Dec. 09, 2025
With the development of transportation technology, the connector industry is moving towards a new generation of miniaturization, lightness and multi-function.
Many automotive connectors have been on the market for decades. Modern cars, light trucks, motorcycles and more all use traditional connectors. Transportation technology has changed a lot.
Transportation technology is making significant advances in response to consumer demand for safer, smarter, and greener vehicles. These developments often make it necessary for designers and OEM manufacturers to find new interconnect solutions.
New developments in vehicle propulsion systems are a key driver for this mission. For example the following factors:
* Traditional internal combustion engine vehicles use 12/14V wiring harness.
* Mild hybrids (also known as power-assisted hybrids and battery-assisted hybrids) are equipped with an additional 48-60V battery system.
* Plug-in hybrid and fully electric vehicles have additional electric and electronic systems. Connectors are required between the motor, inverter and charging mechanism.
Additionally, the proliferation of electronics in vehicles, especially cars, light trucks, etc., means there are more electrical connections than ever before. Even low-end cars now have 30-50 electronic control units (ECUs), while a luxury car can have as many as 150 ECUs. Meanwhile, a high-tech car can have as many as 65 central processing units (CPUs), which requires a different kind of connector technology.
When high voltage interconnection systems come into play, the electrical design must also account for clearance and creepage conditions. Since connectors for high-voltage applications are typically larger than previous 12V interfaces, this can create another design issue. What's more, all connections must fit within the same limited space, which creates space challenges because of the bulky overall cables and connectors in EV systems.
Here are a few points to consider when determining the latest generation of vehicle connectivity solutions.
1. Size and power handling
As OEMs integrate higher levels of functionality into vehicles, the number of connected units will continue to increase, and so will the power requirements. However, the design space remains largely limited and unchanged. Miniaturization has been a major trend in the industry for many years, and compact connectors are one of the solutions. Therefore, when researching interconnect systems, look for the best combination of compact size and power handling.
2. Performance and specifications
Choosing a more compact connector often means compromising or sacrificing functionality. Today, however, connector suppliers offer an expanded range of high-reliability small connectors that meet global OEM specifications for temperature, vibration, and sealing performance. These interconnect systems also feature secondary locking, clip retainer functionality, latch protection and other options.
3. Wire size range
The wide range of connector system wires provides OEMs with greater choice for the entire vehicle application system. Even with different current requirements, the connector can remain the same; only the wire size needs to be changed. A single reusable connector system can simplify and speed up design and manufacturing, while also providing OEMs with a more cost-effective solution. A range of conductor sizes that can support and maintain the connector's specified ingress protection (IP) standards is particularly valuable.
4. Flexibility
The flexibility of the connector system allows for greater functionality and integrability, as well as more opportunities to improve electrical design and the overall vehicle experience. Ultimately, the more flexibility a connector system provides, the more OEM manufacturers can save space, weight, time and money.