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The shift to electric vehicles is rewriting the rulebook for automotive design—and nowhere is this more evident than in the invisible backbone of EV architecture: connectors. At CES 2024, Munro & Associates met with TE Connectivity to explore the future of EV connector engineering. The insights gathered from this conversation shine a spotlight on how terminal systems, modularity, and contact physics shape the reliability and performance of next-generation vehicles.
From mating cycles to megatrends, this discussion underscored that good connectivity isn’t just about making things fit—it’s about making them last, with minimal resistance, maximal integration, and zero surprises.
The Hidden Complexity of “Always Works”
TE Connectivity isn’t a household name, but its technology is embedded in nearly every modern vehicle. These are the unsung heroes—products designed never to be noticed. Whether connecting battery cells, inverters, charging ports, or edge devices, TE’s components are engineered for high-performance environments where failure isn’t an option.
At CES, Jeremy Patterson of TE explained that their philosophy centers on “following the electron.” From 12V to 800V systems, across ADAS and autonomous architectures, TE ensures electrons and data flow without interruption. Their components enable modularity, automation, and serviceability—critical traits in the lean manufacturing world Munro champions.
Megatrends Converge: Electrification, Autonomy, and Software-Defined Vehicles
The industry faces three converging megatrends: EV propulsion, autonomous driving, and software-defined architectures. These trends demand new connector solutions that handle more data, higher voltages, and tighter packaging.
Autonomous systems need robust data interconnects. EVs demand low-loss high-voltage connections. Software-defined vehicles need flexible, scalable network architectures. TE’s connector engineering bridges all three.
Patterson notes that TE is involved in “zonal architectures” and power-dense modules that reduce cable clutter and failure points. This is especially important as systems shift from distributed to centralized computing platforms with increasing reliance on zonal nodes and edge devices.
The Physics of Reliability: Why Connectors Fail (and How to Prevent It)
Much of the discussion at CES focused on contact physics. Specifically, how terminal design, plating, and geometry affect performance over time. The right plating ensures minimal electrical and data loss; the right force balances grip with serviceability.
Every connector must be engineered for its lifecycle. Low-voltage automotive connectors may only require 10 mating cycles. High-voltage components can demand 50. And charging ports—like those for NACS (North American Charging Standard)—must survive 10,000 cycles.
It’s not just about functionality. As Munro’s team pointed out, past cost-cutting decisions around cheap connectors caused fires, faults, and recalls. TE’s precision avoids such risks. Their goal? “Mate it, forget it.” That reliability pays off in leaner design, fewer warranty claims, and greater customer satisfaction.
Designed for Assembly: Why Modularity Matters
A major theme was “design for automated assembly.” TE designs components that snap in correctly the first time—reducing human error, increasing throughput, and enabling modular manufacturing. Every detail matters: snap-fit tolerances, lock-in confirmation, anti-pull features.
Connectors aren’t just passive—they’re active contributors to lean manufacturing. TE builds in redundancy, flexibility, and high signal integrity while ensuring each unit is serviceable and robust.
And they don’t over-engineer. If a part only needs one mating cycle, they design for that. If it needs 10,000, they scale accordingly. This balance between cost and performance defines good connector engineering.
Inside the Battery: BCON+ and Cell-Level Integration
Battery packs are increasingly modular. TE’s BCON+ product line exemplifies this shift. It acts like “Lego blocks” for battery assembly—standardized, low-resistance connectors that enable modularity in everything from packs to individual cells.
With lithium-ion batteries, every micro-ohm counts. Voltage drops lead to inefficiencies, heat, and imbalance. TE’s systems aim to minimize loss while maximizing data capture—critical for state-of-health and charge monitoring.
Their cell-to-cell solutions reduce wiring complexity (“spaghetti wires”) and enhance serviceability. As vehicles move toward individual cell monitoring, such modular, wireless-ready solutions are becoming even more essential.
NACS vs CCS: Standardizing the Future
Another highlight: the transition to NACS, Tesla’s North American Charging Standard. With Europe aligned on CCS2 and China on GB/T, North America’s move toward a universal charging interface simplifies design, infrastructure, and consumer experience.
TE isn’t just supporting NACS—they’re accelerating its adoption. They’ve already tooled up connectors and retrofitting solutions to help OEMs shift architectures quickly.
Patterson emphasized the importance of backward compatibility. TE offers solutions that split AC and DC paths flexibly so legacy architectures can adapt without redesigning entire vehicle systems. From inlets to battery packs, their systems enable seamless transitions between standards.
Miniaturization and the Wireless Push
Even in wireless systems, connectors play a central role. Whether integrating PCBs or miniaturized power electronics, internal signal pathways still rely on robust interconnects.
TE supports miniaturized modules within wireless BMS, DC-DC converters, and onboard chargers. This approach cuts wire clutter, improves airflow, and enables tighter packaging—critical for compact EV platforms and energy-dense applications.
Wireless sensing isn’t truly wireless until it interfaces reliably with power modules—and TE delivers those interfaces with passive elegance.
EV Connector Engineering Takeaways
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Design connectors for lifecycle: Match mating/removal cycles to real-world needs. Overengineering wastes money; underengineering risks failure.
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Modular systems reduce cost: Use standardized, snap-fit solutions to simplify assembly and boost serviceability.
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Plating and geometry matter: Invest in high-quality materials and terminal physics to minimize data/power loss.
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Support next-gen standards: Embrace universal connectors like NACS for ease of use and interoperability.
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Plan for wireless: Even wireless EV systems require robust passive interconnects inside modules.
Why It Matters
Connectors are more than metal and plastic—they’re the foundation of reliable power and data transmission in EVs. As Sandy Munro has often said, “Without good connectors, you’ve just got fancy boxes and dead electrons.”
Companies like TE Connectivity play a pivotal role in making sure those boxes talk to each other, stay connected for 10+ years, and scale with software-defined vehicles and zonal architectures.
This isn’t just plug-and-play—it’s plug-and-perform.
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