The application of transmitting high current and high voltage through connectors is constantly increasing. These applications include electric vehicle (EV) charging, whole house backup batteries, and batteries that support intelligent production and energy storage. In the increasingly expanding field of data centers, power distribution units (PDUs), uninterruptible power supplies (UPS), routers, and power racks can also manage high current inputs under high voltage. Manufacturing and factory floor systems, robots, and environmental control also require this specialized connector.
The connectors in these applications need to connect high current and high voltage inputs in a smaller space while avoiding unnecessary losses. Efficient power transmission is also important in preventing overheating caused by voltage drops, which can damage equipment and trigger fires. At the same time, this connector must support rapid automated assembly and prevent misoperation to prevent equipment damage and rework.
Molex's COEUR socket is a high current, high voltage technology that is suitable for many different types of connectors and can minimize contact resistance in high current applications. Products built around COEUR sockets can ensure reliable connections, accommodate more devices in smaller spaces, and simplify production processes.
Core components of high current and high voltage connectors
The COEUR socket is conical in shape, with multiple inclined spring plates made of high conductivity gold arranged in a circle (Figure 1). The diameter ranges from 3.40 mm to 11.00 mm, and the matching silver pins are designed with crimping dimensions.
COEUR socket connector
Figure 1: The COEUR socket connector has low contact resistance and is suitable for high current and high voltage applications. Its gold contact springs are arranged in a conical shape and have an outward expansion at the top (Image source: Molex)
The pin contacts the spring at the narrowest point of the cone, and the spring slightly expands outward at the top of the cone after exceeding the contact point. The inclined shape ensures that each spring has an elliptical contact area, not just point contact. The larger the contact area, the lower the contact resistance, thereby reducing voltage drop and connector heating.
Another advantage of this low contact resistance design is the ability to more tightly package electronic components, thereby saving space. The height of COEUR sockets is 10.0 mm, which is suitable for various connection situations such as wire to board, wire to partition, board to board, and board to busbar.
Characteristics of high voltage and high current connectors
The connection solution using COEUR socket technology can handle high currents and high voltages. For example, the Sentrality pin and socket interconnect system can handle currents ranging from 75 A to 350 A at voltages up to 1000 V, with a contact resistance of 0.20 m Ω to 0.40 m Ω. These features enable the system (Figure 2) to effectively interconnect printed circuit boards (PCBs) to each other or to busbars in home energy storage, industrial automation, networking, and telecommunications applications.