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High-Voltage Connector Component – Motor Vehicle Manufacturing

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

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

Standards

ISO 15170, DIN 72585, IEC 62196, SAE J1772

Industry Taxonomies & Aliases

Commonly used trade names and technical identifiers for High-Voltage Connector.

Parent Products

This component is used in the following industrial products

Automotive Solid-State Battery Pack

High-energy-density solid-state battery system for electric vehicles

View Product Details

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

Interchangeable Parts

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.

Buyer Feedback

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Related Components

Current Sensor

Current sensor for measuring electrical current flow in automotive battery management systems

Isolation Monitor

An automotive BMS component that continuously monitors electrical isolation between high-voltage battery systems and vehicle chassis to prevent electric shock hazards.

Balancing Circuit

Electronic circuit in automotive BMS that equalizes voltage across battery cells to optimize performance and lifespan.

Communication Transceiver

A bidirectional communication transceiver for automotive BMS enabling data exchange between battery cells and control units.

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.

Can I contact factories directly?

Yes, each factory profile provides direct contact information.

High-Voltage Connector