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Our high-performance High-Voltage Interlock (HVIL) connectors provide critical safety and secure power distribution for Electric Vehicle (EV) battery systems, powertrain applications, and large-scale Energy Storage Systems (ESS). Engineered as a robust automotive-grade solution, these connectors ensure signal integrity and circuit protection under extreme electrical and environmental conditions, making them the preferred choice for global Tier-1 suppliers and OEM/ODM engineering projects.
Integrated Dual-Safety Mechanism
Features a dedicated High-Voltage Interlock Loop (HVIL) coupled with a robust Connector Position Assurance (CPA) system. This dual-safety design physically guarantees full mating and monitors connection status in real-time. It effectively prevents accidental disconnection and electrical hazards under high-vibration, ensuring 100% operational safety and maximizing system uptime during maintenance.
High-Power & Low Thermal Rise
Engineered to support rated voltages up to 1500V and currents up to 600A, utilizing premium silver-plated copper alloy contacts. It delivers highly efficient power transmission with minimal thermal rise, reducing energy loss and ensuring stable equipment operation under heavy EV loads.
Durable Material for Extended Lifespan
Constructed with premium PA66+GF reinforced housing, meeting stringent UL94V-0 flame retardancy standards. This ensures a longer operational lifespan than standard connectors, dramatically reducing your maintenance and replacement costs in high-vibration off-road environments.
Superior Environmental Protection & EMI Shielding
Provides IP67/IP68-rated ingress protection against severe dust and water immersion, alongside integrated 360° shielding. It guarantees superior EMI/RFI performance to maintain signal integrity, keeping your complex electrical systems running flawlessly in harsh outdoor applications.
Proven Mission-Critical Reliability
Validated for an extreme operating temperature range of -40°C to 125°C and a service life exceeding 50 mating cycles. Significantly lowers your Total Cost of Ownership (TCO) with long-term stability you can trust.
Our HVIL series connectors are essential safety components widely utilized in Electric Vehicle (EV) powertrains, Battery Management Systems (BMS), and Energy Storage Systems (ESS). Based on real-world client feedback, these connectors provide reliable high-voltage interlock protection for Power Distribution Units (PDU), Motor Control Units (MCU), On-board Chargers (OBC), and high-power inverter systems, ensuring operational security across the entire high-voltage circuit.
EV Powertrain & Chassis
PDU & MCU Integration
BMS & Battery Systems
As a group-level source manufacturer, Renhotec offers an extensive range of High-Voltage Interlock connectors. The chart below demonstrates our full manufacturing capabilities. You can find the corresponding meaning of each segment on your existing part numbers.
Available in EVH / EVP / EVL / EVS Series
Heavy-Duty Metal & Lightweight Plastic Options
Available in 1-Pin to 6-Pin
Straight / Right-Angle & Shielded / Unshielded
Standard: Orange (X), Black (Y)
Custom: Yellow, Green, Red, Blue
Current Range: 23A up to 600A
With HVIL Loop / Without HVIL
Plug Wire: 2.5mm² to 150mm²
Receptable: Copper Busbar, Threaded Bolts, Wire Crimping
Standard length (e.g., 0.5m) or custom length available
Internal code denoting the specific production facility within our manufacturing group
All certifications listed below are held by Renhotec or our verified manufacturing facilities, ensuring full compliance with international automotive and safety standards.
Our HVIL series is designed for high-power demands, supporting rated currents up to 250A and rated voltages reaching 1500V DC, making them ideal for the latest EV and solar energy architectures.
The HVIL system utilizes a built-in low-voltage signal loop to monitor the connection status. It ensures that the high-voltage circuit is de-energized before the power contacts are separated, protecting users and sensitive electronics from arcing.
Yes, our connectors feature shielding structures that effectively suppress electromagnetic interference, ensuring stable signal integrity and power transmission even in proximity to high-frequency components.
Yes. All products in this series offer IP67 or IP68 rated protection, ensuring they are completely dust-tight and capable of withstanding immersion in water, which is essential for chassis-mounted or outdoor applications.
We use premium PA66 with glass fiber for the shells to ensure thermal stability and UL94V-0 flame retardancy. The contacts are crafted from high-grade copper alloy with silver or tin plating to maintain low contact resistance over 500+ mating cycles.
For in-stock items, orders are typically processed and shipped within 1-2 business days. For standard configurations requiring new production, our agile manufacturing capabilities allow us to deliver in as fast as 7 to 14 days. We recommend contacting our sales team to verify real-time inventory for your specific Part Number.
