Toggle switches are essential components in a wide range of electronic devices, offering reliable control over electrical circuits. Understanding their voltage capabilities, performance characteristics, and technical specifications is crucial for proper selection and application. Below is an in-depth overview of toggle switch parameters, performance standards, and manufacturing processes. **Electrical Performance and Parameters** - **Rated Power**: DC 50V, 0.3A - **Operating Temperature Range**: -20°C to 60°C **Key Electrical Tests** 1. **Contact Resistance Test**: - Conducted under a low current (100 mA) - Requirement: Must be less than 30 milliohms 2. **Insulation Resistance Test**: - Apply 500V DC for 1 minute - Measured between contact terminals and between the plastic body and the base - Requirement: Must exceed 100 megohms 3. **Withstand Voltage Test**: - Apply AC 500V (50–60Hz) for 1 minute with a sensitivity current of 0.5mA - Check between contacts and between the base and the housing - No insulation damage or anomalies allowed **Mechanical Performance Specifications** - **Operating Force**: Typically 250 ± 50 gf - **Terminal Strength**: Withstand 500gf applied in any direction for 1 minute - **No cracks or looseness** in the terminal row **Environmental and Durability Testing** - **Test Conditions**: - Temperature: 5°C to 35°C - Humidity: 45% to 85% - Air Pressure: 80kPa to 106kPa - **Solderability Test**: - Top of terminal immersed in solder bath at 230 ± 5°C for 3 ± 0.5 seconds - Minimum 80% coverage required - Additional test at 260 ± 5°C for 3 ± 0.5 seconds (for furnace welding) - **Life Test (No Load)**: - 100,000 cycles at 60 cycles per minute - Contact resistance must not exceed 200mΩ - **Heat Resistance Test**: - Exposed to 85 ± 2°C for 96 hours - Then cooled to room temperature for 1 hour - No deformation or performance issues - **Cold and Humidity Tests**: - 40 ± 2°C, 90–96% humidity for 96 hours - No visible damage or performance degradation **Component Overview and Manufacturing Process** Toggle switches are typically assembled using the following parts: 1. **Iron Shell**: Made from iron, often electroplated with nickel or blackened to prevent oxidation 2. **Plastic Handle**: Usually made from POM; PA nylon used for fire-resistant or high-temperature applications 3. **Terminals**: Phosphor bronze material, electroplated with silver 4. **Insulation Base**: Electric wood board, stamped for precision 5. **Contact Chip**: Phosphor bronze, electroplated with silver 6. **Round Wave Beads**: Stainless steel, electroplated with nickel 7. **Slingshot**: Bronze, formed via stamping 8. **Decorative Oil**: Non-toxic, environmentally friendly oil (red or green) applied to terminals and base **Common Applications** Toggle switches are widely used in various industries including: - Audio/Video Devices: MP3 players, MP4 players - Digital Products: Digital cameras, video recorders - Communication Equipment: Mobile phones, PDAs, telephones - Security Systems: Video intercoms, surveillance systems - Toys: Electronic toys and games - Computers: Webcams, peripheral devices - Fitness Equipment: Body fat scales, treadmills - Medical Instruments: Blood pressure monitors, thermometers, hospital call systems **Kesta Switch Factory** Specializing in high-quality toggle switches, Kesta provides reliable solutions for diverse industrial and consumer applications. Our products meet international standards and are designed for long-lasting performance and durability. Whether you're looking for standard or custom toggle switches, our factory ensures top-tier quality, precise engineering, and competitive pricing. Contact us today for more information on our extensive product range.
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