Pure Copper Terminals: The "Safety Lifeline" of New Energy Vehicle High-Voltage Systems
Today, as the core technology of new energy vehicles shifts from "range competition" to "endurance in safety," a frequently overlooked yet critically important component is stepping into the spotlight—pure copper terminals. As the core conductive element of high-voltage connection systems, pure copper terminals carry the power transmission between the battery, motor, and electronic control units. Their performance directly determines charging efficiency, operational stability, and thermal runaway protection. With the official implementation of the new national standard GB 38031-2025 in 2026 and the rapid adoption of 800V high-voltage platforms, pure copper terminals are evolving from an "optional material" to a "safety necessity"—becoming the irreplaceable "metal lifeline" of new energy vehicles.
Why Pure Copper?
Copper delivers unmatched conductivity—resistivity 60% that of aluminum, 1.7x thermal conductivity, and 1083°C melting point. It maintains contact stability under vibration and thermal cycling, while aluminum fails faster in high-current, high-heat environments. For 800V systems drawing 400A–800A, copper is the only proven solution.
Tech Breakthroughs
In 2025, Luoyang Copper Processing launched a new alloy achieving 85% IACS conductivity and 650MPa tensile strength—ending foreign monopoly and cutting downstream costs by 30%. Top-Link's high-current terminal reduces contact resistance to 0.03mΩ, with 1.7–2x effective contact area and stable 23K–28K temp rise at 800A. Shenzhen Shenji Electronics holds 17.42% market share with its dual-contact wave structure. These wins reflect full-chain domestic innovation.
Safety Revalued
GB 38031-2025 mandates 24h no-flame after thermal runaway. Copper delays propagation—one supplier's switch from Al to Cu plating extended failure from 8 to 35 minutes. In 800V systems, aluminum arcing probability is 85x higher, vibration failure 7x higher. Lifecycle analysis shows copper saves 1–2% energy loss, boosts vehicle resale value by 8%, and may lower insurance premiums 15–20%.
Broadening Applications
Copper now appears in busbars, ultra-thin foil current collectors, high-efficiency rotors, burst valves, and precision shunts. Lightweighting advances: TE Connectivity's composite wire cuts 5kg copper per vehicle; SAIC IM L6 uses copper-clad aluminum to reduce wiring weight 30% with controlled temp rise.
Moving Forward
China has broken foreign bottlenecks in high-purity wire and high-end alloys. Next-gen high-strength, arc-resistant materials are in validation. As competition shifts from cost to safety, copper terminals are no longer passive carriers—they are active guardians. In these invisible details, the foundation of NEV leadership is being built.
