What are the design considerations for high-power charging connectors?

High-power connector design (350+ kW) addresses: Current capacity (500+ A requiring active cooling or multiple contact pairs), voltage rating (up to 1000V), thermal management (liquid-cooled cables and connectors), contact resistance minimization (<0.3 mohm), durability (10,000+ mating cycles), safety interlocks, ergonomics (weight, handle force), environmental sealing, and locking mechanism. Standards include CCS (CharIN), CHAdeMO 3.0, and NACS (Tesla). Testing includes thermal, electrical, mechanical durability, and environmental exposure. Connector design enables vehicle charging rates - currently the bottleneck for many ultra-fast charging applications.