New Energy HVDC Parts
Product Structure Overview
Metallized Ceramic Body
Metallized ceramic is the core insulation and sealing component of HVDC contactors. It is made of high-purity alumina (Al₂O₃ ≥ 96%) ceramic material through vacuum sintering and metallized sealing brazing technology.
Features and Advantages:
Excellent airtightness (<1×10⁻⁹ Pa·m³/s);
High voltage rating of 5-10 kV DC;
High mechanical strength and strong thermal shock resistance;
Suitable for high vacuum sealing and gas-insulated environments.
Manufacturing Capabilities:
Ceramic body accuracy of up to ±0.02 mm;
Firm adhesion of the metallization layer (Mo/Mn, Ni);
Each product undergoes helium mass spectrometry leak testing.
Moving Assembly
The moving assembly is the core conductive mechanism that enables the on/off operation of the contactor. It consists of a copper conductive rod, a moving contact, a spring system, and guide components.
Structure:
Highly conductive copper rod (Red Copper / CuCr);
Silver alloy movable contact (AgSnO₂, AgSnO₂In₂O₃, and other silver alloys);
Precision positioning of the insulating guide sleeve and spring mechanism.
Product Features:
Sensitive action, strong rebound force, and long fatigue life;
Low contact welding temperature rise, mechanical life of over 100,000 cycles;
Ensures stable conduction of high currents (100A-600A);
Customizable structure and stroke parameters are supported.
Exhaust Vent Component
This component regulates pressure and exhausts gases within the contactor, ensuring safety and stability of the sealed chamber under high-voltage switching conditions.
Functions and Benefits:
Precisely controls the exhaust rate to prevent chamber rupture;
An optional fireproof metal filter structure to prevent arc splashing.
Used with corrosion-resistant stainless steel or nickel-copper alloy;
Suitable for vacuum welding or threaded assembly.
Manufacturing and Testing:
Vent hole diameter tolerance controlled within ±0.03mm;
Vacuum leak test pass rate reaches 100%.
Each batch of products undergoes airtightness and pressure cycle testing.
Yoke Iron
The yoke iron is a key core component in the drive magnetic circuit, forming the electromagnetic circuit and improving the contactor pull-in efficiency.
Structure and Materials:
Using high-permeability cold-rolled silicon steel sheets or pure iron (Fe ≥ 99.9%);
Precision stamping, with rust-proof phosphating or nickel-plating treatment on the surface;
Can be combined with coil assemblies to form a complete electromagnetic system.
Advantages:
High magnetic saturation point and fast response speed;
Reduced electromagnetic loss and heat buildup;
Ensuring the contactor pull-in force and stability.
Materials and Manufacturing Process Details
To ensure reliable insulation and conductivity in high-voltage and high-current environments, XIAMEN APOLLO employs tailored material systems and process controls for different components. The following describes the material configuration and technical characteristics of each component in order of product structure.
1. Metallized Ceramic Body
Material Composition:
High-purity alumina ceramic (Al₂O₃ ≥ 96%) is used as the main insulation structure, and the metallization layer uses a Mo/Mn or Ni system. Through vacuum sintering, metallization, and brazing sealing, a highly airtight and high-voltage insulation barrier is formed.
Manufacturing Process:
The ceramic body is precision-formed and sintered at high temperatures (>1600°C).
The metallization layer (Mo/Mn, Ni) adheres securely and can be plated with silver, nickel, or gold.
Vacuum brazing is used to bond the metal housing for a hermetic seal.
Helium mass spectrometry leak detection yields a 100% pass rate, with a leak rate of <1×10⁻⁹ Pa·m³/s.
Technical Features:
High dielectric strength of 5–10 kV DC;
Strong thermal shock resistance and reliable insulation;
Precision tolerance ≤ ±0.02 mm;
Compatible with various packaging structures (cylindrical, cubic, and special-shaped).
Applications:
Used in EV main contactors, high-voltage relays, energy storage system disconnect units, etc., ensuring system insulation and vacuum sealing reliability.
2. Moving Assembly
Structural Structure:
Composed of a conductive copper rod, a silver alloy moving contact, an insulating guide sleeve, and a spring return system, it is the core mechanism for the contactor's on-off operation.
Material Configuration:
Conductive parts: High-purity red copper or CuCr alloy;
Moving contacts: Silver-based alloys such as AgSnO₂, AgSnO₂In₂O₃, and AgNi;
Insulation support: High-strength PPS and PI engineering plastics;
Spring system: Stainless steel or phosphor bronze for long fatigue life.
Manufacturing Process:
Precision CNC machining and surface silver/nickel plating;
Contacts are resistance-welded or electron-beam-welded (EBW);
On-resistance and mechanical travel are fully inspected.
