U.S. patent application number 09/892429 was filed with the patent office on 2002-01-31 for current limiting device and materials for a current limiting device.
Invention is credited to Aftergut, Siegfried, Duggal, Anil Raj, Lewis, Larry Neil, Nye, David Alan.
Application Number | 20020011591 09/892429 |
Document ID | / |
Family ID | 46256985 |
Filed Date | 2002-01-31 |
United States Patent
Application |
20020011591 |
Kind Code |
A1 |
Duggal, Anil Raj ; et
al. |
January 31, 2002 |
Current limiting device and materials for a current limiting
device
Abstract
A current limiting device comprises at least two electrodes; an
electrically conductive composite material between the electrodes;
interfaces between the electrodes the said composite material; and
an inhomogeneous resistance distribution structure at the
interfaces. During a high current event, adiabatic resistive
heating at the interfaces causes rapid thermal expansion and
vaporization and at least a partial physical separation at the
interfaces; so the resistance of the current limiting device
increases. The composite material comprises at least one polymeric
matrix material and at least one electrically conductive material,
and the polymeric matrix material comprises at least one epoxy and
at least one silicone.
Inventors: |
Duggal, Anil Raj;
(Niskayuna, NY) ; Aftergut, Siegfried; (New Haven,
CT) ; Lewis, Larry Neil; (Scotia, NY) ; Nye,
David Alan; (Clifton Park, NY) |
Correspondence
Address: |
GENERAL ELECTRIC COMPANY
CRD PATENT DOCKET ROOM 4A59
P O BOX 8
BUILDING K 1 SALAMONE
SCHENECTADY
NY
12301
US
|
Family ID: |
46256985 |
Appl. No.: |
09/892429 |
Filed: |
June 28, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09892429 |
Jun 28, 2001 |
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09525810 |
Mar 15, 2000 |
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6290879 |
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09525810 |
Mar 15, 2000 |
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09081888 |
May 20, 1998 |
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6124780 |
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Current U.S.
Class: |
252/511 ;
252/512; 252/514 |
Current CPC
Class: |
H01B 1/24 20130101; H01C
7/13 20130101; H01B 1/22 20130101; H01C 17/0656 20130101; H01C
17/06586 20130101 |
Class at
Publication: |
252/511 ;
252/512; 252/514 |
International
Class: |
H01B 001/06; H01C
001/00; H01B 001/02 |
Goverment Interests
[0002] This invention was developed under government support under
Contact No. N00024-96-R-4126 awarded by the Dept. of the Navy, and
the government may have rights in this invention.
Claims
What is claimed is:
1. A current limiting device comprising: at least two electrodes;
an electrically conductive composite material disposed between the
at least two electrodes; a first interface between the composite
material and a first electrode, and a second interface between the
composite material and a second electrode; and an inhomogeneous
distribution resistance structure at the interfaces whereby, during
a high current event, adiabatic resistive heating of the composite
material at the interfaces causes rapid thermal expansion and
vaporization of the composite material and separation of the
electrodes from composite material and separations within the
composite material proximate the interface so the resistance of the
current limiting device increases; wherein said electrically
conductive composite material comprises a thermosetting material,
and comprises: at least one polymeric matrix material and at least
one electrically conductive material, and the at least one
polymeric matrix material comprises: at least one epoxy; and at
least one silicone and amine containing material, in which the at
least one epoxy and the at least one silicone and amine containing
material combine and react to form a thermosetting, electrically
conductive composite material.
2. The device according to claim 1, where the at least one
electrically conductive material comprises at least one conductive
material selected from the group consisting of: nickel powder,
carbon black and silver powder.
3. The device according to claim 1, the at least one conductive
material comprises about 50% to about 90% by weight of the
conductive composite material.
4. The device according to claim 1, wherein the at least one
polymeric matrix material comprises poly
(methyl)(aminoethylaminopropyl)siloxane (PMAS).
5. The device according to claim 1, wherein the at least one
polymeric matrix material comprises epoxy in a weight percent range
between about 10% and about 90%, and the at least one silicone
containing material in a weight percent range between about 10% and
about 80%.
6. The device according to claim 1, wherein the at least one epoxy
comprises a material selected from the group consisting of:
condensation products of epichlorohydrin and bisphenol-A; and
epoxy-functionalized silicone.
7. The device according to claim 1, the at least one conductive
material comprises about 10% to about 40% by volume of the
conductive composite material.
