Eaton has released its specialised high-power lock box power connectors for use in current and future electrified and internal combustion vehicle solutions.

A component of Eaton’s eMobility businesses’ power connections portfolio, the lock box power connectors offer a space-saving profile, superior performance, cost savings and reduced manufacturing complexity while providing protection against the elements.

“Eaton recommends use of sealed connection systems to meet reliability and durability requirements,” Eaton general manager Chris Mancuso says.

“Additionally, we’ve designed our HPLB terminal system for high-current and high-temperature applications, up to 500 amps and 125°, respectively.”

Unlike traditional box and blade terminals, the connectors use Power Connections’ Connector Positive locks which utilise an “inside-out” contact system with internal spring pressure and multiple contact points.

The unique configuration provides a stronger connection than that of conventional box-and-blade connectors where the female terminal spring squeezes the male blade, which loosen when exposed to heat and vibration, thereby, resulting in a loss of power flow continuity and the possibility of corrosion.

“Power connectors, while a small component, are a critical design element to meet product performance and durability requirements,” Chris says.

“Commercial fleet operators not only expect but require that all vehicle systems have a service life of at least ten years.”

The unique connection also reduces heat radiating from the connection points by an average of -14° per contact. Many modern vehicles have up to 120 such contact points, so leveraging HPLB connectors leads to dramatic temperature mitigation and improved vehicle performance.

The HPLB connectors can be installed by a “pick-and-place” robot, allowing for precise and safe connections every time. Additionally, the HPLB sits flush, unlike traditional connector terminals, reducing space requirements within the vehicle.

“Our HPLB terminal connectors not only lower temperature, but provide extra current carrying capacity,” Chris says.

“So, they are half the size and carry twice the current, and in some applications up to three times the current.”