Technical Features:
Sensitive action and minimal contact bounce;
Excellent conductivity, supporting high current operation from 100A to 600A;
Low contact temperature rise, minimising the risk of welding;
Mechanical lifespan ≥ 100,000 cycles.
3. Exhaust Vent Component
Function:
This component is used for exhausting and pressure regulation within the high-pressure chamber, ensuring internal gas balance and structural safety during switching.
Material and Structure:
Main body material: Corrosion-resistant stainless steel or Ni-Cu alloy;
Optional fireproof filter or porous air diffuser structure;
Sealing connection: Vacuum welding/threaded fastening
Manufacturing and Testing:
Exhaust aperture accuracy controlled to ±0.03 mm;
Vacuum leak and pressure cycle testing performed.
Each component undergoes airtightness testing.
Performance Advantages:
Precisely controlled exhaust rate prevents chamber rupture.
Anti-arc splash design enhances operational safety.
Heat-resistant and corrosion-resistant, ensuring long-term stability.
4. Yoke Iron
Structure and Materials:
High-permeability electrical pure iron or cold-rolled silicon steel sheet (Fe ≥ 99.9%), precision stamped and formed, forms the electromagnetic circuit and enhances pull-in efficiency.
Manufacturing Process:
Multi-layer lamination stamping or integral cutting;
Surface Treatment: Rust-resistant phosphating, nickel plating, or anti-oxidation coating;
Mechanical tolerance ≤ ±0.03 mm, excellent parallelism.
Technical Features:
High magnetic saturation point, fast response speed;
Low electromagnetic loss, stable pull-in force;
Highly precise matching with the moving iron core assembly ensures synchronised operation.
General Parameters and Delivery Capabilities
| Project | Technical Description |
| Layer Material | Pure Silver (99.99%), AgNi, AgSnO₂, AgCu, WCu, NiCu |
| Base Material | Red Copper, Oxygen-free Copper, Cold Rolled Steel |
| Ceramic Material | 96% Al₂O₃ Metallized Ceramic |
| Surface Plating | Silver, Nickel, Gold Plating (Optional) |
| OEM/ODM | Customization Accepted |
| Free Samples | 10–50 pcs |
| Lead Time | 5–7 days for samples, 10–15 days for orders |
| Production Capacity | 2,000,000 pcs/month |
| Quality Standards | ISO9000, IATF16949, RoHS, REACH |
| Applications | EV Relay, HVDC Contactor, ESS, Photovoltaic DC Switchgear |
Manufacturing and Quality Assurance
XIAMEN APOLLO We have independently developed metallized ceramic sealing production lines, precision stamping and CNC workshops, a silver contact welding center, and a high-voltage insulation testing laboratory.
Our production processes strictly adhere to ISO9000 and IATF16949 quality management systems, ensuring that every component meets the high reliability standards of new energy contactors.
Testing procedures include:
Helium mass spectrometry leak testing;
Metal-ceramic bond strength testing;
Conductivity and temperature rise testing;
Arc erosion and mechanical life testing;
Vacuum sealing and insulation strength verification.
All products shipped are uniquely serialized and come with a traceability report.
Typical Applications
New Energy Vehicle High-Voltage DC Contactor (EV/HVDC Contactor)
Energy Storage System (ESS) Disconnect and Control Unit
Photovoltaic Inverter and DC Combiner Box
Industrial DC Power Switching Device
Charging Pile High-Voltage Relay Module
Custom Engineering and Technical Support
XIAMEN APOLLO's engineering team provides complete OEM/ODM technical support:
Ceramic structure and metallization layer design;
Moving contact mechanism motion simulation and life analysis;
High-voltage insulation structure optimization;
Low gas leakage and thermal fatigue resistance design.
From prototype development to mass production, we ensure performance consistency and delivery reliability, helping customers shorten R&D cycles and reduce total costs.
Reasons to Choose XIAMEN APOLLO
Over 30 years of experience in manufacturing electrical metal and ceramic parts.
Full-process in-house production: ceramics → metallization → welding → finishing → testing.
Specialized in the development of core components for new energy HVDC systems.
Monthly production capacity exceeding 2 million units, with flexible delivery.
Free samples, fast prototyping, and customization services are available.
Conclusion
The New Energy HVDC Part series utilizes metallized ceramic insulation technology, a highly conductive copper alloy structure, and high-precision assembly processes to provide high-voltage, high-insulation, and highly reliable current control and safety protection solutions for new energy systems.
XIAMEN APOLLO (Xiamen Apollo Electronics) adheres to its engineering expertise and manufacturing strength to provide reliable core components for new energy high-voltage contactors to customers worldwide.
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