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Precision-engineered high-voltage junction boxes for portable EV charging and Mode 2 EVSE applications. Certified, field-proven and globally deployed.
A High-Voltage (HV) Junction Box is a critical safety and distribution component in electric vehicle (EV) charging systems. When integrated into portable EV chargers and Mode 2 charging equipment, it serves as the central hub for high-voltage cable routing, current protection, and pilot signal management — ensuring that every charging session is both safe and standards-compliant.
Unlike fixed AC wallboxes or DC fast chargers mounted to a permanent structure, portable EV chargers and Mode 2 EVSE devices are designed for mobility and flexibility. The HV junction box within these devices must therefore balance compactness, thermal durability, IP-rated weatherproofing, and the ability to withstand the mechanical stresses of daily transport and deployment in diverse environments.
Mode 2 charging — defined under IEC 61851-1 — uses a standard household AC outlet combined with an In-Cable Control and Protection Device (IC-CPD). The HV junction box in a Mode 2 cable integrates the relay, thermal cutout, leakage current detection, and pilot signal circuitry into one sealed, ruggedized enclosure. This makes it arguably the most safety-critical subassembly in the entire portable charging chain.
Engineered to meet the rigorous demands of mobile, outdoor, and vehicle-integrated EV charging environments.
Integrated over-current relay, ground fault interrupter (GFI), thermal fuse, and pilot signal circuit ensure full IEC 61851 and UL 2594 compliance for Mode 2 portable charging.
Dual-seal connector interfaces and injection-moulded housings rated to IP67 or IP69K allow reliable operation in rain, dust, extreme temperatures from −40 °C to +85 °C.
Supports AC 100 V – 250 V single-phase and 400 V three-phase inputs, with current ratings from 8 A to 32 A, accommodating global grid standards from North America to Europe and Asia-Pacific.
Advanced laminated busbar and injection-moulded busbar technology reduces box volume by up to 35% compared to traditional wired assemblies, critical for cable-integrated EVSE design.
Compatible with Type 1 (SAE J1772), Type 2 (IEC 62196-2), GB/T 20234.2 and other regional EV inlet standards, enabling one platform to serve global OEM programs.
Optional IoT module support for real-time energy monitoring, charging session authentication and remote diagnostics via OCPP 1.6 / 2.0, enabling next-generation smart portable EVSE.
The global electric vehicle supply equipment (EVSE) market reached approximately USD 12.8 billion in 2023 and is forecast to grow at a CAGR exceeding 28% through 2030. Within this, portable and Mode 2 charging products are among the fastest-growing segments, fuelled by the explosion of BEV and PHEV ownership in residential settings where dedicated wallbox installation is not always feasible.
In markets such as China, the European Union, the United Kingdom, and Southeast Asia, government incentive programs have directly accelerated the adoption of portable Mode 2 EVSE as an entry-level charging solution. In the EU alone, over 14 million new BEVs are expected on the road by 2027, a substantial proportion of which will rely on portable Mode 2 charging as their primary or secondary charging method.
The HV junction box supply chain for portable EV chargers is consolidating rapidly. Tier-1 EVSE brands and automotive OEMs increasingly prefer vertically integrated suppliers capable of delivering complete connector system solutions — from laminated busbars and injection-moulded busbars, to the IC-CPD module and finished harness assembly — under a single quality management umbrella. This trend directly benefits manufacturers with deep R&D, precision tooling, and certified testing infrastructure.
Cost pressures are also reshaping the landscape. The move from discrete relay-and-fuse assemblies toward integrated smart protection modules with embedded microcontrollers reduces component count, assembly time, and field failure rates — directly addressing the warranty and returns burden that has historically challenged portable EVSE manufacturers.
Harmonisation between IEC 61851, UL 2594, and GB/T 18487 is accelerating. Manufacturers producing HV junction boxes that satisfy multiple regional certifications simultaneously hold a decisive competitive advantage in securing multinational OEM contracts.
