Wall Switch Terminal Failure Caused By Non-standard Conductor Connections

The reliability of electrical terminal connections directly affects the safe operation of Wall Switch. Directly inserting bare wire cores into terminal blocks instead of plugs violates the electrical connection specifications designed by the equipment manufacturer. Insufficient metal contact area leads to localized overheating, causing stress relaxation of the terminal springs under sustained high temperatures, resulting in an exponential decrease in contact pressure.

Arc erosion accelerates structural degradation. Loose, uncrimped copper wires generate micro-vibrations under AC current, leading to intermittent contact and continuous arc discharge. The silver plating on switch terminals melts and spatters under arc temperatures exceeding 3000°C, exposing the copper substrate and accelerating oxidation. Accumulated carbon particles form conductive channels on the surface of insulating components, causing the power frequency withstand voltage level to drop to a dangerous threshold.

Thermal aging of materials triggers a chain reaction. Under abnormal temperature rises (commonly exceeding 120°C), the glass transition temperature of the terminal plastic support is breached, resulting in loss of mechanical strength and displacement of current-carrying components. Bimetallic springs form brittle alloy layers due to dissimilar metal diffusion, increasing the risk of fatigue fracture. The polycarbonate shell develops intergranular cracks under thermal stress, losing its insulating and protective capabilities.