Dear Customer,

 

Hello! Thank you for your continued support and trust in our company. Here, we would like to announce the National Day holiday notice for 2024.

 

To celebrate the 75th anniversary of the founding of the People's Republic of my country and to show the prosperity and progress of our country, we will arrange a week off for our employees so that they can enjoy this special holiday and spend happy time with family and friends.

 

The holiday time is from October 1, 2024 (Saturday) to October 7, 2024 (Friday), a total of 7 days. During this period, our office will be closed and unable to process and arrange orders normally. Please plan your needs in advance and place orders before the National Day so that we can properly handle and provide services before the holiday.

 

Although our office will be closed, you can still browse and place orders through our online platform. Our online platform will continue to operate normally and accept orders. Please note that your order may be delayed after the holiday because the express delivery service may be affected during the holiday. We will do our best to process your order as soon as possible after the holiday and ensure your satisfaction.

 

We thank you again for your understanding and support. During the National Day, we also wish you and your family a happy and safe holiday! Whether you are a new customer or an old customer, we are very much looking forward to continuing to provide you with quality products and services after the holiday. If you have any questions or needs, please feel free to contact us. Thank you for your cooperation!

 

Happy National Day!

 

Best wishes!

Photovoltaic wire harness application: the light of the future for the solar industry

 

Photovoltaic wire harnesses are a key technology used for interconnection and electrical signal transmission of solar panels and modules. As global demand for renewable energy grows, photovoltaic wire harness applications play an increasingly important role in the solar industry. This article will discuss relevant industry content of photovoltaic wire harness applications, including its principles, technological progress and potential market prospects.

1. Principles and functions of photovoltaic harnesses

A photovoltaic harness is a high-performance interconnection system that integrates fiber optic cables and electrical cables. It can connect multiple battery modules on the solar panel to realize the collection and transmission of power. The function of photovoltaic wire harness is not limited to power transmission, but also includes signal transmission, monitoring and control. It can increase the efficiency of solar panels and simplify the installation and maintenance process of the system.

 

2. Technical progress in photovoltaic wire harness applications

In recent years, photovoltaic wire harness applications have made significant technological progress. On the one hand, the manufacturing process of photovoltaic wire harnesses has been improved, making its transmission efficiency higher and reliability better. On the other hand, attention has also been paid to the design and optimization of photovoltaic harnesses to accommodate solar panels of different shapes and sizes. At the same time, the development of wireless communication and intelligent control technology provides more possibilities for photovoltaic wire harness applications, such as remote monitoring and intelligent optimization.

 

3. Market prospects for photovoltaic wire harness applications

Photovoltaic wire harness applications have broad market prospects. As the global demand for clean energy continues to increase, the solar power generation industry is showing a trend of rapid growth. As a key component in solar power generation systems, the demand for photovoltaic wire harnesses has also increased. Especially in the fields of large-scale solar power plants and building-integrated photovoltaics, the demand for photovoltaic wire harness applications will be further enhanced. In addition, the demand for photovoltaic wire harness applications in emerging markets and developing countries is also increasing, providing the industry with more business opportunities.

 

4. Challenges and solutions faced by photovoltaic wire harness applications

Although the application prospects of photovoltaic wire harnesses are promising, they also face some challenges. First, production costs remain an important consideration. With technological advancement and the expansion of production scale, the cost of photovoltaic wire harnesses is expected to gradually decrease. Secondly, standardization and certification are also issues that the industry needs to pay attention to to ensure product quality and reliability. In addition, the design and installation of photovoltaic wire harnesses should take into account the scalability and adaptability of the system to meet the needs of different markets and application scenarios.

 

in conclusion:

As one of the key technologies in the solar energy industry, photovoltaic wire harness application has huge market potential and prospects. As the demand for clean energy continues to grow, photovoltaic wire harness applications will play an increasingly important role in the field of solar power generation. Through continuous technological innovation and industry cooperation, photovoltaic wire harness applications will make greater contributions to the efficiency improvement and cost reduction of solar power generation systems, and promote the development of sustainable energy.

TE Connectivity's "Industry Technology Index" Annual Report: The Chinese market's optimism about AI technology and commitment to sustainable development rank among the top in the world

Schaffhausen, Switzerland – April 30, 2024 – Corporate executives and engineers in the global technology industry are optimistic about artificial intelligence (hereinafter referred to as “AI”) and sustainable development in general; but they are still unsure about the advancement of their companies The best path for AI and sustainable development.

