Application Watch: Water-resistant connectors find new prospects in automotive industry

Many more electric vehicles are expected to roll off assembly lines and onto roads and highways beginning 2021, beginning the automotive industry's definitive shift toward electrification. In its 2021 Trend Report, ABI Research predicts EVs will break into the mainstream market and by the end of this decade account for up to 25 percent of new vehicles shipped worldwide. There will be 125 million EVs sold by 2030 compared to just three million in 2017, according to the International Energy Agency.

In the upstream sector, including connector manufacturing, this virtually guarantees future prospects in an industry that has suffered a slump due to the pandemic. In 2020, sales volume of vehicles went down to 7.71 million in 11 global markets, sliding by nearly 13 percent YoY, according to Jato Dynamics. This included China, the world's largest automotive market with a flourishing EV segment, whose total sales value suffered a 2 percent dent YoY. The UK, meanwhile, saw the worst with a 28 percent sales drop. Only South Korea realized positive growth.

In 2021, expectations of gradual recovery for the global automotive industry are high. China and South Korea are forecast to achieve the most significant growth thanks largely to their EV sectors, says Jato Dynamics.

Driving R&D

Encouraged by this optimistic outlook, Chinese suppliers of water-resistant connectors will continue growing and enhancing their product selections for automotive use, especially for the growing EV market.

Based on projections by Zhiyan Consulting, automotive connectors worldwide will have a $39.7 billion market by 2025, with $6.17 billion coming from EV-use variants. In China, EV connectors will reach $1.19 billion in the same year, jumping by 72 percent from $690 million in 2020.

Overall, current R&D focuses on robust and reliable designs, which can withstand environmental factors such as dust, moisture, water, heat and vibration. Dongguan Qiaxin's efforts have yielded water-resistant automotive connectors with a sealed cover, in addition to an air-tight gasket, for a firm connection that is also safe from shock.

For EV applications, rugged features that ensure high performance in protecting cable-to-cable connections at higher voltages are important. Shenzhen Connector offers IP67-rated units that have 1,000V rated voltage and 250A rated current and are vibration-resistant, suitable for EVs, ships and communications equipment. The company subjects these connectors to a CASS test for 48 hours to guarantee corrosion resistance.

IP67 & IP68 connectors

Of China's shipments of water-resistant connectors, those for the automotive market currently represent more than 30 percent based on estimates by suppliers interviewed by Global Sources Electronic Components. Consumer electronics, LED lighting, industrial and military applications account for the rest.

Hundreds of water-resistant connector types are available from Chinese manufacturers, with the bulk being round and rectangular variants. The choice is between IP67 and IP68 ratings.

Contacts are usually made of copper or phosphor bronze with gold or nickel plating. Brass is also used. For shells, typical materials are thermoplastic and insulated metal.

All product specifications can be customized to match the requirements of target applications.

Most suppliers follow quality and safety standards, such as CE, CQC, cUL, UL and TÜV, and comply with the RoHS environmental directive.

Material costs and connector prices are expected to stabilize in the coming months.

China's manufacturing sector for water-resistant connectors has over 200 suppliers and includes foreign companies such as Tyco, Amphenol, Delphi, Molex and Yazaki. The top homegrown players include Luxshare, Derun, Jonhon and Yonggui. All offer other types of connectors as well as cable assemblies for a range of applications. Their factories are mostly in the coastal provinces, specifically Guangdong, Zhejiang, Jiangsu and Shandong. There are also companies operating in inland provinces such as Shaanxi and Sichuan.

IP67-, IP68-rated connector

The M12 A-Code connector from Cableforce Electronics Co. Ltd has ≤5mohm contact and ≥100Mohm insulation resistance. The IP67- or IP68-rated unit, with an M12X1.0 lock nut, has 30, 60, 250 or 630V rated and 500, 800, 1,500, 2,500 or 5,000V impulse voltages, and 1.5, 2, 4 or 16A rated current.

An order of at least 1,000 units has a seven-day lead time.

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IPX7-rated connector

For two to four circuits, this H2017-XXPPW7LAR connector from Hsuan Mao Technology Co. Ltd has a 250VAC/VDC, 3A rating, 1,000 minimum insulation resistance and 1,500VAC/min dielectric strength. It operates in -40 to 105 C and meets IEC 60529. The IPX7-rated unit has a body and cover made of white PBT with 15 percent glass fiber, and water-resistant silicone ring and plug.

Order quantity is negotiable. Lead time is 14 days.

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IP67-rated connector with tool-free lock

Shenzhen Renhotec Technology Electronics Co. Ltd markets this IP67-rated HV connector-2694 that has 1,000V rated voltage and 70 to 400A current ratings. The one-pin unit, with a tool-free mechanical lock, withstands more than 500 cycles. It comes in black, red, orange and custom colors.

The minimum order is 10 units. Lead time is five days.

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IP67-, IP68-rated connector

This IP67- or IP68-rated black connector from Zhejiang Tongsheng Electronic Co. Ltd, the TS30245-32P, is made of nylon 66 and has a UL94V-0-rated polyester insulator. It is RoHS-compliant.

The supplier requires an order of at least 500 units for delivery within 14 days.

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