8. The device according to claim 1, the at least one epoxy of the
at least one polymeric matrix material comprising at least a first
epoxy, the at least one silicone containing material comprising at
least a first silicone containing material, the composite material
further comprising at least one further material selected from a
group consisting of: at least a second epoxy, wherein the second
epoxy and the first epoxy are different; and at least a second
silicone and amine containing material, wherein the second silicone
and amine containing material and the first silicone and amine
containing material are different.
9. The device according to claim 8, the second epoxy being selected
from the group consisting of: butyl glycydyl ether; polyglycol
epoxy and epoxy-functionalized silicone.
10. The device according to claim 8, the at least a second silicone
being selected from the group consisting of: aminofunctional
silicone and epoxy-functionalized silicone.
11. The device according to claim 8, the at least one conductive
material comprises about 50% to about 90% by weight of the
conductive composite material.
12. The device according to claim 8, the at least one conductive
material comprises about 10% to about 40% by volume of the
conductive composite material.
13. The device according to claim 8, wherein the at least one
further material comprises between about 6% to about 35% by weight
of the polymeric matrix material.
14. The device according to claim 1, further comprising means for
exerting compressive pressure on the composite material, wherein
the compressive pressure provided by the exerting means is applied
in a direction generally parallel to a direction of current
flow.
15. An electrically conductive composite composition for conducting
electricity in an electrical current limiting device, the
composition comprising at least one polymeric matrix material and
at least one electrically conductive material, the at least one
polymeric matrix material comprises: at least one epoxy; and at
least one silicone and amine containing material, wherein the
composition is capable of carrying current in an electrical current
limiting device.
16. The composition according to claim 15, where the at least one
electrically conductive material comprises at least one conductive
material selected from the group consisting of: nickel powder,
carbon black and silver powder.
17. The composition according to claim 15, the at least one
conductive material comprises about 60% to about 85% by weight of
the conductive composite material.
18. The composition according to claim 15, the at least one
conductive material comprises about 10% to about 40% by volume of
the conductive composite material.
19. The composition according to claim 15, wherein the at least one
polymeric matrix material comprises poly
(methyl)(aminoethylaminopropyl)s- iloxane (PMAS).
20. The composition according to claim 19, wherein the at least one
polymeric matrix material comprises the epoxy in a weight percent
range between about 10% and about 90%, and the at least one
silicone containing material in a weight percent range between
about 10% and about 80%.
21. The composition according to claim 19, wherein the epoxy
comprises a material selected from the group consisting of:
condensation products of epichlorohydrin and bisphenol-A; and
epoxy-functionalized silicone.
22. The composition according to claim 19, the at least one epoxy
of the at least one polymeric matrix material comprising at least a
first epoxy, the at least one silicone containing material
comprising at least a first silicone containing material, the
composite material further comprising at least one further material
selected from a group consisting of: at least a second epoxy,
wherein the second epoxy and the first epoxy are different; and at
least a second silicone and amine containing material, wherein the
second silicone and amine containing material and the first
silicone and amine containing material are different.
23. The composition according to claim 22, the at least a second
epoxy comprising at least one epoxy selected from the group
consisting of: butyl glycydyl ether; polyglycol epoxy and
epoxy-functionalized silicone.
24. The composition according to claim 22, the at least a second
silicone containing material comprising at least a silicone
containing material selected from the group consisting of:
aminofunctional silicone and epoxy-functionalized silicone.
25. The composition according to claim 22, wherein the at least one
further material comprises between about 6% to about 35% by weight
of the polymeric matrix material.
26. The composition according to claim 22, the at least one
conductive material comprises about 10% to about 40% by volume of
the conductive composite material.
Description
[0001] This application is a continuation-in-part of U.S. Ser. No.
09/081,888 filed May 20, 1998, now U.S. Pat. No. ______.
BACKGROUND OF THE INVENTION
[0003] This invention relates to materials for current limiting
devices. In particular, the invention relates to polymeric
materials for current limiting devices, and the devices
themselves.
[0004] Current limiting devices are used in many electrical circuit
applications to protect sensitive components from high fault
currents. Applications range from low voltage and low current
electrical circuits to high voltage and high current electrical
distribution systems. An important requirement for many
applications is a fast current limiting response time,
alternatively known as switching time, to minimize the peak fault
current that develops.
