Products Description
These HVDC Copper Automatic Version Injection Molding Components are more than just a plastic support; it's a cutting-edge product of "Insert Molding" technology.
High Voltage Integrity: Designed for 400V to 1000V+ high-voltage DC environments, it ensures extremely high creepage distances and clearances during high-voltage switching.
Structural Integration: Integrating the conductive copper core, arc-extinguishing chamber support structure, and external mounting interfaces into a single injection-molded part significantly reduces the number of components required for downstream assembly.
Environmental Resistance: Maintaining structural and insulation stability even under extreme temperature variations, mechanical vibration, and coolant corrosion.
Material Advantages: A Dual Performance Showdown
Conductive Core: Utilizes high-purity oxygen-free copper (C1100), boasting superior electrical and thermal conductivity, reducing self-heating during contactor operation.
Insulating Housing: Employs fiber-reinforced polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT), exhibiting excellent flame retardancy (UL94-V0), extremely high heat distortion temperature, and superior chemical corrosion resistance for EV Relay bracket Pure Iron.
Product Nature and Characteristics: An Engineering Paradigm of Composite Functionalism
| Integrated Conductive-Insulating Architecture | The Electrical Pure Iron Stamping for EV DC Contactor internally embeds a precision-stamped copper conductive busbar, externally encapsulated in a layer of high-performance engineering plastic through high-temperature, high-pressure injection molding. This structure achieves low-impedance current transmission and high-dielectric isolation of the housing within the same component, eliminating the risk of insufficient creepage distance due to gaps in traditional assembly methods. It is the core functional carrier within a high-voltage DC contactor. |
| Sealed Base of the Arc-Extinguishing Chamber | As the core support of the contactor, this component often constitutes the physical boundary of the arc-extinguishing chamber. Its characteristics include extremely high airtightness and dimensional stability. In vacuum or gas-filled (such as hydrogen) environments, this component must maintain micron-level deformation control to prevent gas leakage that would reduce arc-extinguishing capability. This endows the product with "sealed container" properties beyond ordinary structural components. |
| Full-Process Automation Features | "Automatic Version" not only represents automated production processes, but also signifies the automated adaptability of product design. Automatic copper core feeding, adaptive adjustment of injection molding parameters, and automatic removal and inspection of finished products ensure a high degree of consistency in the copper core position and plastic overlay thickness of each Iron bracket for EV DC Relay during mass production, eliminating quality fluctuations caused by human factors. |
Application Advantages: Empowering the Core Three-Electric Systems of New Energy Vehicles
1. New Energy Vehicle PDU/BDU Assemblies
As core HVDC Relay skeleton Pure Irons of the contactors in high-voltage power distribution units (PDUs) and battery disconnection units (BDUs), our components, with their high reliability, ensure safe disconnection and overload protection of the battery pack during charging and discharging, acting as a safety guardian for the electric vehicle's power battery system.
2. High-Voltage Fast Charging Systems
With the widespread adoption of 800V high-voltage platforms, the requirements for insulation performance are increasing exponentially. Our products are specifically developed for high-voltage platforms, possessing excellent withstand voltage margins and anti-interference capabilities, perfectly adapting to the high-voltage control circuits of DC fast charging piles and on-board chargers.
3. Commercial Vehicles and Construction Machinery
In scenarios involving severe vibration and harsh environments, such as electric heavy trucks and excavators, our vibration-resistant design and weather-resistant materials offer significant advantages. The integrated structure eliminates the risk of fastener loosening, ensuring the uptime and operational safety of commercial vehicle fleets.
contact us
For high-voltage direct current (HVDC) systems, the value of components lies not only in unit price or material cost, but also in long-term stability, batch consistency, and engineering adaptability. Our HVDC copper-core automated injection molding component solution focuses on engineering collaboration, structural reliability, and controllable manufacturing.
For complete technical support and application solutions, please visit our inquiry page. We will leverage our engineering capabilities and system matching experience to provide more reliable technical assurance for your project.
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