1- Products Name: Flexible Connectors for EV Battery
2- Base Material Standard:
GB: T2Y2 Copper Braided Wire or Copper Stranded Wire
(2.1) The joints at both ends are crimped with high-quality copper pipes or copper lug terminals;
(2.2) Single layer 1.5mm2—150mm2 (multi-layer braided wire can be customized
DIN: E-Cu58 (Number: 2.0065)
EN: Cu-ETP ( Number: CW004A)
ISO: Cu-ETP
UNS: C11000
JIS: C1100
BS: C101
Purity ≥99.99% Copper, Conductivity %IACS≥97, Hardness 80~110HV, Tensile Strength 245-345MPa, other material also can be customized.
3-Surface Treatments:
(3.1) Silver plating
(3.2) Tin plating
(3.3) Nickel plating or Resistance diffusion welding nickel sheet
(3.4) Ultrasonic cleaning
Normally plated thickness is 3μm to 12μm, but all upon customers' request.
4- Insulation Options:
(4.1) PET insulation paper (brands USA GTS, GERMANY KREMPEL, etc with white or milky white colors)
(4.2) PVC dipping (orange and green are the most popular colors)
(4.3) Epoxy powder coating (orange, green and grey are the most popular colors)
(4.4) PE heat shrink tube (orange, green, black, red are yellow are the most popular colors)
(4.5) PA66 plastic housing (white, grey etc are the most popular colors)
Flame Retardant / Fire Resistance: UL94-V-0 or upon you request;
Operating Temperature: -45ºC to +150 ºC
5- Copper Busbar Resistance: ≤0.00001Ω
6- Copper Busbar load voltage 3500VDC to 5000VDC and current 100A to 2000A
7- Copper Busbar Assembly Fixtures: USA PEM stainless nuts, studs, standoffs, screws, etc
8- Free Samples:1-10pcs is allowed
9- Lead Time:Orders 7-10days,Samples 10-20days(including the tooling/die production of Copper Stamped Part);
10- Packing: pearl cotton/blister box inside and carton/pallet outside
11- Certifications: ISO9001, IATF16949, RoHS, REACH, etc.
12- Production Capacity: 50,000,000 pcs/month
13- Applications: film capacitors for new energy electric vehicles and hybrid vehicles, new energy vehicle battery packs, new energy photovoltaic energy storage, power appliances, distribution cabinets, rail transit, cloud server uninterruptible power supplies and other power systems.
Flexible connectors play a crucial role in electric vehicles (EVs), especially in the context of battery systems. These connectors are designed to provide a flexible and reliable electrical connection between various components within the battery pack. Here are some key points about flexible connectors for EV batteries:
1.Material Selection:
Copper or Aluminum: Like busbars, flexible connectors are often made from materials with high electrical conductivity. Copper is commonly used due to its excellent conductivity, while aluminum may be used as a lightweight alternative.
Flexibility:
Stranded Conductors: Flexible connectors typically use stranded conductors to enhance flexibility. This design allows the connector to bend and flex without compromising the integrity of the electrical connection.
2.Connectivity:
Lugs or Terminals: Connectors may have lugs or terminals at each end, facilitating easy and secure attachment to other components within the battery system. These can be crimped, bolted, or welded, depending on the design.
3.Temperature Resistance:
High Temperature Ratings: Flexible connectors must be designed to withstand the operating temperatures within an EV battery pack. High-temperature resistance ensures that the connectors maintain their electrical performance even under demanding conditions.
4.Vibration and Shock Resistance:
Durable Insulation: The connectors may be covered with durable insulation materials to protect them from vibrations and shocks. This is important in the automotive environment where road conditions can be challenging.
5.Current Carrying Capacity:
Sufficient Gauge Size: The gauge size of the flexible connector should be selected to handle the expected current flow within the battery system. This ensures that the connector can effectively carry the electrical load without overheating.
6.Modularity and Design Flexibility:
Customizable Lengths: Flexible connectors are often designed to be modular, allowing for customization of lengths to suit the specific layout of the battery pack. This flexibility is crucial in accommodating different designs and configurations.
7.Safety Standards:
Compliance: Flexible connectors for EV batteries must comply with safety standards and regulations to ensure the overall safety and reliability of the electric vehicle.
Flexible connectors are used not only within the battery pack but also in various parts of the EV, connecting components like inverters, motors, and charging systems. The design and specifications of these connectors are crucial considerations for the efficient and safe operation of electric vehicles.
Contact Information:
Ms.Tina Tian (Sales Manager&Technology Engineer)
Xiamen Apollo Stamping Welding Technology Co., Ltd
Apollo Electronic Components (Xiamen) Co.,Ltd
Add: No.2, Chengyi North Road, Jimei Software Park, Jimei District, Xiamen City, Fujian Province, China, 361022
Mob/WhatsApp/WeChat: 0086-15985814329
Email: tina@stamping-welding.com
Web: www.stamping-welding.com , www.china-electronic-components.com
Since 2010, professional in Metal Stamping & Welding Solutions for New Energy EV & PV Fuse, Battery, Capactior, Relay, Switch, ect!