[0005] There are numerous devices that are capable of limiting the
current in a circuit when a short circuit, otherwise known as a
high current event, occurs. Known current limiting devices include
a composite material that is a filled polymeric material that
exhibits what is commonly referred to as a PTCR
(positive-temperature coefficient of resistance) or PTC effect.
Thus, the material can be referred to as a PTCR composite material.
An attribute of PTCR composite material is that at a certain switch
temperature the material undergoes a transformation from a
basically conductive material to a generally resistive
material.
[0006] In some current limiting devices, the PTCR composite
material, typically polyethylene loaded with carbon black, is
placed under pressure between electrodes. In operation, a current
limiting device is placed in a circuit to be protected. Under
normal circuit conditions, the current limiting device is in a low
resistance and highly conductive state. When a high current
condition occurs, the PTCR composite material heats up through
resistive heating until a temperature above the "switch
temperature" is reached. At this point, the PTCR composite
material's resistance changes to a switched resistance, also known
as a high resistance state, and the current is limited. When the
high current condition is cleared, the current limiting device
cools down over a time period, which may be long, to below the
switch temperature. The current limiting device, which relies on
the PTCR effect of the composite material, then returns to a highly
conductive state. In the highly conductive state, the current
limiting device is again capable of switching to the high
resistance state in response to future high current events. It is
desirable that the conductive material in a reusable current
limiter device exhibit a low initial conductive condition
resistance Ri and a high switched condition resistance, coupled
with a large robustness that is characterized by a high number of
successful repeated pulses, otherwise known as "successful
shots".
[0007] Another current limiting device disclosed in U.S. Pat. No.
5,614,881, the entire contents of which are incorporated by
reference, relies upon material ablation and arcing that occurs at
localized switching regions in composite material. The ablation and
arcing may lead to at least one of high mechanical and thermal
stresses on the composite material. High mechanical and thermal
stresses are of course undesirable, if not controlled.
[0008] The composite material, either a PTCR material or otherwise,
after a switch cycle including ablation or arcing and returning to
a normal circuit condition may further exhibit an altered
resistance, such as a raised initial conductive condition
resistance when compared to the initial conductive condition
resistance before the high current event. This altered resistance
is at least partially due to an incomplete ablation of the
composite material at an interface that leaves non-conducting
ablation products (ablation materials) at the interface that raise
the resistance of the current limiting device. The switched
conductive condition then possesses fewer electrical connections
between the electrodes and the composite material due to the
presence of the non-conducting ablation products at the interfaces,
when compared to the initial conductive condition. The altered
resistance is not desirable as the range of operation for the
associated current limiting device will be changed.
[0009] Known composite materials may only exhibit satisfactory
switching properties, such as a low initial conductive condition
resistance and high switched resistance. The mechanical toughness
of these materials is not as high as needed for some current
limiting device applications, where brittleness of the composite
material may limit repeated operations. Further, known composite
materials for current limiting devices may exhibit satisfactory
mechanical toughness and good switching properties for a first high
current event. While generally acceptable for a first current
limiting application, an initial conductive condition resistance
R.sub.i of these composite materials will not be stable, and
therefore undesirable for successive high current events.
[0010] Carbon black filled polyethylene material is used in a known
current limiting device, a PTCR device available from ABB Control,
Inc. (Prolim 36A Current Limiter). Tests of the carbon black filled
polyethylene material were conducted to determine its ratio between
R.sub.i and R.sub.sw and its robustness when used as the composite
material in a current-limiting device, for example as set forth in
U.S. Pat. No. 5,614,881 (using the Prolim 36A composite material
instead of the composite material of U.S. Pat. No. 5,614,881). The
tests were conducted by abrading the surfaces of a 3/4".times.3/4"
piece of the carbon black filled polyethylene material and placing
the pieces between 1/4" outer diameter electrodes under about 370
psi pressure. Pulses of about 400V, each for about 10 msec, with an
amplifier capable of supplying 200A of current were applied to the
known carbon black filled polyethylene material.
[0011] The results of the test are illustrated in FIG. 1. The tests
indicate that the carbon black filled polyethylene material
exhibited an initial conductive condition resistance, R.sub.i equal
to about 0.15 ohm, a switched condition resistance R.sub.sw equal
to about 16 ohm, and a resistance ratio R.sub.i/R.sub.sw equal to
about 107. The current limiter device with the polyethylene filled
with carbon black material exhibited only 2 repeated pulses. These
results do not lend to a successful reusable current limiter
device.
