I. Market Background: Under High Voltage & High Current, Temperature Rise Control Becomes a Core Challenge

As electric vehicles evolve toward 800V and higher voltage platforms, system power density continues to increase. Key components such as contactors face severe temperature rise challenges under sustained high-current conditions. The lack of temperature monitoring, invisible heat accumulation, and high maintenance costs have become industry pain points.

II. Vicvac’s Answer: Custom-Developed HV DC Contactor

Leveraging deep technical expertise, Vicvac has developed a high-performance high-voltage DC contactor customized for a globally leading German automotive electronics supplier. The product integrates an NTC temperature sensor, enabling real-time and accurate detection of internal temperature rise in the contactor. It provides critical data support for thermal management strategies, effectively prevents overheating faults, and enhances system safety and serviceability. The A-sample has been delivered and is currently undergoing testing in Germany. Mass production is expected to begin by the end of 2028, with an 8-year product lifecycle. For this project, Vicvac will invest in a new automated automotive production line, achieving full process self-sufficiency and control.

III. Key Features

l Smart Temperature Monitoring: Built-in NTC sensor provides real-time thermal status, preventing overheating failures.

l Extreme Interrupting Capability: Safely interrupts 2000A fault current (one-shot operation).

l Ultra-High Withstand: Withstands 1MA²s energy impact – no fire, no housing rupture.

l Long Life & High Reliability: 200,000 mechanical cycles, stable under vibration and shock.

l Safety Feedback: Mirror contact configuration for real-time main contact status.

l Excellent Insulation: 4300 VDC between HV and LV terminals; 2500 VDC open-contact; compliant with IEC 60664-1 & ISO 17409.

l Global Automotive Compliance: IATF 16949-certified, meets REACH, RoHS, ELV; UL94 V0 flammability rating.

IV. Outlook

This A-sample order validates Vicvac’s technical strength in high-interrupting capability, high reliability, and intelligent solutions, as well as its full-chain service capability from R&D to mass production. Vicvac will continue driving the intelligentization and integration of contactors, contributing to the safe development of EVs worldwide.