GB/T EV Charging Cords

GB/T EV Charging Cords uses oxygen-free high-conductivity copper conductors with a maximum impurity content below 0.003%. This ensures consistent current delivery under rated loads of up to 250A, reducing I²R losses and limiting resistive heating across extended charging durations. The high-purity copper meets conductivity class ≥99.97% IACS as per ASTM B170, essential for minimizing voltage drop over long cord lengths in high-capacity charging stations. 

Rated Voltage (DC)

1000V DC

Rated Current Capacity

Up to 250A (DC), depending on conductor cross-section

Conductor Material

Oxygen-Free High Conductivity Copper (OFHC), ≥99.97% IACS

Conductor Cross-Section

16 mm² to 95 mm² (as per current rating)

Contact Resistance

≤ 0.5 milliohms at rated load

Product Description

GB/T EV Charging Cords is insulated with dual-layer cross-linked polyethylene or thermoset elastomers, offering dielectric strength above 20 kV/mm. These materials comply with GB/T 33594 and IEC 60245-4 insulation performance benchmarks, ensuring sustained operation under transient voltage spikes and thermal cycling. The insulation system resists degradation from hydrocarbon exposure, ozone, UV, and ambient humidity fluctuations. 

Insulation Material

XLPE / Thermoset Elastomer, ≥20 kV/mm dielectric strength

Jacket Flame Rating

UL 94 V-0, GB/T 18380.3 flame propagation compliant

Operating Temperature Range

-40°C to +105°C continuous

Thermal Sensor Integration

NTC Thermistor near power contact for temperature monitoring

Flexing Endurance

≥50,000 bending cycles at 5×OD under load

Shielding Configuration

100% Aluminum Foil + 90% Tinned Copper Braid (for data pairs)

Signal Impedance (Control Lines)

120 ±10 Ω (twisted pair for CAN/PLC communication)

Connector Ingress Protection

IP55 (mated), IP67 (unmated)

Contact Plating

Silver over Copper Alloy, ≥5μm thickness

3.5 kV AC, 5 minutes (between conductors and ground)

3.5 kV AC, 5 minutes (between conductors and ground)

Technical Advantages

GB/T EV Charging Cords supports continuous thermal exposure from -40°C to +105°C and transient overloads up to 120°C without loss of mechanical integrity. The cable undergoes thermal shock and heat resistance testing per GB/T 2951.14 and IEC 60332-1. Integrated thermistor lines support real-time temperature feedback at the connector interface to mitigate overheating during high-duty DC charging cycles. 

GB/T EV Charging Cords connectors employ silver-plated copper alloy contact terminals with an initial contact resistance ≤0.5 mΩ. Terminal materials meet GB/T 20234.2 requirements for mechanical endurance, with durability exceeding 10,000 mating cycles under full-rated load. Retention forces and insertion torque remain within specification due to high-precision contact geometry and self-aligning interface design. 

 

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Industry Applications

Public EV Charging Stations

Supports high-current, three-phase charging with 250A DC capability for urban and highway stations using GB/T standard protocols. 

Electric Bus Charging Depots

Handles prolonged DC fast charging cycles at 750–1000V for high-capacity battery systems in electric mass transit applications. 

Commercial Fleet Charging Yards

Provides reliable thermal performance and low-resistance connectivity for multi-vehicle fleet chargers operating under continuous load conditions. 

Battery Swapping Infrastructure

Enables high-frequency mating with robust mechanical endurance suitable for robotic systems in automated battery replacement platforms. 

Residential Wall-Mounted Chargers

Supports GB/T-compliant AC charging at 230V with integrated control pilot signaling for domestic EV installations. 

Industrial EV Manufacturing Lines

Used in test benches and quality control stations requiring repeated plug cycles and accurate voltage/current monitoring per GB/T standards. 

 

GB/T EV Charging Cords

Signal Integrity for Control Communication

GB/T EV Charging Cords integrates shielded twisted-pair (STP) control conductors with 90% braid coverage and 100% foil wrap. The communication lines support high-fidelity PLC and CAN signaling under IEC 61851-1, with controlled impedance of 120 ±10 Ω and low crosstalk. EMI shielding effectiveness exceeds 65 dB in the 1 MHz to 100 MHz range, suitable for dense charging infrastructure. 

GB/T EV Charging Cords is constructed with fine-stranded Class 6 copper and multi-layer stranding geometry for high flex endurance. The assembly passes >50,000 bending cycles at a radius of 5×OD under 5 kg load, validated per GB/T 2951.21 and UL 2556. This is critical for robotic cable management systems or mobile charging applications with continuous movement. 

GB/T EV Charging Cords

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure the GB/T EV Charging Cord performs under continuous 250A DC fast charging?

Frigate uses oxygen-free copper conductors with high current-carrying cross-sections, such as 70 mm² or 95 mm². The cord is tested under full load at 1000V DC per GB/T 20234.3. Real-time thermal profiling is used during validation to detect hotspot formation. This ensures sustained operation without insulation fatigue or thermal runaway. 

