Electric Vehicle Connectors

OEMs look to differentiate their products through performance as more electric-powered vehicles take to the roads. Xtalic improves electric vehicle (EV) performance by increasing the amount of power that can be sent from a charging station to an EV’s batteries, and from its batteries to its electric motors, during a specified time frame.

The Challenge

The temperature of interconnect components increases when additional power is pushed through a cross-section of material. The power is limited by the maximum operational temperature of the selected material.  Silver has been the industry standard for automotive interconnect finishes but only operates safely below 170oC. Xtalic alloys enable vehicles to be driven faster and longer at temperatures above 210oC. This is due to the thermodynamic stability built into our alloys using our patented rapid alloy design platform. Xtalic-enabled components in EVs are also able to charge quicker, climb hills faster, and more often accelerate quickly.

Our Temperature Stability

Traditional silver is pushed to its limits in current electric vehicle applications. To accommodate for the degradation of traditional silver at higher temperatures, automotive OEMs restrict electric vehicle performance during heavy power draw activities — hill climb, charging rate or re-acceleration. In contrast, LUNA® maintains properties at these temperatures allowing for a boost in performance — as is shown in the images to the right.

Our Wear Durability

Traditional silver is also one of the softest interconnect finishes. For most automotive interconnect applications, wear is not a major concern as insertion forces and cycles remain low. This, however,  is not the case for electric vehicle charger applications. While home charging systems may see hundreds of insertions annually,  the proposed high-speed public charging infrastructure for mass deployment will require thousands more. As traditional silver in EV applications wears through, charging efficiency will be reduced. This is a result of the increase in resistivity that results from the wearing of the silver layer material down to the nickel barrier layer. Furthermore, the system stops working altogether as the base copper alloy is exposed to corrosive media. LUNA® has a similar hardness to hard gold — which is a well known interconnect finish and more than 2.5 times harder than standard silver. The figures below demonstrate how wear differentiates across a variety of conditions.

1 Newton Wear Test
3mm Stroke, 6mm Track, & 500 Cycles/hr

LUNA® shows minimal wear
Standard silver wears to the substrate

50 cN Wear Test with Temperature Exposure
200 Cycles

LUNA® shows minimal smooth wear
Standard silver wears to the substrate after temperature exposure