High - current Pogo Pin connector for new energy vehicles

Time：2025-05-15 Views：1 source:

　　High-Current Pogo Pin Connector for New Energy Vehicles: Uncompromised Performance for High-Power Systems

　　Core Performance Advantages for NEV High-Power Applications

　　1. Industry-Leading Current-Carrying Capacity

　　Designed to handle the massive power requirements of NEVs, our connector supports continuous currents up to 150A (peak 200A+)—ideal for battery packs, motor controllers, and fast-charging interfaces. The secret lies in:

　　Oversized Gold-Plated Pins: 80μin gold-plated copper alloy pins (diameter ≥2.5mm) provide exceptional conductivity and resistance to oxidation, ensuring stable power flow even under sustained high loads.

　　Low-Resistance Spring Design: Custom-engineered beryllium copper springs with optimized pitch and force (500–800gf) reduce contact impedance to ≤20mΩ (at 100A), minimizing voltage drop and energy waste.

　　2. Advanced Thermal Management for Safe Operation

　　High-current systems generate significant heat, requiring connectors that excel in thermal dissipation:

　　Heat-Dissipative Housing: Aluminum alloy or copper-injected thermoplastic housings (with thermal conductivity ≥150W/mK) quickly absorb and disperse heat, maintaining operating temperatures within -40°C to +150°C (even under full-load conditions).

　　Thermal Pad Integration: Optional high-conductivity thermal pads between pins and housing further reduce hotspots, ensuring consistent performance in battery compartments or motor bays with extreme heat.

　　3. Rugged Durability for Harsh NEV Environments

　　NEVs operate in challenging conditions—vibrations from uneven roads, moisture in charging ports, and constant thermal cycling. Our connector features:

　　IP68 Waterproof & Dustproof Design: Hermetic seals and double-layer O-ring gaskets prevent water ingress (immersion up to 1.5m) and dust accumulation, critical for outdoor charging interfaces and underbody battery connections.

　　Vibration-Resistant Locking Mechanism: Spring-loaded pins with anti-rotation guides maintain secure contact under 50G shock and 20Hz–2000Hz vibration, eliminating intermittent connections in high-vibration zones like electric motor mounts.

　　4. Safety-Critical Design for Reliability

　　In NEV high-power systems, safety is non-negotiable:

　　Arc-Resistant Insulation: UL94 V-0 rated thermoplastics with a high comparative tracking index (CTI ≥600V) prevent electrical arcing and material degradation under high voltage (supporting up to 1000V DC).

　　Overcurrent Protection (Optional): Integrated PTC thermistors or current-limiting components can be customized to safeguard against short circuits or overloads, enhancing system safety.

　　5. Precision Engineering for Easy Integration

　　Modular Design: Stackable pin arrays and customizable pitch (4.0mm–6.0mm) fit seamlessly into compact battery pack connectors or charging port modules.

　　Self-Aligning Pins: ±0.3mm misalignment tolerance enables quick robotic assembly, reducing installation time by 30% compared to traditional connectors.

　　Target Applications in New Energy Vehicles

　　Battery Management Systems (BMS): Secure high-power links between battery cells and central controllers, supporting real-time voltage/current monitoring.

　　Onboard Chargers (OBC) & DC-DC Converters: Reliable connections for high-efficiency power conversion in 400V/800V electric platforms.

　　Motor Drive Systems: Direct power links to electric motors, ensuring low-loss energy transmission for maximum torque and efficiency.

　　Fast-Charging Interfaces: Compatible with CCS, CHAdeMO, and GB/T charging protocols, enabling stable 350kW+ fast-charging without overheating.

　　Why Choose Our High-Current Pogo Pin Connector?

　　1. NEV-Specific Performance Optimization

　　Our R&D team specializes in NEV power dynamics, ensuring every design parameter—from pin geometry to thermal pathways—is optimized for lithium-ion battery systems and high-voltage architectures.

　　2. Rigorous Testing for Mission-Critical Systems

　　Each connector undergoes:

　　Thermal Cycle Testing: 1000+ cycles between -40°C and +150°C to validate long-term reliability.

　　Salt Spray & Humidity Tests: 96 hours of exposure to simulate coastal or high-moisture environments.

　　High-Current Burn-In Testing: 72 hours at 120% rated current to ensure no performance degradation.

　　3. Scalable Production for Global NEV Brands

　　Automated Manufacturing: High-precision stamping and plating lines ensure consistent quality at volumes up to 100,000 units/month.

　　Dual-Source Supply Chain: Mitigate risks with redundant material suppliers for gold, copper, and engineering plastics.