How to choose the right automotive connector material
Choosing the right automotive connector material requires considering many factors, including the material’s conductivity, corrosion resistance, mechanical strength, and thermal stability. Commonly used materials include copper alloys, aluminum alloys, and stainless steel. Copper alloys are widely used due to their excellent conductivity and corrosion resistance, but they are relatively expensive. Aluminum alloys are lightweight and suitable for applications that require weight reduction. Stainless steel provides good corrosion resistance and mechanical strength, making it suitable for use in harsh environments.
Material cost comparison analysi
Cost is an important consideration when selecting automotive connector materials. When making cost comparisons, a comprehensive evaluation should be made based on material performance and application requirements.
| Material | Cost Percentage (%) | Price Trend |
|---|---|---|
| Copper/Brass | 30-40 | High volatility, fluctuated by up to 40% from 2017 to 2021 |
| Thermoplastic | 20-30 | Significantly affected by petroleum costs |
| Steel | 10-15 | N/A |
| Gold | 5-10 | Increased dramatically in 2020, stable in 2021 |
What are the standardization issues of automotive connector
- The standard system is complex: international standards, regional standards, and corporate standards coexist
- Inconsistent testing requirements: different standards have differences in test items and parameters
- Diversified specifications: connector specifications range from 0.5mm to 9.5mm, with a wide variety
- Dispersed suppliers: There are more than 10 major suppliers in the world, and it is difficult to unify standards
- Different requirements of car companies: Different car companies have different requirements for connector performance
Standardization helps to improve interchangeability and compatibility and reduce production costs. At present, international standards such as ISO, IEC and industry standards such as SAE have put forward specific requirements for automotive connector.
How to ensure the stable performance of connector at different temperatures
Choose the right material: Choose a material with good temperature resistance according to the operating temperature range
Perform a thermal aging test: Verify the performance of the connector under long-term use at high temperatures
Perform a temperature cycle test: Simulate the impact of rapid temperature changes on the connector
Test key parameters: Monitor contact resistance, insulation resistance, etc. at different temperatures
Optimize structural design: Consider the thermal expansion coefficient and reduce temperature stress
How to verify the durability of automotive connector through testing
Verifying the durability of automotive connector is usually achieved through a series of rigorous tests. These tests include mechanical vibration tests, temperature cycle tests, humidity tests, and salt spray tests. These tests simulate various extreme conditions in actual use environments to evaluate the reliability of connectors in long-term use. In addition, electrical tests can also be performed to check whether its conductive performance meets the requirements, thereby ensuring that the product meets industry standards and customer needs.