FR-4 EV Charger PCBA Assembly with 95% Efficiency, IP67 Protection, and 10+ Year Lifespan for Automotive Charging Systems
Price:
negotiable
MOQ:
1unit
Delivery Time:
10-15 working days
Brand:
PCBA ,support OEM
Product Description
High-Reliability EV Charger PCBA Assembly
Professional FR-4 EV charger printed circuit board assembly designed for 10+ years of continuous operation with ISO 9001 certification and comprehensive safety compliance.
Key Product Features
Exceptional Reliability & Performance
- 10+ years continuous operation design with anti-vibration and EMI-resistant construction
- High-efficiency power conversion ≥95% to minimize energy loss and heat generation
- Comprehensive safety protections including over-voltage, over-current, short-circuit, over-temperature, and leakage protection
- Global charging protocol compatibility (CCS, CHAdeMO, GB/T, Type 2)
- Intelligent MCU management with real-time monitoring and 4G/5G/WiFi communication
- Optimized thermal design with heat sinks and thermal paste for stable high-load operation
- Harsh environment adaptability with IP65/IP67 protection and -30°C to +70°C operating range
Technical Specifications
| Category | Parameters |
|---|---|
| Electrical Parameters | Input: AC 100-240V/380V | Output: DC 200-1000V/AC 220V | Current: 10-600A DC/16-100A AC | Power: 3.3kW-200kW+ | Efficiency: ≥95% |
| Mechanical Parameters | Size: 200×150×30mm to 600×400×100mm | Weight: 0.5kg-5kg |
| Environmental Parameters | Operating Temp: -25°C to +55°C | Storage Temp: -40°C to +85°C | Protection: IP65/IP67 |
PCB Construction Details
| Parameter | Description | Typical Values/Options |
|---|---|---|
| Substrate Material | Core material for PCB structure | FR-4 (Tg 130-180°C); Aluminum-based for thermal dissipation |
| Layer Count | Number of conductive layers | 4-6 layers (expandable to 12+ layers) |
| Working Voltage | Input/output voltage range | AC 200-450V (compatible with 220V/380V grids) |
| Rated Current | Maximum continuous current handling | 10-50A (120A peak for fast-charging) |
| IP Rating | Dust and water resistance | IP67 (fully dust-tight and waterproof) |
Manufacturing Process
| Step | Description |
|---|---|
| Material Procurement | Sourcing high-reliability automotive-grade components (capacitors, resistors, MOSFETs, microcontrollers) |
| SMT Assembly | High-precision placement using automated pick-and-place machines with reflow soldering |
| DIP Assembly | Through-hole component insertion followed by wave soldering |
| Testing & Validation | Comprehensive ICT, FCT, and safety testing including insulation resistance and dielectric strength |
| Final Assembly | Integration with heat sinks and protective casings; potting with waterproof materials |
| Quality Assurance | 100% aging test, performance validation, and ISO 9001 compliance verification |
Applications
- Electric Vehicle Charging Stations (AC slow charging and DC fast charging)
- Portable EV Chargers for home or on-the-go charging
- Home Charging Systems integrated into wall-mounted residential chargers
- Commercial Charging Solutions for public parking lots, malls, and commercial venues
- Industrial Charging Infrastructure for fleet charging stations in logistics and public transportation
Customization Services
- Material Selection: Customizable substrates including ceramic for extreme environments
- Layer Configuration: Tailored stack-ups for high-speed signal integrity
- Functional Modules: Integration of RFID, NFC, LCD displays, or OCPP 1.6J communication
- Environmental Testing: Customized thermal cycling, humidity, or vibration protocols
- Compliance Support: Localized certifications including ISO9001, IATF16949, and RoHS compliance
Quality Certifications
Our EV Charger PCBA assemblies comply with international standards including CE, UL, CCC, RoHS, IEC 61851-1, and ISO 16750 automotive reliability requirements.
Manufacturing Excellence
17 Years of PCB Manufacturing Expertise
- Self-owned factory with vertical integration for full supply chain control
- Advanced 8-stage lead-free reflow and wave soldering processes
- Rigorous quality control with AOI, X-ray inspection, and 100% functional validation
- Defect rate <0.2% (industry average <1%)
Custom Service Notice: All products are customized. Please contact our customer service before ordering to confirm product details and requirements.
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Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.
Company
Ring PCB Technology Co.,Limited
Location
Building 36A,Longwangmiao Industrial park, Baishixia Community, Fuyong Street, Bao'an District, Shenzhen,China
Contact Person
Michelle Law