High-Voltage Connector Systems
November 6, 2025
High-Voltage Connector Systems
Contents
1 Introduction 3
2 High-Voltage Connectors for HEVs/EVs 3
2.1 Design and Functional Requirements . . . . . . . . . . . . . . . . 3
2.2 Common Connector Types and Standards . . . . . . . . . . . . . 4
2.3 Materials and Contact Technologies . . . . . . . . . . . . . . . . . 6
3 Power Distribution Systems in High-Power HEVs/EVs 6
3.1 Architecture Overview . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Power Distribution System Technologies . . . . . . . . . . . . . . 7
4 Challenges and Future Trends 8
4.1 Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Emerging Technologies . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Conclusion 9
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High-Voltage Connector Systems
1 Introduction
The rapid advancement of hybrid and electric vehicles (HEVs/EVs) de-
mands robust, reliable, and efficient high-voltage connectors and power
distribution systems. These components serve as the critical backbone in
transferring substantial electrical energy safely and efficiently from battery
packs to propulsion motors and auxiliary systems. The unique operating
environments—ranging from temperature extremes to vibration and expo-
sure to contaminants—impose stringent requirements on connector perfor-
mance and power distribution architectures.
This document explores the state-of-the-art technologies, design chal-
lenges, and practical considerations for high-voltage connectors and power
distribution systems tailored to high-power HEV/EV applications. It aims to
provide engineers and system designers with an in-depth understanding to
guide component selection, system integration, and performance optimiza-
tion.
2 High-Voltage Connectors for HEVs/EVs
2.1 Design and Functional Requirements
High-voltage connectors in HEVs/EVs must handle voltages typically rang-
ing from 200 V up to 800 V or higher, with continuous current ratings often
exceeding 200 A. Key design requirements include:
• Electrical performance: Low contact resistance to minimize power
loss and heat generation, high dielectric strength to prevent insulation
breakdown.
• Safety features: Touch protection, interlocking mechanisms, and clear
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High-Voltage Connector Systems
insulation barriers to prevent accidental contact with live parts.
• Environmental robustness: Resistance to moisture, dust, tempera-
ture cycling, and mechanical shock/vibration per automotive standards
such as ISO 16750.
• Thermal management: Ability to dissipate heat generated under high
current load without degradation.
• Ease of assembly and maintenance: Connectors designed for quick
and secure mating/demating during vehicle assembly and service.
2.2 Common Connector Types and Standards
The market offers several connector types meeting the automotive high-
voltage requirements, often standardized to ensure interoperability and safety.
Table 2.2 summarizes representative connector types and their key specifi-
cations.
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High-Voltage Connector Systems
Connector Voltage Current Standards Key
Type Rating Rating Features
SAE J1772 Up to 1000 Up to 500 A SAE J1772, High power
(Combined V DC IEC 62196 charging
Charging interface,
System) safety
interlocks
CTS 300 V –800 150 A –350 ISO 27186, High-
(Charging V A ISO 6469-3 voltage
Transfer battery con-
System) nections,
touch-safe
Anderson Up to 600 V Up to 350 A UL 1977 Modular,
Powerpole / field-
SB serviceable,
widely used
in EV con-
versions
DEUTSCH Up to 600 V Up to 120 A SAE J2030 Rugged
DT Series sealed
connectors
for harsh
environ-
ments
tableCommon high-voltage connector types used in hybrid and electric
vehicles
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High-Voltage Connector Systems
2.3 Materials and Contact Technologies
Contacts are typically manufactured from copper alloys with plating
materials such as silver or tin to ensure low resistance and corrosion resis-
tance. Insulation housings use high-grade polymers capable of withstand-
ing thermal and mechanical stresses. Advances in composite materials and
contact coatings continue to improve connector durability and performance.
3 Power Distribution Systems in High-Power HEVs/EVs
3.1 Architecture Overview
The power distribution system (PDS) is a complex network responsible
for delivering high-voltage energy from the battery to propulsion compo-
nents and high-power accessories. Figure ?? outlines a typical high-power
PDS structure.
[Figure placeholder: Typical High-Power HEV/EV Power
Distribution Architecture]
Key elements in the PDS include:
• Main Battery Pack: Primary energy source providing high DC voltage.
