Connectors for battery packs in electric vehicles

16th May 2024  |  Electric vehicle

Connectors for battery packs play a vital role in the overall performance, efficiency and safety of EVs. With automakers like Porsche aiming for 800-volt battery systems, the demand for high-performance connectors that can handle increased voltages and currents is greater than ever. This is because they are essential for transmitting power efficiently and safely from the battery to the motor, both for the sake of the vehicle and its users under high-electric loads.

Facing the challenges of higher voltages, environmental stressors and the need for compact design, the EV industry is pushing for innovative solutions in connector technologies. This article explores how cutting-edge developments are setting new standards for connector durability, safety, and performance.

The importance of high-performance connectors

EV battery packs are steadily increasing in voltage, with Porsche setting their sights on 800-volt designs that are almost double that of the current conventional EV. This increase in voltage is a direct solution to improve the battery efficiency, driving range and charging speeds of EVs. However, with voltages on the rise in current and future EV designs, the need for high-performance connectors has become even more important.

EVs require robust connectors that can handle high currents and voltages with utmost reliability. These connectors are pivotal in transmitting power from the battery to the motor and other electrical systems, ensuring that the vehicle operates efficiently and safely. These connectors need to be efficient and protect drivers/technicians from electrocution whilst withstand environmental challenges such as vibrations, temperature fluctuations and corrosion.

Design considerations for EV battery pack connectors

1. High current and voltage handling:

EV connectors must manage significant electrical loads. Typical requirements include operating temperatures of up to 60°C and managing voltages between 400v-1000v whilst fast charging. The design must ensure that connectors can handle these extremes without performance degradation, ensuring safety and efficiency.

2. Durability under harsh conditions:

The operating environment for EVs demands that connectors be highly durable. Factors such as road salt, moisture, and extreme temperatures can lead to corrosion and physical wear. Connectors must be designed to resist these elements to prevent failures that could compromise the vehicle’s functionality and safety.

3. Miniaturisation and space efficiency:

As EV designs become more compact, the space for battery packs and associated connectors is reduced. This miniaturisation needs to be managed without compromising the connector’s integrity and performance. Smaller connectors are prone to issues like fretting corrosion, where small movements degrade the contact points over time. Innovative design solutions are required to counteract these potential failures.

TE Connectivity solutions

  • IPT-HD High-Voltage Connectors: These are designed for high-density, high-voltage applications, offering robust performance in a compact form. They are ideal for use in places where space is at a premium but performance cannot be compromised.
  • PowerTube Connectors (PowerTube 1000 and PowerTube 1400): These connectors provide high reliability and are designed to protect against environmental factors such as moisture and extreme temperatures. Their robust design ensures long-term reliability and safety in the demanding environments that electric vehicles face.
  • AMP+ HVP 800 Connectors & Headers: These connectors feature a robust design that can handle up to 800 volts and are engineered to ensure secure and reliable connections even under the harshest of conditions. The HVP800’s design also focuses on ease of assembly and maintenance, making them an ideal choice for applications requiring frequent connection and disconnection cycles.

Dalroad’s commitment to EV design excellence

The connectors for battery packs in electric vehicles are crucial components that dictate performance, efficiency and safety. With the rise of electric vehicles, the demand for reliable and efficient connectors has never been higher.

At Dalroad, we understand the critical nature of every component in the EV ecosystem. Our catalogue of high-performance connectors, including those from TE Connectivity, is curated to enhance the resilience and lifespan of electric vehicles. We are dedicated to assisting vehicle designers in selecting the perfect components that meet the rigorous demands of modern EVs.

Our team of specialists is always ready to provide expert advice and support, ensuring that you have access to the best components that not only meet but exceed industry standards. Whether you are in the initial design phase or looking to refine existing systems, Dalroad is your partner in the electrification journey.

Contact us today to discover how our solutions can enhance your electric vehicle designs and contribute to a more sustainable automotive future.

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