In the modern industrial world, terminal blocks serve as the crucial joints in the circulatory system of electrical circuits. As essential components for industrial automation and control, they come in a vast variety, from basic PCB terminals to spring-cage and barrier types, each serving a specific purpose. However, as the industry ventures into the deep waters of new energy—facing the harsh environments of energy storage systems, EV charging stations, and high-voltage converters—traditional terminal solutions are no longer sufficient.
So, what are the limitations of conventional terminals? Can they safely and reliably handle hundreds of amps of current? How do they ensure connection stability under intense vibration and high temperatures? To address these critical challenges, a new solution has emerged: high-current new energy terminals, such as Through Wall Power Terminals and Single Stud Type Junction Blocks. These robust, purpose-built connectors are not only designed to carry immense current but also to meet unprecedented demands for safety and reliability.
What Are High-Current New Energy Terminals and Why Are They So Important?
A high-current new energy terminal is an electrical connection component specifically designed for high-power, high-voltage, and high-current transmission applications. Its primary function is to safely and efficiently route power from the inside of an enclosed system (like a battery pack or converter) to the outside, while maintaining the system’s integrity and sealing.
These terminals are vital due to their unique technical features:
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Extreme Current-Carrying Capacity: Unlike traditional terminals, high-current new energy terminals can handle hundreds of amps of current. This is made possible by their use of high-quality conductive materials (such as silver-plated copper alloy) and optimized current path designs, which fundamentally eliminate the risk of overheating and burnout caused by excessive current.
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High-Standard Safety Protection: In high-voltage, high-current new energy equipment, any oversight can lead to severe consequences. High-current terminals often feature patented safety designs, including anti-misinsertion, anti-touch, anti-vibration, and high IP ratings (typically IP67 or higher), ensuring the safety of both operators and equipment.
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Stability in Harsh Environments: New energy equipment often operates in conditions of high temperature, vibration, and humidity. High-current terminals use special structures and materials (like PA66 flame-retardant insulation) to resist displacement from vibration and maintain a long-term airtight connection, ensuring reliable operation under various complex conditions.
The Essential Differences Between New Energy and Traditional Terminals
To better grasp the unique value of high-current new energy terminals, let’s compare them with common traditional terminal types.
| Feature | High-Current New Energy Terminals | Traditional Terminals |
|---|---|---|
| Typical Application | Energy storage systems, EV chargers, high-voltage converters, high-power industrial control | Industrial automation, instrumentation, lighting, low-voltage power distribution |
| Current Capacity | High current, up to several hundred amps (e.g., 300A), designed for high-power transmission | Low current, typically below a few dozen amps (e.g., 41A, 57A) |
| Safety Protection | High-level protection: features like IP67+, anti-misinsertion, anti-touch, flame-retardant | Basic protection: typically IP20, some with basic dust/touch protection |
| Structure & Maintenance | Modular, detachable design, supports multi-directional wiring, easy and low-cost maintenance | Fixed, monolithic design, requiring full component replacement for maintenance, which is time-consuming |
| Technical Focus | High current transmission, high safety, weather resistance | Basic electrical connection, prioritizing cost and versatility |
- Fundamental Difference in Application: Traditional terminals (like barrier-style or spring-cage types) primarily solve connection problems for low-voltage, low-current control signals. In contrast, high-current new energy terminals were created to solve the new challenge of high-power transmission. Their applications are more specific, and their requirements are far more stringent.
- A Generational Leap in Design Philosophy: Traditional terminals are designed with versatility and cost in mind. High-current terminals, however, prioritize safety, reliability, and efficiency above all else. This is reflected in their specialized materials, unique structural designs, and strict international certifications (e.g., UL4128, TUV). For example, a Single Stud Type Junction Block uses a unique stud design to ensure connection stability and high current-carrying capacity—a feat traditional terminals cannot match.
Innovation: How High-Current New Energy Terminals Meet Demanding Applications
High-current new energy terminals are more than just “larger” terminals; they represent a significant innovation in connection technology. These advancements are most apparent in the following areas:
- High Current and Path Optimization: Taking the 300A square through-wall connector as an example, its core lies in the use of high-quality conductive busbars that are precisely nested with the base. This design not only ensures physical connection stability but also optimizes the current path, significantly reducing contact resistance. This effectively controls temperature rise and guarantees long-term stable operation under high current conditions.
- Modularity and Maintenance Convenience: Traditional terminals are often monolithic, requiring the entire part to be replaced if damaged. In contrast, advanced high-current new energy terminals (like Through Wall Power Terminals) feature a modular design. The cover plate, base, and conductive busbar can be detached. This means that during maintenance, only the damaged component needs to be replaced, drastically reducing maintenance costs and time. Additionally, features like four-directional output allow simple rotation to accommodate different cable exit requirements, significantly improving equipment versatility and installation flexibility.
How to Choose the Right High-Current New Energy Terminal
Selecting the correct connector for your new energy application is critical. Here are a few key factors to consider:
Application Scenario and Current Requirements:
- First, determine your equipment type (e.g., energy storage cabinet, EV charger, inverter) and the required maximum current-carrying capacity (A). This will dictate which type of Feed Through Junction Block you need.
- For example, if your application requires a secure single-point connection with high current transmission, a Single Stud Type Junction Block might be the ideal choice.
Safety Certifications and Protection Rating:
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Check if the product complies with international standards (e.g., UL4128, TUV certification). These certifications are crucial for ensuring product safety and reliability. -
Based on your operating environment, select the appropriate IP rating. For applications that may be exposed to moisture or dust, an IP67 or IP68 rating is essential.
Structure and Installation Method:
- Consider the panel thickness of your equipment when choosing a through-wall terminal.
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Understand the product’s installation method (screws, clips, panel cutouts, etc.) to ensure it is compatible with your design and simplifies the on-site installation process.
FAQ
No. While both are electrical connection components, they differ fundamentally in current capacity, safety standards, and application scenarios. Using a traditional terminal in a high-current application is extremely dangerous.
An IP67 rating means the terminal is completely protected from dust ingress and can withstand being submerged in water under a certain pressure for 30 minutes without water entering. This is crucial for new energy equipment in outdoor or harsh environments to ensure long-term, reliable operation.
In some contexts, these terms can be used interchangeably, as both refer to a component that passes through a panel to connect internal and external wiring. However, the former might emphasize a complete connector solution, while the latter might refer more specifically to the component itself.
Suitable for: Lithium – ion battery packs (e – bikes, energy storage systems, etc.); Lead – acid batteries (industrial starting, backup power supplies); Special – purpose batteries (high – power batteries for forklifts, AGVs).
1000V DC & 1000V AC.
Standard current range: 60A – 500A; some models can reach up to 600A.
Panel – mounted, with mounting styles including Busbar, inner screw, outer screw, etc.
Available in brass or copper options. Generally, brass is used for currents below 300A, while copper is used for currents above 300A.
Tin plating.
Housing: PA66 material; Flamability rating is UL94 -V0.
Optional IP54 or IP67 rating.
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