Overview of ceramic fuse industry knowledge

 

The ceramic fuse body refers to the core ceramic component that constitutes the ceramic fuse shell and internal structural support. It is usually made of high-purity alumina or talc porcelain and sintered at high temperature. This component has multiple functions: containing the melt and arc-extinguishing medium, providing electrical insulation isolation, withstanding arc high-temperature impact, and ensuring the mechanical integrity of the fuse. In the energy storage system, the Energy Storage Fuse Ceramic Body is the ceramic body of the energy storage fuse, which is specially used for the DC side protection of the battery energy storage system. Its design must fully consider the thermal cycle stress caused by frequent charging and discharging of the energy storage system and the special extinguishing requirements of the DC arc. Different from ordinary fuse ceramic bodies, energy storage applications set higher standards for the thermal shock resistance and long-term insulation stability of the ceramic body. Photovoltaic Energy Storage Fuse Ceramic Body is a photovoltaic energy storage fuse ceramic body. It is a subcategory developed with the popularization of photovoltaic and storage-integrated systems. It needs to take into account the high-voltage DC characteristics of the photovoltaic side and the frequent load fluctuation characteristics of the energy storage side. PV Energy Storage Fuse Ceramic Body is a key protective component of the photovoltaic energy storage system. Its inner cavity shape, wall thickness distribution and surface finish directly affect the filling effect of the arc extinguishing medium and the constraint ability of the arc.

 

In addition, Ceramic Bodies for Bussmann Series Photovoltaic Fuses represent the industry's highest standards for ceramic material purity, sintering density and dimensional accuracy. Ceramic Body for High Speed ​​Fuses is a ceramic body for high-speed fuses. Its core feature is extremely fast response speed. It is usually used to protect sensitive power electronic devices and requires precise control of the thermal capacity and thermal conductivity characteristics of the ceramic body. Ceramic Bodies for Energy Storage Fuse is a general term for the ceramic body of energy storage fuses, covering multiple application levels from battery cluster protection to battery pack protection. Steatite Ceramic Body for EV Fuse is a steatite ceramic body for electric vehicle fuses. It is a typical solution that balances cost and performance and is suitable for cost-sensitive automotive application scenarios. Ceramic Tube for Energy Storage Fuse is a ceramic tube for energy storage fuses. It is usually designed with a circular or square cross-section. Its wall thickness uniformity and straightness are the keys to ensuring that the melt is centered and assembled. Ceramic Body for Automotive Fuses is the ceramic body of automotive fuses, which must simultaneously meet vehicle environmental requirements such as vibration resistance, temperature cycling, and salt spray corrosion.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The main materials used to manufacture ceramic fuse bodies include alumina ceramics and talc porcelain. In addition, aluminum nitride or beryllium oxide ceramics are also used in certain high-demand applications. Alumina ceramics use high-purity alumina (Al₂O₃) as the main component. According to the different alumina content, it is divided into different grades such as 95 porcelain, 97 porcelain and 99 porcelain. The higher the alumina content, the volume resistivity, mechanical strength and thermal conductivity of the material will also increase, but the manufacturing cost and production difficulty will also increase accordingly. For products such as Energy Storage Fuse Ceramic Body and Photovoltaic Energy Storage Fuse Ceramic Body used in high-voltage DC scenarios, 95% or 99% alumina ceramics are usually used. The volume resistivity of high-purity alumina can reach 10¹⁴-10¹⁵Ω·cm, and the flexural strength exceeds 300MPa. It can maintain structural integrity without bursting at high temperatures (up to thousands of degrees Celsius) generated by DC arcs. Talc porcelain uses talc (hydrated magnesium silicate), clay and feldspar as its main raw materials. Its biggest advantages are good processability and moderate dielectric constant. At the same time, the sintering temperature is low (about 1250-1350°C), and the cost is significantly lower than that of high-purity alumina ceramics. Steatite Ceramic Body for EV Fuse is a typical representative of talc ceramic applications.

 

It has a high cost performance in cost-sensitive automotive applications. It is especially suitable for high-voltage auxiliary circuit protection and low-voltage circuit protection of electric vehicles with a rated voltage not exceeding 800V. Ceramic Body for Automotive Fuses Depending on the application scenario, either alumina ceramics (for high-voltage main circuit protection) or talc porcelain (for low-voltage auxiliary circuit protection) can be used. For products such as Ceramic Body for High Speed ​​Fuses that have special requirements for thermal conductivity, aluminum nitride ceramics are the preferred solution due to their high thermal conductivity (up to 170W/(m·K)), which can quickly conduct the heat generated when the melt melts away, helping to shorten the arc duration. In terms of material supply status, the powder used to manufacture the ceramic body must undergo strict particle size control and purity testing. The volume density of the ceramic body should reach more than 95% of the theoretical density to ensure the electrical strength and mechanical reliability of the product.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The manufacturing process of the ceramic fuse body is a technical system involving multiple precision control links. The typical process flow is as follows: Step 1: Preparation of raw materials – Weigh alumina or talc, clay, feldspar and other raw materials according to the formula and add them to the ball mill. At the same time, add water, dispersant and binder for wet grinding. Grinding fineness directly affects subsequent molding and sintering quality, and the median particle size of the powder is usually required to be controlled within the range of 2-5 microns. The ground slurry needs to undergo iron removal treatment to remove magnetic impurities that may reduce the insulation performance, and then passes through a spray drying tower to produce granulated powder with good fluidity. For high-pressure application products such as Energy Storage Fuse Ceramic Body and Photovoltaic Energy Storage Fuse Ceramic Body, the purity of raw materials is required, and alumina powder with low sodium content needs to be selected to reduce the risk of ion migration at high temperatures.