[0012] Therefore, a need exists for composite materials for use in
current limiting devices that are able to maintain a conductive
surface at the interface, even after a high current event, without
the build up of non-conducting ablation products as in prior
devices, thus maintaining an initial conductive condition
resistance that is generally the same as prior to the high current
event. Additionally, a need exists for composite materials that
possess desirable reproducible electrical and mechanical properties
including a low initial conductive condition resistance, a high
switched resistance, a large resistance ratio, substantially
reproducible initial and switched resistances, mechanical toughness
and durability, large robustness and an ability to provide a large
number of repeated operations, and resistance to mechanical and
thermal stresses.
SUMMARY OF THE INVENTION
[0013] The invention sets forth a current limiting device. The
current limiting device comprises at least two electrodes; an
electrically conductive composite material disposed between the at
least two electrodes; a first interface between the composite
material and a first electrode, and a second interface between the
composite material and a second electrode; and an inhomogeneous
distribution resistance structure at the interfaces. During a high
current event, adiabatic resistive heating of the composite
material at the interfaces causes rapid thermal expansion and
vaporization of the composite material and separation of the
electrodes from composite material and separations within the
composite material proximate the interface so the resistance of the
current limiting device increases. The electrically conductive
composite material comprises a thermosetting material and at least
one polymeric matrix material and at least one electrically
conductive material. The at least one polymeric matrix material
comprises at least one epoxy and at least one silicone and amine
containing material, in which the at least one epoxy and the at
least one silicone and amine containing material combine and react
to form a thermosetting, electrically conductive composite
material. A current limiting device, as in an exemplary embodiment
of the invention, comprises at least two electrodes; an
electrically conductive composite material between the electrodes;
interfaces between the electrodes and the said composite material;
and an inhomogeneous resistance distribution at the interfaces.
During a high current event, adiabatic resistive heating at the
interfaces causes rapid thermal expansion and vaporization and at
least a partial physical separation at the interfaces and of the
composite material proximate the interface so the resistance of the
current limiting device increases. The composite material comprises
at least one polymeric matrix material and at least one
electrically conductive material, where the polymeric matrix
material comprises at least one epoxy and at least one
silicone.
[0014] A further aspect of the invention sets forth an electrically
conductive composite composition for conducting electricity in an
electrical current limiting device. The composition comprises at
least one polymeric matrix material and at least one electrically
conductive material. The at least one polymeric matrix material
comprises at least one epoxy and at least one silicone and amine
containing material, wherein the composition is capable of carrying
current in an electrical current limiting device.
[0015] These and other aspects, advantages and salient features of
the invention will become apparent from the following detailed
description, which, when taken in conjunction with the annexed
drawings, disclose embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] While the features of this invention are set forth in the
following description, the invention will now be described from the
following description of the invention taken in conjunction with
the drawings, where like parts are designated by like reference
characters throughout the drawings, and in which:
[0017] FIG. 1 illustrated an initial conductive condition
resistance R; and switched resistance R.sub.sw for successive
voltage pulses for a known composite material;
[0018] FIG. 2 is an exploded cross-sectional illustration of a
current limiting device; and
[0019] FIG. 3 is an exploded cross-sectional illustration of a
second current limiting device;
[0020] FIG. 4 illustrates an initial conductive condition
resistance R.sub.i and switched resistance R.sub.sw for successive
voltage pulses for a first composite material; and
[0021] FIG. 5 illustrates an initial conductive condition
resistance R.sub.i and switched resistance R.sub.sw during for
successive voltage pulses for a second composite material.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The invention, as illustrated in FIGS. 2 and 3, comprises a
high current multiple use fast-acting current limiting device 1
(hereinafter referred to as a current limiting device). The current
limiting device 1 comprises first and second electrodes 3 and an
electrically conductive composite material 5, such as a polymeric
composite material (hereinafter referred to as a composite
material) filled with a conductor, such as metals, alloys, and
semiconductors, with inhomogeneous resistance distribution
structure 7 under a compressive pressure P. The scope of the
invention includes a current limiting device with any construction
where a inhomogeneous resistance distribution structure 7 is
between the electrodes 3. For example, the inhomogeneous resistance
distribution structure 7 may be between two composite materials 55
in the current limiting device illustrated in FIG. 3. However, this
is merely exemplary and is not meant to limit the invention.
