New Energy Contactor Part
With the development of new energy vehicles and photovoltaic energy storage, the market demand for new energy high-voltage DC contactors, as core components of high-voltage and high-current systems, continues to expand. They have strict requirements on sealing, insulation, conductivity, and other properties in high-voltage DC environments, especially key processes such as "alumina metalized ceramics, vacuum brazing of copper exhaust holes, and laser welding of arc extinguishing chambers".
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Key process technologies
1. Ceramic metallization process
Process: high-purity powder molding → 1300℃ pre-sintering → molybdenum-manganese slurry sintering (1450℃) → nickel plating (3-5μm) → helium mass spectrometry leak detection.
Control: surface roughness Ra≤0.8μm, dimensional tolerance ±0.05mm.
2. Vacuum brazing process
Parameters: silver-based brazing material (Ag72Cu28), temperature 780-820℃, insulation 5-10min, vacuum degree ≤5×10⁻⁴Pa.
Pretreatment: copper degreasing/oxidation layer, post-weld shear strength ≥50MPa.
3. Laser welding process
Arc extinguishing chamber: continuous fiber laser (300-1000W), argon protection, melting depth＞1.5mm, weld without pores/splash.
Inspection: X-ray flaw detection + air tightness test to ensure reliable structure.
Process coordination and performance verification
1. Material matching
Ceramic (7.2×10⁻⁶/℃) and copper (17×10⁻⁶/℃) relieve thermal stress through the flexible brazing structure (wavy exhaust pipe), and withstand -40℃~+150℃ cycle.
2. Quality control
Full process traceability: material batch, process parameters (accuracy ±1%), and test data can be checked.
Strict testing:
Electrical: contact resistance ≤0.5mΩ, withstand voltage 5000V AC/1min;
Mechanical: 100,000 lifespans, vibration (20-2000Hz) without failure;
Environment: stable performance in salt spray (96h), and damp heat (500h).
3. Technical advantages
- Breaking capacity: 1500VDC/1000A, electrical life>100,000 times, failure rate<0.3‰, adapting to the high-reliability requirements of new energy vehicles/photovoltaic energy storage.
We're professional new energy contactor part manufacturers and suppliers in China, specialized in providing high quality customized service. We warmly welcome you to buy high-grade new energy contactor part from our factory.
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