 4 is made of a material whose coefficient of thermal expansion is between those of the substrate material 2 and the contact element 5. In the case of a glass substrate 2 and a metallic contact element 5, the coefficient of thermal expansion is preferably in the range of 12 to 13 (x 10-6 K-1). For example, the cold spray layer 7 is, for this purpose, produced from titanium (Ti).
    [0049] By means of the cold spray layer 4 arranged between the conductive coating 6 and the metallic contact element 5, the possible occurrence of thermal stresses in the contact composite 1 at the time of large temperature changes can be effectively combatted. Since the cold spray layer 4 is sprayed directly onto the electrode 3, a particularly stable connection between the electrode 3 and the cold spray layer 4 can also be achieved. The danger of rupture of the contact composite 1 due to thermal stresses can thus be significantly reduced.
    [0050] Figure 2 describes another exemplary modality for a contact composite 1 according to the invention that presents a variant to the contact composite 1 of Figure 1. To avoid unnecessary repetitions, only the differences in relation to the contact composite of Figure 1 are explained and otherwise reference is made to the statements made therein. Consequently, the cold spray layer 4 is sprayed directly onto the conductive coating 6, with electrode 3 applied to the cold spray layer 4 and contacted by the metallic contact element 5. This contact composite 1 is distinguished by a particularly stable connection between the layer. cold spray 4 and the conductive coating 6 in addition to the effect of a reduction in thermal stresses.
    [0051] Figure 3 describes another exemplary modality for a contact composite according to the invention that presents another variant to the contact composite 1 of Figure 1. To avoid unnecessary repetitions, again, only the differences in relation to the contact composite of the Figure 1 are explained and otherwise reference is made to the statements made in it. Consequently, the cold spray layer 4 serves as an electrode for the conductive coating 6 and is, for that purpose, sprayed directly onto the conductive coating 6. It is therefore possible to do the same without an electrode other than the cold spray layer 4 for the introduction of the heating current into the conductive coating 6. This contact composite 1 is also distinguished by a particularly stable connection between the cold spray layer 4 and the conductive coating 6 in addition to the effect of a reduction in thermal voltages, with the production of the composite of contact 1 also simplified compared to composite contact 1 of Figure 1 or Figure 2, since no separate electrode 3 is required.
    [0052] The present invention makes available a contact composite for a flat electrical structure, for example, a panel heating element or a flat antenna, in which, by means of a spray layer that is disposed between the substrate and the contact element, a reduction in the difference in the thermal expansion coefficients of the adjacent components of the contact composite can be achieved. The occurrence of thermal stresses can thus be effectively countered. Additionally, the ductility of the contact composite is significantly improved. The danger of rupture of the contact composite due to thermal stresses can be clearly reduced. Reference List 1 contact composite 2 substrate 3 electrode 4 cold spray layer 5 contact element 6 conductive coating
    权利要求:
    Claims (14)
    [0001]
    1. Electrical contact composite (1) comprising: a flat substrate (2) with an electrically conductive coating (6) applied thereto, an electrode (3) which is electrically connected to the conductive coating (6), a metallic contact element (5) which is not a solder and which is electrically connected to the electrode (3) and serves for the connection of the conductive coating (6) with an electrical component, a sprayed layer (4) produced by a thermal spray method, in which the sprayed layer comprises at least one metal and/or at least one metal alloy, the sprayed layer (4) being disposed between the conductive coating (6) and the contact element (5) and having a coefficient of thermal expansion which between the thermal expansion coefficients of the substrate (2) and the contact element (5), a sprayed layer (4) sprayed by a thermal spray method onto the conductive coating (6), wherein the sprayed layer (4) comprises at least one metal and/or at least one metal alloy. The electrical contact composite (1) characterized by the fact that it comprises: a metallic contact element (5) which is not produced by a spraying method, but configured instead in the form of a pre-contact contact part. manufactured, which is not a solder and which is electrically connected to the sprayed layer and serves to connect the conductive coating to an electrical component.