[0023] The inhomogeneous resistance distribution structure 7 is
typically chosen so that at least one thin layer of the composite
material has a significantly higher electrical resistance than the
remainder of the material. The inhomogeneous resistance
distribution structure 7 is preferably positioned proximate (near,
adjacent or in contact with) to at least one electrode 3 and
composite material interface 8, and has a significantly higher
resistance than an average resistance for a layer of the same size
and orientation. The term significantly higher means that the
resistance is higher in degrees noticeable during current flow so
as to influence current flow, as discussed in further detail
hereinafter.
[0024] The thin layer comprises a thickness that is in a range of
10 .mu.m to about 200 .mu.m regardless of the total thickness of
the composite and exhibits a resistance that is at least about 10%
greater than a resistance for a layer of the same size and
orientation. The higher resistance thin layer can be created by
providing a lower number of conductive filler particles that carry
electrical current, in the thin layer than in another thin layer of
the same size and orientation. This layer can be positioned at the
interface, for example but not meant to limit the invention, by
roughening the at least one of composite material and electrode
surfaces, so only a subset of the conducting filler particles that
would normally carry current with complete electrode and composite
material contact are utilized. Alternatively, an incomplete thin,
for example less than about 1 .mu.m, layer of non-conducting
material could be placed between the electrode and composite
material. A thin higher resistance layer could also be placed in
any region within the composite material by reducing the
concentration of conducting filler particles within that
region.
[0025] The current limiting device 1 is under compressive pressure
P in a direction perpendicular to the thin high resistance layer.
The compressive pressure P may be inherent in the construction of
the current limiting device 1. Alternatively, the compressive
pressure P may be exerted by a resilient structure, assembly or
device 10, such as, but not limited to, a spring.
[0026] Composite materials that exhibit acceptable mechanical
stability above about 100.degree. C. and adequate mechanical
toughness for at least a first switching are disclosed. For
example, a conductor filled epoxy material is disclosed in U.S.
patent application Ser. No. 08/896,874, filed Jul. 21, 1997, and a
conductor filled silicone material is disclosed in U.S. Pat. No.
5,614,881, assigned to the Assignee of the instant application and
of which the entire contents of each are fully incorporated
herein.
[0027] In operation, the current limiting device 1, as embodied by
the invention, is placed in the electrical circuit to be protected.
During normal operation, the initial conductive condition
resistance R.sub.i of the current limiting device is low. For
example, the resistance of a current limiting device 1 is generally
equal to the resistance of the composite material 5 plus the
resistance of the electrodes 3. When a high current event occurs, a
high density current flows through the current limiting device 1.
In initial stages of a high current event, resistive heating of the
current limiting device is believed to be adiabatic (without loss
or gain of heat), and the high resistive layer heats up much faster
than the remainder of the current limiting device 1. The adiabatic
resistive heating is followed by rapid thermal expansion and gas
evolution, both from the composite material 5 being ablated.
[0028] The thermal expansion and gas evolution lead to a partial,
and sometimes a complete, physical separation (separation) of the
electrodes 3 from the composite material 5 at an interface region
(interface) 8. Additionally, parts of the composite material at,
and in, the thin layer ablate and produce gas products. The
ablation created gas products causes separations within the thin
layer. The net result from these separations is reduced electrical
connectivity between the electrode and the remainder of the
composite material. The separations produce gaps at the interface 8
and a higher over all switched resistance to electric current flow.
Therefore, the current limiting device 1 limits the flow of current
in the circuit.
[0029] When conditions are present for the high current event to be
cleared or otherwise interrupted, for example by any appropriate
external clearing means (manual or automatic), the current limiting
device 1 is returned to its initial structural configuration. A low
resistance state should be regained due to the compressive pressure
P (inherent in the device or by an outside means), which acts to
push the separated layers together, allowing electrical current to
be able to flow. The current limiting device 1 is reusable for many
such high current event conditions.
[0030] The resistance after a first switching in prior known
current limiting devices may not be as low as prior to the high
current event, since ablation causes a build-up of non-conducting
ablation products at the interfaces. Further, the composite
materials in prior devices may not possess sufficient toughness to
maintain its structural integrity and withstand repeated high
current events at high temperatures associated with arcing and
resistive heating.
