With the emergence of new alloy materials and plastics and customer requirements, contact technology is also constantly developing. However, efforts are still being made to address the main issues that cause switch interruptions, such as the inability to produce completely smooth metal contact surfaces, resulting in the following problems:
fever
Under the microscope, it can be observed that there are many "protrusions" and "grooves" on the contact surface. When the contacts are closed, only the protruding parts are actually in contact with each other. Therefore, the true current carrying surface is much smaller than its apparent area. Because the current is only carried by a small portion of the designed surface area, the heat generated is concentrated on the protruding parts, resulting in the formation of a high resistance oxide layer.
As the resistance increases, more electrical energy will be converted into heat, leading to the formation of more oxides. This spiral effect will generate "hot spots", reduce the efficiency of the switch, and when two surfaces are fused together, it will cause the switch to completely fail.
Using contact grease can solve this problem. The lubricant film can significantly increase the effective contact area because the thin film formed by the lubricant allows current to pass through. In this way, the switch has the contact surface area originally envisioned by the designer. The 'hot spot' has been eliminated, and the contact resistance remains low and stable.
electric arc
Uninlubricated contacts often generate arcs (extremely small electrical sparks) when opening and closing. The arc electrode is destructive because it generates heat, leading to the formation of oxides, and due to the high energy of the arc, it may produce corrosive agents, causing surface corrosion or damage to the contact coating. The ionization effect of air and the associated temperature rise may cause metal migration on the contact surface, resulting in the formation of new protruding grooves - a common problem in high-power contacts.
The arc problem often occurs in "closed&open" type switchgear, where the contacts may bounce several times before finally closing each time they close. This exacerbates the problem discussed earlier, where the current in the circuit is constantly fluctuating and noise causes poor signal quality.
The converter using contact lubricant does not have this problem because the lubricant adds anti arc additives to prevent arcing, corresponding temperature rise, and the formation of corrosive chemicals. Discharging air from the metal contact surface can prevent pollutants in the air from forming an insulation barrier on the metal. Contact lubricant can form a "cushion" between the contacts, thereby reducing the phenomenon of jumping.
Manual sensation
The tactile sensation of the switch during operation has become a humanized performance indicator, especially in the automotive industry. The technical advantage of contact grease allows it to determine the feel of a certain switch, which may appear powerful and decisive on the dashboard of commercial vehicles, but smooth and quiet on luxury cars.
Electronic contact grease can reduce friction, improve the electronic performance of current passing through the metal interface of switches and connectors, and form an ultra-thin film layer of oil film when the contacts are closed. Due to the "quantum tunneling effect", current can flow smoothly, while the contact grease that becomes thick film after disconnection is insulating and can prevent leakage.
Experiments have shown that contact lubricants can extend the service life of switches by over 200%, while exhibiting excellent performance in various environments, saving valuable time and expensive maintenance costs. In the 21st century, the global promotion of green environmental protection and product humanization has added contact lubricants to the design of perfect switches to improve their performance. When choosing to use contact lubricants in the product design stage, expensive materials such as gold, silver, and electric wood are avoided as much as possible, thereby improving performance and saving considerable costs. This is what is called perfect.
The application range of contact grease is very wide, including PC edge connectors, relays, switches for washing machines, electric kettles, hair dryers, etc. For important switches and contacts that require frequent and stable operation. In the automotive industry, contact grease is widely used to ensure reliable, safe, and long-lasting operation of switch contacts, while improving the tactile sensation of switch devices. These contact lubricants can also be applied to motor commutators to reduce friction and noise, enhancing their lifespan.
