Powering the Transition to E-Mobility: Amphenol’s DuraEV™︎ and DuraSwap™︎ Connector Solutions

As electrification becomes the defining transformation in the global transportation landscape, the technologies enabling safe, reliable, and efficient power transfer are of paramount importance. The expansion of electric vehicles (EVs), e-mobility platforms, and distributed energy storage systems has introduced stringent new requirements for the electrical and mechanical performance of connectivity solutions.

The following presents a comprehensive technical overview and industry perspective on two critical innovations from Amphenol Communications Solutions’ Power Solutions division: the DuraEV and DuraSwap connector families. These products are designed to support the evolving needs of the e-mobility sector, from EV charging infrastructure to modular battery architectures.

Industry Context: E-Mobility Growth and Connectivity Demands

The rapid global adoption of e-mobility is being driven by a combination of environmental regulations, advancements in battery and charging technology, and the growing demand for cleaner urban transportation. Several key trends are shaping the market:

Key Market Trends:

1. Swappable Battery Systems and Battery-as-a-Service (BaaS)

Modular battery systems are increasingly favored in applications requiring rapid energy replenishment, including two- and three-wheeled vehicles, last-mile logistics fleets, and drones. These systems allow for operational flexibility and reduced charging downtime.

2. Expansion of EV Charging Infrastructure

Public and private investment in EVSE (Electric Vehicle Supply Equipment) is accelerating, requiring standardized, robust connectors that can operate reliably in varied environmental conditions and user scenarios.

3. Integration of Signal and Control Lines

Modern EV architectures demand connectors that support not only high current power transfer but also signal lines for battery management systems, diagnostics, and control interfaces.

4. Durability and Low Total Cost of Ownership (TCO)

High mating cycle counts, ingress protection, and long-term mechanical reliability are essential for reducing service requirements and operational disruptions, particularly in commercial and fleet applications.

DuraEV: Advanced Connector Solutions for EV Charging Interfaces

The DuraEV series is engineered for use in both fixed and portable EV charging applications. It is designed to deliver high power throughput while incorporating critical safety features and signal integration capabilities.

Technical Specifications:

• Configuration: 2 power + 4 or 6 signal contacts
• Current Rating: Up to 70 A continuous; short-duration peaks up to 100 A
• Voltage Rating: Up to 120 VDC
• Mating Durability: Rated for 10,000 cycles
• Ingress Protection: IP67 with optional dust caps
• Safety Features: First-Mate Last-Break (FMLB), Connector Position Assurance (CPA), and finger protection
• Compliance: IEC 63066, UL standards

Applications:

• Vehicle onboard charging interfaces
• Residential and commercial wall-mounted chargers
• Portable charging systems
• Vehicle-to-grid (V2G) energy interfaces

DuraSwap: High-Cycle Connectors for Swappable Battery Platforms

The DuraSwap family is purpose-built for environments where battery modules are frequently connected and disconnected. It is particularly well-suited to automated and high-usage systems, offering a compact, rugged interface with enhanced usability.

Technical Specifications:

• Configuration: 2 power + 6 signal contacts
• Current Rating: Up to 70 A
• Durability: Rated for over 10,000 mating cycles
• Ingress Protection: IP67 in both mated and unmated states
• Mechanical Features: Blind-mating, Poka-Yoke orientation, unidirectional engagement
• Operating Temperature: –20 °C to +90 °C
• Housing Materials: UL94V-0, metal bushings for torque and panel sealing

Applications:

• Battery swap stations for light electric vehicles
• Autonomous ground vehicles (AGVs) and robotics platforms
• Modular energy storage systems
• Battery charging docks and mobile power modules

Comparative Overview

Strategic Relevance in the E-Mobility Ecosystem

Amphenol’s connector solutions are engineered to address key challenges and priorities for OEMs and infrastructure providers:

Future-Proof Design: DuraEV and DuraSwap are aligned with the shift toward modular, intelligent power systems. Their hybrid design enables integration of power and control in a single, compact connector format.

Operational Efficiency: High mating durability and robust sealing ensure that these connectors are suitable for continuous use in demanding environments, reducing the frequency of maintenance and replacement.

Safety and Compliance: Both connector families include comprehensive mechanical safety features and comply with international standards, providing assurance in critical automotive and industrial applications.

Global Engineering and Customization Support: Amphenol’s worldwide R&D and manufacturing footprint allows for rapid customization and scalable production, supporting both large OEMs and emerging mobility startups.

Conclusion

The transition to electrified transport demands innovation at every level of the power chain — from battery management to grid interfaces. Connectors such as DuraEV and DuraSwapserve as critical enablers in this ecosystem, offering the performance, safety, and integration capabilities required for scalable and reliable e-mobility solutions.

By delivering advanced mechanical design, hybrid power/signal integration, and high cycle life, Amphenol Communications Solutions is helping to build the infrastructure of the electrified future — with products engineered to meet the needs of both today's systems and tomorrow’s innovations.