Better, Faster, Stronger | Technologies Advance, But EV Battery Goals Remain the Same at 2024 Battery Show

Direct from Detroit, MI, reports from the 2024 Battery Show confirm that no matter how electric vehicle (EV) battery systems continue to evolve, the goals remain the same. Whether the battery type is sodium-ion, solid-state or lithium-ion, battery systems need to deliver higher power-to-weight/size ratios, faster charging capabilities, and better battery efficiency (longer driving ranges). In addition, EV system developers are looking for solutions that simplify their designs, ease assembly and get them to market faster.

From the EV powertrain to the battery management system, connector solutions play a key role in meeting design goals. Three connector technologies that continue to gain traction in EV battery systems include FPC/FFC connector solutions, floating connectors and hybrid connector solutions.

ADVANCING CONNECTOR SOLUTIONS FOR EV BATTERY SYSTEMS

FPC/FFC Connectors

Compared to traditional discrete wire connectors, FPC/FFC connectors offer significant advantages. Discrete wire connectors demand more man-hours for harnessing because they require soldering, crimping, and insertion into each contact. Additionally, they are heavier relative to the number of cores. In contrast, FPC/FFC connectors simplify the process. By directly inserting the FPC into the plug housing and attaching a retainer, connections can be completed without specialized tools. These connectors also offer consistent quality and lightweight performance, making them ideal for hybrid and EV battery systems. Their compact size, cost-effectiveness, and tool-free installation make them a standout choice for space-constrained automotive applications such as in-vehicle battery cells and onboard modules.

For example, FPC/FFC connectors like the new ZK1, TF70 and TB4 Series from Hirose combine miniaturization and design flexibility with a rugged and safe design for harsh environment operations found in automotive applications. The FPC/FFC connectors are well-suited, increasing the capacity and supporting advanced functions of EV battery systems. The ZK1 Series and TB4 Series meet USCAR-2 Compliance, satisfying automotive requirements for vibration and heat resistance.

Floating Contact Systems

Floating contacts allow the connector to absorb various amounts of alignment errors or vibration.

Board-to-board connectors, such as the FX26 Series with a floating contact system, further simplify assembly and reduce labor costs while saving space. These connectors are ideal for densely populated systems requiring multiple connectors on the same two boards. In addition, connectors with a floating contact design provide superior vibration resistance for more reliable operation. The floating contact system enhances vibration resistance for reliable operation, reduces stress on solder joints caused by misaligned connectors, and prevents solder cracking to increase durability. With features like high data rate capabilities, EMI shielding, and small footprint pitches, floating connectors streamline the design and assembly of smart industrial products.

Hybrid Connectors

Hybrid connectors are also increasingly gaining traction in micro-mobility battery systems. By consolidating power and data signals into a single, space-saving solution, hybrid connectors simplify designs while maintaining high-speed transmission and noise prevention through a shielded housing. The result is a more efficient and compact solution for connecting the complex array of elements found in EV battery systems. 

Connectors like the BH12 Series wire-to-wire offers 20A current and 1A signal and are IPX6/IPX7 waterproof. These lightweight, durable, and easy-to-assemble connectors are commonly used in e-Bikes and e-Scooters, offering efficiency and reliability in compact systems.

For more information on how Hirose Electric's connectors can transform your wearable device design, visit hirose.com or contact our team of experts today.