We welcome sample requests from our corporate clients. We can provide specific models for your engineering team to perform fit-form-function testing and ensure full compatibility with your system.
Renhotec provides a comprehensive One-Stop Solution from concept to mass production. Please note that project timelines scale with the complexity of your design - ranging from rapid modifications of standard connectors to fully bespoke mold developments.
A swift and successful product rollout is a collaborative partnership. We work closely with your engineers, and the overall lead time relies heavily on timely feedback and prompt sample validation from your team.
Demand
Provision
Feasibility
Analysis
Quotation &
Contract
Mold
Design
Raw Material
Preparation
Trial Mold
Sampling
Mass
Production
Delivery &
After-sales
HVIL, or high voltage interlock loop connector, is a safety feature of hybrid and all-electric vehicles that protects people during the assembly, repair, maintenance and operation of a vehicle. The HVIL system is in place to protect those who may come into contact with high-voltage components at any stage of the electric vehicle lifecycle. HVIL acts as a circuit breaker that sends an alert or trouble code to the driver if a high-voltage connection becomes loose, disconnected or damaged during the vehicle’s operation. It also helps protect a vehicle’s driver and passengers in the event of an accident.
The exact composition of high voltage interlock loop connector plugs may vary depending on the model and manufacturer, but in general, they contain: Housing, Contacts, Pins, Locking Mechanism, Sealing Ring etc.
High-voltage interlock connectors include solutions for high-voltage, high-current, and signal connections for hybrid and electric vehicle high-voltage power harnesses and signal connections. It is available in a wide range of product options, 1 core to 3 cores, rated from 23A to 250A, touch resistant, single or multi-core shielded cables are available.
HVIL connectors applications including High Voltage Power Distribution, Battery Pack, Motor Controller, Electric Air Conditioning, Electric Heater, etc…
The high-voltage connector is an electrical connection component used to transmit high-voltage current and signals, providing 800V-1000V voltage transmission, which is widely used in new energy vehicles, power systems, rail transit, and other fields.
The high-voltage connector is mainly composed of four basic structures: contacts, insulators, housing, and accessories. The contacts are the core for electrical connectivity. The insulator supports the contacts and ensures electrical insulation. The housing is used to protect the entire connector.
There are many types of high-voltage connectors, including unipolar/multipolar, shielded/unshielded, metal/plastic housing, straight/angled, threaded/locking, etc. In addition, depending on the application scenario, there are various models suitable for different voltage levels and current carrying capacity.
Most high voltage connectors, such as Renhotec models, operate within a temperature range of -40 ° C to +125 ° C. However, the specific operating temperature range may vary according to different models and application scenarios.
The high voltage connector must meet electrical performance requirements such as insulation resistance, dielectric loss Angle tangent, discharge current, and voltage resistance test at the rated voltage. During the production process, high voltage connectors are usually subjected to 100% voltage resistance and insulation testing to ensure that there is no risk of poor voltage resistance or insulation during assembly.
Many high-voltage connectors, including Renhotec models, offer IP67, IP68, and IP69K protection ratings. This means they provide excellent dust and water resistance, ensuring reliable performance in harsh environments like rain, dust storms, or high-pressure cleaning.
The service life of high voltage connectors is affected by factors such as material quality, production processes, and operating conditions. In general, high-voltage connectors that have been rigorously tested and verified have high reliability. For example, in mechanical shock and vibration tests, the connector is required to be free of damage, cracking or deformation after completion of the test.
The maintenance of high voltage connectors is very important, mainly including the following aspects:
- Regularly inspect and clean] contact surfaces to remove dirt and oxides.
- Check the fastening of the fixture to ensure the stability of the connector.
- Check the integrity and wear resistance of the insulation material.
- Check the conductivity and heat dissipation of the electrode.
- Periodically test insulation resistance, contact resistance and other performance indicators.
In new energy vehicles, high voltage connectors are mainly used in high voltage control boxes, air conditioning compressors, car chargers, DC-DC converters, PDU, MSD, charging ports, and more. With the high voltage development trend of new energy vehicles, the demand for high voltage connectors is also increasing.
Future trends for high voltage connectors include integration, intelligence, lightweight, and high performance. Examples include smart connectors with sensors for remote monitoring and diagnostics, and connectors using new materials (e.g., advanced composites) and optimized structures to reduce weight while maintaining strength.
