Sealed connectors for electric vehicles operating in harsh environments

Sealed connectors are pivotal in the reliable operation of commercial and industrial EVs. Without them, contaminants and particulars can jeopardise electrical connections, leading to potential safety risks and operational failure of the EV.

In this article, we unpack what sealed connectors are, why they are so important and examine some industry-leading models that are perfect for commercial EV designs.

Why are sealed connectors important for commercial EVs?

Sealed connectors are key in commercial EV applications where rough environments and heavy use are commonplace. The ‘sealed’ aspect of these connectors means they are impervious to external contaminants like water, dust, dirt and other particles that can get in the way of the electrical connections. This is achieved through special designs and materials that creates a barrier against these contaminants to ensure reliability and longevity.

The effectiveness of a sealed connector is measured by its Ingress Protection (IP) rating. The IP rating system classifies the degree of protection provided against solids and liquids. For example, an IP67 rating means that the connector is completely protected against dust ingress and can withstand immersion in water up to a depth of 1 metre for 30 minutes. Higher ratings, such as IP68, indicate even greater resistance to dust and water, capable of withstanding continuous submersion.

• Protection from contaminants: Sealed connectors are designed to withstand extreme temperatures, vibrations and corrosive environments. This is critical for commercial EVs that need to operate over long distances and through varied environmental conditions.
• Enhanced safety: By preventing contaminants entering the connection points, sealed connectors reduce the risk of short circuits and electrical failures. This is critical for commercial vehicles that carry valuable goods and people to ensure vehicle and occupant safety
• Less frequent maintenance: The robustness of sealed connectors means they require less maintenance over time. For commercial fleet operators, this means lower maintenance costs and less downtime, leading to more efficiency and profit.

TE’s AMP+ HVA & HVP connectors: High-performance sealed solutions

When it comes to high-performance sealed connectors, TE Connectivity’s AMP+ HVA and HVP series stand out. These connectors are designed specifically to meet the rigorous demands of commercial EVs, providing exceptional sealing and durability.

AMP+ HVA series
These connectors are designed for high-voltage applications, making them ideal for transmitting the significant power levels required by commercial EVs. The “HVA” designation stands for High-Voltage Automotive, highlighting their specialisation in high-voltage transmission. They offer robust sealing against environmental contaminants, ensuring reliable performance in demanding conditions. This is shown by both the 280 and 630 models being rated at IP67.

AMP+ HVP series
The HVP series, or High-Voltage Power connectors, are engineered to handle even higher power requirements. These connectors are perfect for applications that require exceptional durability and reliability. The robust design of HVP connectors ensures they can withstand the harshest environments while maintaining optimal performance, perfect for industrial applications. The superior durability of these sealed connectors is proven by both the 800 and 1100 models being rated at IP6k9k.

Integrate the right components for your commercial EV

High-performance sealed connectors play a pivotal role in commercial EV design. They enable efficient operation and charging of EVs, ensuring the safety and reliability of these vehicles under harsh conditions. Sealed connectors provide the protection and durability needed to keep commercial EVs running smoothly, reducing maintenance costs and enhancing operational efficiency.

At Dalroad, we offer a wide range of components designed to enhance the resilience and lifespan of commercial EVs. Read our guide below to find out all the information you need to optimise your commercial EV design, one component at a time.