High-Voltage EV Connectors & Custom Injection Molded Housings
Product Overview & Engineering Identification
Product Name:
High-Voltage EV Connectors / Plug & Socket Assemblies
Product Type:
Specialized custom-molded high-voltage, high-current electrical connection systems for electric vehicles (EVs) and hybrid electric vehicles (HEVs).
Core Function:
Secure, stable, and sealed power distribution from battery packs to inverters, motor controllers, and auxiliary electric systems under high thermal and mechanical stress.
Primary Target Buyers:
Tier-1 automotive wiring harness manufacturers, EV powertrain engineers, electric vehicle component distributors, and OEM automotive procurement teams.
Technical Specifications & Material Compliance
To satisfy strict automotive grade requirements, our high-voltage connectors are manufactured under our IATF 16949:2016 certified quality management system.
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Technical Parameter |
Specification / Range |
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Housing Material Options |
High-performance engineering thermoplastics: PBT-GF30, PA66-GF30, LCP, or PPS (customized per thermal index requirements) |
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Terminal Material |
Copper alloys (High-conductivity copper, phosphor bronze) with silver or tin plating |
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Voltage Rating |
Up to 1,000V DC (customizable based on application architecture) |
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Current Rating |
Ranging from 30A to 300A+ (depending on terminal cross-section and pin configuration) |
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Environmental Sealing |
IP67 / IP68 ingress protection (tested for dust-tightness and continuous submersion resistance) |
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Operating Temperature |
-40°C to +125°C / +150°C (thermal endurance backed by material data sheets) |
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Machining / Molding Tolerance |
Precision injection molded housings with critical dimensions controlled to ±0.01 mm via CMM inspection |
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Regulatory & Compliance |
RoHS compliant, REACH compliant, UL94 V-0 flame retardant standard |
Key Manufacturing & Engineering Controls
In-House Tooling & DFM:
Every connector housing begins with rigorous DFM (Design for Manufacturability) analysis-optimizing draft angles, wall thickness, and gate locations to eliminate warpage and ensure a precise, airtight fit with internal silicone seals and metal terminals.
Precision Metal Stamping & Machining:
Terminal pins and shielding components are produced using advanced CNC turning and high-speed stamping to maintain micro-level tolerances and low contact resistance.
Environmental & Electrical Testing:
Finished assemblies and sample batches undergo rigorous verification, including dielectric withstanding voltage (DWV) testing, insulation resistance checks, and leakage rate verifications under simulated pressure and thermal stress.
Application Scope & Specific Use-Cases
These high-voltage connectors are designed for demanding automotive power architectures:
Battery Packs (BMS):
Secure power transmission and signal connection between modular battery compartments.
Electric Inverters & Motor Controllers:
High-current power linking capable of withstanding electromagnetic interference (EMI) shielding requirements.
On-Board Chargers (OBC) & PDU (Power Distribution Units):
Sealed housing architectures resistant to moisture, road salt, and vibrational fatigue.
Required Information for Customization & RFQ
Because EV power architectures vary by platform, we do not supply generic off-the-shelf units for critical high-voltage circuits. To accelerate your technical evaluation and quotation, please provide the following details:
Engineering Files:
3D CAD models (STEP / IGES format) and 2D drawings with critical tolerance callouts.
Electrical Parameters:
Working voltage, maximum continuous current, and expected contact resistance.
Environmental Demands:
Operating temperature range, mating cycles, and required IP sealing rating (e.g., IP67/IP68).
Commercial Metrics:
Estimated annual volume (EAU), batch sizes, and target project timeline.