TE Launches Full Range of Aluminum-to-Copper High-Voltage Connectors to Accelerate the Large-Scale Deployment of Lightweight 800V Connectors
TE Connectivity, a global leader in connectivity and sensing, recently launched its full range of aluminum-to-copper high-voltage connector solutions. These solutions include three core series: the aluminum wire welded TE CSJ, HVA280, and HVA630. Through material innovation and process breakthroughs, TE addresses the reliability challenges of replacing copper with aluminum in high-voltage scenarios, accelerating the lightweighting, cost reduction, and low-carbonization of 800V high-voltage platforms for new energy vehicles.
Currently, the goals of cost reduction and efficiency improvement in new energy vehicles are deeply intertwined with the dual-carbon goals. Vehicle lightweighting and copper-saving and carbon-reducing wiring harnesses have become core industry requirements. Traditional copper high-voltage connectors are heavy and expensive, making them unsuitable for 800V high-voltage fast charging and large-scale cost reduction requirements. While aluminum offers advantages in lightweighting and low cost, it has long been hampered by technical bottlenecks in connection reliability, creep resistance, and electromagnetic compatibility, hindering its large-scale application in high-voltage, high-current scenarios. TE's newly launched aluminum-to-copper high-voltage connector series is the industry's first mature aluminum-to-copper high-voltage connection solution to achieve full-scenario coverage, encompassing both new energy vehicles and energy storage, completely overcoming the technical obstacles to the implementation of "aluminum-to-copper" on the 800V platform.
Core Product Matrix, Adapting to All 800V Scenario Needs
TE CSJ High-Voltage Connector: A new generation of high-current high-voltage connection system, supporting aluminum wire welding and copper wire crimping/welding, SG3 vibration resistance, compatible with core components such as motors, simplifying the wiring harness assembly process by 30%, balancing compact size and high current carrying capacity (TE Connect...).
HVA280 High-Voltage Connector: Primarily designed for medium-current scenarios, adapting to the mainstream power requirements of the 800V platform, balancing lightweight design and reliability, widely covering high-voltage circuits in passenger cars and commercial vehicles.
HVA630 High-Voltage Connector: A flagship product with a rated voltage of 850V, precisely matched to high-power fast charging scenarios of 250kW-350kW and above, perfectly compatible with 800V high-voltage fast charging vehicles, boasting industry-leading current carrying capacity and withstand voltage rating.
Three Core Advantages Empowering Industry Cost Reduction and Carbon Reduction
Extreme Lightweighting, Significant Cost Reduction: The entire product line can help reduce copper usage in vehicle electrical circuits by 18%-100%. Aluminum has only 1/3 the density of copper, significantly reducing the weight of connectors and wiring harnesses, while mitigating the risks of copper price fluctuations and effectively controlling the overall vehicle BOM cost.
Reliable Connection, Maximized Performance: Utilizing TE's proprietary aluminum wire ultrasonic welding technology, the welding time for a single wire is controlled within 1 second, ensuring compatibility with existing automated production lines. Through structural reinforcement, insulation enhancement, and optimized heat-resistant colloids, it addresses the challenges of aluminum wire oxidation and creep, offering excellent vibration resistance and electromagnetic compatibility. Protection levels reach IP6K9K and IP68, meeting the demands of demanding automotive environments.
Low Carbon and Environmentally Friendly, Practicing Dual Carbon: After large-scale deployment, it is expected to contribute to reducing carbon dioxide emissions in China by over one million tons annually, aligning with the global trend of low-carbon development in the new energy industry and helping automakers achieve their full lifecycle carbon reduction goals.
Ecosystem Collaboration, Driving Large-Scale Industry Transformation
TE's successful implementation of aluminum-to-copper high-voltage connectors is not a breakthrough in a single product, but rather the result of years of technological accumulation and ecosystem collaboration across the industry chain. Previously, TE had collaborated with automakers, material suppliers, and equipment manufacturers to build an innovation ecosystem, overcoming industry challenges such as high-temperature creep of aluminum alloys and aluminum wire welding processes, reducing aluminum wire welding time from 10 seconds to 1 second, adapting to the mass production rhythm of vehicles. As a global leader in connectivity technology, TE has always adhered to the philosophy of "expanding boundaries together, creating value together," focusing on technological innovation in core sectors such as new energy vehicles and energy storage. The release of this full series of aluminum-to-copper high-voltage connectors marks the official transition of "aluminum-to-copper" in the high-voltage connector field from the technology verification stage to the large-scale application stage, injecting strong momentum into the popularization of 800V high-voltage platforms and accelerating the development of the new energy vehicle industry towards lighter, more energy-efficient, and lower-carbon directions.
