Accelerating the Charge: EV Charging Connectors Evolve
Charging an electric car still takes longer than filling up a gas car. But that is about to change, and it all comes down to the connectors. The latest charging connectors are ready to dramatically upgrade charging infrastructure.
At the moment, the slow EV charging experience remains one of the key barriers to electric car adoption. However, 2024 brought about a number of dramatic advancements in EV and battery design, and new charging connector technologies that will lead to a faster recharge for the next wave of vehicles.
For drivers who have access to workplace or home charging, charging the car at slow Level 1 or 2 speeds is as easy as recharging a phone. However, for drivers who live in apartment buildings or drive long distances, Level 3 fast charging is a necessity. A year ago, EV connector types varied by vehicle, with multiple interfaces in use around the world. However, that variety is a roadblock in the simplification of charging infrastructure. The U.S. Infrastructure Law of 2021 included plans to create a nationwide charging network, and one funding requirement was that it be accessible by all brands of cars. (Europe and China continue to use other standards.)
ITT Cannon’s enhanced second-generation CCS2 connectors for the EU market are available in 200A, 250A, and 300A variants with an additional boost mode up to 500A.
Recognizing the need for a single charging standard, in 2023 SAE International announced that Tesla’s interface, which was both the most common and most reliable connector in use, would become the NACS (North American Charging Standard) connector, standardized as SAE J3400. This five-pin connector accommodates AC single and three phase charging. But that was not the last word.
The NACS connector interface (Image: The Joint Office of Energy and Transportation)
In September 2024, SAE released the updated J3400 EV Coupler Recommended Practices which covers the general physical, electrical, functional, safety, and performance requirements for conductive power transfer to an electric vehicle using the coupler. This update renames the NACS (now the North American Charging System) and outlines improvements that go beyond Tesla’s original design to improve thermal safety, power transfer (up to 1 megawatt), and charging voltage (up to 1,000 volts; Tesla’s original was 500V). It also sets new requirements for adaptors, which will be needed for vehicles with charging inlets that predate the J3400 to access the network.
The interconnects inside these EV charging systems, from the pins inside the plugs to the charger cables that transfer the energy as well as the external housing, play a significant role in improving the speed and performance of the EV charging experience. Here are some of the latest products that will transform EV ownership.
Smiths Interconnect has released an award-winning new contact solution for EV charging plugs. The Hypertac Green Connect Contact Technology is a lead-free and beryllium-free high power contact solution with unparallelled low contact resistance, which reduces heat build-up and allows the contacts able to handle far greater current loads in smaller contact assemblies. An improved crimp design on the socket side increases the contact area between the contact body and the multi-stranded cable.
“The Hypertac Green Connect contact technology is expected to bring a sea change in the BEV charging industry,” said Mark Kelleher, connectors BU director at Smiths Interconnect. ”With its unrivalled performance to transfer energy at boost mode, long-term durability, and compliance with global standards, we are setting a new benchmark for high-performance connectors that will meet the needs of an evolving market.”
HARTING’s EV charger plug is ruggedized for the demands of outdoor and frequent use with features like PA66 fiberglass and thick wall design. HARTING offers a simplified, efficient, and elegant design with interchangeable connector faces that can be configured to meet the needs of the U.S. and European markets. At electronica 2024, the company also demonstrated EV charging equipment for forklifts and industrial vehicles, as well as charging cables.
Phoenix Contact’s mission to promote an all-electric society through superior connectivity includes EV and EV charging technologies. Also at electronica, the company showed AC and DC cables for fast charging, as well as charging inlets and sockets for home use and charging stations.
Phoenix Contact’s award-winning Charx connector
“Pure e-mobility is a key factor on the path to the All Electric Society. A convenient and carbon-neutral charging process not only requires a fast charging network for electric vehicles, but also coupling with other sectors. With our high-performance and intelligent CHARX products, we can help get customers ready for the e-mobility of the future – sustainable, networked, and practical,” said Joachim Pucker, senior director market segment infrastructure, Phoenix Contact E-Mobility GmbH.
Weidmüller’s AC Smart fast-charging wallbox in a parking ramp.
Despite a rapidly improving public charging infrastructure, the majority of EV owners charge at home, and that’s part of the appeal — imagine if you needed to go somewhere to charge your phone? Home EV chargers are the height of automotive convenience. At electronica 2024, Weidmüller showcased its latest equipment for the home charging market, including the AC Smart fast-charging wallboxes for home and commercial use. Easy to use, durable, and quick to charge, these boxes bring the pump to the user at home, work, or out and about town.
Even though the NACS connector is becoming the new U.S. standard, millions of EVs and other forms of electric mobility will continue to use the previous connector interfaces, and new equipment — including adaptors — will be needed.
Amphenol Industrial’s new ER Series SAE J1772 connector
Amphenol Industrial’s new ER Series SAE J1772 connector is designed for charging vehicles that require the J1772 interface at home or at commercial chargers. This rugged connector and charging cable provide a current rating of up to 80A, with a voltage capacity of 250V AC. Its ergonomic design and durable construction ensure it withstands more than 10,000 mating cycles and performs in challenging environments, from icy conditions to high temperatures. It supports everything from slow, overnight charging to faster, high-current applications.
Ultimately, a combination of technologies will be needed to bring about widespread EV adoption. Easy charging at home and work, as well as at local destinations and on the interstate will make e-mobility even more convenient than gas vehicles.
To learn more about the companies mentioned in this article, visit the Preferred Supplier pages for Amphenol Industrial, HARTING, ITT Cannon, Phoenix Contact, Smiths Interconnect, and Weidmüller.
Like this article? Check out our other articles on EVs and HEVs, our Automotive Market Page, and our 2024 Article Archive.
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