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EV Connectors

Our EV connectors are designed for high-current, low-resistance transfer, utilizing high-conductivity materials such as copper alloys and silver-plated contacts to minimize power losses. These connectors are optimized to handle high-voltage and high-amperage requirements, ensuring that the charging process is fast and energy-efficient. The contact resistance is carefully controlled to ensure that energy losses are kept to a minimum, improving the overall thermal performance of the charging system. This precision engineering ensures that each connector delivers maximum efficiency, even under prolonged high-load conditions. 

Material Options

Nickel-plated copper, stainless steel, high-grade thermoplastics, aluminum alloys

Cable Diameter Range

6 mm to 25 mm

Temperature Range

-40°C to +85°C

Load Capacity

50 A to 500 A (depending on connector model)

Vibration Resistance

Designed to withstand up to 30 G of vibration
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Product Description

Thermal management is an integral part of the design. The connectors have advanced heat dissipation capabilities that ensure optimal performance even in demanding charging environments. Thermal cycling tests confirm that the connectors maintain structural integrity and electrical performance over time, even under extreme temperature fluctuations. This capability is critical for environments that experience wide temperature variations, ensuring consistent and reliable operation. 

Corrosion Resistance

IP67-rated, corrosion-resistant alloys, resistant to saltwater, industrial pollutants

EMI Shielding

Integrated conductive metal shielding and grounding to reduce interference

Mounting Options

Panel mount, through-hole, surface mount, and rail-mount configurations available

Compliance Standards

IEC 62196, UL 94, RoHS, CE, ISO 9001

Custom Features

Customizable cable length, connectors, and housings for specific applications

UV Resistance

UV-stabilized plastics ensuring long-term outdoor use

Fire Resistance Rating

UL 94-V0 rated materials for flame retardancy

Chemical Resistance

Resistant to oils, fuels, and other industrial chemicals

Thermal Expansion Tolerance

< 2 x 10^-6 /°C (ensures dimensional stability under varying temperatures)

Dynamic Load Testing

Tested for dynamic load tolerance in harsh operational environments

Precision Tolerances

±0.1 mm for connector pins, ±0.2 mm for housing dimensions

Technical Advantages

The mechanical durability of EV connectors is paramount, as they are subjected to varying environmental conditions, including temperature extremes, exposure to moisture, and physical stress. Our connectors are built to withstand the rigorous conditions of indoor and outdoor environments, with IP67-rated sealing that guarantees protection against dust ingress and water submersion. The use of corrosion-resistant alloys and high-strength polymer housings further enhances the longevity of the connectors, ensuring that they remain reliable for years of service. 

Vibration resistance is another key consideration in the design of our connectors. The connectors are tested for high-vibration environments, such as industrial applications or electric vehicles in motion. The internal locking mechanisms and robust mechanical construction prevent loosening or disconnection, ensuring stable electrical connections even in challenging operational settings. This durability is vital for reducing maintenance costs and downtime, making the connectors reliable for fleet operators and charging station developers. 

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Industry Applications

Automated Guided Vehicles (AGVs)

Provides robust connectors for autonomous, battery-powered material handling systems in industrial environments, supporting quick recharging cycles. 

Marine Electric Propulsion Systems

Used for connecting charging stations to electric-powered marine vessels, ensuring high-efficiency energy transfer for onboard systems. 

Electric Aviation Systems

Delivers power to electric aircraft ground support equipment, enabling efficient energy transfer for battery-powered aviation operations. 

Microgrid Systems

This technology facilitates power integration between EVs and microgrid systems, supporting dynamic energy exchange and enhancing energy resiliency. 

High-Efficiency DC-DC Converters

Electric vehicle power converters ensure stable, high-efficiency voltage conversion for various in-vehicle systems. 

Electric Heavy Machinery

Connectors are used in electric-powered construction and mining equipment, supporting rapid recharging in operational environments. 

High-Quality Manufacturing and Rigorous Quality Control

The manufacturing of our EV connectors adheres to the highest standards of precision engineering, with rigorous quality control protocols at each stage of production. Each connector is subjected to a series of tests that simulate real-world conditions, including electrical load testing, mechanical stress testing, and environmental stress testing. These tests ensure that each connector can withstand the demands of high-frequency use and maintain reliable performance over its lifespan. 

We also prioritize traceability in our production processes, utilizing advanced metrology and serial number tracking to ensure that each connector meets the highest quality standards. This commitment to excellence ensures that your investment in EV connectors translates to reliable, long-term performance in your charging infrastructure. 

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate’s EV connector ensure compatibility with multiple global charging standards?

Frigate’s EV connectors are designed with modular interfaces that support CCS, CHAdeMO, and Tesla Supercharger standards. The connectors ensure seamless integration with diverse charging infrastructures by utilizing interchangeable contact pins and adjustable power systems, allowing for universal compatibility and easy adaptation to future protocols. 

What materials are used in Frigate’s EV connectors to maximize performance and longevity?

Frigate’s EV connectors incorporate high-performance copper alloys, nickel-plated contacts, and specialized polymer insulations. These materials offer high electrical conductivity, resistance to oxidation, and mechanical durability, ensuring consistent performance under high currents, extreme temperatures, and long-term environmental exposure. 

How do Frigate's EV connectors maintain secure connections in harsh industrial environments?

Frigate’s connectors are engineered with high-tensile strength housings and precision-locking mechanisms that withstand vibrations and physical stress. IP67 sealing and robust contact retention systems prevent moisture, dust, and contaminants from interfering with the connection, ensuring uninterrupted service even in demanding industrial and outdoor environments. 

What testing processes does Frigate implement to ensure the reliability of its EV connectors in high-voltage applications?

To simulate real-world conditions, Frigate’s EV connectors undergo electrical stress testing at high voltages and thermal cycling. The connectors are also tested for contact resistance and insulation integrity using high-voltage dielectric testing to ensure they can withstand continuous operations in high-power EV charging systems without failure. 

How does Frigate address the issue of electromagnetic interference (EMI) in EV connectors?

Frigate integrates EMI shielding using conductive metal enclosures and specialized coatings that reduce electromagnetic interference. Additionally, the connectors feature grounding systems that dissipate unwanted electrical noise, ensuring minimal disruption to vehicle electronics and external systems, which is essential for fast-charging networks and high-precision applications. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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EV Connectors

Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

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