High Voltage Connector Components and Classification

Among the different types of ev connectors used in new energy vehicles, automotive high-voltage connectors are high-technology composite products with complex structures and many parts. Their core technology involves current-carrying capacity, temperature rise, plug life, protection level, resistance to condensation and electromagnetic interference, vibration and shock resistance, and other performance requirements. With dozens of types of components involved, they are among the more sophisticated high-voltage components used in automotive systems.

The high-voltage terminal connector has more components and complex structures, and different applications correspond to a variety of products. One of the plastic/metal shell high-voltage connectors is a type of high-voltage connector with a main shell of engineering plastic/metal alloy, mainly used in electric passenger cars/electric buses, logistics vehicles, commercial vehicles, in the entire vehicle high-voltage circuit system, to achieve the transmission of electrical energy devices. Its operating temperature is generally between -40°C and 125°C, the current is between 10A and 300A, and the voltage can reach 750-1.000VDC.

The terminal is the core of the high voltage connector and has a high technical content. The female terminal structure is more complex, with strip metal crimped to form the connection body, while the male terminal, also called a pin, is used for connection with the PCB. Similar conductive contact structures can also be found across different types of charger pins used under different charging standards for electric vehicles. Copper alloys such as brass and phosphor bronze are generally used as raw materials for the production of female terminals.

Insulator shell is one of the basic structural components of the high-voltage terminal connector. Is the shell of the high-voltage connector, to protect the internal components and structure of the connector, in connection with the role of fixed connectors and connected equipment. At this stage, the shell mainly has a metal shell and plastic shell two categories, of which the plastic shell is mainly used in the field of passenger cars.

Insulation body is the name of the high-voltage connector insulation parts in general. At this stage, the high-voltage terminal connector insulation materials can be selected from the better performance of polyphthalamide (PPA) plastic, but also PA66, PBT ABS, PC, etc.. And high-voltage wire harness insulation materials are mainly used cross-linked polyolefin and silicone rubber.