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The development of high voltage connectors has gone hand in hand with the development of electric vehicles. The development of high voltage connectors has gone through the following generations.
- The first generation of high-voltage connectors was developed from industrial connectors.
- The second generation of high-voltage connectors added a high-voltage interlocking function.
- The third generation of high-voltage connectors had a plastic housing and added shielding.
- The fourth generation of high voltage connectors added a secondary unlocking function.
This article will explain the third and fourth generations of high voltage connectors from the world’s leading high voltage connector manufacturers.
Tyco Electronics (TE)
TE has the majority of the market share and many of its connector components are the “standard” in the connector industry.
AMP+ HVA 280 High Voltage connector System
The AMP+ HVA 280 is a high voltage connector from TE that offers thousands of design possibilities and flexible layouts.
TE’s AMP + HVA 280 high-voltage interconnect system includes finger-resistant, touch-safe, two- or three-position, low- to medium-current plugs and headers designed for excellent flexibility in hybrid and electric vehicles equipment applications. The connector system offers multiple latching options and an integrated internal HVIL, allowing package size optimization and routing flexibility.
In addition, the HVA 280 series offers over 3,000 combination options to provide solutions for a wide range of equipment and harness applications such as battery packs, DC/DC converters, vehicle chargers, electrical connectors, and high voltage power distribution.
Mechanical Feature
- Terminal: 2.8mm MCP, 064 MQS
- Wire range: 2 mm² to 4 mm² multi-core or individually shielded wire
Electrical Features
- Voltage rating: Up to 600V individually shielded wire. Up to 850V multi-core wire
- Current rating: Up to 40A at 85℃
- IP rating: IP67
- Shielding: 360° from wire to the device
- Temperature range: -40℃ to 140℃
AMP+ HVP 800 High Voltage Connector System
TE’s AMP+ HVP 800 high-voltage connector system for high currents safely delivers high currents and voltages from batteries to inverters and electronic motors of up to 250 amps on 50 mm2 wires.
Touch-proof 2 or 3-position connectors and heads designed with 90 and 180-degree plugs with integrated internal HVIL function and EMI shielding. This HVP 800 series features a wide temperature and line range and a wide range of keying options for many electric vehicle applications.
Mechanical Feature
- Terminal: 8 mm pin and socket
- Wire range: 16 mm² to 50 mm² discrete shielded wire
Electrical Features
- Voltage rating: 650V, 850V, 1000V
- Current rating: Up to 250A
- IP rating: IP67
- Shielding: 360° from wire to the device
- Temperature range: -40℃ to 140℃
TE’s connectors are industry standard in terms of environmental resistance, mechanical specifications and electrical parameters, and continue to dominate the emerging connector track in new energy vehicles, which is distinct from traditional vehicles.
Amphenol
HVMC 14mm 2 Pos 180°Metal High Voltage Connector
Amphenol’s highest power battery connector, this automotive compliant two-pole connector mates high power output with robust, lasting design.
Mechanical Features
- Terminal: 14mm radsok, silver plated
- Wire size: 70 / 95 / 120 mm² shielding
- Unmating force: ≤ 100N
- Housing material: aluminium alloy
- Terminal material: copper alloy
- Other: HVIL contact system
Electrical Features
- Voltage rating: 1000V DC
- Current rating: 95mm²=400A, 120mm²=450A
- IP rating: IP67
- Shielding: 360° from wire to the device
- Temperature range: -40℃ to 140℃
- Mating cycles: 50 Min
- RFI/EMI protection: Metal Shielding
HVMC 2.4mm 2 Pos 180°Metal High VoltageConnector
This product is also suitable for high voltages and currents like the HVMC 14mm 2 Pos 180°Metal High Voltage Connector, except it is suitable for cables from 2.5 mm² to 4 mm².
Mechanical Feature
- Terminal: 2.4mm radsok, silver plated
- Wire size: 2.5 / 4 mm² shielding
- Unmating force: ≤ 100N
- Housing material: PA66-GF25% UL94-V0
- Terminal material: copper alloy, silver plated
- Other: HVIL contact system
Electrical Features
- Voltage rating: 1000V DC
- Current rating: 2.5mm²=20A, 4mm²=32A
- IP rating: IP67
- Shielding: 360° from wire to the device
- Temperature range: -40℃ to 140℃
- Mating cycles: 50 min
- RFI/EMI protection: Metal shielding
As automotive automation increases, so do the requirements for the environmental resistance of connectors as a bridge between electronic components. Amphenol’s connectors generally perform very well in harsh environments and favour customers.
JONHON
JONHON made its name in the Harsh Environment Connectors industry and has worked with many car manufacturers before the rise of new energy vehicles in China. When China’s other connector manufacturers respond, it has been difficult to surpass JONHON. At present, JONHON has a good share of high-voltage connectors in China.
HVIL series connectors
As you can tell from the name of this series, this is a metal-shell high-voltage connector with HVIL function.