These insights come from the 2024 Industry Technology Index from TE Connectivity (TE), a global industry technology leader in connectivity and sensing. TE conducted a survey of 1,000 respondents from multiple industries in China, Germany, India, Japan and the United States. Based on the survey results, TE released its second annual report on the current status of innovation.

TE CEO Terrence Curtin said: "TE has invested significant resources in sustainability and AI, and we know other companies are doing the same. We wanted to explore how these two trends affect the innovation process, and how innovation can reflect To move both forward, we found that managers who set company goals and engineers who are responsible for achieving those goals still need to work together to achieve them successfully."

The results of this survey indicate that executives and engineers are divided on the implementation of AI. Three-quarters of executives believe engineers should be responsible for driving AI implementation; however, 68% of engineers want leadership to develop a clearer implementation plan. When asked about short-term plans, 79% of engineers and executives expect their companies to increase investment in AI training within the next three years. Respondents in the Chinese market are particularly optimistic about integrating AI within the enterprise and understand the competitive advantages that AI will bring (China - 90% vs. Global - 70%). But at the same time, Chinese engineers are also more worried about whether their companies can use AI responsibly (China-48% vs. global-33%).

In response to questions about their company's sustainability practices, most engineers expressed a strong passion for the environment. 87% of engineers believe it is personally important to them to support solutions to climate change at work. This sentiment runs deep among the engineering community: 34% of engineers said they would leave their job if their organization did not provide opportunities to support sustainability initiatives. Survey data shows that executives need to do more to instill confidence in the engineering community. Because when asked whether they are satisfied with their company's sustainability plans, executives are five percentage points more satisfied than engineers.

Focusing on the Chinese market, research shows that sustainable development is very important to Chinese companies. Chinese respondents are more likely to believe that sustainable development is “extremely important” (China-69% vs. Global-53%) and believe that their companies have integrated sustainable development into corporate culture (China-84% vs. Global-76 %). In addition, the Chinese market also has the highest recognition rate for "Companies provide employees with clear sustainable development goals or implementation frameworks" (China-73% vs. Global-61%).

To view the full version of the 2024 Industry Technology Index and analytical insights from TE’s team of managers and engineers, please visit: te.com/techindex.

 

 

 

 

 

About TE Connectivity

 

Headquartered in Switzerland, TE Connectivity (hereinafter referred to as "TE") is a global industry technology leader committed to creating a more secure, sustainable, efficient and connected future. TE's broad range of connectivity and sensing solutions enable the transmission of power, signals and data, continuing to drive the development of next-generation transportation, renewable energy, automated factories, data centers, medical technology and more. TE has more than 85,000 employees worldwide, of which more than 8,000 are engineers, and cooperates with customers in nearly 140 countries around the world. TE believes in "EVERY CONNECTION COUNTS". For more information, please visit www.te.com.cn or follow TE’s official WeChat account “TE Connectivity”.

ntroduction:

In today's fast-paced digital age, where connectivity and communication are paramount, the role of cannot be underestimated. Whether it's transmitting data, powering devices, or connecting the world, cables serve as the lifeline of our modern society. In this blog post, we delve into the intricate world of cables and explore their evolution, significance, and the latest advancements in cable technology.

 

1. A Brief History:

Cables have come a long way since their inception. The early days saw the use of rudimentary copper wires, which gradually evolved into coaxial cables for telecommunication purposes. However, as technology progressed, the demand for faster speeds and higher bandwidths paved the way for optical fiber cables, revolutionizing the industry. Optical fibers offered unparalleled speed, reliability, and the ability to transmit vast amounts of data over long distances.

 

2. Powering Connectivity:

With the advent of the internet and the proliferation of connected devices, the demand for cables skyrocketed. From Ethernet cables enabling local network connections to submarine cables spanning continents, these lifelines of connectivity facilitate global communication and the exchange of information. High-speed fiber optic cables now connect data centers worldwide, ensuring seamless transmission of data and enabling cloud computing, video streaming, and real-time collaboration.

 

3. Enabling Energy Transfer:

Cables not only transmit data but also deliver electrical power to various devices. Power cables play an essential role in distributing electricity from power plants to homes, businesses, and industries. With the focus on renewable energy, specialized cables, such as high-voltage direct current (HVDC) cables, are being used to efficiently transmit electricity over long distances, connecting remote renewable energy sources to population centers.

