Heavy Duty 2+5 Battery Swap Connector Port Explosion Proof 250V
Explosion Proof battery swap connector
,250V battery swap connector
,250V swappable battery connector
Heavy duty 2+5 battery swap port
Product Description:
The Explosion-proof Battery Swap Interface is a rugged and highly safe power connection designed specifically for battery swap stations, electric vehicles, energy storage systems, and environments with flammable or explosive risks. Built to comply with stringent explosion-proof standards, this connector ensures reliable power delivery, stable signal transmission, and exceptional resistance to interference under the harshest operating conditions. It offers an ideal connectivity solution for rapid battery replacement applications.
Crafted using premium industrial-grade materials, the connector's housing consists of high-performance PBT thermoplastic reinforced with 30% glass fiber, achieving the UL94-V0 flame retardancy rating. This robust plastic casing provides superior resistance to high temperatures, mechanical stress, aging, and electrical insulation challenges. The internal conductive terminals are fashioned from high-purity copper alloy, ensuring outstanding electrical conductivity and structural integrity.
Electrically, the battery swap connector supports up to 250V AC and incorporates a dual-circuit design. The high-voltage power terminal can handle currents up to 30A, while the low-voltage communication terminal supports 1A for signal exchange. It features excellent electrical characteristics including a maximum contact resistance of 50 milliohms, a dielectric withstand voltage of 1500V DC for one minute, and a minimum insulation resistance of 100 megaohms, effectively mitigating risks such as electric leakage, arcing, and short circuits.
Mechanically, the interface is engineered to endure frequent plug-and-play operations, with a maximum mating force of 60 Newtons and a minimum withdrawal force of 30 Newtons, delivering consistent feedback and secure locking. It guarantees a minimum of 5000 mating cycles, making it highly suitable for continuous battery swapping usage.
Designed for demanding environments, this explosion-proof connector operates reliably over a wide temperature range from -40°C to +105°C, resisting extreme cold, intense heat, and rapid temperature changes. The surface finishes enhance durability: terminals are nickel-plated at 3 micrometers thickness, while the crown yellow contact points are plated with 0.075 micrometers of gold to prevent oxidation, reduce contact resistance, and maintain stable power and signal transmission over time.
Combining explosion-proof features, flame-retardant materials, high current capacity, and exceptional longevity, this battery swap interface is widely applied in electric motorcycles, electric vehicles, energy storage cabinets, and explosion-proof industrial equipment. It delivers safe, dependable, and efficient connection solutions for commercial and industrial energy systems requiring fast battery replacement.
- Explosion-proof & Flame Retardant: PBT GF30% housing with UL94-V0 certification providing flame and explosion resistance suitable for hazardous environments.
- Dual Circuit Design: Separate terminals for high-current power and low-current communication.
- Excellent Electrical Safety: High dielectric strength and insulation resistance to prevent electrical leaks.
- Premium Plating Technology: Nickel plating on terminals and gold plating on contact points for oxidation resistance and stable conductivity.
- Durable Mechanical Performance: Over 5000 insertion cycles, ideal for frequent battery swaps.
- Wide Temperature Resistance: Operates reliably from -40°C up to +105°C.
- Maximum Voltage Rating: 250V AC
- High Voltage Power Terminal Current: 30A
- Low Pressure Communication Terminal Current: 1A
- Maximum Contact Resistance: 50 mΩ
- Dielectric Withstanding Voltage: 1500V DC for 1 minute
- Minimum Insulation Resistance: 100 MΩ
- Maximum Mating Force: 60N
- Minimum Withdrawal Force: 30N
- Durability: At least 5000 mating cycles
- Operating Temperature Range: -40°C to +105°C
- Housing Material: PBT with 30% Glass Fiber, UL94-V0 rated
- Contact Material: Copper Alloy
- Terminal Plating: 3μm Nickel
- Crown Yellow Contact Plating: 0.075μm Gold
Features:
Explosion-proof & Flame Retardant Structure: This product is constructed with a high-strength PBT GF30% thermoplastic housing that meets the UL94-V0 flame retardant standard. Such design effectively prevents arcing, open flames, and explosion hazards, ensuring safe operation in energy storage systems and environments where flammable materials are present.
Dual-circuit Independent Design: It features separate high-current power terminals rated at 30A and low-current communication terminals rated at 1A. This segregation of power and signal lines eliminates signal interference, guaranteeing stable and reliable battery swapping performance.
Superior Electrical Insulation Performance: The product offers low contact resistance up to a maximum of 50mΩ, withstands high voltage resistance of 1500V DC, and maintains a minimum insulation resistance of 100MΩ. These characteristics effectively prevent electrical leakage and short circuits, ensuring long-term safety in connections.
Premium Copper Alloy Conductivity: Crafted using high-purity copper alloy contacts, combined with 3μm nickel plating on terminals and 0.075μm gold plating on contact points. This combination provides excellent electrical conductivity along with robust anti-oxidation and anti-corrosion properties.
Optimized Mechanical Insertion Feel: Designed with a balanced mating force of ≤60N and a withdrawal force of ≥30N, it ensures smooth insertion, secure locking, and prevents loose contacts even during frequent battery replacements.
Long Service Durability: The component supports over 5000 mating cycles, making it ideal for high-frequency plug-and-play applications commonly found in battery swap stations and electric vehicles.
Wide Temperature Adaptability: It functions reliably across a broad temperature range from -40°C to +105°C, demonstrating resilience against high temperature aging and brittleness caused by extreme cold.
High Safety Industrial Grade Structure: Featuring a compact, reinforced housing that is shock and pressure resistant, this product is well-suited for use in electric motorcycles, battery swap cabinets, and energy storage equipment.
Technical Parameters:
The interface operates at a rated voltage of up to 250 V AC maximum. The high voltage power terminal is rated for 30 amperes, while the low pressure communication terminal supports up to 1 ampere. The contact resistance is maintained at a maximum of 50 milliohms to ensure efficient electrical connectivity. Additionally, the dielectric withstanding voltage is tested at 1500 volts DC for one minute, and the insulation resistance is guaranteed to be no less than 100 megaohms.
Regarding mechanical performance, the maximum mating force required is 60 newtons, ensuring secure connections without excessive effort. The minimum withdrawal force to disengage the interface is set at 30 newtons to avoid accidental disconnections. The device also boasts durability with a minimum rating of 5000 mating cycles, supporting long-term reliable use.
Designed to operate in harsh environments, the interface functions reliably within a temperature range from -40 degrees Celsius up to +105 degrees Celsius, accommodating various challenging conditions.
The housing of the interface is constructed from a thermoplastic material composed of PBT (Polybutylene Terephthalate) reinforced with 30% glass fiber, which also meets UL94-V0 flame retardant standards. Contacts are made from high-purity copper alloy, ensuring excellent conductivity and durability.
Terminal surfaces are plated with 3 micrometers of nickel to provide corrosion resistance and durability. Contact points receive a finer plating of 0.075 micrometers of gold, enhancing conductivity and reducing wear during connections.
