Break arcs are generated between electrical contacts in a DC 42 V resistive circuit. Contact materials are Ag/SnO2 and Ag/ZnO. Circuit current when contacts are closed is varied from 5 A to 21 A. The radial magnetic field to drive break arcs is formed between the contact gap with a permanent magnet embedded in the cathode. The arc motion is observed with a high-speed camera. Experimental results with the magnet are compared with those without the magnet. Following results are shown. Similar experimental results to pure silver contacts are obtained for Ag/SnO2 and Ag/ZnO contact pairs. The rotational motion of the break arcs and the shortening effect of the arc duration are confirmed. The ring-shaped, wide and uniform traces are observed on the contact surfaces after break operations. This result shows the prevention effect of local erosion of electrical contacts and the reduction of total amount of contact erosion. The rotational frequency f is increased with the increase of the arc current Iarc. These results for Ag/SnO2 and Ag/ZnO contact pairs are similar to the results for pure silver contacts in our previous experiments. The rotational frequency of the break arc for the Ag/SnO2 and Ag/ZnO contacts is lower than that for the pure silver contacts.

The paper presents the state of knowledge about thermal-erosion processes in contacts of low-voltage switching devices for power engineering on switching currents under short-circuit conditions. The graphical models of the short arc and the distribution of arc power introduced into contacts are shown. The method for measurements of a contact temperature during an electric discharge has been elaborated. The obtained test results are presented, i.e. changes of a contact temperature as a function of arc parameters such as current, energy, and integral ∫idt. The tests have shown that a "break point" exists on the curve expressing the relationship between a temperature rise and arc parameters in the range of high currents. The location of this point is dependent on a diameter of contacts and a value of current, and is associated with thermal energy delivered to electrodes. It has been observed that for each diameter of contacts there exists such value of an energetic quantity of arc (current, ∫idt, energy), at which diameters of arc roots are the same as a contact diameter. Above this value, the shape of a curve is changed. The obtained results explain and confirm the discontinuity of a curve expressing a contact arc erosion as a function of current, which was observed earlier by the other research workers.

This paper presents a comprehensive explanation of the formation of the electric arc between opening contacts in a current carrying electric circuit. As the contacts begin to open a molten metal bridge forms between them. The rupture of this bridge and the initial formation of the electric arc are studied in both atmospheric air and vacuum using experiments to determine the direction of metal transfer between the contacts as a function of time after the rupture of the molten metal bridge. High speed streak photography is also used to show the rupture of the molten metal bridge and the initial formation of the electric arc. Analysis of these data show that a very high-pressure, high-temperature metal vapor zone exists between the contacts after the rupture of the molten metal bridge. Under this condition a pseudo-arc forms where current is carried by metal ions and an anomalous, high net transfer of metal to the cathodic contact occurs. The pressure in this region decreases rapidly and there is a transition to the usual electric arc, which still operates in the metal vapor. In this arc the current is now mostly carried by electrons. The data shows that there is still a net transfer of metal to the cathode, but now its volume is a function of the arcing time.

We fabricated and examined current limiting effect for InP Gunn diodes with stable depletion layer mode operation of diodes for high efficiency Gunn oscillators. Current limiting at the cathode was achieved by a shallow Schottky barrier at the interface. We discussed fabrication procedure, the results for negative differential resistance and rf tests for InP Gunn diodes. It was shown that the fabricated Gunn diodes have the output power of 10.22 dBm at a frequency of 90.13 GHz. Its input voltage and corresponding current were 8.55 V and 252 mA, respectively.

Tin and its alloys have been applied for the plating of electrical contacts for low electrical power conditions. In particular, tin-plated contacts are widely used as connector contacts in automotive applications and as make-break contacts in keyboard switches. In the relationship between contact resistance (R) and contact load (W) for both solid and plated tin, singularities have been found. Previously established and well known theories on the deformation of contact interfaces cannot explain these singularities. In this study, to clarify these singularities, and to obtain a contact model explaining this phenomenon, contact traces for contact load were examined by SEM and STM. The obtained microscopic images indicated piling-up at the periphery of the contact area for both solid and plated tin. In this case the contact configuration comprised a platinum probe with a hemispherical tip surface and a flat tin surface for both solid and plated. When the probe was loaded, this tip of the probe sank into the soft tin surface owing to its lower hardness. In case of solid tin, the sinking of the probe surface into the tin surface causes piling-up around the periphery of the contact trace. In this deformation process, since the periphery of the indentation of the indented contact area severely slid against the surface of the platinum probe while applying a contact load, the contact resistance rapidly decreased with load. In this case, the center portion of the true contact area was not affected mechanically; thus, the surface film on the bottom portion of the deformed of the flat surface did not break down mechanically. On the other hand, in the case of a tin plated surface, similar piling up occurred; however, it was accompanied by scattering and separation of tin crystal grains from the surface. As a result of this process, a decrease in contact resistance similar to that for the solid tin occurred. Since the piling-up of the contact surface is a very important process in the application of connectors, the above-mentioned unusual characteristics were clarified in this study.

