Ningbo Fenghua Bolong Machinery Manufacturing Co., Ltd. is one of the leading manufacturers and suppliers of ev copper battery terminals in China. Please feel free to buy durable ev copper battery terminals made in China here from our factory. All customized products are with high quality and competitive price.
Core Advantages
Red Copper High-Conductivity Solution - Oxygen-free copper TU00 material, conductivity ≥58 MS/m, internal resistance approximately 50% lower than brass. Suitable for main power circuits in power batteries, minimizing thermal losses during high-current charge/discharge cycles. The cold heading integral forming process ensures this conductivity advantage is consistently delivered at ±0.02mm precision, meeting the performance consistency requirements of automotive-grade high-current connection components.
Plating Protection Solutions - Offering nickel, silver, tin, and gold plating options. Nickel plating thickness 2-8μm (customizable based on corrosion protection requirements), salt spray test up to 48+ hours, particularly suitable for copper-glass isolation protection during high-temperature ceramic sealing processes; silver plating contact resistance ≤0.5mΩ, compatible with laser welding and ultrasonic welding processes with high joint consistency. All plating solutions are optimized for adhesion on cold headed terminal surface conditions, accommodating different downstream process windows.
Stainless Steel Weather-Resistant Solution - 304/316 stainless steel maintains surface stability at sealing temperatures above 800°C with no oxide scale formation, suitable for high-temperature hermetic sealing processes. Also meets corrosion resistance requirements for long-term outdoor service, providing a reliable terminal selection path for high-temperature or highly corrosive operating conditions.
Aluminum Alloy Lightweight Solution - 6061 aluminum alloy terminals achieve approximately 65% weight reduction compared to copper materials. In certain battery pack structures, every 1kg of weight reduction contributes approximately 0.5-1km of driving range. The cold heading process ensures structural strength of aluminum alloy at high precision, balancing lightweighting with mechanical reliability.
Brass Cost-Effective Solution - H59/H62 brass strikes a balance between moderate conductivity (15-28 MS/m) and cost, suitable for non-main-power circuit signal connections or cost-sensitive projects. Also enjoys ±0.02mm precision and mechanical consistency delivered by the cold heading process.
Unified Precision Guarantee - No Secondary Machining Required - Regardless of material selection, all terminals are delivered at ±0.02mm tolerance, burr-free, with consistent dimensions. Ready for direct feeding into downstream ceramic sealing or plating processes upon delivery, with no secondary sizing required. This reduces handling steps and helps battery manufacturers streamline supply chain management.
Technical Specifications
|
Material Option |
Conductivity |
Recommended Plating |
Typical Application Scenarios |
|
Red Copper (Oxygen-Free TU00) |
≥58 MS/m |
Nickel/Silver/Bare |
Main power circuit high-current connections |
|
H59/H62 Brass |
15-28 MS/m |
Nickel |
Signal connections / Cost-sensitive projects |
|
304/316 Stainless Steel |
~1.4 MS/m |
None required |
High-temperature sealing / Corrosive environments |
|
6061 Aluminum Alloy |
34-38 MS/m |
Nickel |
Lightweight-priority structures |
Size Range: Diameter Φ2–Φ20mm, Length 3–150mm (customizable)
Precision & Process: ±0.02mm tolerance, 6-station cold heading integral forming
Plating Options: Nickel (2-8μm), Silver, Tin, Gold
Quality Systems: IATF 16949, ISO 14001, ISO 45001, IECQ QC080000
Production Capacity: Maximum daily capacity of 1.5 million pieces, reliably supporting large-scale EV project deliveries
Quality Control
|
Stage |
Control Measures |
|
Incoming Material |
100% material certificate verification - chemical composition and mechanical properties double-confirmed with batch labeling |
|
In-Process Monitoring |
Real-time parameter calibration and data archiving - SPC on critical dimensions, real-time die temperature monitoring |
|
Finished Full Inspection |
100% AI visual inspection (dimension + appearance) + mechanical performance batch sampling + plating thickness sampling |
|
Traceability System |
Finished batch ↔ Raw material batch ↔ Production parameters ↔ Inspection data - full two-way traceability |
Application Scenarios
Material selection for terminals determines downstream process windows and in-service performance. Below are typical selection guidelines:
High-Temperature Conditions - Stainless Steel / Nickel-Plated Copper Terminals
When battery sealing structures undergo high-temperature ceramic-to-glass sealing processes (above 800°C), stainless steel withstands thermal cycling without oxidation. For copper base material with nickel plating, the nickel layer acts as a diffusion barrier during sealing, preventing adverse reactions between copper and glass
High-Conductivity Requirements - Red Copper / Silver-Plated Copper Terminals
Power battery high-current charge/discharge scenarios are highly sensitive to terminal internal resistance. Red copper conductivity ≥58 MS/m, with silver plating further reducing contact resistance to ≤0.5mΩ level, suitable for main power circuit connections.
Lightweight Priority - Aluminum Alloy Terminals
In certain battery pack structures, every 1kg of weight reduction contributes approximately 0.5-1km of driving range. 6061 aluminum alloy terminals combined with cold heading process achieve weight reduction while maintaining structural strength at high precision.
Cost-Sensitive Projects - Brass Terminals
For non-main-power circuits or signal connections with relatively relaxed conductivity requirements, H59/H62 brass offers moderate conductivity performance at a more economical price point.
Plating Solution Process Compatibility:
|
Plating Option |
Compatible Processes |
Key Performance Indicators |
|
Nickel (2-8μm) |
Welding, Crimping |
Salt spray 48h+, adhesion ≥15N |
|
Silver |
High-current connections |
Contact resistance ≤0.5mΩ |
|
Tin |
Laser welding |
Superior solder wetting, no spatter |
|
Gold |
Signal/Low-voltage connections |
Ultra-low contact resistance, oxidation resistant |
Custom Services
Material Selection Consulting
Material recommendations based on your operating conditions (operating temperature, current load, environmental corrosivity, cost budget)
01
Custom Sizing
Per drawing or sample - diameter Φ2–Φ20mm, length 3–150mm range
02
Plating Customization
Nickel/Silver/Tin/Gold - thickness and process parameters adjustable per downstream welding or crimping requirements
03
Sample Support
1.5-day rapid changeover - small-batch trial production available for material and process validation
04
Volume Delivery
From pilot runs to million-level mass production - shared production line across multiple materials with flexible changeover and stable delivery
05
Whether you are selecting terminal materials, evaluating plating solutions, or need customized recommendations for specific operating conditions, our engineering team provides full support from material recommendations through sample validation to mass production delivery.
Contact Us for Your New Project
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