 

4. Advancements in Cable Technology:

The cable industry continues to witness exciting advancements that push the boundaries of what was once thought possible. Here are a few notable innovations:

 

   a. Fiber Optic Cables: The relentless pursuit for faster speeds has led to the development of new generations of fiber optic cables capable of transmitting data at staggering rates. The deployment of dense wavelength division multiplexing (DWDM) technology has further increased the capacity of these cables, allowing for terabits of data transmission over a single fiber.

 

   b. High-Performance Power Cables: As the demand for electricity grows, power cables are being engineered to handle higher voltages and currents efficiently. Superconducting cables, which transmit electricity with zero resistance, are being researched and developed for applications requiring massive power transmission.

 

   c. IoT and Smart Cables: With the rise of the Internet of Things (IoT), cables are now evolving into intelligent, interconnected systems. Smart cables equipped with sensors can monitor temperature, moisture, and other parameters, providing real-time insights and predictive maintenance capabilities.

 

Conclusion:

The evolution of cables has been instrumental in shaping the world we live in today. From transmitting data at lightning-fast speeds to delivering electricity to remote locations, cables have become indispensable in every aspect of our lives. As technology continues to advance, we can expect further innovations in cable design and functionality, keeping us connected and empowered in an ever-evolving digital landscape.

The key role of cables: connecting the signal harness of the world

 

Date: September 18, 2024

 

Cables are essential infrastructure in modern society, playing a crucial role in various industries. As a signal harness connecting the world, cables carry various information and energy, providing us with important functions such as communication, power transmission, and data exchange. This article will delve into the importance of cables and their applications in different fields.

 

1. Communication field:

 

In the era of global interconnectivity, communication has become the cornerstone of modern society. Whether it is telephone, Internet or mobile communication, cable is the core component to realize these communication networks. Fiber optic cables enable high-speed broadband through the transmission of optical signals, meeting people's needs for information transmission.

 

2. In the field of power transmission:

 

Cables play a crucial role in power transmission. High voltage cables transport electricity from power plants to homes, factories, and offices, providing a continuous energy supply for our daily lives and economic activities. With the rapid development of renewable energy, cables also play a key role in the transmission and distribution of clean energy such as solar and wind power.

 

3. Data centers and computer networks:

 

Modern data centers and computer networks cannot do without the support of cables. The massive servers and network equipment in data centers require a large number of high-speed data connections, and cables provide stable and reliable signal transmission, ensuring efficient processing and transmission of data.

 

4. Transportation and automotive industry:

 

Cables also play an important role in the field of transportation. In transportation vehicles such as trains, subways, and airplanes, cables are used for control, communication, and power transmission of various systems. In addition, the rise of electric vehicles in the automotive industry has also brought about an increased demand for cables, which are used to transmit energy from batteries and connect vehicle control systems.

 

5. Medical technology:

 

The advancement of medical technology cannot be separated from the application of cables. From the connection of medical equipment, image transmission to patient monitoring systems, cables provide critical technical support for the healthcare industry. High quality cables ensure accurate and reliable data transmission, which is crucial for medical diagnosis and treatment.

 

In summary, cables play an indispensable role as signal harnesses connecting the world in modern society. Whether it is communication, power transmission, data centers, transportation, or medical technology, the application of cables is extensive and diverse. With the continuous advancement of technology, the performance and functionality of cables are also constantly improving, creating a more convenient, efficient, and reliable living and working environment for us. We look forward to the further development of cable technology and making greater contributions to the progress of human society.

There are many options for plating terminals, generally divided into four categories: noble metals, inert metals, alloys and dispersions. The first three categories are already established and used, while decentralization is just beginning to emerge to address the need for high-power connectivity in electric vehicle charging and similar applications. We begin with a brief review of basic electroplating system concepts, then describe the properties of noble metals, inert metals, and alloys, and conclude with a brief overview of the potential advantages of dispersions.

 

 

 

Plating systems are typically multi-layer structures, where the top layer can be a relatively thin coating. Inert metal surfaces like tin are often found in consumer products. Industrial, military, medical and other high-performance applications often turn to precious metals. Precious metals are often used as alloys. For example, pure gold is too soft for many applications, while gold alloyed with cobalt, nickel, or iron, known as "hard gold," is used to provide greater durability (Figure 1). Other precious metals such as silver can also be used as alloys to increase hardness.

 

precious metals

 

 

 

Gold is highly conductive even at low voltages. It has excellent oxidation and corrosion resistance compared to other options. It is ideal for use in environments with high humidity or frequent heat cycles.

 

 

 

Silver performs well in high power applications. It is less expensive than gold and is a good choice for larger, high-current contacts.

