Battery Connect Wire —— Professional Custom Battery Connection Wires Manufacturer
In modern battery systems, battery connect wires are key components that ensure stable, safe, and efficient power transmission. As a professional wire harness manufacturer, Linkwings offers a wide range of battery connection wire products, covering everything from standard battery wires to high-current power wires.
Battery Connect Wire Categories
Battery connection wires are core components that connect critical equipment such as battery packs, inverters, and power modules. Different application scenarios have varying requirements for cable structure, conductor type, and connector configuration. As a professional custom cable harness manufacturer, Linkwings offers a variety of battery connection wire solutions to meet diverse needs ranging from standard applications to industrial-grade heavy-duty systems.
Standard Battery Connect Wires
Product Features:
- Made with high-purity multi-strand bare copper or tin-plated copper conductors for superior conductivity
- The jacket material is oil-resistant and wear-resistant PVC or XLPE, providing excellent insulation properties
- Available in red and black dual colors for quick identification of positive and negative terminals
- Supports crimping of copper terminals, fork-type terminals, and bare wire end processing
Application Scenarios: Home inverters, lead-acid battery packs, and general electric equipment
Heavy Duty Battery Cables
Product Features:
- Conductor gauge range from 4 AWG to 1/0 AWG, supporting currents up to 200A or higher
- Tin-plated copper multi-strand conductors with strong oxidation resistance and long service life
- Thickened jacket material with high-temperature resistance and high tensile strength, suitable for industrial applications
- Compatible with quick connectors (e.g., Anderson, DIN terminals)
Application Scenarios: Electric forklifts, ESS energy storage systems, high-current busbar connections
Quick Connect Battery Wires
Product Features:
- Equipped with standard connectors at both ends (such as Anderson, XT60, DC head, etc.)
- Soft sheath, supports small bending radius wiring
- Can be labeled, heat shrinkable identification, directional lock design
- High plug-in life, suitable for applications requiring frequent plugging and unplugging
Application Scenarios: RVs, portable energy storage boxes, modular photovoltaic storage inverter systems
Multi-branch connection cable
Product Features:
- Single-end input, multi-end output, clear structure
- Supports customizable branch length, branch quantity, and numbering labels
- Can be equipped with heat-shrink tubing for branch protection and pull-out prevention
- Commonly used for parallel protection or monitoring of battery voltage/temperature/current signals
Application Scenarios: Internal wiring of energy storage systems, battery monitoring modules, BMS parallel interfaces
Waterproof Battery Wires
Product Features:
- Connection ends are sealed with heat-shrinkable rubber sleeves or injection-molded waterproof heads.
- Overall meets IP67/IP68 protection ratings.
- Conductors and terminals are made of corrosion-resistant materials (tin-plated copper, silver-plated copper).
- Supports industrial quick-lock waterproof connectors.
Application Scenarios: Marine power systems, outdoor photovoltaic power generation, mobile power stations.
Technical Specifications & Datasheet
| Parameter | Technical Specification |
|---|---|
| Wire Gauge Range | 4 AWG to 1/0 AWG (Other sizes available upon request) |
| Conductor Material | Stranded bare copper / tinned copper |
| Conductor Structure | Multi-strand flexible copper wire |
| Cross-sectional Area | 21 mm² (4 AWG) to 53 mm² (1/0 AWG) |
| Rated Voltage | 600V / 1000V (depending on application) |
| Max Current Capacity | 150A to 300A (based on ambient temperature and cooling) |
| Jacket Material | PVC / XLPE / TPE (customizable) |
| Jacket Properties | Oil-resistant, abrasion-resistant, heat-resistant, UV-proof |
| Operating Temperature | -40°C to +125°C (XLPE up to 150°C) |
| Bending Radius | ≥ 4 × OD (dynamic), ≥ 3 × OD (static) |
| Terminal Options | Copper lug, fork terminal, Anderson plug, XT60, DC plug |
| Protection Level (Optional) | IP65 / IP67 / IP68 (based on connector sealing) |
| Flame Rating | UL VW-1, FT1, FT2 (depending on jacket material) |
| Compliance Standards | UL 1232 / UL 758 / RoHS / REACH / ISO 9001 |
| Packaging Options | Bulk reel, custom cut lengths, pre-assembled kits |
| Certification Documents | Factory test reports, material declarations, 3rd-party certs |
Customization Capabilities of Linkwings
Different types of battery systems have vastly different requirements for connection cables. Parameters such as wire gauge, current, voltage, protection rating, terminal structure, and color coding must all be customized according to actual operating conditions. As a professional battery connect wire manufacturer, Linkwings offers a one-stop customization service covering design, prototyping, testing, and mass production.