Mechanical Feature
- Wire size: 2.4mm² to 4mm² shielded wire, 2.5mm² to 6mm² unshielded cable
- Housing material: plastic
- Plating: M-passivation of aluminium alloy, Z-nickel zinc plating on aluminium alloy
Electrical Features
- Voltage rating: 600V AC
- Current rating: 2.5mm²=20A, 4mm²=32A, 6mm²=40A
- IP rating: IP67
- Temperature range: -40℃ to 125℃
EVH3 Series Connectors
The EVH3 series adds a secondary unlocking function to its predecessor. Four-key error-proofing, high-voltage interlocking, shielding, and a single seal on the socket make this connector highly durable in harsh environments. This series features a straight outlet for 10mm² and 16mm² harnesses and is suitable for electrical connections between onboard chargers, battery packs, PDUs, air conditioners, and PTCs.
Mechanical Feature
- Wire size: 10mm², 16mm²
- Housing material: plastic
Electrical Features
- Voltage rating: 1000V AC
- Current rating: 80A
- IP rating: IP67
- Temperature range: -40℃ to 125℃
It is worth mentioning that the size of the high-voltage connectors of AVIC is different from almost all other manufacturers, and it is almost impossible to find the same alternatives on the market, so the user viscosity of its products is very high.
Recodeal
Recodeal has been a well-known connector company in China in recent years. It has developed several core technologies such as board-to-board RF connector technology, high-voltage high-current connector technology, power change connector technology, etc. The mechanical, electrical, and environmental performance of Recodeal’s connector has improved dramatically.
RED series 2/3 core high voltage plastic shielded connector
The safety features of this range are excellent, with a secondary locking function, IPXXB protection, a six-key keypad, and a shield interlock. According to the official documentation, although there is no built-in HVIL, this feature is available as an option.
Mechanical Feature
- Terminal: 2, 3
- Wire size: 2.5mm² to 4 mm²
- Housing material: Plastic
- HVIL: optional
Electrical Features
- Voltage rating: 1000V DC
- Current rating: 2.5mm²=16A, 3mm²=19A, 4mm²=25A
- IP rating: IP68
- Shielding: optional
- Temperature range: -40℃ to 140℃
However, compared to the other three manufacturers, the electrical parameters of Recodeal’s products are slightly inferior. At a rated voltage of 1000V, the Recodeal’s product has a maximum current of 16A at 2.5mm² and 25A at 4mm², but the TE and Amphenol products have a maximum current of 20A and 32A, respectively.
Renhotec
Renhe Technology Group was established in May 2005, as one of the top electronic connectors manufacturers and suppliers in China, they have done a better job of cost control. You can get almost all commonly used connectors, adapters, and cable assemblies from us at good factory prices.
HVIL 23A Series
This range has excellent insulation, high voltage interlocks, secondary unlocks, and various anti-misplug designs, which makes it excellent in extreme environments. These products are typically used in PDUs, Air conditioning, Defrosting, Electric heating, DCDC.
Mechanical Feature
- Terminal: 2, 3
- Wire range: 2.4mm² to 4mm²
- Mating cycles: ＞100
- Salt spray: MAX 96h
- Flammability rating: UL94 V-0
- Terminal material: cooper alloy, silver plating
Electrical Features
- Voltage rating: 960V AC, 1000V DC
- Current rating: 16A to 23A
- IP rating: IP67
- Shielding: 360° from wire to the device
- Temperature range: -40℃ to 125℃
HVIL 125A Series
The HVIL 125A Series is one of Renhotec’s many high-voltage, high-current connectors. It features HVIL, secondary unlocking, and anti-mistake insertion. It has excellent electrical insulation and is commonly used in PDUs, batteries, motors, motor controllers, etc.
Mechanical Feature
- Terminal: 2
- Wire range: 25mm²
- Mating cycles: ＞100
- Salt spray: MAX 96h
- Flammability rating: UL94 V-0
- Terminal material: Copper alloy, Silver plating
- Shell material: PA66
Electrical Features
- Voltage rating: 960V AC, 1000V DC
- Current rating: 125A max
- IP rating: IP67
- Shielding: 360° from wire to the device
- Temperature range: -40℃ to 125℃
Compared to the four brands above, renhotec is less well known. However, with excellent cost control, their products are priced significantly compared to other brands. With their consistent product quality and low prices, they are also a good choice in high voltage connectors.
Summary
Through comparative analysis, we can see that the first-mover advantage of the oldest companies is still undeniable.
On the one hand, the design and manufacture of moulds is a prerequisite for mass production. On the other hand, automatic machine assembly is the key to automated production, precision stamping, and injection moulding.
In addition, high-voltage connectors how to adapt to its high voltage, high current operating environment and ensure the safety of automotive electronic systems, is still every connector manufacturers need to continue to overcome technical difficulties.