High-Current Waterproof Connector for Automotive Heating Systems
In automotive systems, especially in heating and thermal management applications, connectors must withstand high current loads, vibration, and harsh environmental conditions. A leading automotive client approached Qianwei Precision to develop a reliable, high-current waterproof connector capable of long-term stable performance.
Customer Requirements
Our customer needed a connector solution with the following specifications:
Application:
Automotive heating system
Environment:
Vehicle interior with vibration exposure
Electrical Rating:
50A / 500V high-current transmission
Key Challenge:
Strong mechanical stability under vibration
Waterproof performance (IPX7)
Low resistance and high conductivity
Long service life with repeated insertion cycles
Qianwei Precision Solution
Custom Connector Design
Qianwei Precision engineered a high-current automotive connector assembly with:
Dual-end structure:
One side integrated with PTC terminal connection
The other side designed for secure plug-in interface
Insert molding technology ensuring structural integrity and sealing performance
Optimized contact structure to reduce resistance and heat generation
Performance Advantages
Superior Electrical Performance
Low contact resistance ensures efficient power transmission. Stable performance under continuous high current loads.
Outstanding Mechanical Reliability
High insertion/extraction durability (100+ cycles minimum). Excellent vibration resistance for automotive environments.
Robust Environmental Protection
IPX7 waterproof rating ensures safe operation in humid or wet conditions. Corrosion-resistant tin plating extends service life.
Materials & Manufacturing
Terminal Material:
Brass (high conductivity and durability)
Housing Material:
PBT (excellent insulation and thermal resistance)
Surface Treatment:
Tin plating for enhanced corrosion resistance
Process:
- Precision stamping
- Insert molding
- Full inspection and packaging
Parameter | Specification |
Current Rating | 50A |
Voltage Rating | 500V |
Waterproof Level | IPX7 |
Mounting | M4 / M5 options |
Temperature Resistance | -50°C to 150°C |
Conductivity | Low resistance, stable current flow |
Testing & Certification
The product passed comprehensive validation tests:
- Salt spray test
- Insertion & withdrawal force test
- Contact resistance test
- Dielectric strength test
- Waterproof performance test
- Durability lifecycle test
Compliance: RoHS, REACH
Results & Customer Feedback
After implementation, the client reported:
Improved connector reliability in high-current operation
Enhanced system safety and durability
Stable performance under long-term usage
Customer Feedback:
“The product demonstrates excellent stability and reliability in our application.”
Why Choose Qianwei Precision?
- Strong expertise in custom terminal and connector solutions
- Advanced manufacturing processes including insert molding
- Strict quality control and full testing capabilities
- Proven experience in automotive, energy, and industrial applications
This customized solution significantly improved connection reliability and durability in demanding automotive environments. Qianwei Precision continues to deliver high-performance, application-specific connector solutions tailored to customer needs.
Products
FAQ
Qianwei Precision supplies precision terminals and connectors for a wide range of EV applications, including battery systems, power distribution units (PDU), onboard chargers (OBC), inverters, DC-DC converters, and charging interfaces.
Absolutely. Our terminals and connectors are widely used in battery modules, battery packs, and BMS connections, supporting reliable power and signal transmission.
We focus on low contact resistance, optimized contact force, robust insulation compatibility, and strict quality control, reducing the risk of overheating, arcing, and connection failure.
Qianwei Precision manufactures under IATF 16949 and ISO 9001 quality management systems, and products comply with RoHS and REACH requirements.
Our EV components are designed to withstand continuous vibration, mechanical shock, and thermal cycling, ensuring long-term reliability under real-world vehicle operating conditions.
Contact
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