DEGSON 1800 Series High-Voltage Connectors: Delivering Reliable Connections for New Energy Vehicle High-Voltage Systems
DEGSON 1800 Series High-Voltage Connectors: Delivering Reliable Connections for New Energy Vehicle High-Voltage Systems
As new energy vehicles continue to evolve toward higher voltage and faster charging, 800V high-voltage platforms have become the industry mainstream, with some premium models even beginning to explore higher voltage levels. This trend places greater demands on high-voltage connectors — they must not only withstand higher voltages and currents, but also ensure long-term reliability within limited installation space. The DEGSON 1800 Series High-Voltage Connector, developed specifically to address this need, is the solution.
Meeting High-Voltage, High-Current Transmission Requirements
The DEGSON 1800 Series High-Voltage Connector features a rated voltage of 1000V DC and supports multiple current ratings depending on the wire gauge: 130A @ 85°C with 25mm² cable, 200A @ 85°C with 35mm² cable, 250A @ 85°C with 50mm² cable, and up to 280A @ 85°C with 70mm² cable. This wide current coverage enables flexible adaptation to different power requirements, from passenger cars to commercial vehicles. Whether for internal battery pack connections, motor controller interfaces, or the incoming and outgoing lines of the Power Distribution Unit (PDU), this connector is fully applicable.
The product offers two cable exit angle options — 90° and 180° — allowing OEMs to select flexibly based on wiring space constraints, avoiding the need for additional adapters or bends due to limited installation angles.
Reliable Protection in Harsh Environments
The operating environment of new energy vehicles is complex and variable, requiring connectors to withstand vibration, temperature fluctuations, water and dust ingress, and more. The DEGSON 1800 Series High-Voltage Connector achieves protection ratings of IP68 and IP6K9K. The former ensures complete dust protection and normal operation under continuous immersion, while the latter withstands high-pressure, high-temperature water jet cleaning, meeting the demands of harsh commercial vehicle applications.
The operating temperature range spans from -40°C to +125°C, adapting to outdoor conditions from cold winters to hot summers. The vibration rating complies with USCAR-2 V2 requirements, ensuring that continuous vibration during vehicle operation does not cause poor contact or terminal loosening.
In terms of electrical safety, the product's insulation resistance exceeds 200MΩ under 1000V DC conditions, and it passes the dielectric withstand test at 3000V AC for 60s with leakage current below 5mA, providing reliable electrical isolation for high-voltage systems. It also features standard High-Voltage Interlock (HVIL) functionality, which can promptly cut off high-voltage output when the connector is not fully mated, ensuring the safety of maintenance personnel.
Engineering Excellence in Detail Design
In terms of structural design, the DEGSON 1800 Series incorporates multiple details to enhance reliability:
• Rotary CPA (Connector Position Assurance) Device: An industry-first rotary CPA design that offers stronger vibration resistance compared to traditional push-type structures, effectively preventing accidental disengagement caused by vibration.
• Terminal Secondary Lock Design: The socket terminal features an added secondary locking mechanism, providing dual protection against terminal backout and avoiding the risk of terminal withdrawal under high-current conditions due to thermal expansion/contraction or vibration.
• Modular High-Voltage Interlock: The depth of the HVIL module can be configured according to customer requirements, adapting to different vehicle safety strategies.
• Optional Single-End Waterproofing: Even when not mated with a mating connector, the single end of the connector can still meet waterproof and dustproof requirements, facilitating assembly line production and after-sales maintenance.
• Captive Rear-Installed Cable Gland: Featuring a split design, there is no need to thread the gland onto the cable in advance, reducing the risk of missing glands on the production line. The gland provides deep cable retention, ensuring that even cable bending does not affect the interior of the connector.
Additionally, the assist mechanism features an anti-extraction design to prevent accidental disengagement during rotation; and the gear-type wheel mechanism achieves a more compact external dimension while ensuring smooth operation feel.
Broad Applicability and Compatibility
The DEGSON 1800 Series High-Voltage Connector is suitable for both passenger cars and commercial vehicles, balancing performance, space, and cost-effectiveness. The product is designed with full consideration of compatibility with similar connectors on the market, enabling drop-in replacement and reducing customer switching costs. The terminal interface size and style can also be customized based on the customer's installation interface depth, meeting the special requirements of different projects.
Conclusion
In the progression of new energy vehicle high-voltage systems toward higher voltages and larger currents, connector reliability is directly related to vehicle safety and performance. Through solid material selection, rigorous structural design, and flexible configuration options, the DEGSON 1800 Series High-Voltage Connector provides the industry with a pragmatic technical choice. Its product parameters cover the full chain of requirements from mechanical durability to electrical safety, and the engineering optimizations in every detail reflect a deep understanding of real-world application scenarios. For vehicle and battery pack manufacturers pursuing system stability and long-term reliability, this is a fundamental component worth attention.
