The JST XAD significantly reduces electric losses through the precise design of the contact interface, and the core technological breakthrough is the optimization of contact resistance parameters. The connector body is high-purity copper alloy (CuNiSn, conductivity ≥100% IACS standard), 0.25μm gold plating layer, rated current 15A working condition, the contact resistance is stable control at 0.35mΩ±0.02mΩ, 23% lower than traditional tinning process. In CTP3.0 battery pack demo test in Ningde era, the high-voltage bus system with JST XAD improves the energy transmission efficiency up to 99.2%, and the daily energy loss of a single module is reduced by 0.18kWh, in which 9 million KWH electricity can be saved every year with 50GWh battery annual output, which is equivalent to reducing carbon emission by 7,200 tons. Its innovative four-finger reed structure achieves dynamic contact pressure compensation, even under the 50Hz vibration environment (amplitude ±1.5mm), it is still able to maintain impedance fluctuation ≤2%, successfully applied to CRRC’s 350km/h high-speed railway traction system, the fault rate of pantograph – contact line connection is decreased by 67%.
Durability-wise, the JST XAD improves plug-in and plug-out life to as much as an industry-high 150,000 times (IEC 60512-9-3 test standard) through its dual locking system and self-cleaning contact structure. Bosch ESP 9.3 system life test data shows that the contact impedance is 102% of the initial value after 10 years equivalent test at -40 ° C to 150 ° C temperature cycling (20 times a day) and 85% relative humidity. This function extends NIO ET5’s domain controller connector maintenance time to 8 years / 240,000 km, and reduces the after-sales maintenance fee by 52% compared with the previous generation of products. It possesses IP69K protection grade and 0.08N·m~1.2N·m adjustable locking torque, in BYD Ocean network charging pile coastal scenario test (salt spray concentration 5% NaCl), achieved a zero corrosion record within 5000 hours, and charging gun failure rate has been reduced from the industry average of 0.8 times / 10,000 times to 0.12 times / 10,000 times.
The right xad’s modular construction offers significant cost benefits, its patented snap-on construction reducing assembly time to 3.2 seconds per point (400% faster than screw connections), which helped Tesla Shanghai Gigawatt reduce the amount of Model Y harness stations from 38 to 22 and increase single-line production time to 45 seconds. The connector is able to adapt to the wire diameter series of AWG 28 to 4 and reduces the number of material types by 30% through the adaptive terminal design, which saves the weight of the vehicle harness of Xopeng G9 by 4.7kg and reduces the overall cost of the harness by €21.5 per vehicle. In Huawei Digital Energy’s global PV project, its 1500VDC system voltage and 25mm² cut-off capacity support have brought the power density of series inverters to 1.2W/cm³, reducing the BOS cost of a single MW system by $12,000.
In the performance of data transmission, the jst xad high-speed version (HS series) realizes 28Gbps PAM4 signal transmission, and in the application of Nvidia Orin autonomous driving platform, the bit error rate of the LVDS channel is maintained below 10^-15, the delay fluctuation is ±5ps, and the lidar point cloud data transmission frame rate is increased to 40fps. By the self-developed EMC shielding technology (shielding efficiency ≥90dB@10GHz), NIO ET7’s 5G-V2X antenna array crosstalk problem was solved and SNR was enhanced by 8.3dB. According to Strategy Analytics’ research, the smart cockpit systems with this solution reduce the wiring length by 28%, reduce $46 of material cost per set, and increase the industry average profit margin by 2.4 percentage points.
Market verification data show that the penetration rate of jst xad in the high-voltage connector market for new energy vehicles jumped from 12.6% in 2021 to 29.4% in 2023, including 46 large-scale projects such as Mercedes-Benz EVA platform and general Ultium battery system. It is compatible with 300A continuous current super charging version (temperature rise ≤30K), and has been applied in Shell’s global charging network, making 480kW liquid-cooled superfilling efficiency over 97.6% and annual operating income per pile increase by 5800. Frost & Sullivan estimates that by 2025, this technology will propel the global connector market size growth of 12.7B, with new energy vehicle applications reaching 38%, and continue to reset the performance benchmark in the area of electrical connectivity.