In electric vehicle (EV) architectures, high-voltage (HV) traction systems coexist with low-voltage (LV) high-speed data networks, such as Automotive Ethernet. This configuration creates a complex electromagnetic environment in which impedance mismatches at connector interfaces can lead to signal degradation, electromagnetic interference (EMI) noncompliance, and power loss. This FAQ outlines the technical methods used to identify […]
EV Engineering
How adhesives and sealants impact EV connector reliability and service life
Electric vehicle (EV) connectors must operate reliably despite intense vibration, thermal cycling, moisture exposure, and elevated temperatures. Adhesives and sealants applied to connector housings, cable entries, and termination points significantly improve sealing performance, vibration resistance, and mechanical stability. These materials can also introduce long-term failure modes driven by thermal expansion mismatch, chemical aging, and environmental […]
How are EV wiring harnesses different?
Wiring harnesses, sometimes called cable assemblies or cable looms, are used in every corner of the electronics industry, including consumer appliances, commercial devices, robotics and industrial systems, computers and servers, telecommunications equipment, medical systems, aerospace platforms, and of course, trucks and automobiles. However, the wiring harnesses used in electric vehicles (EVs) are among the most […]
What is the best copper alloy for connectors in renewable energy and EV applications?
Copper is important in supporting renewable energy and electric vehicles (EVs). For example, there are about 5.5 tons of copper used per megawatt (MW) of photovoltaic generation, and there are 183 pounds of copper in an EV, compared with only 48 pounds in an internal combustion engine (IEC) vehicle. Not all copper is the same; […]
What is electric vehicle supply equipment (EVSE)?
EVSEs provide power to charge EV batteries at Level 1 and Level 2 voltage ratings. Electric vehicle (EV) owners rely on electric vehicle supply equipment (EVSE) to charge their batteries efficiently. Often referred to as charging stations or docks, EVSEs provide a reliable and safe connection between EVs, the electric grid, and other energy sources. […]
Where are liquid-cooled connectors and connectors for liquid cooling used in EVs?
Liquid-cooled connectors are used for carrying high power levels like those found in extreme fast charging (XFC) EV chargers. Connectors for liquid cooling are more common and used for cooling EV battery packs, cooling XFC EV charging stations, and other thermally demanding applications. This FAQ reviews the performance and use cases for liquid-cooled connectors and […]
