Eaton has announced that its Mobility Group will supply its High-Power Lock Box (HPLB) SQ8 connector system to a major global OEM for a new PHEV platform. This agreement is the first application of the SQ8 variant in a PHEV.
The SQ8 configuration of the HPLB connector features a patented, inverted terminal contact design that combines a stainless-steel spring to maintain consistent contact force—especially after repeated thermal cycling—with a copper current carrier to maximize conductivity. Eaton says this design addresses common failure modes like mechanical relaxation found in high-vibration electric vehicle environments.
The HPLB SQ8 terminal has been internally tested and benchmarked against publicly available competitor data, reportedly delivering a 25 to 35 percent improvement in current-carrying capability for a given wire size, and 30 to 60 percent higher current per unit volume, which can support lighter and more efficient vehicle platforms.
The HPLB SQ8 connector is designed for demanding applications such as battery disconnect units (BDUs), high-voltage heaters and propulsion systems in EVs, PHEVs and heavy-duty commercial vehicles. The system supports up to 270 amps of current with minimal resistance loss and operates at temperatures up to 125 degrees Celsius. It offers a tool-free push-click-pull mating process that requires only 70 newtons of force, intended to reduce operator fatigue and eliminate the need for mechanical levers.
Technical highlights include a two-piece terminal compatible with 25 to 70 mm² wire gauges, flexible 90-degree and 180-degree terminal orientations for demanding packaging constraints, eight spring-loaded contact points, and compliance with USCAR-2 T3/V2/S3 and ISO standards. The connector is finger-proof, validated for up to 10 mating cycles, and features QR code-enabled part traceability for logistics and quality control.
Eaton notes that its HPLB family of connectors, including the previously released SQ4 variant, has already been deployed in commercial truck platforms, select electric vehicle applications, and high-current heating systems.
Source: Eaton