• Main Contactor and Fuse: Safety devices for protection and isolation.
• High-Voltage Distribution Box: Central hub integrating connectors,
relays, and wiring harnesses.
• Inverter/Converter Interfaces: Link battery power to electric motors
and auxiliary converters.
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High-Voltage Connector Systems
• Grounding and Shielding: Critical for electromagnetic compatibility
(EMC) and safety.
3.2 Design Considerations
The design of PDS must optimize the following aspects:
• Electrical efficiency: Minimizing voltage drop and resistive losses
through optimized conductor sizing and contact selection.
• Thermal management: Effective heat dissipation strategies to main-
tain reliability.
• Modularity and Scalability: Allowing integration of different battery
capacities and powertrain options.
• Safety and Compliance: Meeting international automotive standards
such as ISO 26262 for functional safety and ISO 6469 for high-voltage
systems.
3.3 Power Distribution System Technologies
Table 3.3 compares key technologies employed in high-power distribu-
tion systems.
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High-Voltage Connector Systems
Technology Description Advantages Limitations
Busbars (Cop- Solid Low resistance, Rigid, less
per/Aluminum) conductive high current flexible for
strips for capacity layout changes
current
distribution
High-Voltage Flexible cables Modular, easy Higher
Harnesses with installation resistance,
connectors weight
considerations
Power Integrated Compact, Increased
Distribution modules with centralized complexity and
Units (PDUs) fuses and control cost
relays
Printed Circuit Embedded Space-saving, Thermal
Boards (PCBs) power reduced wiring dissipation
with Power distribution in challenges
Layers compact design
tableComparison of high-power distribution system technologies
4 Challenges and Future Trends
4.1 Challenges
Designing high-voltage connectors and power distribution systems for
HEVs/EVs faces several persistent challenges:
• Increasing power density: Higher voltages and currents demand con-
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High-Voltage Connector Systems
nectors and systems that can safely handle greater electrical loads with-
out excessive size or weight.
• Thermal management: Managing heat in compact connectors and
distribution units to prevent premature failure.
• Reliability under harsh conditions: Ensuring long-term durability
amid vibration, mechanical shock, and environmental exposure.
• Safety and regulatory compliance: Adapting to evolving standards
and ensuring user safety during rapid charging and operation.
4.2 Emerging Technologies
Several promising developments aim to address these challenges:
• Advanced contact materials: New alloys and plating techniques re-
ducing contact resistance and improving corrosion resistance.
• Liquid cooling connectors: Integrating cooling channels to directly
manage heat within connectors.
• Wireless power transfer: Research ongoing into contactless high-power
energy transfer to eliminate physical connectors.
• Smart connectors: Embedded sensors providing real-time monitor-
ing of temperature, current, and connection integrity.
5 Conclusion
High-voltage connectors and power distribution systems form the vi-
tal infrastructure enabling the operation of high-power hybrid and electric
vehicles. With demanding electrical, mechanical, and safety requirements,
their design and integration require deep multidisciplinary expertise and
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High-Voltage Connector Systems
adherence to evolving standards. This document has outlined the core de-
sign principles, technologies, and challenges faced in this domain, provid-
ing a comprehensive reference for engineers and designers. Future innova-
tions promise to further enhance system efficiency, safety, and reliability,
fostering broader electrification in transportation.
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High-Voltage Connector Systems
References
• SAE International. SAE J1772 Electric Vehicle and Plug in Hybrid Elec-
tric Vehicle Conductive Charge Coupler, 2017.
• International Organization for Standardization. ISO 16750 Road vehi-
cles –Environmental conditions and testing for electrical and electronic
equipment, 2018.
• International Organization for Standardization. ISO 26262 Road vehi-
cles –Functional safety, 2018.
• DEUTSCH. DT Series Connectors Datasheet, 2021.
• Anderson Power Products. SB and Powerpole Connector Catalog, 2022.
• Tesla Inc. Battery and Powertrain Architecture Overview, 2020.
• IEEE Transportation Electrification Community. Advances in EV High
Voltage Connector Technologies, 2021.
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