The Importance of New Energy Crown Springs in Electrical Applications

The Importance of New Energy Crown Springs in Electrical Applications

As the core connection component of the high-voltage electrical system of new energy vehicles, the new energy crown spring plays an irreplaceable role in ensuring the efficiency, safety and reliability of power transmission. Its importance is mainly reflected in the following five dimensions:

1. Electrical performance optimization: ensuring stable transmission of large currents

1. Low contact resistance and efficient conduction

The crown spring significantly reduces the contact resistance (typical value <0.5mΩ) and energy loss through multi-point contact design (such as shutter-type spring structure). For example, in the high-voltage wiring harness, the crown spring jack can have dozens of contact points, which is more than 65% higher than the contact area of ​​the traditional wire spring, effectively reducing the temperature rise (ΔT<15℃@600A) and avoiding insulation aging caused by local overheating.

2. High-frequency signal stability

In the signal transmission between the charging pile and the vehicle control system, the elastic contact characteristics of the crown spring can suppress contact jitter and ensure the integrity of high-frequency signals (such as CAN bus). Its adaptive pressure adjustment capability (contact pressure range 5-20N) adapts to plug-in vibration and reduces signal bit error rate.

2. Environmental adaptability: Coping with harsh working conditions

1. High voltage resistance and insulation protection

The crown spring jack is equipped with a shielding layer design (such as PPA plastic shell) to achieve a creepage distance of ≥24mm, meeting the insulation requirements of the 600V high voltage system. The application of silicone rubber sheath makes its compressive strength reach 3.5kV/mm, adapting to high humidity and salt spray environments.

2. Vibration resistance and fatigue resistance

The vibration frequency of new energy vehicles can reach 20-200Hz during driving. The corrugated leaf structure of the crown spring (such as Amphenol Radsok technology) absorbs impact through elastic deformation, and the plug-in life is more than 10,000 times (traditional leaf springs are only 5,000 times).

3. Lightweight and space efficiency

1. Material and structural innovation

The use of beryllium copper alloy (such as C17410) to replace traditional brass reduces the density by 15% (8.9→7.7g/cm³) while maintaining conductivity (≥120MS/m). The compact crown spring design reduces the connector volume by 30%, which is suitable for compact battery pack layout.

2. Integrated design

The double-spring composite structure (such as the positive and negative electrodes share the crown spring) reduces the number of connection points, and the overall height of the high-voltage connector is compressed to 12mm (the traditional design requires 18mm), which improves the space utilization rate in the cabin.

IV. Safety and reliability guarantee

1. Anti-mistouch and short-circuit protection

The directional plug-in design of the crown spring jack (such as conical surface matching) ensures that the plug is correctly positioned and the contact pressure is evenly distributed to avoid the risk of short circuit caused by misalignment. Experimental data shows that its anti-misplug reliability reaches the IP2X standard.

2. Extreme temperature tolerance

Through heat treatment (solid solution + aging) and surface plating (silver plating thickness 5-10μm), the crown spring maintains a stable elastic modulus (change rate <5%) in the range of -40℃~150℃, which is suitable for the working conditions of the battery thermal management system.

V. Cost and maintenance economy

1. Full life cycle cost optimization

The tool-free installation design of the crown spring (such as the self-locking end cap) reduces assembly time (saving 3 minutes per piece) and supports quick replacement. Compared with the claw spring, the maintenance cost is reduced by 40%.

2. Cost reduction through large-scale production

The stamping process (accuracy ±0.02mm) keeps the unit price of the crown spring at ￥2-5/piece, which is 60% lower than the customized wire spring solution. Domestic substitution (such as domestic C17510 beryllium copper) further compresses material costs by 30%.

Development trend

1. Material upgrade: The application of nanocrystalline beryllium copper (conductivity 135MS/m) and carbon fiber reinforced plastic (CFRP) housing drives the power density to 3kW/L.

2. Intelligent integration: The intelligent crown spring with built-in NTC temperature sensor monitors the contact point temperature in real time and warns of overheating risks.

3. Green manufacturing: Cyanide-free electroplating process replaces traditional silver plating, reduces heavy metal pollution, and complies with RoHS 2.0 standards.

The technical iteration of new energy crown springs is directly related to the range, charging speed and safety standards of new energy vehicles, and its innovation has become the core focus of industry competition.