[0031] The composite material, as embodied by the invention,
typically ablates without causing or building up non-conducting
ablation products at the interface. The composite material permits
the current limiting device to return to its approximate initial
conductive condition resistance R.sub.i. Further, the composite
material retains its mechanical and structural stability at
elevated temperatures, for example at temperatures in a range
between about 100.degree. C. to about 200.degree. C., and has a
toughness that withstands large mechanical forces generated during
repeated high current events.
[0032] The composite material, as embodied by the invention,
comprises a polymeric matrix material that comprises at least one
epoxy, at least one silicone, and at least one conductive material.
The polymeric matrix material comprises a polymeric matrix material
that is derived from epoxy and silicone precursors, where at least
one of the epoxy and silicone precursor is filled with a conductive
material, such as an electrically conductive filler, for example a
metal, alloy or semiconductor. Alternatively, the conductive
material is added as a separate component to the polymeric matrix
material to form the composite material. This composite material
provides an initial conductive condition resistance R.sub.i that is
low, and a switched resistance R.sub.sw that is high. The composite
material exhibits generally stable initial conductive condition
resistances R.sub.i after repeated high current events, so the
composite material ablates cleanly resulting in no or a reduced
build-up of non-conducting ablation products between the electrode
and the material compared to prior current limiter devices. This
resultant surface permits the electrodes and composite material to
generally retain its initial surface configuration, and thus
generally retains its initial conductive condition resistance
R.sub.i.
[0033] The composite material comprises at least one epoxy, at
least one silicone, and at least one conductive material and
exhibits thermal and structural stability at temperatures greater
than about 100.degree. C. The material is stable at increased
temperatures so as not to adversely effect structural properties at
high temperatures. and not to adversely effect temperature
dependent features. Accordingly the composite material is
mechanically tough and structurally stable to withstand more
repeated high current events, than prior current limiter devices.
The composite material's mechanical toughness is believed to be
due, at least in part, to the incorporation of silicone into the
polymeric matrix material, which provides bonds that are able to
withstand large forces.
[0034] The epoxy for the composite material is selected from the
group comprising condensation products of epichlorohydrin and
bisphenol-A (Epon 828 Shell), an epoxy-functionalized silicone
monomer, for example DMSE01 (Gelest Inc.), Araldite DT025 (CIBA),
butyl glycidyl ether (epoxy), and other appropriate epoxy
materials. The epoxy component of the polymeric matrix material is
in a range between about 10% to about 90% by weight. The silicone
for the composite material is selected from the group consisting of
poly(methyl)(aminoethylaminopropyl)siloxane (PMAS), and
Aminosilicine (Magnasoft ULTRA from WITCO Corp.), each of which
comprises an amine and is provided in a range from about 10% to
about 80% by weight of the polymeric matrix material. As is known
in the art, amines and epoxies mix and react to form a
thermosetting material.
[0035] The conductive material comprises a conductive filler
material selected from the group comprising nickel powder, silver,
carbon black and appropriate conductive materials. The conductive
material comprises about 50% to about 90% by weight of the total
composite material, with the polymeric matrix material comprising
the remainder of the composite material. Alternatively, the
conductive material can be expressed in terms of volume percentage,
for example comprising about 10% to about 50% by volume, which
corresponds to about 50% to about 90% by weight for a metal filler
(silver and nickel powder). The percentages are approximate weight
percentages, unless otherwise specified. Further, weight percentage
of the conductive material is for the entire composite material and
the weight percentage of the polymeric matrix material components
are for a subtotal for a polymeric matrix material that is mixed
with the conductive material.
[0036] The resistance stability of the composite material 5 after
repeated high current events is believed to be partially due to
chemical bonds derived from epoxy groups. The nature of the bonds
leads to an essentially complete ablation over a substantially
uniform thickness layer at the interface 8. The composite material
5, when ablated, does not produce a build-up of non-conductive
ablation products that will raise the overall resistance of the
current limiting device. Thus, the after switching resistance is
generally the same as the initial conductive condition resistance
R.sub.i.
[0037] Several exemplary composite materials have been prepared
that exhibit the desirable aspects of the composite material, as
embodied by the invention. In the following discussion, the
percentages are approximate weight percentages, unless expressed
differently. Further, in the examples and throughout this
application, terms are sued as understood by a person of ordinary
skill in the art with their reasonably understood meanings. For
example, the term "generally" means commonly, usually, and
normally. Other such terms are used with a reasonable everyday
meaning, unless expressly discussed. The following composite
materials and methods of formulation are merely exemplary, and are
not meant to limit the invention in any way.