Break arcs are generated between silver electrical contacts in a DC 42 V-10 A resistive circuit. Break arcs are driven by the radial magnetic field. The magnetic field is formed between the electrical contacts with a permanent magnet embedded in the cathode. The arc motion is taken with a high-speed camera and contact surfaces are observed after break operations. Experimental results with the magnet are compared with those without the magnet to confirm the effect of the embedded magnet. For break operations with the magnet following results are shown. Break arcs are rotationally driven by the radial magnetic field in the direction according to Lorentz force. The shortening effect of the arc duration is confirmed. The traces of the arc spots on the contact surfaces are ring-shaped, wide and uniform. This result shows the prevention effect of local erosion of electrical contacts. The rotational frequency of the break arc depends on the Lorentz force with the radial magnetic field.

In prior work, contact welding phenomena were observed in automotive relays during break of motor inrush current. The switching performance of the type of relay investigated could be correlated with the parameters: over-travel, coil suppression, and the break current. In the present work the author further explores the impact of both the contact material (silver tin oxide versus fine grain silver) and the contact surface topography (brand new and pre-aged contacts). He further assesses the robustness of the system "relay" with those parameters using the Taguchi methods for robust design. Furthermore, the robustness of two alternative automotive relay types will be discussed.

VI time responses of a conventional electromagnetic relay during breaking contact operations were measured. In a conventional switching circuit, unstable contact resistance, irregular bouncing, and poor reproducibility were confirmed. Using a transient current switch circuit and two sharpened contact electrodes, bouncing during a breaking operation was suppressed, and unstable contact resistance changes and reproducibility of breaking operation were also improved.

Characteristics of conductive elastomer that is composed of silicone rubber and dispersed carbon black particles show conductive and elastic properties in one simple material. This material has been widely applied to make-break contacts of panel switches and connectors of liquid crystal panels. However, since surface state of the contact is very soft, it is difficult to remove contaminant films of contaminated opposite side contact surface and to obtain low contact resistance owing to break the film. This is an important problem to be solved not only for the application of make-break switching contact but also static connector contacts. This study has been conducted to examine some complex structures of the elastomer which indicate removal characteristics for contaminant films and low contact resistance. As specimens, six different types of elastomer contacts composed of different type of dispersed materials as carbon and metal fibers, metal mesh, and plated surfaces were used. The contacts of opposite side were Au and Sn plated contact surface on a printed circuit board (PCB) which is usually used in the static connector and make-break contacts. In order to contaminate contact surfaces of PCB, the surfaces were subjected to exposure in an SO2 gas environment. The elastomeric contacts contained hard materials showed lower contact resistance than only dispersed carbon particles in the elastomer matrix for both contaminated PCB contact surfaces.

At high signal frequencies (i.e. in the GHz range), a connector must be considered as part of an electromagnetic transmission line. At these frequencies, the impedance characteristics of the connector stemming from the distributed inductance and capacitance of pins and the associated wiring, must be carefully controlled; insertion losses must be minimized and undesirable coupling between non-neighboring pins giving rise to crosstalk must be avoided to achieve optimal signal transmission. This paper reviews fundamental issues associated with the performance optimization of multi-conductor connector structures for high speed signal transmission. The paper complements an earlier publication that reviewed the major factors affecting electrical contact resistance at high frequencies [1].

The possibility of using three kinds of new type composite materials as material for high speed sliding contacts was investigated. The results of this investigation were compared with the results of the low speed tests that were reported earlier. As a result of the above, it was discovered that for high speed rotation in the range from 0.014 m/s to 2 m/s, the order of merit did not significantly change. Based on this, it was concluded that if solid lubricant is effectively supplied to the sliding surface, the influence by frictional heat generated by high speed is slight. Of the three kinds of composite material, it was clarified that composite material (CMML-1) had the lowest contact resistance and Composite Material (CMML-3) had the lowest maximum frictional coefficient of friction. 'CM' and 'ML' are initialisms for 'Composite Material' and 'Material of Lubrication' respectively. The number that is attached to the material name is a numeric value that was set by this laboratory.

Contact surfaces are exposed to the atmosphere in general applications. Therefore, gases in the atmosphere such as oxygen and H2O are adsorbed on and react with the contact surface. Products formed on the surface such as copper oxide films degrade contact resistance characteristics. This surface contamination is an important problem for electrical contact applications. The author has studied the effect of humidification on contact resistance characteristics. In this paper, the effect of humidity on the growth of an oxide film on a copper surface was clarified. An increase in the humidity results in a decrease in the thickness, in contrast, a decrease in the humidity increases the thickness linearly. Changes in the oxide film thickness based on the level of humidity were measured by ellipsometry. Surface state changes influenced by humidification were analyzed topographically using a scanning tunneling microscope. The mechanism of the effect of humidity on the film thickness was discussed on the basis of the deduction of the copper oxide film by H2 from the adsorbed H2O. Moreover, the changes in contact resistance levels for both static and sliding contacts due to humidity were measured, and a dependence on humidity was found.

