HC-STAK: Delivering improved xEV drivetrain performance with a modular, flexible connector design and high-power throughput
As automakers scale toward higher-voltage xEV architectures, a versatile connector solution that can handle surges, thermal stress, and vibration is essential.
TE Connectivity’s HC-STAK family of high-voltage interconnection systems is purpose-built for the next generation of electric, hybrid, plug-in hybrid, and fuel-cell vehicles, from passenger cars to high-powered electric trucks. With a scalable fork-contact design supporting up to 400 amps of continuous current and 1000 VCD, the HC-STAK 25, 25XE, and 35 variants deliver flexible, compact, and safe connectivity for high-voltage EV drivetrain architectures. When routing power between the battery, inverter, and the e-motor, HC-STAK offers superior current handling, EMI shielding, andvibration resistance, all in a touch-safe installation-friendly design.
The HC-STAK family delivers unmatched performance, scalability, and reliability for the evolving demands of electric mobility.
1000 V
All HC-STAK connectors are rated for up to 1000 volts DC
400 A
Maximum current carrying capacity at 85°C (HC-STAK 35 variant with 95 mm² wire )
125° C
-40° to +125° C operating temperature range
HC-STAK Portfolio At-a-Glance
HC-STAK Benefits
- Built for power & acceleration: successfully deployed in high-demand xEV applications where acceleration and towing power are critical, including passenger cars, delivery vans, and electric pickup trucks
- Scalable power range: supports currents between 180 A to 400 A depending on connector variant, wire size, and conductor material
- High-voltage capability: rated for up to 1000 VDC, enabling compatibility with modern xEV architectures
- Modular contact design: layered fork terminals allow up to 64 contact points per circuit for greater flexibility
- Low-resistance interface: fork-style terminals & optional ultrasonic welding significantly reduce power loss
- EMI control: 360-degree shielding delivers system integrity in highly electromagnetic environments
- Copper & aluminum conductor support: Al & Cu single-core conductor alternatives enable cost-efficient optimization
- Compact & lightweight: delivers high current in a small package; simplifies integration in space-constrained areas
Documents & Specifications
HC-STAK 25 Interconnection System
HC-STAK 25 XE Interconnection System
HC-STAK 35 Interconnection System
Featured HC-STAK Components
Technical Solution Paper PDF (English)
TE Connectivity’s HC-STAK Series High-Voltage Interconnection System is specifically designed to provide a safe and reliable high-voltage connection between an xEV’s battery power distribution unit and the drive unit (inverter + e-motor). With a voltage rating of up to 1000 VDC and a maximum current carrying capability of up to 400 A (using the HC-STAK 25 variant with a 95 mm2 cable size), the HC-STAK family delivers a high-performance drivetrain connector system that is both scalable and capable of reliable high-power distribution to each component.
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