High Voltage Cable Connectors for Electric Vehicles

High voltage automotive connectors are used in electric and hybrid vehicles to connect the vehicle powertrain to the battery. They must provide reliable connections; prevent accidental disconnect under load; ensure high-strength durability; and be cost-effective.

Electric vehicles have a higher number of phases, typically three phases for traction motor and two for drive motor. Hybrids often have one more phase on the traction side than on the drive side. Because of this difference, there is a need for different types of connectors based on application requirements.

A typical high-voltage connector consists of several parts: housing, contacts, lugs, seals and gaskets. The housing provides mechanical protection as well as electrical isolation between phases and circuits. Contacts are usually made from copper or brass and are crimped onto wire ends with lugs that make contact with contacts inside housings. Seals are used between contacts to prevent moisture ingress into housings during operation under high voltage conditions. Gaskets provide electrical insulation between mating parts of housings during operation under high voltage conditions.
The automotive high voltage connectors is usually located at the rear of the vehicle within easy reach of technicians performing routine maintenance. The connector is designed with internal strain relief so that it may be disconnected without any tools or special training. This ensures that the connector will not inadvertently disconnect under load during operation.