Ceramic Tube For New Energy Fuse
Products Description
Our Ceramic tube for new energy fuses is primarily used in the following product structures:
EV Fuse Ceramic Body (New Energy Vehicle Fuse Ceramic Body)
HV DC Fuse Ceramic Tube (High Voltage DC Fuse Ceramic Tube)
PV Fuse Ceramic Housing (Photovoltaic Fuse Ceramic Housing)
Energy Storage Fuse Ceramic Tube (Energy Storage Fuse Ceramic Tube)
Cylindrical Fuse Ceramic Body (Cylindrical Fuse Ceramic Body)
Arc-extinguishing Ceramic Tube (Arc-extinguishing Ceramic Tube)
High Voltage Fuse Insulation Ceramic (High Voltage Fuse Insulation Ceramic Component)
Our products support various sizes, wall thicknesses, structural forms, and customized development, adaptable to different new energy fuse solutions and international standard requirements.
Design Advantages: Decoupling Mechanical Stress and Electrical Geometry
| Flexible Stress-Distributed Wall Thickness Design | Utilizing finite element method (FEA) simulations, we have meticulously modeled the internal gas expansion pressure experienced by the Ceramic Body for Electric Vehicle Auxiliary Fuse at the moment of fusion. The tube wall thickness employs a gradual or optimized distribution design, eliminating stress concentration points at corners or edges, a common feature in traditional ceramic tubes. This achieves ultra-high fracture toughness while maintaining overall lightweight and compactness. |
| Precision Metallization and Sealing Interface Design | To meet the high-reliability assembly requirements of the fuse's copper end caps (e.g., roll fastening, riveting, or brazing), the ceramic tube ends can be provided with highly customized geometric steps, knurled grooves, or micron-level surface metallization layers (e.g., Mo-Mn coating followed by nickel plating). The sealing interface features extremely high dimensional tolerance control (outer diameter and roundness tolerances controlled at the micron level), ensuring a tight fit with the metal end cap and achieving long-lasting airtightness and extremely high pull-out resistance. |
| Inner Wall Anti-Adhesion and Flow Channel Optimization | The inner wall of the ceramic tube can be designed with a smooth surface or a micro-textured surface according to the customer's filling process. A smooth inner wall facilitates the uniform filling of arc-extinguishing media such as quartz sand, avoiding void defects; while the specially designed micro-texture increases the resistance of arc creepage along the surface during high-current interruption, further shortening the arc extinguishing time. |
Manufacturing Process: From Nanoscale Powder to Precise Macroscopic Dimensions
Consistency is the lifeline of high-voltage DC safety devices. We employ rigorous process discipline to ensure a high degree of uniformity in the microstructure and macroscopic dimensions of every ceramic tube:
High-Shear Homogeneous Slurry Casting: Unlike traditional dry pressing processes that can lead to density gradients, we utilize high-shear homogeneous slurry casting technology for complex, irregularly shaped tubes. The slurry achieves isostatic solidification in the mold, ensuring absolute consistency in volume density from the inner wall to the outer wall and from the end to the middle section of the ceramic tube, eliminating sintering stress and the source of microcracks.
Precise Temperature Control Sintering over a Wide Temperature Range: High-temperature sintering is performed in a full-length tunnel kiln, with the furnace temperature profile optimized through finite element thermodynamic simulation. Precise temperature control of ±1℃ is implemented in key temperature zones such as debinding, phase transformation, and densification, ensuring complete corundum crystal development and tight grain boundary bonding, reducing apparent porosity to the limit, and creating a truly dense insulating framework.
Diamond Precision Grinding and Polishing: After sintering, the Ceramic Body for High Speed Fuses enters a high-precision machining process. Diamond grinding wheels are used for end face grinding and inner and outer diameter precision grinding to ensure that the flatness and perpendicularity of the pipe end meet the stringent requirements of the fuse sealing assembly, while eliminating surface micro-defects caused by sintering and improving surface flashover voltage.
Application Advantages: Covering All New Energy Scenarios
New Energy Vehicles
DC fast charging modules for charging piles, on-board high-voltage distribution units (PDUs), and main circuit protection for battery packs. Platforms from 400V to 800V require a ceramic body for EV Fuses to provide reliable insulation and arc suppression.
Photovoltaic Power Generation Systems
DC combiner boxes, inverter input side, and string protection. 1500V high-voltage photovoltaic systems place extremely high demands on the voltage withstand and arc resistance of fuse tubes. Our ceramic tubes maintain sufficient insulation strength at 1500V and do not crack during full-range DC interruption.
Energy Storage Systems
Battery cluster protection, PCS DC-side protection, and power distribution circuits for energy storage containers. Energy storage systems are often deployed in outdoor or semi-outdoor environments, requiring even higher weather resistance and mechanical strength from the Ceramic Tube for EV BS Series.
Rail transit and industrial power supplies
auxiliary circuits for train traction systems, large frequency converters, and data center UPS. These applications require ceramic tubes to maintain structural integrity under high-frequency vibration and a wide temperature range.
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We not only provide standardized Ceramic Tube for EV DC Fuse, but also offer integrated engineering support solutions based on customers' fuse structures, breaking requirements, and new energy application environments. These solutions range from material development and structural optimization to mass production, helping projects achieve more stable and reliable mass production.
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