In high-voltage, high-current interconnect scenarios, the material selection of the contact interface directly determines the reliability, energy efficiency and service life of the system. Qiao Ye (JVT) 3902 pin and socket interconnect system relies on the differentiated coating design - the pin and socket compliance tail is silver-plated, and the socket contact area is equipped with a gold-plated claw spring. The dual advantages of "efficient conduction + stable contact" are constructed. Combined with its touchpoint technology and self-alignment function, it has become the preferred solution for board-to-board, busbar-to-board and busbar-to-busbar connections. This paper will focus on the core advantages of silver-plated coatings and gold-plated claw springs, and combine the technical characteristics of the system with application scenarios to carry out in-depth analysis.

Core coating technology: the differentiated value of silver-plated coatings and gold-plated claw springs

The coating design of the JVT3902 system is not a simple application of a single material, but is based on the precise matching of the current transmission path and the contact reliability requirements. The silver plating layer bears the core responsibility of "efficient current conduction", while the gold-plated claw spring focuses on the construction of "stable contact interface". The two work together to achieve stable transmission of 75A-350A high current and up to 600V voltage, and the contact resistance is as low as 0.20mΩ-0.40mΩ, providing a solid guarantee for high-power scenarios.

1.1 Silver plating: high conductivity and low consumption current transmission core

The pin body and socket non-contact end (compliance tail) of the JVT3902 system are treated with high-purity silver plating, which gives full play to the physical characteristics and conductivity advantages of silver and becomes the "performance cornerstone" of high-current transmission. Its core advantages are reflected in the following three aspects:

Excellent electrical conductivity, reducing transmission loss

Silver is the most conductive metal material at room temperature, with a resistivity of only 1.5910 Ω · m at 20 ° C, far superior to copper (1.7210 Ω · m) and gold (2.4410 Ω · m). In the JVT3902 system, the synergistic design of the silver coating and the gold-plated claw spring exhibits the ultimate electrical performance in the 11mm 350A high current scenario - through multiple touchpoint current shunting and low impedance transmission paths, the contact resistance of the single connector is stable at 0.40mΩ at a full load of 350A, and the temperature rise is controlled within 30K (far exceeding the 50K limit of the IEC 61984 standard). Taking the new energy vehicle transmission system as an example, when 350A current is transmitted through the system, the power loss of a single node is only 49W (P = I ² R = 350 ² 0.4010 ^ ³), which is 66.7% energy saving compared to the 147W loss of traditional tin-plated connectors (contact resistance of about 1.2mΩ). With the low voltage drop characteristics of the system, the vehicle's cruising range can be increased by 3% -5%, perfectly adapting to the fast charging and strong power requirements of the 800V high-voltage platform.

Excellent mechanical adaptability for improved connection fault tolerance

Silver has good ductility and flexibility, and its coating can adapt to the 1.00mm radial fluctuation caused by automatic alignment technology during the mating process between the pin and the socket, reducing the damage of mechanical stress to the contact interface. At the same time, the soft characteristics of the silver plating layer enable it to form a closer fit with the bus surface in the bus pressing scene (such as the knurling crimping process), avoiding the local temperature rise caused by the contact gap. In the vibration environment of industrial robots, this mechanical adaptability can effectively buffer the vibration shock, prevent the connection from loosening, and ensure continuous power supply.

Balanced cost-effectiveness for batch applications

Compared to the full-gold-plated solution, the differentiated design of "silver-plated body + gold-plated touchpoint" guarantees core performance while significantly reducing material costs. The market price of silver is much lower than that of gold, and the silver plating process of the JVT3902 system is mature. The uniformity and adhesion of the coating have been strictly tested, and it can withstand 200 plug-and-pull cycles without coating shedding. This advantage enables it to achieve a balance of "high performance + low cost" in batch application scenarios such as data center servers and energy storage systems, reducing the manufacturing cost of end point equipment.

