EV Charging Solution

Application

Description

High-current interconnect solutions for EV charging stations, onboard chargers, and battery management systems. Our power connectors support up to 50A per contact with robust designs for outdoor and automotive environments.

Core Advantages

High Current Capacity Power connectors rated up to 50A per contact with low contact resistance, minimizing power loss and heat generation in charging systems.
High Voltage Safety Custom high-voltage connectors with enhanced creepage and clearance distances for safe operation up to 1000V DC.
Outdoor Durability UV-resistant materials and wide temperature range (-40°C to +125°C) ensure reliable operation in outdoor charging environments.
Automotive Qualification Components available with AEC-Q200 qualification and testing to automotive standards for onboard applications.

Recommended Bill of Materials (BOM)

Item Part Number Description Quantity Datasheet
1 BTB-5020-V-10 5.08mm 20-pin power connector for charging modules 30 📄 Download
2 CUS-BTB-HV-20 High-voltage 1000V connector for DC bus 20 📄 Download
3 WTB-VH-3P-CR 3.96mm 3-pin power entry connector 80 📄 Download
4 CUS-CAB-ASSY-01 Custom overmolded cable assembly for control signals 25 📄 Download

Applications

EV Charging Stations
Onboard Chargers
Battery Management
Power Distribution

Technical Specifications

Voltage Rating
Up to 1000V DC
Current Rating
Up to 50A per contact
Operating Temperature
-40°C to +125°C
Protection Rating
IP65 (outdoor enclosures)
U V Resistance
UV-stabilized materials for outdoor use
Safety Standards
UL, IEC, automotive qualified options

Customer Success Stories

ChargeFast Networks

EV Charging Infrastructure | 150kW DC Fast Charging Stations

Challenge

Needed reliable high-power interconnects for 150kW DC fast charging stations with outdoor exposure, high vibration, and thermal management requirements.

Solution

Implemented Bronze Tech high-current board-to-board connectors and custom high-voltage interconnects with enhanced creepage distances for 1000V operation.

Results

Successfully deployed 500+ charging stations. Zero thermal issues with 50A rated connectors. Passed UL certification for EV charging equipment.

EV Power Systems Ltd.

Electric Vehicles | Onboard Charger Module

Challenge

Required compact, high-voltage connectors for onboard charger with limited space and strict automotive qualification requirements.

Solution

Used custom high-voltage board-to-board connectors with 8mm creepage and automotive-grade materials. Optimized PCB layout for thermal management.

Results

Passed AEC-Q200 qualification. Achieved 40% space reduction vs previous design. Operating reliably in 10,000+ vehicles.

FAE Expert Insights

D

Dr. Thomas Anderson

Principal Engineer - Power Solutions

20 years

Professional Insights

[Data Pending] FAE insights to be added based on actual application experience with this solution.

Key Takeaways

  • Use 5.08mm pitch or larger for high-current applications
  • Verify temperature rise under actual operating conditions
  • Ensure adequate creepage distance for DC voltage levels
  • Specify UV-resistant materials for outdoor installations
  • Consider AEC-Q200 qualification for onboard applications

Decision Framework

Solution Selection Decision Framework
Steps:
  1. Evaluate application requirements and performance metrics
  2. Compare solution advantages considering cost and supply chain
  3. Reference success cases and customer feedback
  4. Consult FAE for professional recommendations

Ready to Implement This Solution?

Contact our FAE team for design support and quotes

Contact Us Now

Frequently Asked Questions

What connectors are recommended for EV charging power modules?

For EV charging power modules, we recommend the BTB-50 series (5.08mm pitch) for high-current applications up to 15A per contact, and the CUS-BTB-HV series for high-voltage DC bus connections up to 1000V. The 5.08mm pitch provides adequate spacing and current capacity for power distribution. For control signals, use the BTB-27 series (1.27mm pitch). Always verify temperature rise under actual operating conditions and ensure adequate PCB copper area (2oz minimum recommended) for heat dissipation.

Use BTB-50 for power, CUS-BTB-HV for high voltage, BTB-27 for signals.

How do I ensure safety in high-voltage EV applications?

For high-voltage EV applications (400V-1000V), safety is paramount. Use connectors specifically designed for high voltage like our CUS-BTB-HV series with enhanced creepage (8mm) and clearance (6mm). Ensure connectors are rated for your maximum working voltage with safety margin. Use touch-safe designs where user access is possible. Implement proper interlocking and HVIL (High Voltage Interlock Loop) circuits. All high-voltage connectors should be clearly marked and accessible only to qualified personnel. Follow applicable standards including IEC 60664 for insulation coordination.

Use high-voltage rated connectors. Implement HVIL. Follow IEC 60664.