Stamped Soft Iron Bracket
Products Description
The Stamped Soft Iron Bracket is a key structural component in the electromagnetic drive system of high-voltage DC contactors in new energy applications, undertaking the triple functions of magnetic circuit closure, coil support, and mechanical positioning. This part is not a single, independent component, but rather works in conjunction with the coil frame, moving iron core, stationary iron core, and contact system to form a complete electromagnetic actuation circuit.
Main Product Features and Functions
Electromagnetic Conductivity Core Function
As the EV Relay Pure Iron Stamping Part, it constructs the contactor's closed magnetic circuit, concentrating the coil magnetic field, reducing magnetic reluctance loss, improving the contactor's opening and closing response speed, reducing the probability of arcing during high-voltage circuit switching, and optimizing the overall energy conversion efficiency of the new energy power system.
01
Structural Positioning and Load-Bearing Function
The EV HVDC Contactor Bracket adopts a U-shaped bent one-piece structure with pre-drilled standard mounting holes. It supports the coil assembly and the moving and stationary contact bases, fixing them inside the contactor's plastic housing. It withstands vehicle vibration and instantaneous impact stress in the DC circuit, maintaining the internal component assembly position without displacement.
02
Corrosion and Conductivity Protection
A copper base layer and nickel composite plating uniformly cover the surface of the Precision Stamped EV Relay Bracket substrate, isolating it from moisture and electrolyte corrosion. This also improves the conductivity of the contact surface, preventing overheating caused by increased contact resistance under long-term high-voltage conditions and stabilizing the thermal management of the entire high-voltage DC system.
03
System Electromagnetic Shielding Auxiliary Function
A continuous, electrical pure iron magnetic permeability structure absorbs stray magnetic fields generated by contactor switching, reducing electromagnetic radiation interference to the vehicle's BMS, energy storage main control board, and other weak current control systems, simplifying EMC rectification work during system integration.
04
Material Properties and Advantages
- Magnetic Properties: Extremely low coercivity, high saturation permeability, hysteresis loss far lower than ordinary cold-rolled steel, outputting greater electromagnetic attraction force under the same coil power, reducing contactor coil power consumption, and optimizing energy loss in new energy systems.
- Mechanical Properties: Excellent plasticity, suitable for high-precision bending and deep drawing, no springback deformation after stamping, ensuring strong dimensional stability of Precision Metal Stamping for EV Contactors under long-term vibration conditions.
- Impurity Control: Strict control of carbon, sulfur, and silicon impurity content to avoid impurities creating magnetic domain barriers and ensuring batch-to-batch consistency of magnetic properties.
- Advantages of Copper Underlayer: Fills the micropores on the surface of the EV Relay Pure Iron Stamping Part, improving the adhesion of the nickel layer and preventing plating peeling; the excellent conductivity of the copper layer reduces the contact resistance of the metal contact surface and reduces heat loss.
- Advantages of Nickel Surface Layer: In EV HVDC Contactors... A dense, passivated, and corrosion-resistant layer is formed on the bracket surface, resisting damp heat and salt spray corrosion, and isolating the substrate from air and electrolyte corrosion; the surface has a uniform metallic luster and does not chemically react with the internal insulation material of the contactor, making it suitable for the internal environment of the high-pressure sealed cavity.
Frequently Asked Questions
Does the Precision Stamped EV Relay Bracket support customized design?
Yes. Based on the contactor structural drawings or samples provided by the customer, we can perform magnetic circuit simulation analysis and optimize the yoke geometry, providing customized mold development services.
Can you provide material certification and testing reports for the Electric Vehicle Contactor Pure Iron Base?
We can provide raw material certificates, magnetic performance test reports, dimensional test reports, plating thickness test reports, and RoHS/REACH compliance declarations.
Does the Stamped Pure Iron Bracket for Contactor support other surface treatment processes?
In addition to copper base plating + nickel plating, zinc plating is also available, depending on the customer's contactor operating environment and welding requirements.
What packaging method is used for High Precision Pure Iron Stamping for EV Parts, and is it suitable for long-distance cross-border transportation?
It uses anti-static and moisture-proof double-layer packaging. Products from the same batch are packed in a rigid, moisture-proof cardboard box with an inner cushioning layer to prevent damage and surface scratches. The outer box is labeled with the model number, batch number, and quantity for easy product traceability. This packaging solution is suitable for global cross-border logistics needs such as sea and air freight.
contact us
If you are looking for highly compatible, long-life metal structural component solutions for new energy HVDC contactors, or need to evaluate the customized production of all-metal relay parts, please contact our engineering team via email or email. We will provide DFM analysis and Stamped Soft Iron Bracket sample support based on your system parameters (voltage, current, life requirements, etc.).
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