E-mobility demands reliable and stable connections

In the era of the electric transition, the demand for efficiency, reliability, and miniaturization intertwines with the need to manage high power and harsh environments. In this scenario, TE Connectivity (TE) offers interconnected solutions for the electrification of mobility. The company, with over 85,000 employees worldwide and annual revenues exceeding $16 billion, is active in high-tech sectors, from industry to aerospace, including automotive.

A strategic component for electrification

TE Connectivity has historical roots in the world of industrial connectivity and has progressively transformed into a leading player for high-performance components capable of withstanding extreme mechanical, thermal, and electrical stresses. The automotive sector accounts for over 40% of its business, with offerings that include connectors, terminals, sensors, thermal management systems, and power electronics solutions. In the field of e-mobility, TE supports vehicle manufacturers and tier-one suppliers worldwide, providing critical components for electric powertrains, charging systems, inverters, control units, and battery modules. It’s a complex challenge, where reliability, safety, and industrial scalability become fundamental parameters. This is the context for TE’s latest innovation: the High Current PCB power tap.

Claudio Barberi, Product Manager of TE Connectivity, describes in detail this new solution.  «This product was born from a specific request by one of our customers, a major OEM, who needed to deliver high current to a circuit board. From there, TE developed an enhanced solution, with several design features to improve retention and resistance to vibrations.»
Barberi explained that the power is suitable tap up to 40 A, thanks to a design fine-tuned for both electrical conduction and thermal dissipation. Additionally, it comes with a pre-assembled screw treated with a Nylok film, a solution that helps ensure greater retention even in the presence of vibrations, making it particularly suitable for electric vehicles.

Design choices

According to the report, TE introduced a series of special features for the power tap. In addition to the Nylok film, which stabilizes tightening, the last three threads of the screw are deformed- a technique that drastically helps reduce the risk of accidental loosening. 
«The fastening element was designed to ensure stable and durable mounting even in the presence of strong vibrations, such as those typical of the automotive sector or heavy commercial vehicles,» says Barberi. The connection is also facilitated by four anti-rotation ribs, which stabilize the component during assembly with fork terminals, and by two central poststhat facilitate positioning on the PCB during soldering.
One of the main strengths of the new power tap is its versatility. Although it was born from a specific request, the product was designed to adapt to different application scenarios. 
«No structural modifications are required to extend its use to other sectors: if necessary, we can implement customizations for particular applications», confirms Barberi. This flexibility allows the component to be used not only in the electrification of passenger vehicles but also in other segments such as electric agriculture, industrial vehicles, and battery-powered urban transport.

A bridge to electric vehicle onboard systems

The power tap is well suited for systems where high electrical power needs to be delivered directly to a circuit board. Among the most relevant examples, Barberi mentions «onboard chargers, battery modules, and power systems for commercial vehicles or heavy trucks, where the demand for reliability and electrical continuity is particularly critical.» In these systems, thermal management is another key factor: the Power Tap is designed to offer the maximum dissipation surface relative to its nominal current, helping to improve the stability and service life of devices.
Another advantage is the ease of integration into existing production processes. The component fits into conventional assembly lines and allows for a reduction in wiring complexity, paving the way for more compact, lightweight, and scalable solutions – fundamental in next-generation electric powertrains.

Looking to the future

The TE team is already working on an even more compact version of the power tap, designed for applications in even tighter spaces. This is a natural evolution aimed at the centralized architectures of next-generation electric vehicles, where every millimeter of space counts. After all, innovation is part of the company’s DNA.  
«TE Connectivity constantly invests in research and development to anticipate the needs of a rapidly evolving market. The challenges are many, but so are the opportunities,» Barbieri emphasizes. The Product Manager, finally, draws his conclusions on the launch of the high current pcb power tap, which strengthens its position in the electrification landscape by offering a reliable, compact, and easily integrable solution. A component that well represents the company’s approach: starting from a concrete customer need, transforming it into an innovation opportunity, and making it available to a broader audience through smart design and quality engineering.

(by Lara Morandotti)