On the high-voltage fast-charging connector, Model 3 uses a plug-in high-voltage connector HCStak 35 customized by TE (Tyco), which is used to connect the car battery and the charging harness. The insert structure is Tesla’s consistent choice, which can increase the welding options of aluminum wires. Compared with the equivalent cylindrical terminal, its size is smaller, the current carrying is better (about 20%), and it can be used for electrical system layout. Save as much space as possible.
From the design point of view, the terminals of HC Stak 35 are connected with 35 pieces of knife-fork terminals through copper plates (35mm thick). Since the terminals at the socket end are formed by superimposing 35 pieces of DEFCON terminals, they can be similar to building blocks according to the needs of different ports. Different, by changing the number of laminations to form different types of connectors, this modular design method can further reduce the cost of terminal processing. The HC Stak 35 is equipped with a 95 mm² high-voltage wiring harness, which can support Model 3 charging for 15 minutes, adding 279 kilometers of fast charging and long-lasting battery life. However, the plug-in connector also has its shortcomings. It is not resistant to unplugging, and the plug is easily deformed, so that the positive and negative plugs cannot be kept on the same level.