Producing High Quality Flexible Connectors for the Traction Battery Market
IntraConn is relatively new as a European Company, however has been associated with a Company which has been manufacturing connectors for more than 15 years. That company supplied connectors and bolts to most countries in the Southern Hemisphere as well as large Battery Manufacturers.
In 2011 was decided to invest in the European market. To this purpose, was agreed that IntraConn would be formed for the sole purpose of supplying quality connectors at a reasonable price, this accompanied by excellent service.
This gives IntraConn the potential to develop into a large European player in the market with the best know-how and thus unlimited growth capability.
Essentially a flexible connector consists of several components, namely
In designing and manufacturing, only the best materials are used for our connectors and our plant and equipment are comparable to any modern factory.
The lugs are manufactured using the purest copper available on the market and our cable is procured locally to our specification, complying with the requirements that are needed for the aggressive environment found in the battery industry.
All cables meet the IEC 60332 – 1 standards and are fully operational in temperatures ranging from - 30°C to + 70°C.
From an acid resistance perspective, our connectors have been exposed to a large variety of testing, the most aggressive being immersed in a solution of H2SO4 for a period of 7 days.
The acid concentration was at a temperature of 60°C with an Sg of 1.28. No adverse effects were noted by the testing authority.
Our company can also supply flame retardant connectors where necessary. Comparative resistance testing was also carried out against local European manufacturers and the IntraConn design was found to be superior.
This is attributed to two factors, the quality of the cable and our decision to utilize the ultra sonic welding technique when welding the lugs. This ultra sonic welding system is ideal for welding of cables as it is a cool process with minimum heat buildup, which results in the bond between the outer sheathing material and the copper wire remaining intact and not allowing ingress of acids, which is the primary cause of corrosion in battery connectors.
The end cap mouldings are injection moulded onto the connector and the same material is used as the sheathing on the cable, thus ensuring that there is perfect seal between the cable and lug.
Our connectors have been extensively tested at testing authorities as well as in the market and we are justifiably proud of the results to date.
We are also able to supply Bolts, Single End Connectors and Rigid Connectors.
IntraConn continuously strives to improve the way it operates, in all possible aspects: increasing market share, driving down costs, managing risk more effectively or improving customer satisfaction. A quality management system is necessary to provide a framework capable to monitor and improve performance in the area of activity. IntraConn is ISO 9001 and ISO 14001 certified.
ISO 9001 is by far the world’s most established quality framework, currently being used by almost one million organizations in more than 160 countries, and sets the standard not only for quality management systems, but management systems in general. It is designed to help organizations ensure that they meet the needs of customers and other stakeholders while meeting statutory and regulatory requirements related to a product.
ISO 14001 sets out the criteria for an Environmental Management System. It can be used by any organization that wants to improve resource efficiency, reduce waste, and drive down costs. Using ISO 14001 can provide assurance to company management and employees that environmental impact is being measured and improved. Its main aim is to assist companies in continually improving their environmental performance, while complying with any applicable legislation.
IntraConn products are also RoHS compliant, thus conforming to strict standards and extensive documentation and having passed all relevant tests. The RoHS certificate is in compliance with the Directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment, which was adopted in February 2003 by the European Union. The RoHS 1 directive restricts (with exceptions) the use of six hazardous materials in the manufacture of various types of electronic and electrical equipment.
The growth and development of the company have increased significantly our distribution network. Besides a wide network in Greece, IntraConn has also an important export activity, as our connectors are exported in several countries.
IntraConn successfully passed all necessary controls and acquired the ISO 9001 and 14001 certifications. These quality management systems are necessary to provide a framework capable to monitor and improve performance in the area of activity, as well as assist in continually improving our environmental performance.