Industrial connectors in new energy vehicles

New energy vehicles still show drawbacks such as insufficient range, lower perceived safety and inconvenient charging, but overall they have become a new industrial growth point and an unstoppable development trend. For the connector industry this trend is a rare opportunity: experts estimate that a single car of the future will use 600-1,000 electronic connectors, far more than the number used today.

Growth in the vehicle and charging markets

The design of new energy and hybrid vehicles commonly relies on large-capacity lithium batteries, which drives a comprehensive upgrade of the automotive electrical and electronic architecture. Connectors are central to that upgrade. The growth also opens large markets for manufacturers of electric vehicles, home and roadside charging stations, and charging cables.

Electric vehicles will be connected to a new, more efficient power transmission infrastructure, the smart grid, rather than remaining dependent on fossil-fuel delivery systems. As more electric vehicles and related equipment come to market, manufacturers face an increasing need for software, hardware and suitable components. Above all, they must win consumer confidence in the safety of the vehicles and the application components.

High-voltage connection requirements

The electric-vehicle connector is a plug-and-socket combination whose main function is to transmit power from outside the vehicle into the car. It contains an insulated contact housing carrying power, ground, communication and navigation-control connections. SAE J1772 has been designated as a standard device in the United States, although other configurations may still be permitted.

The connector housing must be a polymer insulating material with a defined flammability class and the required electrical and heat-resistance characteristics. In high-voltage environments, the design must protect drivers and service technicians, so the reliability of the whole electrical system has to be considered. The connection system is a key part of high-voltage power lines, especially the design of high-power connection wiring.

Sealing and high-voltage interlock

Two aspects of high-voltage connection design deserve particular attention: the high-voltage interlock loop (HVIL) and environmental sealing of the connector, which prevents short circuits between high-voltage terminals in vehicle use. Unsealed lines invite failure modes such as short circuits, so sealing is critical. Wire-ring seals and connector perimeter seals keep moisture out and prevent overheating or sparking. Because the risk of ignition rises with voltage, high-voltage systems need a stronger seal than traditional 12 V systems.

HVIL is a feature of high-power connection systems and prevents arcing when a live connector is disconnected in power electronics. The connection system must not be disconnected while live. When disconnection is imminent, the interlock loop signals the power supply to cut off in time. This protects passengers, maintenance personnel and first responders in an accident. In short, the development of new energy vehicles is a rare opportunity for the industrial connector industry.