High-Voltage & Versatile Busbar Connector Systems
A versatile, scalable connector system designed for limited-clearance applications. TE Connectivity’s HC-STAK family of high-voltage connectors supports the increased demands of tomorrow’s passenger car and commercial electric vehicles. In situations where component spacing is especially tight, a traditional plug-and-header solution may not be feasible.
The HC-STAK Busbar Connector System eliminates the need for bolt-driven electrical connections, providing a scalable and separable interface in one of the smallest high-voltage package designs available. Its unique terminals are comprised of layered, double-ended fork contacts that provide 25 contact points per centimeter of busbar width.
The stack thickness can be adjusted to match the application’s current requirements by simply adding or subtracting fork layers. This design allows the terminals to flex and float independently, maintaining contact and performance despite twist, angularity, or terminal offset. The HC-STAK Busbar Connector System has passed customer-specific vibration requirements, exceeding USCAR V1.
KEY BENEFITS:
- Increased voltage and current transfer capabilities: up to 1000 VDC and more than 400 A continuous at 85°C
- Flexible: options available that can be mated with busbars of 2.5 mm or 3.5 mm in thickness
- Eliminates the need for torque control associated with bolted busbars and eyelets
- Stacked fork terminals provide a plurality of contact points for high current transfer, with no performance loss if individual forks are momentarily separated from the circuit
- USCAR Class T4 temperature, S3 sealing, V1 vibration
- Simplifies busbar-to-busbar connectivity
- Improves manufacturing efficiency and cost-performance compared with welding
- High power transfer in a compact package size
Applications
- Electric vehicle (passenger cars and commercial vehicles) inverter to e-motor
- Any busbar-based application, especially those with narrow clearance space
The HC-STAK terminal system is a layering of identical, double-ended fork contacts that can act independently and float within the cavity. Contact is maintained with negligible impact on the performance despite terminal offset.
