High-Voltage Connector Technical Analysis

1. Application of High-Voltage Connectors in NEV Systems

Definition & Application:
High-voltage connectors for new energy vehicles (NEVs) emerged as a distinct category driven by the rapid development of the NEV industry. Their primary function is to ensure current conduction across the vehicle’s high-voltage interconnection system.

Technical Requirements:
Compared with traditional connectors, NEV connectors impose higher requirements on reliability, safety, insulation, and protection performance due to elevated voltage levels and more complex operating conditions.

Component Structure:
High-voltage connectors typically consist of three major parts:

• Housing and sealing components

• Insulating components

• Conductive contact pairs

2. Key Design Considerations for High-Voltage Connectors

Temperature Rise & Derating Curve:
Temperature rise is a critical performance indicator. Excessive temperature rise can lead to thermal damage or burn-out. Derating curves guide customers in determining appropriate operating conditions.

High-Voltage Interlock (HVIL):
HVIL ensures safety during power-up and power-down of high-voltage systems. The HVIL signal circuit opens or closes earlier than the high-voltage power circuit during mating or unmating.

Locking Mechanism:
Secondary locking mechanisms ensure the reliability of the primary lock and improve ergonomics and handling during operation.

Ingress Protection:
The protection levels of high-voltage connectors have increased significantly. While IP67 used to be the mainstream requirement, higher ratings such as IP6K9K are becoming the trend to support demanding environments.

Electromagnetic Shielding:
High-voltage systems require effective shielding to prevent signal interference, particularly as autonomous driving technologies become more prevalent.

Material Selection:
Material selection for insulation and conductive contacts must consider lightweight design, environmental conditions, shielding strategy, and mechanical integrity.

Connector Selection Criteria:
Connector selection involves evaluating installation location, rated voltage, rated current, shielding requirements, ingress protection level, and system interface parameters.

3. Development Trends of High-Voltage Connectors

Platformization & Customization

• Platformization:
  Future battery and vehicle architectures will increasingly adopt platform-based designs. Connector manufacturers must engage in deeper technical collaboration with OEMs to develop platform-ready products.

• Customization:
  Specialized solutions will be required for segmented applications such as autonomous driving systems, IoT-connected vehicles, and other emerging vehicle categories.

Miniaturization & Lightweighting

• Miniaturization:
  Connector size reduction can be achieved through high-performance copper alloy conductors and miniaturized terminal systems.

• Lightweighting:
  Adoption of aluminum conductors in place of large-diameter copper conductors supports vehicle lightweight strategies and improves energy efficiency.

Conclusion

With continuous technological advancements in the NEV sector, high-voltage connectors face increasing challenges and opportunities across technical specifications, system design, and market applications. Through accumulated expertise and rapid market iteration, domestic connector manufacturers are steadily improving product performance and are well-positioned to gain greater influence in the global market.