The rapid evolution of electro mobility is driving increasingly stringent requirements for safety and compactness in high-voltage applications. Specialized high-performance polymers enable a forward-looking solution for connections up to 1'000 V, replacing metal components and setting new standards in high-volume production through consistent functional integration.
The rapid evolution of electro mobility is driving increasingly stringent requirements for safety and compactness in high-voltage applications. Specialized high-performance polymers enable a forward-looking solution for connections up to 1'000 V, replacing metal components and setting new standards in high-volume production through consistent functional integration.
In modern electric (BEV) and hybrid vehicles (PHEV) installation space is a critical factor. Innovative high-voltage connectors are therefore used for connections at the battery, motor and inverter. These represent some of the most compact solutions on the market in classes 4 (up to 250 kW) and 5 (up to 340 kW). This competitive advantage is achieved through EMS high-performance polymers specifically optimized for e-mobility applications.
Efficient metal replacement through functional integration
The injection molding solution allows complex mechanical features to be integrated directly into the plastic component, replacing machined aluminum parts. Thanks to excellent flowability thin-walled components with high weld line strength can be realized. The high mechanical strength and precision enable the lever to be attached via a snap-fit connection directly to an integrated pivot point on the housing – eliminating the need for additional bearings or fasteners.
Maximum operational safety and cost efficiency
The polyamides used support high precision laser marking and maintain color stability even after 1'000 hours at 150 °C. These connectors reliably withstand loads under demanding thermal and mechanical operating conditions ranging from -40 °C to +140 °C. To ensure maximum safety, the halogen free and flame-retardant secondary locking mechanism prevents contact corrosion.
Costs are reduced through material savings of up to 20% and fully automated production processes without the need of preheating metal inserts. With GWP values of 2.7 to 3.9 kg CO₂e/kg, the system also offers a compelling sustainability profile. Furthermore, the standardized design conserves resources in tooling and maximizes efficiency in high-volume production.
