Unique Aluminum Connector Design, Lightweight & Corrosion-Resistant with a Heavy Duty Seal

Electric Vehicle Engine Application

The Challenge:

One of the major US automotive manufacturers was developing a totally-electric version of their popular pick-up truck for fleet sales to utility companies throughout North America. Part of their program specifications called for a lightweight yet heavy-duty electric alternative fuel drive cell. To accomplish this, the car manufacturer and their drive-system vendor would need a connector that was lightweight, corrosion-resistant and watertight with stainless steel jacketed cable so that the electrical circuitry of the vehicle could be protected from road abrasion and the climate. The car manufacturer contacted Remke Industries.

The Remke Solution:

To meet the specific requirements of the application, the Remke Flexible Solutions Team proposed an aluminum connector with nickel-plating that would be lightweight and corrosion resistant. Their prototype also featured an O-Ring for a watertight seal, and a nickel-plated ferrule that would the protect the cable. The cable suggested by Remke’s Flexible Solutions Team would feature an over-braiding that would slide onto a ferrule and then a stainless-steel clamp that would hold the overbraiding onto the connector to ensure an environmental seal. This unique connector was offered in two versions – one with a PG 16 metric thread and the other with a standard ½” NPT thread. The connector Remke developed would be used to connect the battery pack to the drive train and the drive train to the computer module. This connector would also terminate the mechanical stainless steel shielding so that the cable would not get damaged.

The Remke Solution met all of the criteria and parameters provided. The car manufacturer and their drive-train vendor were especially pleased with the lightweight materials & design.