Classification and Applications of Automotive Connectors

Classification and Applications of Automotive Connectors

There are many ways to categorize automotive connectors—by signal/power function, by geometry, by voltage class, or by vehicle zone. The most widely used classifications and their real-world applications are summarized below.

1. By Electrical Function
- Low-voltage connectors (≤ 60 V)
Applications: battery-management system (BMS), lighting, HVAC, window/door modules, instrument cluster, fuse box—both in ICE and EV platforms.

- High-voltage connectors (60 V – 800 V, 10 A – 300 A)
Applications: new-energy “three-electric” system—battery pack, PDU, on-board charger, DC/DC converter, PTC heater, AC/DC charge inlet. A BEV normally carries 15–20 HV pairs; 800-V architectures can exceed 20–25 pairs.

- High-speed connectors (RF, differential, Automotive Ethernet)
Applications: cameras, mmWave/LiDAR, GPS, V2X antenna, infotainment and ADAS domain controllers—any link that operates in the GHz range.

2. By Construction / Package Style
- Multi-pin rectangular connectors – high-density signal paths for ECUs, clusters and head units.
- Sealed / waterproof connectors – engine bay, chassis sensors, head- & tail-lamps; rated IP67-IP69K.
- High-temperature connectors – turbo-charger, exhaust and O₂-sensor zones; continuous 150 °C+.
- Quick-disconnect connectors – battery, relay and fuse-box locations that must be service-friendly.
- Wire-to-wire & wire-to-board terminals – Bullet, Spade, Ring, Butt styles for harness repairs, grounding or low-current branches.

3. Typical Applications by Vehicle Domain
- Propulsion: HVIL connectors, 3-phase motor interfaces, sealed ignition-coil & fuel-injector connectors.
- Chassis & Safety: waterproof wheel-speed (ABS/ESC) connectors, multi-pin air-suspension connectors, 800-V fast-charge inlets.
- Body & Convenience: quick-disconnect sun-/window-lift connectors, seat-harness multi-pins.
- Infotainment & ADAS: FAKRA / Mini-FAKRA coax (cameras, radio), HSD / Ethernet links (domain controllers, T-Box).

Driven by 800-V architectures, L3+ autonomous driving and full-vehicle OTA updates, the next generation of connectors will focus on higher voltage, higher data-rate, superior sealing, smaller footprints and integrated smart latches or temperature sensing.