 

Step 2: Molding – Fill the granulated powder into a precision mold, and obtain a green body through dry pressing, isostatic pressing or slip molding. Dry press molding is the most commonly used method. The molding pressure is usually between 50-150MPa, and the pressure holding time needs to ensure that the gas in the powder is fully discharged. For tubular products such as Ceramic Tube for Energy Storage Fuse, isostatic pressing or extrusion is usually used to achieve uniform density distribution and better straightness. For Ceramic Body for Automotive Fuses, due to the large volume, high-speed dry pressing is usually used with multi-cavity molds to improve production efficiency. Step 3: Green body trimming – There may be flash or burrs on the edges of the formed green body, which need to be removed manually or mechanically. For ceramic bodies with internal cavities or through-holes (such as Steatite Ceramic Body for EV Fuse, which may require reserved melt installation grooves), drilling or grooving is also required in the green state, because the hardness of the ceramic after sintering is extremely high, and subsequent machining costs will increase significantly.

 

Step 4: High-temperature sintering – The green body is sintered at high temperature in a tunnel kiln or shuttle kiln. The sintering process is divided into three stages: the pre-sintering stage (room temperature to about 600°C) is used to discharge the organic binder; the high-temperature sintering stage (alumina ceramics is about 1600-1700°C, talc porcelain is about 1250-1350°C) to achieve diffusion and densification between particles; the cooling stage needs to control the cooling rate to avoid cracking caused by thermal stress. For Ceramic Body for High Speed ​​Fuses, due to its special thermal conductivity requirements, the microstructure after sintering needs to be uniform and dense, and the porosity should be controlled at a low level. Step 5: Precision grinding – For ceramic bodies that require strict matching dimensions, grinding is required after sintering. Diamond grinding wheels and CNC grinders can be used

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The application industries of ceramic fuse bodies cover a wide range of fields from traditional power distribution to new energy power generation, from electric vehicles to industrial automation. In power systems, ceramic fuse bodies are used for transformer protection, distribution cabinet overcurrent protection, and matching fuses for high-voltage switchgear. The materials are required to have high-voltage withstand levels and anti-pollution capabilities. In the field of new energy, Energy Storage Fuse Ceramic Body is widely used in electrochemical energy storage power stations, industrial and commercial energy storage systems and household energy storage equipment. The short-circuit current characteristics of energy storage systems are significantly different from those of photovoltaic systems - the battery short-circuit current rises faster and has a higher peak value. Therefore, the ceramic body of the energy storage fuse needs to have higher mechanical tensile strength and better resistance to arc erosion. Photovoltaic Energy Storage Fuse Ceramic Body is mainly used in integrated photovoltaic and storage systems. This type of system couples photovoltaic power generation and battery energy storage on the DC side, which places higher requirements on the DC breaking capacity of the fuse ceramic body.

 

In the electric vehicle industry, Steatite Ceramic Body for EV Fuse is used in high-voltage battery pack protection, PDU (high-voltage power distribution unit) and charging circuits of electric vehicles. The operating voltage of electric vehicles is usually between 400V and 800V, and some high-voltage platforms have reached 1000V. The ceramic body of the fuse needs to maintain stable insulation performance at this voltage level. Ceramic Body for Automotive Fuses covers a wider range of automotive application scenarios, including circuit protection in low-voltage auxiliary circuits (12V/24V), such as window controls, seat adjustments, lighting systems, etc. In the field of industrial automation, Ceramic Bodies for Energy Storage Fuse is also used in UPS uninterruptible power supplies, industrial energy storage systems and backup power protection in data centers. In addition, Ceramic Body for High Speed ​​Fuses mainly serves scenarios such as rail transit, ship electric propulsion, and high-power converters that have strict requirements on protection response speed. Ceramic Tube for Energy Storage Fuse, as the core structural component of energy storage fuses, is widely used in containerized energy storage power stations and modular energy storage systems. Its size specifications usually need to match the protection parameters of the energy storage converter (PCS).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The engineering team can quickly complete the Ceramic tube for new energy fuse body solution design based on your rated voltage, breaking capacity and installation interface requirements. Welcome to submit drawings or technical specifications for process evaluation and sample docking.