Riveted Electrical Connection Components
Products Description
Riveted Electrical Connection Components are made by tightly bonding a metal substrate, conductive contacts, and structural support components through cold riveting or solid-state joining processes, forming a stable current path and mechanical support.
These assemblies are widely used in:
High-voltage switchgear
Electrical control systems for new energy vehicles
Industrial motors and electromagnetic control
Energy storage systems and inverters
Electrical relays and contactors
Power distribution units (PDUs)
Their core value lies in maintaining a stable conductive path and reducing contact resistance, minimizing structural loosening and performance degradation caused by vibration, thermal shock, or long-term use.
Production Equipment and Processes: Refined Manufacturing Adapted to Electrical Connection Standards
Raw Material Selection: High-conductivity substrates such as T2 copper and copper alloys are selected, with a conductivity ≥98% IACS and impurity content ≤0.05%, ensuring conductivity. Insulation materials use UL94 V-0 grade PA66, PBT, or flame-retardant silicone, with a temperature range of -40℃ to 125℃. Surface treatment materials use high-purity silver, tin, and gold plating, complying with RoHS and REACH environmental standards. All materials have passed specialized testing in the electrical connection industry.
Precision Stamping: Conductive terminals are formed using multi-station precision stamping presses, with dimensional tolerances ≤±0.03mm and conductive cross-sectional area errors ≤±5%, ensuring uniform current transmission and avoiding localized heating. The terminal riveting groove design is optimized through finite element simulation to enhance the engagement with the conductor.
Integrated Riveting Process: Hydraulic/pneumatic precision riveting machines are used to Stamping Electrical Contacts conductors and terminals. Riveting force is controlled between 500-2000N to ensure a tight, gap-free, and effective connection, with adequate pull-out force. Post-riveting shaping ensures a neat appearance and maximizes conductive contact area.
Conductive Surface Treatment: Depending on the application, processes such as silver plating (thickness ≥3μm), tin plating (thickness ≥5μm), and gold plating are used. The plating adhesion is ≥5N (cross-cut adhesion test), and the contact resistance is ≤5mΩ. The plating is uniform, free of pitting and peeling, improving conductivity and corrosion resistance.
Insulation and Sealing Integration: Injection molding is used to integrate the insulating sheath and conductive terminal. The sheath is free of bubbles and cracks and fits tightly to the terminal. Silver Contact Riveted Assemblies with a sealing structure incorporate a silicone sealing ring, with compression controlled at 15%-20%, ensuring a protection rating of IP65 or higher.
Design Advantages: Engineering Wisdom in System-Level Connectivity Solutions
Ergonomic Installation Design
Our Moving Spring Armature Riveting Assemblies feature a professional ergonomic design, ensuring a simple and efficient installation process. All installation interfaces are optimised for easy operation by installers in various working environments. A unique installation guide structure ensures quick alignment, avoiding common errors in traditional connection installations.
Modular Interface Design
The In-Mold Riveting Electrical Contacts utilise a standardised interface design, perfectly compatible with mainstream electrical systems on the market. A unique positioning structure ensures quick alignment during installation, avoiding installation problems caused by misalignment in traditional connection methods. This design simplifies the installation process, reducing installation time and costs.
Compact Space Utilisation Design
The Electrical In-Die Riveted Connections feature a compact design that significantly reduces installation space while maintaining connection reliability. Compared to traditional connection methods, space occupancy is reduced by 25%, allowing for more compact electrical equipment design and providing an ideal solution for high-density installation environments.
Application Advantages
| Electric Vehicles (EV/HEV) | Internal module connections within battery packs and high-voltage distribution units (PDUs). Its vibration resistance and lack of thermal damage are crucial for ensuring battery safety and lifespan. |
| Renewable Energy | Wind power converters, photovoltaic inverters, and energy storage systems (ESS). In these devices requiring a lifespan of over 25 years, the long-term reliability of riveting is unmatched by traditional connection methods. |
| Rail Transportation and Aerospace | Train control systems and airborne electronic equipment. In these fields with stringent requirements for vibration, shock, and extreme temperatures, riveting is a proven, highest-level safety connection technology. |
| Industrial Automation and Servo Drives | In-Mould Riveting Components Connecting IGBT modules and capacitor busbars in high-power servo drives. Its low-inductance design helps reduce switching noise and improve system performance. |
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