Precision Metallized Ceramics
Products Description
Precision Metallized Ceramics are not merely structural components, but functional parts that deeply integrate electrical, materials, and structural engineering.
In HVDC contactors, their main value lies in:
Constructing reliable insulation boundaries in high-voltage DC systems
Achieving stable, solderable, and encapsulated connections between ceramics and metals
Maintaining dimensional stability and structural integrity under complex operating conditions
Supporting reliable operation under long-term high-frequency operation and thermal cycling environments
This product is particularly suitable for scenarios with extremely high safety and consistency requirements, such as high-voltage systems in new energy vehicles, DC circuits in energy storage systems, and DC power distribution and power control modules.
Core Attributes and Technical Features
| Metal-Ceramic Metallographic Bonding Characteristics | An active metallization process achieves a metallurgical-grade bond between the metal layer and the ceramic substrate, resulting in high bonding strength with no risk of peeling or detachment. It can withstand the mechanical vibration and thermal shock generated by the frequent switching of the high-voltage DC contactor. The metallized layer thickness is uniform and controllable, with stable conductivity, effectively carrying large current transmissions, while simultaneously working with the ceramic substrate to achieve reliable high-voltage insulation. |
| High-Voltage Insulation Core Characteristics | Using high-purity alumina and beryllium oxide insulating ceramics as the substrate, it possesses excellent electrical insulation performance and high breakdown voltage, easily adapting to HVDC high-voltage DC operating conditions from hundreds to thousands of volts, effectively preventing short-circuit faults caused by high-voltage arc breakdown. The ceramic substrate boasts stable insulation resistance, exhibiting no performance degradation even in high-temperature and humid environments, ensuring the reliability of high-voltage system insulation. |
| Arc and High-Temperature Resistance | The ceramic substrate possesses excellent high-temperature resistance, capable of withstanding temperatures exceeding 1500℃ generated during arc extinction without softening or cracking. The metallization layer utilizes a special metal formula resistant to high temperatures and arc erosion, effectively resisting arc erosion, preventing metal layer melting or evaporation, and extending the service life of the contactor's arc-extinguishing chamber. |
| Structural and Sealing Adaptability | Full-specification customization is supported. The external dimensions, metallization layer distribution, mounting hole positions, and sealing groove structure can be customized according to the structural requirements of different high-voltage DC contactor models. The product exhibits high flatness and perpendicularity precision, adapting to the vacuum sealing requirements of the contactor housing, ensuring the sealing performance of the arc-extinguishing chamber, and preventing moisture and dust from entering and affecting the arc-extinguishing effect. |
Core Processes: High-Temperature Activated Metallization and Precision Atmosphere Sintering
Exquisite Treatment of Ceramic Substrates
We select alumina ceramics with 95% to 99.7% high purity and fine grains. Before metallization, the ceramic surface undergoes rigorous cleaning and ultrasonic treatment to ensure it is free of contamination, providing a clean "stage" for subsequent chemical reactions.
Precision Coating of Metallization Paste
Our independently developed metallization paste has a closely guarded formula. It consists of high-purity metal powders (molybdenum, manganese) and activators (such as silicon, aluminum, etc.) mixed in precise proportions and uniformly coated onto designated areas of the ceramic with micron-level precision using screen printing or dispensing processes.
Precision Atmosphere Sintering
This is the "heart" of the manufacturing process. The coated ceramic parts are placed under a precisely controlled hydrogen or reducing atmosphere during the sintering process, which lasts for several hours. At temperatures reaching 1500°C, the activator reacts with the ceramic surface to generate a new compound transition phase, simultaneously "welding" the metal powder particles together and fusing them into the ceramic matrix.
Electroplating and 100% Non-Destructive Testing
After sintering, the metallized layer surface is electroplated with nickel/gold to enhance solderability and oxidation resistance. Finally, each product undergoes rigorous testing, including bond strength testing, pull-out force testing, airtightness testing, and microstructural analysis under a high-powered microscope, ensuring 100% compliance.
Application Advantages: Demonstrating its "Foundation Stone" Nature in Critical Scenarios of the Power System
New Energy Vehicle HVDC Contactor
As a critical sealed electrode within the vacuum switch tube, it bears the responsibility for switching the main circuit. metallized ceramic components directly determines the safety of the vehicle's high-voltage system and is one of the last lines of defense against battery thermal runaway.
Photovoltaic/Energy Storage HVDC Contactor
In high-voltage, high-current DC bus systems, it ensures safe switching and maintenance isolation. Its long lifespan and high reliability are key to reducing system operation and maintenance costs and improving power generation availability.
Other High-Voltage Power Electronic Equipment
Such as high-voltage relays, vacuum circuit breakers, and insulating substrates for power modules, these components excel in any application requiring a permanent and reliable interface between insulation and conductivity.
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