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THE ELASTIC CONTACTS —
Technology for the Next Generation of Power Electrical Engineering
Full contact area • Ultra-low contact resistance • Extra-low contact effort
No heating • No welding • No Alpha-spot • No bounce • No levitation
PM12K – A New Generation of Ultra-High-Current DC Contactors
PM12K – A New Generation of Ultra-High-Current DC Contactors
PORTA MOTORA is developing the PM12K, a compact 12 kA DC contactor for Battery Energy Storage Systems (BESS), utility-scale photovoltaic (PV) installations, hydrogen electrolysers and other high-current DC applications.
The PM12K introduces a new contact architecture based on CLMC (Capillary Liquid Metal Contacts), combining ultra-low contact resistance with a compact mechanical design.
Key targets
Key targets
Rated current: 12,000 A DC
Target contact resistance: below 500 nΩ
Compact core dimensions: approximately 120 × 120 × 250 mm
Weight: less than 8 kg
Direct busbar mounting
Fast bistable magnetic actuator
No moving busbar assemblies
The PM12K prototype is currently under construction in Germany.
Its development is based on many years of research and experimental validation, including 200,000 AC-4 switching cycles and recent independent high-current measurements demonstrating 6270 A DC, 4.63 mV voltage drop and approximately 738 nΩ contact resistance.
Our objective is to demonstrate a new compact architecture for ultra-high-current DC switching, addressing the growing needs of BESS, renewable energy and hydrogen power systems.
Independent High-Current Testing (contacts only)
Independent High-Current Testing (contacts only)
Independent high-current validation at RITTER Starkstromtechnik GmbH (Germany).
During testing, our CLMC contact architecture demonstrated:
6,270 A DC
4.63 mV voltage drop
738 nΩ contact resistance
Stable thermal behaviour.
Arc Formation During Contact Opening
Arc Formation During Contact Opening
This video illustrates what happens when conventional solid electrical contacts separate under load and how an electric arc is initiated.
In conventional contacts, current is concentrated in microscopic a-spots (constriction spots). As the contacts separate, these highly localized current paths generate extremely high current density and temperature, creating favorable conditions for arc ignition.
PORTA MOTORA's CLMC (Capillary Liquid Metal Contact) technology operates on a different principle. The capillary liquid-metal interface distributes the current over a much larger effective contact area, significantly reducing current constriction and local overheating during contact separation.
As a result, the conditions leading to arc initiation are substantially reduced, providing a promising basis for compact, high-current DC switching systems.
We have the composite liquid metal contacts since 1985!
The Pristine State of FMKW Composite Contact. This is our proprietary composite liquid metal contact before testing.
Elastic Composite Liquid Metal Contact after testing. Zero erosion detected on the contact surface
Application Case: Elastic contacts integrated into High-Voltage DC contactors for EV (Electric Vehicles) and BESS (Battery Energy Storage Systems).
Applications
High-Current Switchgear.
High-Voltage Switchgear.
EV Fast Charging Stations.
DC contactors for EV
Energy Storage Systems (BESS).
Industrial Circuit Breakers
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