New Energy Vehicle Application Analysis of Metal High Current Connector

For metal connectors, we often see them used for signal transmission in some communication, medical and other high-frequency electronic industries; of course, a large number of metal connectors are also used in industries such as industry and rail transit; our earliest contact is also from industry According to the shape of the metal connector, the metal connector can be divided into circular and rectangular; according to the frequency, it can be divided into high frequency and low frequency.

Of course, in the application of metal high-current connectors in the electric vehicle industry, metal connectors have four outstanding advantages compared with plastics in the conduction of high currents: excellent shielding performance, good heat dissipation, and strong environmental resistance The performance and the size of the installation interface are smaller.

1. Excellent shielding performance of high current connector

With the development of new energy vehicles, more and more complex and more electrical functions are piled up, and the shielding performance requirements of the whole vehicle are also getting higher and higher. For high-voltage systems, the layout of wiring harnesses can basically be designed reasonably, while The coverage rate of the shielding layer of the cable itself of the high-voltage harness has generally exceeded 85%. For the high-voltage connector at the connection point of this system, the shielding performance is very important. If the shielding is a surface-to-point Therefore, the shielding performance of high-voltage connectors is a very important point.

2. Heat dissipation capacity of high current connector

The conduction of high-current connectors requires the connector itself to have very good heat dissipation capabilities. For the connector, like protection and shielding, there are still three points to consider, and its own temperature sources also come from these three areas. : board end connection area, mating end, and wire end crimping area; if these three areas are not handled properly, it is easy to cause excessive temperature and deformation of the material; because the conduction current is large, the temperature is high It is true that we require the temperature rise of the connector to be less than 50K, but in fact, the long-term high current leads to high local temperature. If the plastic grade material will also form a high temperature inner cavity area on the terminal as the central axis, Because the thermal conductivity of the plastic material is small, compared with metal, it is about 1/500~1/600 of the metal, so this will lead to a high temperature in the inner cavity of the connector for a long time, which will cause a series of problems; from this point Generally speaking, under the same cable specification, regardless of the influence of three-point contact, metal has a better heat dissipation capability than plastic.

3. High-current connectors have strong environmental resistance

For more complex working conditions, we need high-voltage connectors to have very good environmental resistance. We found that many high-voltage wire harnesses and connectors are directly suspended from the ground and are closer to the ground, which makes the connectors often appear in relatively In a complex environment, high temperature resistance, low temperature resistance, aging, salt spray, oil pollution, protection, impact, etc. require connectors to do very well. Due to the physical characteristics of the material itself, if it appears in a humid and hot environment for a long time. The high water absorption rate of its physical properties will lead to a decrease in the insulation performance of the material itself, causing an alarm failure.

Similarly, under extreme cold and high temperature long-term working conditions, plastics will also have brittle cracks, deformation and failure of protection; many times, problems with connectors occur under some very extreme conditions, and these conditions are difficult to pass the test of the laboratory. Static test analysis shows that because the working environment is relatively complex, it is difficult to construct a microscopic mathematical model for testing; of course, we also need to consider the poor salt spray resistance of metal connectors.

4. The size of the installation interface of the high-current connector is smaller

Because of the lack of shielding cover, the width of the metal connector can be made smaller. Compared with the plastic connector, it can basically be reduced by more than 10mm. In some small installation spaces, this size will be very important, the more the number of pins, the larger the size of the optimization.