Hybrid battery wire harness bundled with the full set of nickel-plated, copper bus bars and stainless steel wide flange nuts for a long-lasting repair.
WIRE HARNESS:
The wire harness is designed for Gen 3 (2010-2015) Toyota Prius. It was engineered and developed in the USA, with three main goals in mind:
1. To be as efficient or more efficient than OEM in transmitting a signal between the battery modules and the ECU.
2. To be more durable and reliable than OEM wire harness.
3. To be more cost-effective than the OEM wire harness alternative.
Here are some notable benefits of ACENBAY Hybrid Battery Wire Harness for Gen 3 (2010-2015) Toyota Prius, as compared to the Toyota OEM wire harness:
➡ Voltage sensor tabs are thicker than OEM for increased durability.
➡ Voltage sensor tabs are made of a better conductive copper alloy compared to the OEM
(a metallurgical study was done on OEM material for proper selection of copper alloy with equal or superior heat rating and conductivity properties)
➡ Voltage sensor tabs crimping connection resists double the amount of pull-out force compared to the strength of the OEM sensor tabs crimping connection.
➡ Voltage sensor tabs crimping connection is sealed to protect the wires from corrosive electrolytes and to improve durability.
➡ Wires' operational temperature rating is greater and internal resistance is lower, compared to the OEM.
➡ The existing orange wire harness frame/housing is intended to be reused with a new wire harness (please watch a short 15 video with easy step-by-step instructions).
By reusing the existing wire harness housing, manufacturing cost savings are passed on to the customer, and as an added bonus, plastic waste pollution is minimized.
BUS BARS & WIDE FLANGE NUTS:
Nickel-plated bus bars are engineered to enhance the quality of a hybrid battery repair. Compared to the OEM, they offer two main benefits:
➡ These bus bars boast a remarkable up to 20% reduction in internal resistance compared to OEM, resulting in more efficient electrical current conduction between the modules, mitigating heat generation—an infamous culprit behind premature battery failure. Our test under load consistently demonstrated an average of 6°F drop over different test durations, compared to the OEM.
➡ A thin layer of Nickel plating protects the copper against corrosive electrolytes, prolonging the cleanliness of the electrical connection between the hybrid battery modules.
Our Wide flange hex nuts are custom-made to match the wide flange size of the OEM nuts, unlike anything currently available on the aftermarket. The modified wide flange design distributes the pressure evenly across a larger contact area, enhancing conductivity. To demonstrate this, we've conducted a Finite Element Analysis (FEA) illustrating the contact pressure profile at 48 lb-in torque, showcasing a superior performance compared to typical DIN 6923 flange nuts found with our competitors.
In addition, the solid stainless steel material provides an excellent protection against corrosion.
Additional cost savings to keep in mind:
➡ We offer free USPS Priority Mail shipping on all domestic orders of $50 or more. Ordering a compatible Bus Bars and Flange Nuts kit with your wire harness will qualify you for free shipping.
➡ We do not collect tax on orders from most states.
Please note that the wire colors do not correspond to the factory wiring diagram. In the future, the wire harness will be supplied preassembled in the orange frame, but until then the wire harness is to be installed in the existing/reused wireframe, based on the order of length of each of the wires, from longest to shortest (Please refer to the wire color sequence in the listing photos).
Reach out if you have any questions: contact@acenbay.com