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High-voltage connectors, auxiliary ones such as low-pole connectors for sensors and actuators and high-pole connectors for control units, as well as signal terminals. In an all-electric architecture, the electric motor, the battery pack, the charger unit, and the electronic power converter handle the majority of the current handled by connectors.
High-voltage connectors are typically bright orange in colour to help technical employees quickly identify them. The key is having the ability to withstand thermal ageing and maintain their colour and tone for at least a few years.
The Global Automotive High Voltage Connector Market accounted for $XX Billion in 2023 and is anticipated to reach $XX Billion by 2030, registering a CAGR of XX% from 2024 to 2030.
The design of EV connectors presents unique difficulties. Power losses caused by the high current are inversely correlated with contact resistance between the connector’s mating surfaces. Automotive connectors need to be able to withstand conditions with wide temperature variations.
The pressure holding the two connected parts of a terminal together also affects contact resistance. High insertion forces, which are unfavourable in the current car manufacturing environment, are produced by high compression forces.
EV connectors may be larger and heavier than desired due to mechanical dimensional restrictions, which runs counter to the industry trend toward smaller, lighter, and more affordable electronic controllers and connectors.