I have a question I've been meaning to ask since that forum member started that whole debate. I guess it's time to bite the bullet and ask. Does it make a difference that we are working with 3-6 volts in our mods and the ratings for these switches are always done @125 volts AC and/or 12 volts DC? I mean if it's rated, say .5amp at 12 volts DC, wouldn't that be 1 amp at 6 volts and 2 amps at 3 volts? I am not sure how that works, but it might explain why we have so little problems using these.
Switches should only be used for what voltage/current they are rated for.
I've been an electronic technician for over 12 years now.....
I haven't tried any mods as of yet so I don't have any "practical" info to base this on except just general techie rules of thumb.
The current rating is maximum expected working current within the AC/DC voltages given.
Too much current can cause the contacts to "weld" together.
Too much voltage and it may arc across the contacts, enough voltage and the arc would be constant across the contacts until something broke, melted, fried or what have you.
DC carries a higher chance of switch failure than AC.
The DC is always "on", AC is switching "on" and "off" about 50-60 times a second. So if it started to arc across terminals that switching on and off action of the AC gives it more of a chance to break the arc.
Also, assuming the main load in the atomizer is a coil it might be more of an inductive load, which wants a constant current supply. So an over current condition might be more probable.
Of course there is practice vs. theory, so if people are using 500ma switches at around 3-5 volts with success, right on!
Using a lower voltage vs. more current than rated, along with the fact that it is only on for 3-7 seconds at a time, it is just might be OK.
There is always a chance for it to fail, but that chance is always there no matter what.
Oh well, don't know if that makes any sense, it's way late and I babble.
I believe if it works and it's practical, people are already having success with it.......why the hell not!