 

 

 

Palladium has high electrical and thermal conductivity and is resistant to corrosion. It is harder than gold or silver, making it a good choice for applications that require more durability.

 

 

 

Rhodium is harder than palladium and is resistant to corrosion and acids. It is ideal for applications requiring good wear resistance and high hardness.

 

 

 

 

 

inert metal

 

 

 

Tin is non-toxic and therefore suitable for some medical applications. This is low cost and suitable for applications requiring a small number of mating cycles.

 

 

 

Nickel is very hard, durable and corrosion-resistant. Its combination of durability and high conductivity makes it suitable for high-use applications.

 

 

 

Copper is one of the most conductive metals, but it requires a protective layer to prevent corrosion. It is often used as a basis for subsequent metal plating.

 

 

 

 

 

metal alloy

 

 

 

White bronze is a non-magnetic alloy composed of copper, tin and zinc that is more conductive than nickel. It is ideal for many medical and RF connectors.

 

 

 

Palladium-nickel alloy is corrosion-resistant and has low contact resistance. It has good solderability and can handle a large number of mating cycles. Palladium-nickel plating often flashes gold.

 

 

 

Electroless nickel plating can be applied to both conductive and non-conductive surfaces. Electroless nickel plating contains up to 14% phosphorus. The higher the phosphorus content, the greater the corrosion resistance, but the hardness decreases.

 

 

 

Nickel-phosphorus alloy has high wear resistance and corrosion resistance. They have good weldability but have lower electrical conductivity than other alloys.

 

 

 

 

 

Silver graphite dispersion

 

 

 

Silver-graphite dispersions have been developed for use in contacts in high-power applications such as electric vehicle chargers. It combines the properties of fine silver and hard silver. The fine silver matrix provides high conductivity and the graphite increases wear resistance and supports high cycle life. Uniform and random dispersion of graphite particles is one of the keys to high durability (Figure 2).

Summarize

 

 

 

A wide range of plating options are available to support varying levels of conductivity, environmental ruggedness, durability and other application needs. With the development of graphite dispersion plating materials, the traditional choice between precious metals, inert metals and various alloys is expanding.

As electric vehicles (EVs) gain popularity, understanding their components becomes increasingly important for both manufacturers and consumers. One of the most critical elements in an electric vehicle is the wiring harness. This complex assembly of wires, connectors, and terminals serves as the backbone of the vehicle’s electrical system, playing a vital role in its operation. Let’s delve into what a wiring harness does in an electric vehicle and why it matters.

 

Power Distribution

In electric vehicles, the wiring harness is primarily responsible for distributing electrical power from the battery to various components. This includes supplying power to the electric motor, onboard chargers, and auxiliary systems such as lighting and infotainment. The electric vehicle wire is designed to handle high voltage and current levels, ensuring efficient energy transfer while maintaining safety standards. Proper power distribution is essential for maximizing the performance and range of the EV.

 

Connecting Essential Components

The wiring harness connects various critical components within the electric vehicle, allowing them to communicate and function together seamlessly. This includes connections between the battery management system, electric motor controller, and charging systems. The integration of these components through a custom wiring harness is crucial for ensuring that the vehicle operates efficiently and effectively. Tailoring the harness for specific vehicle models allows manufacturers to optimize performance and reliability.

 

Supporting Charging Infrastructure

Charging an electric vehicle requires robust and efficient connections to ensure that energy flows smoothly from the charging station to the vehicle's battery. The wiring harness plays a significant role in this process, especially regarding the car charging cable. It connects the charging port to the battery management system, enabling safe and efficient charging. High-quality automotive wiring connectors are vital in this setup, ensuring secure and reliable connections that can withstand the rigors of regular use.

 

Ensuring Safety and Reliability

Safety is paramount in electric vehicles, and the wiring harness contributes significantly to this aspect. A well-designed harness is constructed from durable materials that can withstand high temperatures, moisture, and vibrations. This durability helps prevent electrical shorts and failures, which could pose serious risks. Furthermore, the wiring harness integrates safety features such as fuses and circuit breakers, protecting the vehicle’s electrical system from overloads.

 

Simplifying Maintenance and Repairs

Another benefit of using a wiring harness in electric vehicles is the simplification of maintenance and repair processes. Instead of dealing with a multitude of individual wires, technicians can work with a single, organized assembly. This streamlined approach not only speeds up repairs but also reduces the likelihood of errors during installation or maintenance. Automotive wiring connectors facilitate quick connections and disconnections, making it easier to service the vehicle when necessary.