1.2 Gold-plated claw spring: stable and reliable contact interface guarantee

The contact area of the socket of the JVT3902 system is designed with a gold-plated claw spring. The gold-plated claw spring is integrated into the conical socket through touchpoint technology to form a multi-touchpoint contact structure. Its advantages are concentrated in contact stability and environmental adaptability, which is the key to the "long-term reliability" of the system:

Super chemical stability, resistant to harsh environmental erosion

Gold has a strong chemical inertness. In the wide operating temperature range of -40 ° C to + 125 ° C, the gold-plated claw spring will not undergo chemical reactions such as oxidation and vulcanization, and can effectively resist oil pollution and humidity changes in the industrial environment, as well as electrolyte vapor corrosion in the battery compartment of new energy vehicles. In the application of charging stations in coastal areas, high humidity and salt mist environment can easily lead to oxidation failure of ordinary connectors touchpoint, while the gold-plated claw spring can achieve trouble-free operation for more than 5 years, greatly reducing maintenance costs.

Low contact resistance stability for long-term performance

The gold-plated layer has a smooth surface and a low coefficient of friction, which can reduce touchpoint wear and maintain stable contact resistance during the insertion and unplugging process. The gold-plated claw spring of the JVT3902 system forms a multi-point conductive channel through a multi-contact beam design (multiple gold-plated claw springs are built into each socket). Even if a single contact point is slightly worn, it will not affect the overall contact performance. The test data shows that after 200 plugging and unplugging, the system contact resistance change rate is less than 5%, which is far better than the industry average standard of 15%. It is especially suitable for long-life cycle equipment such as data center servers and satellite power distribution systems.

Multi-touchpoint collaborative design for enhanced current distribution

Combined with claw spring touchpoint technology, the gold-plated claw spring forms a radially distributed multi-touchpoint around the pin with an inclined contact beam structure, evenly distributing the current to each contact point to avoid overload of a single touchpoint current. This design is particularly valuable in the 350A high-current scenario. The 11mm specification connector has 8 gold-plated claw springs built in, and each touchpoint only carries about 44A when the 350A current passes, which is far lower than the rated load limit of a single touchpoint (60A). The temperature rise of a single touchpoint is controlled within 30K, which effectively avoids the problem of coating melting or material aging caused by local overheating. In high-frequency high-power start-stop scenarios such as BUSBAR connections for new energy vehicles, this current distribution capability can extend the service life of the connector to more than 10 years/1 million cycles, which is 2 times higher than that of traditional single touchpoint connectors. At the same time, the multi-touchpoint redundancy design ensures that even if a touchpoint has a slight failure, the system can still maintain more than 90% of the conductivity and ensure driving safety. In high-frequency start-stop scenarios such as 5G remote radio units (RRUs), this current distribution capability can also effectively extend the life of the touchpoint and reduce the risk of failure due to local overheating.

Second, the synergy effect of coating advantages and system technology

The silver-plated coating and gold-plated claw spring of the JVT3902 system do not exist in isolation, but are deeply integrated with the core technology of the system to form a "1 + 1 > 2" synergy effect, further amplifying its application value:

2.1 Integration with claw spring touchpoint technology: raising the upper limit of power bearing

The claw spring touchpoint technology maximizes the contact surface area through the design of conical sockets and multi-contact beams, while the low contact resistance characteristics of gold-plated claw springs and the high conductivity characteristics of silver-plated pins make this design effective in the 350A high current scenario. The gold-plated claw spring and silver-plated pins of the 11mm connector form 8 sets of effective contact pairs, with a total contact area of 15mm ². With the high conductivity of silver, the ultra-low impedance path is constructed, so that the system can still maintain a stable contact resistance of 0.40mΩ when 350A current passes. Compared with the same specification of fully silver-plated connectors (contact resistance at 350A is easy to rise to 0.6-0 mΩ), its power loss is reduced by 33% -50%; with the system's uniform 10.00mm height compact structure, it can achieve the dual goal of "high power density + low energy consumption" in the limited installation space of the new energy vehicle BUSBAR, while avoiding the accelerated aging of peripheral components caused by excessive heat generation. Even the 3.4mm specification (75A) connector can achieve a low contact resistance of 0.25mΩ at only 2.00mm mating height, which is suitable for high-density packaging requirements of supercomputers.

