FCI Unveils High Power Connector Designs For Electric & Hybrid-Electric Vehicles

FCI announced that it will unveil what it describes as several innovative high power connector solutions developed to face the demand of high performance from virtually all Automotive OEM worldwide and starting with Electric Vehicle (EV) and Hybrid Electric Vehicle (HEV) programs scheduled for launch in 2010/11.

Building on FCI Motorized Vehicle (MVL) division’s expertise in the automotive sector, the new RCS and APEX high power connector ranges are said to incorporate a series of ground-breaking features that reflect the unique challenges presented by EV and HEV applications.

In developing APEX and RCS High Power connector families, FCI is introducing almost simultaneously what it describes as two very innovative terminal technologies: Apex® 950, benefiting from FCI’s Apex design to reach current carrying capacity up to 150A, and new RCS-800 terminals featuring a 8 mm round pin design that is said to facilitate more efficient use of space than an equivalent square terminal. These round RCS terminals also provide a high number of contact points and can operate up to 250A and above, depending on exact customer’s specification. Moreover, special surface platings have been employed to protect against the possibility of surface damage caused by arcing.

The incorporation of a 2-step mating process guarantees the connectors cannot be disconnected while high currents are applied. Two separate movements are required of the user, and there is a three second delay between the power being cut off and connector being free for release. This safety device is supplemented by a number of other features. The terminals are encased in a plastic protective grid that physically prevents them being touched. FCI’s solution does feature an "interlock" device too, ensuring that there is no risk of unmating during load. Additionally, the company’s ErgoMate axial mating system helps achieving a lower profile solution while reducing both mating forces and chance of mis-mating. High levels of shielding and sealing are employed to offer what is described as best-in-class interconnect solutions for EV and HEV.