 

Customization for Performance

The ability to create a custom wiring harness allows manufacturers to tailor the electrical system to meet specific performance requirements. Whether it’s for high-performance electric vehicles or those designed for particular applications, customization ensures that the wiring harness can handle the necessary power levels and environmental conditions. This adaptability is particularly important as electric vehicle technology continues to evolve.

 

In conclusion, the wiring harness is a fundamental component of an electric vehicle, serving multiple essential functions that contribute to its performance, safety, and reliability. From power distribution and component connectivity to supporting charging infrastructure and simplifying maintenance, the wiring harness plays a vital role in the operation of electric vehicles. As the demand for EVs continues to grow, understanding the significance of wiring harnesses and their components, such as electric vehicle wires, car charging cables, and automotive wiring connectors, will be crucial for anyone involved in the automotive industry or considering an electric vehicle.

 

A Battery Management System (BMS) wire harness is an essential component in battery systems, playing a crucial role in managing the performance and safety of batteries. As industries increasingly adopt advanced energy storage solutions, understanding the significance of these wire harnesses is vital for manufacturers, engineers, and users alike.

Understanding the BMS Wire Harness

The BMS wire harness is an assembly designed to connect various components of a battery management system, such as battery cells, control modules, and sensors. This intricate network of wires and connectors facilitates seamless communication and efficient energy flow, ensuring optimal battery operation. The harness is engineered to handle high currents and voltages while maintaining reliability and safety.

Key Functions of a BMS Wire Harness

    Safety Monitoring: One of the primary roles of a BMS wire harness is to enable real-time monitoring of critical parameters like voltage, current, and temperature. This monitoring is crucial for preventing issues such as overcharging and overheating, which can lead to battery failure or safety hazards.

    Energy Regulation: The harness allows effective management of energy by connecting the BMS to different battery cells, ensuring that energy is distributed appropriately throughout the system. This optimizes performance and extends the life of the battery.

    Communication: Effective communication among battery components is vital for maintaining system integrity. The harness facilitates this communication, allowing the system to respond swiftly to changes in battery conditions and improving overall efficiency.

 

Applications of BMS Wire Harnesses

BMS wire harnesses find applications across various industries, underscoring their versatility:

Solar Energy Systems:

In solar applications, the wire harness connects solar panels to batteries, enabling efficient energy transfer and reliable operation. It is crucial for managing the energy generated by photovoltaic systems and ensuring effective storage and utilization.

Electric Vehicles (EVs)：

For electric vehicles, the BMS wiring configuration plays a critical role. It connects multiple battery cells and facilitates communication among them, ensuring safe and efficient power distribution. The design configuration of the harness in electric vehicles is tailored to meet the unique demands of this dynamic industry, highlighting the importance of specialized wiring solutions.

Energy Storage Systems (ESS)：

BMS harnesses are essential in both residential and grid-scale energy storage solutions. They connect batteries to inverters and other components, ensuring effective energy management. Custom wiring harnesses for battery management systems can be developed to meet the specific needs of different applications, enhancing their overall effectiveness.

Medical Devices：

In the medical field, reliability in battery systems is paramount. The BMS wire harness ensures that medical devices function correctly, providing stable power and real-time monitoring to enhance patient safety.

Designing an Effective BMS Wire Harness

Creating an effective wire harness involves several considerations:

    Material Selection: High-quality materials are critical for ensuring durability and flexibility, especially in high-performance applications like electric vehicles and industrial energy systems.

    Current Rating: Wires used in the harness must be rated to handle the expected current loads, ensuring safe operation under all conditions.

    Temperature Resistance: The ability to withstand varying temperatures is essential, particularly in applications where heat generation is a factor.

    Connector Quality: Reliable connectors are crucial for maintaining stable connections and preventing energy loss, essential for the efficiency of the entire system.

In summary, the BMS wire harness is a vital component in modern battery systems, ensuring safe and efficient operation across various applications. By facilitating communication, monitoring, and energy regulation, it significantly contributes to the functionality and longevity of battery systems. As industries continue to innovate and embrace advanced energy solutions, the importance of well-designed wire harnesses, such as custom wiring solutions for battery management systems, will only increase, solidifying their role in the future of energy management.

What is a connector?

Connectors are electronic components that connect the flow of electricity and electrical signals.

 

Connectors support various fields in modern society. Next, we will introduce the functional characteristics of connectors and the technology and production process that support them.

