Reliability testing is crucial for ensuring the long-term, stable operation of connectors. These tests encompass mechanical performance (e.g., mating/unmating force, durability), electrical performance (e.g., contact resistance, withstand voltage), and environmental adaptability (e.g., temperature and humidity, salt spray, vibration), and are conducted in accordance with international standards such as the IEC 60512 series (e.g., IEC 60512-13-2 for mating/unmating force testing). Statistics indicate that approximately 30% of electronic system failures can be traced back to connector performance degradation.
For applications such as more-electric engines and new energy vehicles, high-voltage, high-current connectors impose specific requirements regarding contact design (e.g., hyperboloid grid-cage structures, crown-spring contacts), insulation and sealing, and arc protection; operating voltages can exceed 1080V, with currents reaching 300A. In recent years, high-current contact technology has been continuously optimized to meet the demands of more-electric engines, increasing current-carrying capacity while maintaining conductor dimensions.
Looking toward 2030, connector technology is evolving toward faster data transmission rates (e.g., 224 Gbps-PAM4), higher power throughput, and smaller form factors, alongside the exploration of contactless connection technologies. Contactless connection technology, which transmits power and signals over short distances via magnetic inductive coupling, holds potential applications across the automotive, industrial, and consumer electronics sectors.