- Wire length, color, and sheath material options available
- A wide variety of connectors/terminals (copper lugs, fork-shaped, quick-connect)
- Supports drawing development, 3D modeling, and sample verification
- One-stop delivery of wire crimping, heat shrink, and label packaging
- Supports OEM/ODM and low minimum order quantity trial production
Applications of Battery Connect Wire
Battery Connect Wire is a core component in electrical power systems, directly affecting the electrical performance, safety, and service life of the entire system. Different application scenarios have different requirements for the current-carrying capacity, flexibility, environmental adaptability, and termination methods of connecting wires. As a professional wire harness manufacturer, Linkwings has provided mature solutions for multiple industries.
1. Energy Storage Battery Pack Connection (ESS)
In residential energy storage, commercial and industrial energy storage, and containerized battery systems, battery connection cables must meet the requirements of high current carrying capacity, long-term stable operation, and modular installation.
Linkwings’ Solution:
- Utilizes high-conductivity multi-strand tin-plated copper conductors to effectively reduce voltage loss
- The jacket is made of XLPE/TPE material, offering high-temperature resistance, UV resistance, and corrosion resistance, suitable for outdoor or underground enclosures
- Custom lengths, numbered labels, and heat-shrink jacket packaging are available to enhance on-site installation efficiency
- Optional branch line structure and terminal unified packaging are available to comply with BMS and inverter interface standards
2. Electric Vehicles / RVs / AGVs Power Cable Assemblies
These applications place extremely high demands on cable flexibility, resistance to bending, and connection reliability in vibration-prone environments.
Linkwings’ solutions:
- Utilizes an ultra-flexible twisted copper wire structure for easy routing in narrow, curved channels
- Includes quick-connect terminals (e.g., Anderson plugs, DC connectors, etc.) for convenient installation and replacement
- Terminal crimping meets IEC/UL pull force standards to ensure connection strength
- Supports high protection ratings (IP67) for encapsulation, suitable for high-humidity and high-dust vehicle environments
3. UPS Connection to Inverter
In server rooms, server rooms, data centers, and other locations, UPS and battery connections must have high safety and continuous power supply capabilities.
Linkwings’ solution:
- Provides 4 AWG to 1/0 AWG high-current-carrying cables to meet system high-load operation requirements
- Pre-installed ring-shaped copper terminals for quick screw-fixed installation
- Sheath material features flame-retardant, oil-resistant, and wear-resistant properties, compliant with industrial standards
- Optional red and black dual-color, polarity labels to enhance maintenance efficiency and error prevention
4. Main power connection for industrial equipment
Industrial applications such as electric forklifts, welding robots, and AGV platforms require stable, high-power main power cables.
Linkwings’ solutions:
- High-strength conductors and thickened jackets with tensile strength, abrasion resistance, and oil resistance
- Diverse terminal types (e.g., fork terminals, heavy-duty connectors) for quick connection to equipment interfaces
- Optional jacket corrugated tubes and braided mesh for enhanced structural strength and protective performance
- Comprehensive design drawings and bulk production solutions for standardized components
5. Photovoltaic System and Lithium Battery Interface
Solar energy storage systems require efficient connections between panels, batteries, and control modules, and must operate stably in outdoor environments over the long term.
Linkwings’ solution:
- Utilizes UV-resistant XLPE sheathing + tin-plated copper conductors to withstand high temperatures and intense sunlight
- Compatible with MC4, PV, and BMS connectors for precise alignment, reducing wiring errors
- Offers multi-pole cable harness combinations for integrated power and signal wiring
- Supports IP67 protection structure to enhance reliability in outdoor construction environments
FAQs about Battery Connect Wire
1. Does Linkwings offer custom lengths and terminals for its battery connect wires?
Answer:
Yes, we offer comprehensive customization services, including cable length, sheath color, conductor structure, and terminal type. We can also process entire cables according to drawings and pre-install heat shrink tubing and labels to meet the installation requirements of different projects and equipment.
2. Are your conductors pure copper or copper-clad aluminum (CCA)?
Answer:
We only use high-purity oxygen-free copper or tin-plated copper conductors and never use copper-clad aluminum (CCA) wire. Linkwings focuses on the electrical performance and safety reliability of its products. All conductors undergo resistance testing and material verification to ensure low resistance, high conductivity, and long service life.
3. What voltage and current ranges are battery connection wires suitable for?
Answer:
Our battery connection wire product line supports rated voltages of 600V to 1000V and current ranges of 50A to 300A, depending on the wire gauge (such as 4 AWG to 1/0 AWG), conductor structure, and usage environment. We can recommend suitable cable specifications based on the power parameters of the customer’s equipment.
4. Can your cables be used outdoors or in harsh environments?
Answer:
Yes. We offer a variety of environmental-grade sheathing material options, such as XLPE, TPE, low-smoke halogen-free, etc., which are UV-resistant, oil-resistant, and waterproof (IP67/IP68). For outdoor applications, we also offer protective solutions such as terminal potting and heat-shrinkable sleeves to ensure a durable and secure connection.