 

Fields of use of connectors

 

Connectors are not only used in cars, smartphones, computers and other items that are closely related to our lives, but also in all electronic-related terminal devices. Because connectors need to cope with various design styles and uses, there are many types of connectors. What kind of connection effect will be produced by using connectors? Let's take a computer as an example.

 

First, there is the memory slot. It is a slot installed on the PCB board inside the computer case and used to connect to the memory card.

 

Secondly, there is a connector for the PCB board inside the computer. Electronic circuits are composed of multiple substrates according to different functions. Connectors are needed to connect these substrates. In addition, connectors are also needed to connect the LCD screen and keyboard to the PCB board.

 

Finally, there is the interface connector. This is a connector used to connect the computer host and printers, mobile devices, TVs and other external devices.

 

In addition, there are card holder connectors for connecting various cards.

Advantages and necessity of connectors

 

So, why do we need to use connectors?

 

For example, when connecting the internal PCB board of the device, although the circuit can be directly connected, it will take a long time to operate. And the removal and other work during repairs are more time-consuming. However, by connecting with connectors, it is easy and quick to "connect" and "disconnect". Therefore, mass production, division of labor production, repair and maintenance work can be easily realized. The interface between peripheral machinery and the network is naturally the same. With the evolution of various devices, the convenience of "connecting" and "disconnecting" of connectors is indispensable.

Connector structure accessories

 

So, what is the structure of the connector?

 

The connector is composed of a pair of plugs and sockets to perform its functions. The plug and socket are composed of terminals that carry electricity, insulators made of plastic to maintain the insulation function between the terminals, and shell parts that protect it.

 

The most critical terminal in the connector component is made of copper alloy material with high conductivity. One side is a plug terminal without elasticity, and the other side is a socket terminal processed with an elastic structure, which can make the plug and the socket tightly combined. The jack is contacted with the plug, and the elastic structure of the connector makes it tightly combined, completing the connection or transmitting power and signals.

Technical factors supporting connectors

 

Connectors have the mission of keeping the power and electrical signals of all electronically connected machines connected smoothly in any environment. In order to improve its reliability, we introduce several technical factors that can support connectors.

 

1. Contact reliability technology

 

In order to make power and electrical signals "uninterrupted", "unchanged" and "undecayed", contact reliability technology is particularly important. In order for the terminal to contact the electrical with stable performance, the terminal spring must be a metal structure with elasticity. Even if the connector is plugged in and out many times, the socket terminal will return to its original position due to its elastic function. If the contact force is unstable, it will not be able to engage normally. Using operability and spring characteristics to improve the contact reliability of the terminal is the most basic and important technical factor.

2. Simulation evaluation technology

 

Next, let's take a look at simulation evaluation technology. Connectors are required to have high-speed and non-interrupted waveforms, and to avoid electromagnetic noise that may cause machine malfunctions. For this reason, when designing connectors, simulation evaluation technology such as structural design is also a very important technical factor.

3. Environmentally resistant design technology

 

In addition, connectors used in outdoor facilities such as automobiles are often affected by vibration and impact, temperature, humidity, wind and rain. Moreover, environmentally resistant design technology that can withstand exhaust gas and dust and always maintain stable contact is also an important technical factor. Our company evaluates contact reliability by implementing various evaluation tests.

Manufacturing technology that supports the production of connectors

 

In addition to launching more competitive new energy models, automakers are also intensively laying out charging networks. In the past two years, 800V high-voltage platforms and 4C charging technologies have been launched one after another, and the era of comprehensive fast charging is approaching. Tesla, Xiaopeng, Ideal, Zeekr, Huawei and other companies are accelerating the construction of supercharging stations and supercharging piles across the country, providing higher charging power and energy replenishment efficiency to bring an evolved charging experience to end users and eliminate mileage anxiety.

 

 

 

On the policy side, the country's strong support for new energy vehicle charging facilities is driving it to become an emerging hot market. As early as 2020, new energy charging piles have been included in one of the seven key areas of "new infrastructure". After years of development, it has been quite effective. According to statistics from the China Charging Alliance, in 2023, the increase in charging infrastructure will be 3.386 million units, and the increase ratio of piles to vehicles will be 1:2.8, which means that the construction speed of charging piles can basically meet the rapid development of new energy vehicles.

 

When the focus is on the charging pile industry chain, downstream companies have an increasingly strong demand for high-power supercharging, DC fast charging, liquid cooling, etc. This demand is transmitted to upstream charging equipment component suppliers, including charging guns, charging cables, power modules, controllers and other components must be upgraded accordingly, and meet safety requirements such as high temperature resistance and high voltage resistance to support the implementation of higher-specification charging piles.