    [0002]
    2. Contact composite (1), according to claim 1, characterized by the fact that the thermal expansion coefficient of the sprayed layer (4) is in the range of a middle third of a value range for thermal expansion coefficients limited by thermal expansion coefficients of the substrate (2) and the contact element (5).
    [0003]
    3. Contact composite (1), according to claim 2, characterized by the fact that the coefficient of thermal expansion of the sprayed layer (4) corresponds at least approximately to an average value formed from the coefficients of thermal expansion of the substrate ( 2) and the contact element (5).
    [0004]
    4. Contact composite (1), according to any one of claims 1 to 3, characterized in that the sprayed layer (4) is sprayed on the electrode (3).
    [0005]
    5. Contact composite (1), according to claim 4, characterized in that the sprayed layer (4) has a layer thickness of 2 to 50 times that of the electrode (3).
    [0006]
    6. Contact composite (1), according to any one of claims 1 to 5, characterized in that the sprayed layer (4) is sprayed on the conductive coating (6).
    [0007]
    7. Contact composite (1), according to any one of claims 1 to 6, characterized in that the contact element (5) is electrically connected by means of a lead-free solder to the electrode (3).
    [0008]
    8. Contact composite (1), according to any one of claims 1 to 7, characterized in that the sprayed layer (4) comprises one or a plurality of metals and/or metallic alloys, selected from silver, copper, gold, aluminum, sodium, tungsten, brass, iron, chromium, lead, bismuth, titanium, tin, zinc, molybdenum, indium, nickel, platinum, vanadium, cobalt, thallium and niobium.
    [0009]
    9. Contact composite (1), according to any one of claims 1 to 8, characterized in that the sprayed layer (4) contains at least one electrically insulating material.
    [0010]
    10. Electrical structure with a flat substrate (2) and an electrically conductive coating (6) applied to the substrate (2), characterized in that it comprises at least one electrical contact composite (1) as defined in any one of claims 1 to 9.
    [0011]
    11. Method for producing an electrical contact composite (1) characterized in that it comprises the following steps: providing a flat substrate (2) with an electrically conductive coating (6) applied to it, producing an electrode (3) that is electrically connected to the conductive coating (6), producing a metallic contact element (5) which is not a weld and which is electrically connected to the electrode (3) and serves for connecting the conductive coating (6) with an electrical component, producing, by means of a thermal spray method, at least one sprayed layer (4) comprising at least one metal and/or at least one metal alloy, the sprayed layer (4) being disposed between the conductive coating (6 ) and the contact element (5) and has a thermal expansion coefficient that is between the thermal expansion coefficients of the substrate (2) and the contact element (5).
    [0012]
    12. Method according to claim 11, characterized in that the sprayed layer (4) is sprayed on the electrode (3).
    [0013]
    13. Method according to claim 11, characterized in that the sprayed layer (4) is sprayed on the conductive coating (6).
    [0014]
    14. Method for producing an electrical contact composite (1) characterized in that it comprises the following steps: providing a flat substrate (2) with an electrically conductive coating (6) applied to it, producing a metallic contact element ( 5), in which the contact element is not produced by a spray method, but configured instead in the form of a prefabricated contact part, which is not a weld and which is electrically connected to the spray layer ( 4) and serves for the connection of the conductive coating (6) with an electrical component, spraying a sprayed layer (4), by means of a thermal spray method, on the conductive coating (6), with the sprayed layer (4 ) comprises at least one metal and/or at least one metal alloy and has a thermal expansion coefficient which is between the thermal expansion coefficients of the substrate (2) and the contact element (5).
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    法律状态:
    2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-10-01| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-11-03| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application [chapter 6.1 patent gazette]|
    2021-03-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-05-25| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 01/08/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP11176894.1|2011-08-09|
    EP11176894|2011-08-09|
    PCT/EP2012/064992|WO2013020863A1|2011-08-09|2012-08-01|Electrical contact composites and method for producing electrical contact composites|
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