EXAMPLE I
[0038] A first composite material comprises a polymeric matrix
material formed from at least one epoxy and at least one silicone,
and at least one conductive material. The composite material of
Example I comprises about 65% of a conductive material and 35% of
an epoxy-functionalized silicone as the polymeric matrix material.
The conductive material of Example I is derived by dispersing the
conductive material into a silicone containing material, such as a
epoxy-functionalized silicone monomer, followed by curing epoxy
groups of the monomer with an appropriate catalyst. The conductive
material (often referred to as a filler) comprises nickel powder
(Nickel 255 A/C Fines from Novamet Corp.) and the
epoxy-functionalized silicone monomer comprised a liquid
epoxy-containing dimethylsiloxane (GE UV9430). The liquid was
polymerized to a solid with an iodonium salt catalyst, for example
bis(4-dodecylphenyl)iodonium hexafluoro antimonate (GE
UV9380C).
[0039] In particular, Example I is formed from 35 g of GE Silicones
UV9430 (epoxy on-chain. polydimethylsiloxane) that is hand-mixed
with 1.1 g of GE Silicones UV9380C (iodonium cure catalyst) and 65
g of Nickel 255 A/C fines powder (available from Novamet Corp.) in
a beaker. 78.6 g of the mixture is placed in a 3".times.3"
Teflon.RTM. mold with a 13 lb. static applied load. This mixture is
placed in an oven at 170.degree. C. for 2 hours. The material is
then taken out of the mold, and followed by post curing for 2 hours
at 200.degree. C.
[0040] Current limiting devices were made with the above-described
composite material by abrading surfaces of the composite material,
and placing the composite material between the electrodes, under 60
psi pressure, to create a current limiting device with an
inhomogeneous resistance distribution. A slightly higher resistance
occurs at an interface between the electrode and composite
material. The exemplary current limiting device comprises 1/4"
outer diameter electrodes and a 3/4".times.3/4" piece of composite
material that is about 1/8" thick.
[0041] Current limiting properties of the above described current
limiting device were tested by successively applying about 400V
voltage pulses, each for 10 msec, with an amplifier capable of
supplying 200A of current (test conditions are similar as discussed
in the background). The current limiting device switched with the
application of each voltage pulse. FIG. 4 illustrates an initial
conductive condition resistance R.sub.i before each switching event
and switched resistance R.sub.sw for successive and repeated
voltage pulses. The switching properties indicate an initial
conductive condition resistance R.sub.i, a higher switched
resistance R.sub.sw, and generally stable values for successive
pulses. Further, when the size of a current limiting device with
the Example I composite material is increased in area by factor of
about 60, and the same approximate current density and voltage are
applied as above, the composite material possesses similar
electrical and mechanical results without any substantial
performance loss.
EXAMPLE II
[0042] A second composite material, as embodied by the invention,
is derived by dispersing a conductive filler in a polymeric matrix
material, where the polymeric matrix material is formed from a high
temperature capability epoxy resin that is cured with an
appropriate material, such as an amino-containing silicone resin.
The composite material comprises about 70% of a conductive
material, for example a nickel material, as discussed above, and
about 30% of a polymeric matrix material. The polymeric matrix
material comprises about 100 parts of an epoxy resin, such as
condensation products of epichlorohydrin and bisphenol-A (Epon
828), and about 82 parts of poly
[(methyl)(aminoethylaminopropyl)siloxane (PMAS) as the silicone
containing material.
[0043] In particular, Example II is formed from 16.5 g of Epon 828
(an aromatic epoxy available from Shell) and 13.5 g of 89124
(methylaminoethylaminopropyl-substituted polydimethyl siloxane)
(available from GE Silicones) that are hand-mixed together. 70 g of
Ni-255 A/C fine is then added, and the whole mixture is
hand-blended using a mortar and pestle. This hand-blended mixture
is then further mixed in a Semco tube mixing device for 10 minutes.
The mixture is then poured into a 3".times.3" aluminum mold and
placed under 100 PSI pressure for 1 hour at 100.degree. C. followed
by post-curing for 2 hours at 150.degree. C.
[0044] FIG. 5 illustrates an initial conductive condition
resistance R.sub.i before a switching event and a switched
resistance R.sub.sw for successive voltage pulses in a current
limiting device, applied in a similar manner as discussed above in
Example I, however using the composite material of Example II. The
switching properties illustrated in FIG. 4 illustrate a low initial
conductive condition resistance R.sub.i, a high switched resistance
R.sub.sw and generally stable values for successive pulses. Also,
similar to Example I, when the area of a current limiting device is
increased by a factor of about 60, there is no discernible loss of
performance.