 

In the design of charging piles, the choice of materials is crucial. Especially for indicators such as thermal conductivity, sealing, insulation, and flame retardancy, breakthroughs in materials are needed, including silicone materials. Silicone can be used as thermal conductive adhesive, sealant, adhesive, etc., and is widely used in core components such as thermal management, charging protection, and power modules of charging piles, playing a key role in charging pile components.

 

What challenges does the popularization of supercharging technology bring to charging facilities?

 

If new energy vehicles want to get a charging experience close to that of fuel vehicles, they must improve their charging efficiency in an all-round way. This is why car companies are striving to bring 4C or even 5C supercharging technology to consumers while promoting the 800V high-voltage platform.

 

In August 2023, CATL launched the world's first lithium iron phosphate 4C supercharging battery-Shenxing Supercharging Battery, claiming to achieve 10 minutes of charging and a range of 400 kilometers. After that, 4C fast charging has entered the field of vision of consumers more and more frequently.

 

How is 4C supercharging defined? Simply put, XC refers to the charging rate, that is, the ratio of the maximum charging current that the battery can accept during charging to the rated capacity of the battery, represented by C, which is usually used to describe the speed of charging. Specifically, if the vehicle is equipped with a 100kWh battery pack, the charging power can reach about 200kW at a rate of about 2C; at a rate of about 4C, the charging power can reach about 400kW; at a rate of 6C, the charging power can reach about 600kW. In short, the higher the charging rate, the faster the charging speed.

 

If you want to truly popularize supercharging, in addition to power batteries and high-voltage platforms, you must also adapt to high-power DC charging piles. The power output capacity of the charging pile and the stability of the power supply will affect the charging rate. High-power charging piles and stable power supplies can provide higher charging rates.

 

 

The charging pile is mainly composed of charging gun, charging cable, shell, control module, thermal management module, charging protection module and other components. From AC slow charging to DC fast charging, and then to super fast charging, which may gradually become popular in the future, all components need to be upgraded iteratively to adapt to the change of charging power.

 

In fact, before the super charging technology, in the process of the development of charging piles from AC slow charging to DC fast charging, problems such as high cost, grid burden, compatibility, battery life, and difficult installation have been roughly solved.

 

On the basis of DC fast charging technology, super fast charging provides a higher charging rate, so the charging pile needs to bear higher power, larger current, and higher heat generation. At the same time, it is also necessary to solve the problem of excessive size and weight of the charging pile and stricter cable flexibility requirements.

 

For the charging gun, in order to achieve fast charging, the super charging gun needs to be able to transmit large current. This requires the charging gun to have good conductivity and heat dissipation design to ensure safe and efficient current transmission.

 

 

 

Supercharging technology also needs to be equipped with a complete safety protection mechanism, including overcurrent protection, overvoltage protection, short circuit protection, etc. Charging piles and charging guns should have monitoring and protection functions to prevent malfunctions and dangers during charging.

 

Not only that, since high-power charging will generate a lot of heat, charging piles and charging guns need to be equipped with an effective cooling system to prevent overheating, including fans, heat sinks, water cooling and other heat dissipation methods.

 

What are the requirements for materials for the upgrade of charging facilities?

 

With the increase in charging power, charging piles not only need to design more advanced structures to meet the thermal conductivity under high power, but also, on the material side, it is imperative to use materials with strong insulation, high temperature resistance and high thermal conductivity.

 

Taking the thermal management system of charging piles as an example, unlike traditional air cooling, supercharging requires more use of liquid cooling to solve efficiency and heat dissipation problems. At present, the most commonly used liquid cooling methods on the market are water-based cooling and oil-based cooling. Water cooling has better heat dissipation performance, lower cost, and is more environmentally friendly; oil cooling has good electrical insulation, lower evaporation rate and chemical stability.

 

In the past few years, oil-cooled cables have been used in super charging guns, gaining a first-mover advantage. At present, some manufacturers have developed oil-cooled super charging piles and charging guns, but as the operating time goes by, the cost disadvantage of oil cooling becomes more and more prominent. Now more manufacturers are beginning to study and test water-cooled cables and water-cooled super charging guns.

