Products Description
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Our Pure Iron Cores for EV Relay and Stamping Core are designed to meet the extreme demands of new energy vehicles, featuring:
Material Purity: 99.9% pure iron (ASTM A484 compliant) ensures high magnetic permeability (μi ≥3,000 H/m) and low coercivity (Hc ≤150 A/m), minimizing energy loss in high-frequency switching.
Cold Heading Excellence: The proprietary cold heading process forms complex geometries (e.g., flat, U-shaped, L-shaped cores) with dimensional accuracy ±0.02mm, eliminating post-machining for cost efficiency.
Stamping Precision: Laser-cut stamping for thin-section cores (0.5-3mm thickness) with burr-free edges, ideal for compact relay designs in 800V+ high-voltage systems.
Key Advantages
1. Cold Heading Technology for EV Demands
High-Strength Forming: Cold heading enhances material density (99.9% compactness), increasing core strength by 20% compared to hot-formed alternatives-critical for vibration resistance (20g acceleration) in EV powertrains.
Precision Without Waste: Net-shape forming reduces material waste to <5%, achieving cost savings of 15% vs. traditional machining methods while maintaining magnetic consistency batch-to-batch.
Rapid Prototyping: Custom cold heading dies for Relay Core Cold Heading can be developed in 7 days, ideal for EV OEMs requiring fast iteration for new relay designs.
2. Magnetic Performance & Compliance
| Feature | Technical Advantage | EV Benefit |
| Low Hysteresis Loss | Iron loss ≤0.8W/kg at 1kHz/1.5T | Extends battery range by minimizing relay energy consumption |
| High Saturation Flux | Bs ≥2.1T for compact core designs | Enables smaller, lighter relays for space-constrained BMS modules |
| RoHS-Compliant Surface | Electroless nickel plating (5μm, lead-free) | 500+ hours of salt spray resistance for battery tray environments |
3. Factory-Direct Solutions for New Energy
Cost Efficiency: Factory price is 25% lower than distributors, with bulk pricing starting at $0.45/pcs for 10,000+ Stamping Cores for New Energy Relay units.
Certifications: Full compliance with IATF 16949 (automotive quality), RoHS 2.0, and REACH-essential for global supply chains.
Scalable Production: 50,000pcs/month cold heading capacity, with a 3-day lead time for standard cores (100x50x1mm) and 10a -day turnaround for custom geometries.
Applications in EV Systems
High-Voltage Relay Cores
Battery Management Systems (BMS): Used in battery disconnect relays, enabling fast response times (≤10ms) for overcurrent protection in 400V-1,000V systems.
On-Board Chargers (OBC): Low-loss cores optimize energy transfer during AC-DC conversion, supporting 22kW+ charging rates.
Motor Control & Safety Relays
Electric Motor Controllers: High-strength Relay Iron Core withstands 150°C motor temperatures, ensuring stable magnetic coupling for torque control.
Safety Interlock Relays: Cold-headed cores, providing reliable switching in emergency power-off scenarios.
Charging Infrastructure
DC Fast Chargers (50kW-350kW): Stamping cores reduce electromagnetic interference (EMI) in connectors, ensuring stable communication during ultra-fast charging.
Factory Strengths: EV-Dedicated Manufacturing
1. Vertical Integration for Precision
In-House Cold Heading: 20+ cold heading machines with 10-100 ton force capacity, capable of forming complex Stamping Core for New Energy Relay geometries (e.g., stepped sections for multi-pole relays).
Magnetic Testing Lab: Automated B-H curve analyzers verify core performance, with 100% batch testing for EV-critical parameters (saturation flux, coercivity).
2. Customization for New Energy Innovations
Geometry Options:
- Flat cores for compact relays (30% smaller than conventional designs).
- Embossed cores for improved adhesive bonding in sealed relay housings.
Surface Treatments:
- Zinc-nickel plating (8μm) for marine-grade corrosion resistance in offshore EV charging stations.
- Thermal oxide coating for 2x better insulation in high-humidity battery compartments.
3. Rigorous Quality Assurance
5-Tier Inspection for EV Use:
1. Material Purity: XRF screening to ensure iron content and <0.1% total impurities (C/Si/Mn).
2. Dimensional Accuracy: CMM scanning for flatness (≤0.01mm deviation) and hole positioning (±0.02mm).
3. Magnetic Consistency: Random batch testing of B-H curves to ensure μi variation <5% across production runs.
4. Environmental Stability: 1,000-hour salt spray and vibration (20g, 10-2000Hz) to simulate real-world EV conditions.
5. RoHS Compliance: Full traceability of raw materials to conflict-free sources.
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