[0045] In addition to Examples I and II, other formulations of
composite materials comprising at least one epoxy (MC1), at least
one silicone (MC2), and at least one conductive material were
prepared. Table 1 lists the compositions for each material. The
percentages listed in Table 1 are approximate weight percentages,
unless otherwise specified. Again, the weight percentage of the
conductive material is for the entire composite material and the
weight percentage of the polymeric matrix material components,
MC1-MC3, are for a subtotal for a polymeric matrix material that is
mixed with the conductive material. Therefore, for Example A, the
composite material comprised about 70% of a conductive material and
about 30% of polymeric matrix material amount, where the polymeric
matrix material comprises about 71% of an epoxy and 29% of PMAS.
The switching properties of materials in Table I exhibit a low
initial conductive condition resistance R.sub.i, a high switched
resistance R.sub.sw and generally stable values for successive
pulses. Table 1 also lists average resistances for initial
conductive conditions and switched conditions, as well as a
resistance ratio. Also, the table lists the number of repeated
pulses, also known as "successful shots" for the samples.
[0046] Examples A-D set forth composite materials that are
substantially similar to Example II, however the ratio between the
epoxy content (MC1) and the PMAS (MC2) is varied. These composite
materials indicate that the ratio of epoxy and silicone can be
varied and provide acceptable current limiting properties. Example
E indicates that nickel concentrations other than about 70% (by
weight) can be employed in a composite material, as embodied by the
invention.
[0047] Examples F-J are similar to Example II, however, at least
one additional component, such as one of: an epoxy, an epoxy
reactant, and a polyglycol epoxy; a butyl glycydyl ether; and a
further silicone containing material such as an aminofunctional
silicone and epoxy-functionalized silicone, is included in the
polymeric matrix material of the composite material. The additional
material increases processability of the composite material, for
example, by at least one of increasing a pot-life and decreasing
viscosity of the polymeric matrix material during preparation, so
conductive filler can be more easily incorporated into the
composite material.
[0048] Examples K and L indicate that composite materials in
accordance with one aspect of the invention, are derived by
combining an epoxy-functionalized silicone, an amino-silicone and a
conductive material. Further, Example K indicates that conductive
materials other than nickel can be utilized in composite materials.
Example M indicates that an epoxy, which is combined with an
epoxy-functionalized silicone and an aminosilicone, can also be
utilized to comprise a composite material's polymeric matrix, as
embodied by the invention.
[0049] In still another example, Example N, a composite material
comprises a polymeric material matrix that is fabricated from a
mixture comprising approximately equal weights of two
epoxy-functionalized siloxanes:
1,1,3,3-tetramethyl-1,3-bis-((2-oxabicyclo(4.1.0)hept-3-yl)-ethyl)disilox-
ane and polydimethylsiloxane terminated with
ethyl-2-(7-oxabicyclo(4.1.0)h- ept-3-yl) groups. One hundred parts
of this mixture are catalyzed with about 3 parts of an iodonium
salt catalyst, for example bis(4-dodecylphenyl)iodonium hexafluoro
antimonate (GE UV9380C) to form the polymeric matrix material.
About thirty-five parts of this polymeric matrix material is
combined with about 65 parts of a conductive material, for example
nickel powder.
[0050] The performance of the composite material of Example N
indicates an initial conductive condition resistance R.sub.i, a
higher switched resistance R.sub.sw, and generally stable values
for successive pulses.
[0051] Therefore, as discussed above, the at least one epoxy of the
at least one polymeric matrix material can comprise at least a
first epoxy. The at least one silicone containing material can
comprise at least a first silicone containing material. The
composite material can further comprise at least one further
material selected from a group consisting of at least a second
epoxy, in which the second epoxy and the first epoxy are different;
and at least a second silicone and amine containing material,
wherein the second silicone and amine containing material and the
first silicone and amine containing material are different. The
term different is used as understood by a person of ordinary skill
in the art in which the materials are not alike in their
characteristics.
[0052] While various embodiments have been described herein, it
will be appreciated from the specification that various
combinations of elements, variations or improvements therein may be
made by those skilled in the art, and are within the scope of the
invention.
* * * * *