 

The working principle of water-cooled cables and water-cooled super charging guns is that the water-cooling tube is designed outside the multi-strand charging wire, and water flows in the middle of the tube. Relying on the thermal conductivity of the tube itself, the heat generated by the multi-strand charging cable is transferred to the coolant in the middle of the tube. These coolants exchange heat with the outside world through electronic pumps to achieve temperature control of cables and super charging guns.

 

Based on this principle, many manufacturers used ordinary nylon tubes as the water-cooling tubes in the middle of water-cooled cables. Due to the use of PA material, the thermal conductivity is only 0.2W/m·K. When the current exceeds 400A, the temperature rise accelerates sharply. At this time, due to the insufficient thermal conductivity of the water-cooling tube, the heat cannot be transferred out in time. After calculation, it was found that based on the common structure of the current cables, if the goal of high current fast charging is to be achieved, the thermal conductivity of the cold water pipe must be greatly improved, at least 1.5W/m·K or more. Therefore, the upstream and downstream of the industry chain pay more and more attention to the innovative application of high thermal conductivity materials, and thermal conductive silicone tubes have become one of the key components of thermal management of super charging piles.

 

 

 

 

In addition to the temperature control of the charging cable, how to reduce the temperature rise of the charging gun head during the charging process is also a pain point in the current charging pile design. At present, it is difficult to solve the heat dissipation problem by air cooling. By using innovative thermal conductive potting glue, the heat of the gun head connector can be efficiently transferred out to ensure that the charging efficiency will not decrease due to the temperature increase, and at the same time, the user experience during operation can be further improved.

 

On the other hand, when the voltage platform of new energy vehicles in the future generally reaches 800V, the charging current reaches 600A, and the charging power reaches more than 400kW, any problems in the charging process may cause extremely serious consequences. Therefore, the sealing and anti-leakage properties of structural materials will be unprecedentedly valued.

 

Under the new trend, how to innovate on the material side?

 

When it comes to upstream material suppliers in the charging pile industry chain, Dow is the first to bring many innovative designs and cutting-edge ideas to the industry. Dow can not only provide a rich selection of materials, but also customize exclusive solutions for higher-power DC fast charging infrastructure (including charging stations, charging guns (connectors), cables and charging cabinets) to meet more stringent market needs.

 

In the field of charging facilities, Dow focuses on three major directions. First, in terms of thermal management materials, Dow provides a wide range of adhesive products including caulking agents, adhesives, non-curing thermal interface materials, immersion coolants, gels and potting glues to solve the heat dissipation pain points in charging facilities; in terms of protection and assembly materials, Dow provides adhesives, sealants and conformal coatings to provide all-round protection for charging components; in addition, Dow can also provide elastomers, solid thermal conductive silicone rubber and liquid silicone rubber to support insulation, thermal conductivity and other needs.

 

For example, capturing the thermal conductivity requirements of the charging cable mentioned above, Dow has developed a new thermal conductive silicone rubber - SILASTIC™ HTE5015-90U silicone rubber, which solves the key technical difficulties in the water-cooled super charging gun solution - the cooling water pipe must have both high thermal conductivity and high strength and high toughness materials. The most significant advantage of this product is that it has a higher thermal conductivity, with a thermal conductivity of up to 1.5W/m·K, which can cool the cable of the super charging gun with a current of 600A and provide thermal protection. At the same time, good physical properties and resistance to harsh environments allow it to be used to extrude thermally conductive silicone tubes. High hardness and high strength enable direct twisting with cables. In addition, better flexibility, durability, high and low temperature resistance, coolant resistance, insulation and other indicators provide long-term protection for super charging guns.

 

In response to the heat dissipation and sealing needs of charging gun heads, Dow has developed a series of products. Dow's DOWSIL™ TC-6040 thermal conductive potting glue has a thermal conductivity of 4.0W/m·K, which can quickly cool down overheated charging guns, which will not be hot, and ensure the normal operation of the modules inside the system, especially the most important inverter module. Long-term reliability; for the sealing requirements of liquid-cooled charging piles, the sealing rings and wiring harness sealing rings made of Dow's silicone elastomer materials have achieved good waterproof effects.

 

Conclusion

 

After years of vigorous development in the new energy vehicle industry, the pain points of end users have gradually transitioned from cruising range to efficient energy replenishment experience, and the promotion of high-power and high-efficiency charging facilities is imminent. In this process, upstream and downstream companies in the industrial chain need to work together to cope with the various challenges faced by the fast charging trend, from batteries to charging facilities, from materials to applications. We hope that the leading companies in the upstream and downstream of the industrial chain can bring more efficient and easy-to-use solutions to the fast charging development of new energy vehicles.