Products Description
The Flat Iron Core for Automotive Relays is a sheet- or plate-like soft magnetic component specifically designed for compact, high-power-density automotive relays. Fabricated from thin sheets of high-permeability, low-loss silicon steel or specialized soft magnetic alloys-processed through precision stamping, heat treatment, and insulating lamination-its core function is to provide a flattened magnetic flux path characterized by low magnetic reluctance and high saturation magnetic induction. As such, it serves as a critical core component for achieving the miniaturization, lightweighting, high reliability, and high-efficiency electromagnetic actuation required in automotive electromagnetic actuators, such as the high-voltage DC relays used in new energy vehicles.
Product Characteristics
Flat, Low-Profile Design
The compact, flat geometry of Precision Stamping EV Relay Core is specifically engineered to meet the stringent spatial constraints and lightweighting requirements of New Energy Vehicles (NEVs), effectively minimizing the overall height of the electromagnetic assembly.
Isotropic Magnetic Flux Density Distribution
The base material of Pure Iron Flat Core for EV Relay undergoes high-pressure densification and metallographic reconstruction to ensure highly consistent transmission efficiency of magnetic flux lines across both the lateral and longitudinal axes of the flat surface, thereby preventing localized magnetic saturation.
Exceptional Surface Flatness
The Stamped and Formed Relay Core contact face interfacing with the armature is subjected to micron-level precision grinding; this process virtually eliminates the air gap, enabling the achievement of exceptionally high static holding force even at low excitation currents.
Production Process
Stamping and Initial Inspection: Using a high-speed press equipped with progressive dies, iron laminations-incorporating all functional features-are stamped out. These laminations undergo a 100% initial inspection for dimensions and visual appearance using an optical sorting machine to screen out parts with excessive burrs or Deformed High-Voltage EV Relay Flat Core Stamping Part.
Annealing and Purification: The Stamped Flat Pure Iron Core for EV Relay are placed into a bell-type hydrogen annealing furnace or a vacuum furnace and subjected to prolonged annealing at temperatures exceeding 800°C. This process serves to relieve internal stress, remove impurities such as carbon and sulfur, promote grain growth, and restore high magnetic permeability. This constitutes the critical step that determines the final magnetic properties.
Insulation Coating: A uniform insulating film is applied to the surface of the Precision Stamping EV Relay Core via roller coating or spray coating, followed by high-temperature curing.
Stacking and Curing: The insulated Pure Iron Flat Core for EV Relay is stacked in the specific sequence and quantity prescribed by the design. They are then secured using methods such as self-riveting, laser spot welding, or adhesive bonding, and may undergo hot-press molding to set their shape and cure, thereby forming a cohesive core assembly.
Stabilization Treatment: The laminated Stamped and Formed Relay Core undergoes a low-temperature annealing process (e.g., at 300–400°C) to relieve internal stresses generated during the stacking and curing stages, thereby stabilizing both the magnetic properties and the dimensional integrity of the component.
Product Customization Process
1. What material grades are available for the High Voltage EV Relay Flat Core Stamping Part?
We offer grades of electrical steel and soft magnetic alloys such as 35W270, 50WW270, DT4C, and 50W470.
2. What level of insulation performance is achieved for Precision Stamping EV Relay Core?
The interlayer insulation resistance is ≥ 500 MΩ, and the high-voltage withstand capability is ≥ 3 kV, thereby meeting the requirements for high-voltage automotive applications.
3. Is the Pure Iron Flat Core for EV Relay more susceptible to magnetic saturation compared to traditional iron cores?
No. By precisely calculating the cross-sectional area and magnetic path length-and by utilizing high-quality soft iron materials with high saturation magnetic induction-we ensure that the core maintains ample saturation margin within its rated operating range.
contact us
If you are seeking a Flat Iron Core solution for automotive relays that optimizes both size and energy efficiency, we invite you to contact our technical team for customized selection support and detailed specifications.
Hot Tags: flat iron core for automotive relay, China flat iron core for automotive relay manufacturers, suppliers, factory
