Customized Electrical Bi-Metal Contact
Products Description
Our Customized Electrical Bi-Metal Contacts can be flexibly developed to suit different electrical system structures, including:
Moving Contacts
Fixed Contacts
Planar Composite Contacts
Spot-Welded Composite Contacts
Irregularly Shaped Conductive Contacts
High Current-Carrying Composite Contacts
Low/Medium Voltage Switch Contacts
Miniature Relay Composite Contacts
Contactor Bridge Contact Assemblies
Products can be customized according to customer drawings to adapt to different assembly structures, switch travel, and conductivity requirements.
Wide Range of Applications
Industrial Control Relays & Contactors
As core moving/stationary contacts, they withstand high-frequency AC/DC motor control loads.
Household Appliance Thermostats & Micro Switches
High-sensitivity miniature Round Silver Bimetal Rivets ensure safe temperature rise during high-frequency switching.
EV DC Breakers and Relays
Meeting the extremely demanding requirements of on-board high-voltage DC (HVDC) systems for high power density and surge protection.
Smart Grid Circuit Breakers (ACBs) and Molded Case Circuit Breakers (MCCBs)
Used as Bimetal Silver Composite Contact Rivets, signal contacts, or trigger points in core arc-extinguishing circuits of main power distribution lines.
Design Advantages: Spatial Interplay Between 3D Topology and Arc Flow Field
| Bounce Suppression and Mass Topology Optimization of Moving Contacts | Moving contacts are prone to bounce at the moment of closing, triggering arc reignition. We use an asymmetric silver layer distribution design (e.g., thickening at the tail and thinning at the head) to precisely adjust the centroid position and moment of inertia of the Switch Bimetal Silver Contact, combined with the high elastic modulus of the silver alloy, effectively attenuating the mechanical bounce amplitude. |
| Magnetic Blowout Streamline Design of Stationary Contacts | Considering the characteristic of the Silver Bimetal Rivet Contacts as the arc initiation point, we design the working surface of the silver alloy as a specific micro-curvature arc or slope, guiding the arc root to move rapidly towards the contact edge under the action of the Lorentz force, shortening the arc dwell time and reducing local ablation. |
| Bionic Stress Relief: Structure of the Interface | At the interface between the silver layer and the copper substrate, a micro-concave-convex interlocking topology is designed. This three-dimensional interlocking structure not only increases the effective bonding area of the interface but also transforms the single normal shear into a composite force state of normal and tangential under tangential impact, thus multiplying the interface's anti-peeling margin. |
Production Process Overview
Material Incoming Inspection
Silver alloy wire (AgNi, AgSnO₂, etc.) and T2 copper wire undergo composition and dimensional testing, with accompanying material reports.
01
Pre-cleaning and End-face Cutting
Silver alloy wire and copper wire are simultaneously and precisely cut by an automatic feeding device, keeping the cut ends fresh, clean, free of oxidation and organic contamination-crucial for subsequent welding quality.
02
First Forming (Pre-forging and Centering)
The silver alloy wire and copper wire are precisely centered, and cold pressure is applied in the pre-forming cavity to initially bond them together.
03
Second Forming (Cold Forging and Final Forging)
Transferred to a cavity mold with the required head shape, higher pressure is applied to force the metal to diffuse outwards and fill the cavity, forming the final geometry of the rivet-like or sheet-like contact.
04
Stress-relieving heat treatment
The pre-made Bimetal Electric Rivet Contact is placed in a vacuum annealing furnace, heated to 380°C according to a specific temperature curve, and held at that temperature for about 1.5 hours. They are then slowly cooled to room temperature to eliminate internal stress from cold working and prevent oxidation.
05
contact us
We not only provide standardized Button Bimetal Rivet Electrical Contact products, but also offer integrated engineering support based on customers' current ratings, switch structures, assembly methods, and lifespan requirements. This support ranges from material composites and structural optimization to mass production, helping projects achieve more stable and consistent long-term mass production support.
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