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Waterproof high-voltage EV assembly for new energy vehicles

Waterproof high-voltage EV assembly for new energy vehicles

Specifically designed for high-voltage system integration in new energy vehicles (pure electric/hybrid), its core purpose is to achieve integrated high-voltage power transmission and low-voltage signal communication for key components such as battery packs, inverters, drive motors, and OBC on-board chargers. It also features IP67~IP68 waterproof protection, making it suitable for wet/water-prone environments such as the vehicle chassis and battery pack compartment.
Product Features:
√ Fully waterproof and sealed, suitable for water-related applications
√ High-voltage integration for more reliable transmission
√ Vehicle-grade durability, suitable for harsh environments
√ Compliant compatibility for efficient installation and maintenance
Product Description

Specifically designed for high-voltage system integration in new energy vehicles (pure electric/hybrid), its core purpose is to achieve integrated high-voltage power transmission and low-voltage signal communication for key components such as battery packs, inverters, drive motors, and OBC on-board chargers. It also features IP67~IP68 waterproof protection, making it suitable for wet/water-prone environments such as the vehicle chassis and battery pack compartment. The assembly employs an integrated wiring harness layout, high-voltage sealed connectors, and a multi-layered protective structure, along with automotive-grade certified terminals and a complete set of installation accessories. It possesses high voltage resistance, strong waterproofing, vibration resistance, and electromagnetic interference protection, and can withstand complex operating conditions such as high and low temperatures, bumps, and oil contamination during vehicle operation. It is a core integrated component ensuring the safe, stable, and efficient operation of high-voltage systems in new energy vehicles.

Product Specifications
Customization Dimension Optional Parameter Range Description
Vehicle & System Compatibility Customization Compatible with EV models (BYD / Tesla / NIO / Xpeng, etc.); Matching 30kW~300kW power systems and various battery pack interfaces Vehicle model, power system layout drawing, and interface specifications required to ensure precise compatibility of the integrated wiring harness with the entire vehicle
Power & Specification Customization High-voltage: DC 600V~2000V, Current 50A~800A, Conductor Size 6~150mm²; Low-voltage: 24~14AWG ≥50mm² high-voltage conductor recommended for high-power vehicles (>200kW); Conductor upsizing required for extra-long distances (>8m) to reduce power loss
Material & Protection Customization Conductor: Tinned Copper / Bare Copper / Silver-plated Copper; Sheath: XLPE/TPU/Teflon; Protection Level: IP67~IP68 IP68 protection for frequent wading scenarios; TPU sheath for low-temperature regions (<-40℃); Teflon for severe oil contamination environments
Connector & Terminal Customization Connectors: Waterproof Sealed / Explosion-proof / Quick-Connect; Terminals: Crimp / Board-to-Board / Insulation Displacement Connector (IDC) Explosion-proof connectors for high-voltage systems (>1000V); Quick-connect connectors for frequent maintenance scenarios; IDC terminals for bulk assembly
Integrated Function Customization Integrate Temperature Sensor / Overcurrent Fuse / Voltage Detection Module / EMC Filter Component Sensor model, fuse rated current, and detection module signal protocol to be specified; Filter components must meet the vehicle’s electromagnetic compatibility (EMC) requirements
Layout & Length Customization Length: 1m~15m (Supports differentiated lengths for multi-branches); Layout: Integrate power/signal branches as needed Vehicle wiring harness layout drawing required; Branch positions must avoid chassis moving parts to prevent damage from pulling
Marking & Compliance Customization Custom Vehicle Number / Voltage Level / Safety Warning / Compliance Marking Free laser marking for bulk orders (≥30 sets) with labels such as “High Voltage Danger” / “Waterproof IP68” to meet vehicle compliance inspection requirements
Packaging Customization Individual Moisture-Proof Packaging per Set / Bulk Anti-Static Packaging / Export-Customized Packaging Standard delivery with individual moisture-proof packaging; UN 38.3-compliant anti-static packaging optional for export vehicle matching to prevent transportation damage
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