1. Electrical performance requirements

The design of electric connectors for new energy vehicles should meet specific electrical performance requirements to ensure safety and stability in high-voltage systems. First, considering the voltage requirements of new energy vehicles, the rated voltage of the connector must be set above 200V. Secondly, insulation resistance is a key criterion for evaluating whether the connector can avoid leakage or short circuit under high voltage, and its value should meet industry standards, such as not less than 100 MΩ. In addition, the voltage resistance of the connector is also an important consideration. It should be able to withstand a voltage of at least 1000V to ensure the safety of application in the high-voltage system of new energy vehicles.

2. Mechanical performance requirements

The plug-in force is a key indicator for evaluating the convenience of connector operation. Its design must ensure that it is easy to plug and unplug while avoiding excessive looseness. Generally, the plug-in force should be controlled within 100 N. In addition, the mechanical durability of the connector is defined as the number of times it can be repeatedly plugged and unplugged without losing stability and reliability, which should ideally exceed 50 times. Since new energy vehicles may encounter vibration during operation, electric connectors must have excellent vibration resistance to ensure that their electrical and mechanical properties are not affected at the specified vibration frequency and amplitude.

3. Temperature adaptability requirements

The temperature adaptability requirements of electric connectors are very strict, and they need to maintain normal operation in a wide temperature range of -40℃ to 125℃. This means that at any temperature within this range, its electrical and mechanical properties must remain stable without degradation or failure. This standard ensures the reliability and efficiency of electric connectors under various extreme environmental conditions.

4. Anti-corrosion performance requirements

The selection of connector materials is related to its anti-corrosion performance. The shell is preferably made of metal materials with excellent corrosion resistance, such as aluminum or zinc alloy, and the surface can be sandblasted. The contact part is selected as copper, and gold plating, silver plating, nickel plating and other processes are used to improve its conductivity while meeting the anti-corrosion requirements. The connector should have good sealing performance to prevent the intrusion of harmful substances such as moisture and dust, and effectively avoid corrosion. The sealing structure should be well designed to ensure the sealing effect in various harsh environments. A layer of anti-corrosion coating can be applied on the surface of the connector to enhance its anti-corrosion performance and ensure that the connector is tightly plugged in and not easy to loosen. Special sealing packages can be used to ensure that the connection is not corroded by moisture and corrosive substances. Regular maintenance and inspection of the connector is an important measure to ensure its long-term anti-corrosion performance.