The paper presents a method for testing transport of composite contacts materials under electrical arc conditions at high currents and for polarized electrodes. Tests and the discussion of results were carried out for silver-metal, silver-metal oxide and silver-tungsten carbide contact materials. Additionally, tungsten electrode was used as the second contact which was either cathode or anode. Spectrometric analysis of arc erosion components transported onto the second electrode and into the surroundings was carried out.

Arc occurrence rates were measured for Ag contacts in DC resistive and inductive load circuits. In inductive load conditions, arc occurrence rates in general came close to 100% at around 0.4 A, the conventional minimum arc current level of Ag. In resistive load conditions, the similar results were obtained with 30 V, while arc occurrence rates close to 50% were still obtained at around 0.4 A with 14 V and 10 V. Careful attention should be paid to the term "minimum arc current" to avoid misinterpretation thereof.

We proposed a method for suppressing arc ignition in mechanical contact devices using a transient current switch and a capacitor. We applied the method to conventional reed switches. For the electric circuit analysis, we clarified the momentary voltage-current characteristics at breaking operation of reed switches by FEM analysis. We could also estimate the capacitance of the contact electrodes at the metal bridge rupture by FEM analysis, and would derive the non-arcing condition using SPICE simulation. The suitable capacitor value in the transient current circuit for arc ignition suppression would be depend on the load impedance, the power supply, the time depending contact resistance R(t)s, the contact capacitance, and the minimum arc voltage and current.

At frequencies in the GHz range, an electrical connector must be considered as part of an electromagnetic transmission line. This paper reviews the effect of signal frequency on constriction resistance, interfacial capacitance and contact inductance at an electrical interface in a high speed connector. The deleterious effects of contact degradation at pin-receptacle junctions on transmitted signal integrity, are addressed. For frequencies in the GHz range, an electrical interface becomes capacitively coupled if contact resistance increases sufficiently. Contact deterioration may also lead to the generation of parasitic third-order harmonics that contribute to loss of signal integrity.

Arc occurrence rates are measured for Ag and Pd contacts operated in a DC resistive load circuit. Based on the obtained results, it is confirmed that arc certainly occurs at current levels lower than the conventional minimum arc current value for each of the tested contact materials. Arc occurrence rate in general comes close to 100% at the conventional minimum arc current level. Accordingly, careful attention should be paid to use of the term "minimum arc current" in order to avoid misinterpretation thereof.

In order to study the growth of transferred pips, we operated Ag/SnO212 wt% contacts mounted on an electromagnetic relay in a DC14 V-21 A the resistive circuit as make-only contacts, and took photographs of the transferred pips formed on a cathode surface. In this experiment, the pip shape was different depending on whether the movable contact was the cathode or anode. When the movable contact was the cathode, pip grew high, and became 0.7 mm height at maximum. Sometimes, the pip collapsed. Sticking occurred, when the pip shape became H/Dr0.5 and H/Ga0.5, where H is pip height, Dr is diameter of pip root, and Ga is gap length of open contacts. Judging from this result, we can predict that when a pip grows to H/Dr0.5 and H/Ga0.5, sticking will easily the occur. When the movable contact was the anode, no tall pip was formed, because of pip breakages. Sticking occurred for three samples although the pips grew to H/Dr0.5 and H/Ga0.5. In this case we could not obtain a numerical relationship between of the pip shape and the occurrence of sticking.

AgCdO12wt% contacts mounted on electrical relays were tested in a dc 14 V-21 A or 42 V-8.4 A resistive circuit as make-only contacts. In this experiment, we took photograph records and measured arc duration and number of bounces. A transferred pip was grown on the cathode surface, and its height H grew H/Ga>0.5, where where H is height of pip, Ga is the contact separation, sticking occurred easily. Neither the rapidity of growth or the shape of the transferred pip influenced circuit conditions, but there were differences observed for the each sample. Since the arc discharge of switching operations at make-only contacts occurs during a rebound, the arc duration, as well as the number of bounces fluctuates.

Novel contact materials such as extrinsic conducting polymers can improve contact performance and enable device miniaturisation. This paper presents an investigation of conducting polymer materials used to minimise the effect of fretting slip at the contact interface of connector terminals. Initial experimental studies are presented and a mechanical model is used to describe the polymer interface slip and stick characteristics. For fretting to be minimised the polymer must be sufficiently elastic, with a high coefficient of friction with the contacting terminal, and a sufficient normal force to ensure no slip. Experimental studies of a polymer-tin interface are conducted to characterise contact resistance performance under fretting conditions. A resistance model of the polymer interface is developed.