What flame retardant properties does Frigate provide in GB/T EV Charging Cord for high-risk environments?

Frigate uses jacketing materials rated UL 94 V-0 and certified to GB/T 18380.3 for flame propagation. These compounds resist ignition and self-extinguish in case of arc faults. The cord passes vertical flame and glow wire testing for charging stations with high short-circuit exposure. It supports arc resistance exceeding 150 seconds as per ASTM D495. 

How does Frigate’s GB/T EV Charging Cord manage electromagnetic interference during smart charging sessions?

Frigate incorporates foil and braided shielding over twisted-pair data lines to block EMI. Shielding effectiveness exceeds 60 dB across the 1–100 MHz range. This protects PLC and CAN communication in EVSE networks. Signal quality remains stable even in high-frequency switching environments like urban charging hubs. 

How does Frigate validate the environmental sealing of GB/T EV Charging Cord connectors?

Frigate performs IP55 (mated) and IP67 (unmated) ingress tests using thermal shock, water immersion, and dust chamber procedures. Silicone gaskets and multi-lip sealing structures are used to prevent ingress at connector interfaces. Salt spray tests per GB/T 2423.17 validate corrosion resistance. The cable is qualified for outdoor and coastal EVSE locations. 

What testing does Frigate conduct to ensure mechanical durability of GB/T EV Charging Cord in mobile charging applications?

Frigate tests cables for over 50,000 flex cycles at 5×OD bend radius under loaded conditions. Mechanical endurance is verified per GB/T 2951.21 standards using automated flex rigs. Cord terminations are reinforced with strain relief molded transitions. This makes the design suitable for robotic arms and mobile depot charging. 

 

What makes Frigate’s GB/T EV Charging Cord better than off-the-shelf options?
  • Built using oxygen-free copper with ≥99.97% conductivity, ensuring consistent current flow even at 250A DC loads over long charging durations. 
  • Designed to reduce voltage drop and resistive heating, which helps avoid performance degradation in high-power EV applications. 
  • Insulated with dual-layer XLPE or thermoset elastomers that can withstand thermal shocks and transient voltage spikes. 
  • Tested for long-duty cycles under load, ensuring mechanical integrity over thousands of charging operations. 
  • Engineered as a performance-driven solution, not a commodity product, offering superior stability in demanding environments. 
Can the cord be customized for different power ratings and installation needs?
  • Available in a range of conductor cross-sections (16 mm² to 95 mm²) to match your specific current requirements and charging duration. 
  • Custom jacket materials can be selected based on the environment—whether indoor, outdoor, high-flex, or oil- and chemical-exposed areas. 
  • Cable lengths can be tailored to installation constraints like compact stations, wall-mount setups, or ceiling-suspended reels. 
  • Insulation thickness and type can be adjusted based on required dielectric strength and flexibility. 
  • Shielding and connector configurations can be fine-tuned for data signal integrity in smart charging systems. 
How reliable are the connectors in outdoor and industrial environments?
  • Each connector is tested for IP55 protection when mated and IP67 when unmated, ensuring water and dust resistance under all use conditions. 
  • Multi-lip silicone seals and gaskets maintain integrity during temperature shifts, water spray, and dust exposure in rugged locations. 
  • Silver-plated copper alloy terminals maintain low contact resistance and support over 10,000 mating cycles under full-rated load. 
  • Retention force and insertion torque are carefully balanced to prevent connector wear while ensuring secure engagement. 
  • Field-tested for use in environments like coastal chargers, public highways, and fleet yards with unpredictable weather. 
How does Frigate help during the early stages of product integration or prototyping?
  • Offers technical collaboration to define optimal conductor sizing, insulation, and shielding based on your system needs. 
  • Assists in connector interface planning, including torque specifications, thermal sensor placement, and cable routing. 
  • Provides thermal performance data and mechanical stress insights to align with your test conditions and application cycles. 
  • Shares lessons learned from similar deployments to help avoid design flaws and reduce time to deployment. 
  • Supports early-stage prototyping with quick-turn samples and feedback loops to validate fit and performance. 
What happens if we encounter installation issues or unexpected thermal behavior in the field?
  • Frigate offers direct access to technical specialists who can assess field data, images, or measurements for quick diagnosis. 
  • Thermal or EMI issues are analyzed with practical recommendations like adjusting shielding layers, modifying termination methods, or changing flex paths. 
  • Assistance is provided for cable routing changes or mechanical stress points, especially in mobile or robotic charging systems. 
  • Recommendations include thermal sensor tuning, connector geometry changes, or bending radius adjustments to extend cable life. 
  • Fast-response troubleshooting helps reduce downtime and ensures smoother integration into your existing infrastructure. 
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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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GB/T EV Charging Cords

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