The all-new eHV60 is suitable for auxiliary high-voltage functions, including DC/DC converters, on-board chargers, electric compressors, and e-axle electric drive axles in electric and hybrid vehicles
Design to meet strict industry standards while providing compact and efficient alternatives to replace old products, making it easier to integrate into space constrained systems
Verified second source channels can reduce supply chain risks, improve procurement flexibility, eliminate expensive redesigns, and accelerate product launch
Molex, a global electronics leader and connectivity innovator, has launched the first product in its eHV high-voltage connector and terminal portfolio, designed to provide safe and reliable high-performance electrical connections for high-voltage power source circuits in auxiliary and primary systems of pure electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs). The first product in this series is the eHV60 high-voltage automotive connector, which is very suitable for connecting auxiliary high-voltage circuits such as DC/DC converters, car chargers, electric compressors, and e-axle electric drive axles.
Scott Whicker, President and Senior Vice President of Molex's Automotive and Innovative Solutions Division, stated that the new eHV60 aligns with Molex's broader automotive product portfolio, aimed at enhancing supply chain resilience and reducing overall manufacturing costs. As the latest expansion of the product portfolio, Molex's eHV high-voltage connector series provides a compact and efficient solution that not only enhances procurement flexibility but also allows for easy integration into space constrained systems.
The constantly expanding connector ecosystem
Molex's high-voltage terminal and connector series products expand the company's comprehensive connector ecosystem, which aims to ensure that products comply with global standards and have certification qualifications. The new Molex eHV60 complies with strict USCAR-2 and LV215 industry standards, and has been validated as a direct replacement for old products in both electrical and mechanical aspects. This provides dual sourcing options for automobile manufacturers and first tier suppliers, while ensuring risk-free system integration and faster project initiation.
In addition, eHV60 has a compact appearance, 30% smaller than existing products, which helps to deploy faster in space limited auxiliary high-voltage systems.
The shielding interface design of eHV60 ensures strong shielding against electromagnetic interference (EMI), which is crucial for maintaining signal integrity and system safety in high voltage environments. As an auxiliary high-voltage system connector, eHV60 supports up to 1000 volts and 64 amperes circuit connections at 80 ° C, making it an ideal choice for medium power applications, while also establishing safe, reliable, and efficient high-voltage connections between system components.
Proven connection technology strength
Molex fully supervises all aspects of the design and manufacturing of the new eHV series products, with factories in North America, Europe, and Asia that support localized production while ensuring faster response to customer needs and compliance with regional regulations. Continuous investment in robust design processes enables R&D and product engineers to simulate, manufacture, validate, and commercialize industry-leading products. Long term experience in precision terminal production, connector assembly, and high-voltage quality testing has been supported by Molex Global Reliability Laboratory, whose engineering team meets the market's strict requirements for quality and reliability with decades of experience in electronic and power interconnect solutions, certification, and standards.
In addition, thanks to strong supplier relationships, the company ensures a stable supply of high-performance plastics and high-pressure materials such as electroplating solutions. In addition to improving supply continuity and design flexibility, these supplier relationships also play an important role in reducing Bill of Materials (BOM) costs. In addition, Molex's advanced internal mold and plating capabilities accelerate design iterations and further improve quality, which is crucial when initiating new projects or adapting to design changes.
Simplified system integration
System level integration with Molex's busbar, battery connectors, cables, custom plugs, and 48 volt automotive system solutions simplifies the creation of high-performance one-stop power distribution systems. Molex's experience in high-speed data communication and universal power supply used in ultra large scale data centers is particularly important for designing high-voltage connectors that can withstand a wide range of vibrations, thermal cycles, and mechanical loads.
Product launch date
The eHV60 connector is scheduled to be launched in the first quarter of 2026 and will be included in Molex's existing automotive connector series, while also being the first product in the eHV series.