2.2 Synergy with guide post automatic alignment technology: reducing the risk of mating damage

The 1.00mm radial float function of the guide post automatic alignment technology solves the alignment problem of PCB and busbar mating. The smooth surface of the gold-plated claw spring can reduce the friction resistance during pin mating and reduce the wear of the coating; while the flexibility of the silver-plated pin can buffer the mechanical impact during the mating process and avoid the touchpoint deformation caused by rigid collision. In the dense layout of the power distribution unit (PDU) in the data center, this synergy effect can increase the connector installation pass rate to more than 99.5%, greatly improving the construction efficiency.

III. Core application scenarios: practical manifestation of coating advantages

The advantages of silver-plated coatings and gold-plated claw springs are precisely adapted in different application scenarios, becoming a key support for solving high-power connection problems in various fields, especially in the high computing power requirements of large data servers and the strong power transmission scenarios of automotive BUSBAR. The specific application performance is as follows:

IV. Market Competitive Advantage and Application Recommendations

4.1 Competitive differentiation: coating design builds technical barriers

In the current high-power connector market, Tyco Electronics, Amphenol and other manufacturers mostly use fully silver-plated or fully gold-plated solutions, while the "silver-plated + gold-plated" differentiated design of the JVT3902 system forms a significant competitive barrier in the 350A high-current scenario: the contact resistance of the Tyco MULTI-BEAM Plus 350A connector is about 0.55mΩ, and the power loss at 350A is 67.375W; the contact resistance of the Amphenol EnergyKlip 350A product is about 0.6mΩ, and the loss is 73.5W. The contact resistance of the JVT3902 system is 0.40mΩ, which makes the loss only 49W, which is 27% -33% energy saving compared with competitors. At the same time, the temperature rise (30K) of the JVT3902 at 350A full load is lower than that of Tyco (45K) and Amphenol (48K), and the environmental adaptability is better. Compared with the full silver-plated solution, its gold-plated claw spring enhances contact stability and environmental adaptability; compared with the full gold-plated solution, its silver-plated body reduces material costs by more than 30%. In the 600V/350A scenario, the comprehensive performance and cost advantages of the JVT3902 system are particularly outstanding, making it the preferred choice for customers of new energy vehicles and data centers.

4.2 Application selection suggestions

• 350A high current scenario special project verification: In the electric vehicle transmission system, high-power energy storage inverter and other scenarios above 300A, it is necessary to confirm the thickness of the silver plating layer (JVT3902 standard is more than 3μm) and adhesion, and verify whether the temperature rise of the connector is 30K when the 350A is fully loaded through the temperature rise test to ensure the current transmission efficiency and safety performance.

• Harsh environment focused gold-plated claw spring: In scenes such as coastal charging stations and industrial oil pollution environments, a gold-plated layer thickness of 0.75μm at the contact point should be selected to strengthen the environmental corrosion resistance.

• Batch applications place emphasis on process stability: in batch scenarios such as data centers and servers, it is necessary to verify the consistency of the manufacturer's silver plating and gold plating processes to avoid performance fluctuations caused by uneven plating.

V. Summary

The silver-plated coating and gold-plated claw spring design of the JVT3902 system are one of its core competencies in the field of high-power interconnection such as 350A. The silver-plated coating builds a high-efficiency transmission path for 350A high current with "high conductivity, flexibility and economy", and the gold-plated claw spring ensures the long-term reliability of the contact interface with "stability, corrosion resistance and low consumption". The two cooperate with claw spring touchpoint, guide post self-alignment and other technologies to enable the system to achieve excellent performance of "0.40mΩ low resistance, 30K low temperature liter, 49W low consumption" when fully loaded at 350A. This performance effectively solves the pain points of traditional connectors "high loss, high temperature rise, short life" in scenarios such as BUSBAR and high-power energy storage inverters in new energy vehicles, and realizes the comprehensive value of "high power bearing, low energy consumption transmission, and long-term reliability". With the continuous expansion of high voltage and high current scenarios, this differentiated coating design will further highlight its technical and market advantages, providing strong support for the performance upgrade of end point equipment.