High-Voltage Connector: Voltage Rating Up to 1000V DC

Component Specifications

Definition

A specialized electrical connector designed to handle high-voltage applications in automotive solid-state battery packs. It ensures reliable and safe electrical connections between battery modules, management systems, and vehicle powertrains, with robust insulation and shielding to prevent arcing, leakage, and electromagnetic interference.

Working Principle

Operates by establishing a secure electrical pathway through conductive terminals housed within an insulated body. It uses locking mechanisms and sealing to maintain connection integrity under vibration, temperature fluctuations, and high current loads, with materials and design minimizing resistance and heat generation.

Materials

Terminals: Copper alloy (e.g., C18150) with silver or tin plating; Housing: Thermoplastic (e.g., PPS, PPA) with high dielectric strength; Seals: Silicone or fluorosilicone rubber; Insulation: High-voltage rated materials meeting UL or IEC standards.

Technical Parameters

Parameter	Typical range	Notes & selection driver
IP Rating	IP67 or higher
Current Rating	Up to 400A
Voltage Rating	Up to 1000V DC
Contact Resistance	< 1 mΩ
Insulation Resistance	> 1000 MΩ
Operating Temperature	-40°C to 125°C

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Standards

ISO 15170, DIN 72585, IEC 62196, SAE J1772

Parent Products

This component is used in the following industrial products

Automotive Solid-State Battery Pack

The Automotive Solid-State Battery Pack is a complete battery pack assembly designed for integration into electric vehicle platforms.

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Engineering Analysis

Risks & Mitigation

Electrical arcing due to improper mating
Insulation breakdown under high voltage
Thermal runaway from poor contact resistance
Corrosion in harsh environments

FMEA Triads

Trigger: Insufficient sealing
Failure: Moisture ingress leading to short circuits
Mitigation: Use IP67-rated seals and regular inspection

Trigger: Terminal oxidation
Failure: Increased contact resistance and overheating
Mitigation: Apply protective plating and ensure clean mating surfaces

Industrial Ecosystem

Compatible With

Typical Suppliers & Equivalents

Compliance & Inspection

Tolerance

±0.1 mm for terminal alignment, voltage withstand test at 1.5x rated voltage for 60 seconds

Test Method

ISO 15170 for electrical performance, DIN 72585 for mechanical durability, and environmental testing per IEC 60068.

Procurement Evaluation Criteria

A practical evidence checklist for RFQ preparation and supplier evaluation.

Technical documentation

Request current drawings, revision history, and a signed specification sheet.

Manufacturing capability

Verify equipment lists, process limits, capacity, and representative production evidence.

Inspection readiness

Confirm test methods, calibrated equipment, sampling plans, and traceable reports.

Supplier transparency

Check the legal entity, factory address, ownership, certifications, and direct contacts.

CNFX does not score or rank suppliers. Buyers must verify all claims and documents with the legal manufacturer before ordering.

Manufacturers of High-Voltage Connector

2 companies list this product among what they make. Company figures are quoted from each company's own website; every card states where the relationship came from.

DEGSON

Zhejiang, CN

Also makes: Feed-through Terminal Blocks, Power Distribution Module, Power Distribution and 9 more

Listed on the company's own website · profile compiled by CNFX from public sources

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SVL Electric

Jiangsu, CN

Also makes: Feed Box, Circuit Breaker, Pressure Switch and 6 more

Listed on the company's own website · profile compiled by CNFX from public sources

View profile Send enquiry

Manufacturer listings support early research and capability understanding. They are not certification, ranking, or transaction guarantees.

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Frequently Asked Questions

What is the primary function of a high-voltage connector in a battery pack?

It safely transmits high-voltage electrical power between battery modules and to external systems like inverters or chargers, ensuring reliability and preventing electrical hazards.

How does it differ from standard automotive connectors?

It is designed for higher voltage and current ratings, with enhanced insulation, shielding, and safety features to handle the demands of electric vehicle powertrains.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records. See the editorial policy.

Preliminary Technical Classification

This page supports structured research, RFQ preparation, and supplier evaluation. It does not replace buyer-led supplier qualification, standards review, or technical approval.

High-Voltage Connector