EU EcoDesign regulations and OEM ESG commitments are driving demand for HV junction boxes manufactured from halogen-free, recyclable polymers with energy-efficient production processes and full lifecycle traceability.
Next-generation portable chargers are pushing toward 22 kW AC three-phase outputs. HV junction boxes must evolve to handle higher continuous current, improved thermal dissipation and arc-fault detection at these elevated power levels.
Vehicle-to-grid (V2G) functionality in portable EVSE is emerging, requiring HV junction boxes to support bidirectional current flow, advanced power electronics integration, and grid synchronisation safety features.
HV junction boxes for portable EV charging serve a diverse and expanding ecosystem of deployment contexts — from consumer residences to heavy industrial fleet management.
The majority of global Mode 2 EVSE deployments occur in residential settings. Homeowners without a dedicated wallbox use portable Mode 2 cables plugged into a reinforced domestic socket, with the HV junction box providing arc-fault protection, ground fault detection, and thermal monitoring to prevent house fires.
Original equipment manufacturers (OEMs) bundle portable Mode 2 EVSE kits in the vehicle boot as an emergency charging solution. The HV junction box must withstand vibration, extreme temperature cycling, and humidity levels inherent to automotive in-vehicle storage environments.
Hotels, resorts, Airbnb hosts, and parking operators deploy portable Mode 2 EVSE to serve guest EV charging needs without the capital expense of permanent AC wallbox installations. HV junction boxes here must be tamper-resistant and durable under shared-use conditions.
Light commercial EV fleets — delivery vans, utility vehicles, taxi services — increasingly rely on portable Mode 2 EVSE as a low-infrastructure, rapid-deployment charging option at overnight depot locations. HV junction boxes for fleet use require higher duty cycles and enhanced thermal endurance.
EV owners engaged in camping, caravanning, and off-grid travel need portable chargers that operate from campsite power pedestals, generator outputs, or solar inverters. HV junction boxes in this application must excel in wide-temperature performance and ingress protection.
Electric construction machinery, industrial AGVs, and mining vehicles require rugged portable HV charging solutions. Junction boxes in this segment demand IEC Ex / ATEX considerations, robust vibration resistance, and high-current (up to 32 A) sustained delivery.
Founded in 1999, SANCO is well known as a connection system solutions provider and a national high-tech enterprise integrating R&D, design, manufacturing, sales and after sales support for connectivity products. It is committed to becoming a leader in the field of connectivity technology and products.
SANCO specializes in the R&D and manufacturing of electrical interconnection systems for automotive, rail transit, industrial, communications, and energy storage applications, including: high voltage EV connector, energy storage connector, EV charging connectors, manual service disconnect (MSD) units, Laminated busbar, Injection-molded busbar, signal and circular connectors, cell contact systems (CCS) and various precision components.
As a prominent industry leader, SANCO delivers comprehensive connection system solutions to clients worldwide. Our products are exported to over 100 countries worldwide, including major markets like China, North America, Europe, and Asia-Pacific. Our solutions have been widely adopted by global Fortune 500 companies and industry-leading enterprises.
Customization across the Industry Chain, Innovation Driving the Future
SANCO has spent over two decades perfecting the art and science of high-voltage connector and junction box design. Our HV junction boxes for portable EV charging and Mode 2 EVSE reflect this accumulated expertise in every detail — from the precision-injection-moulded housing that achieves consistent wall thickness and dimensional stability across millions of production cycles, to the laminated copper busbars that minimise resistive losses and inductance at high continuous currents.
Our engineering team works directly with EVSE OEMs, automotive Tier-1 suppliers, and charging network operators at the earliest design stages, co-developing custom HV junction box assemblies that meet specific dimensional envelope, thermal budget, and certification requirements. This deep-collaboration model accelerates time-to-market by up to 40% compared to standard component sourcing approaches.
SANCO's vertically integrated manufacturing — combining precision stamping, injection moulding, automated assembly, and in-house certified testing — ensures traceability and quality consistency across every unit. Our IATF 16949-certified processes guarantee automotive-grade quality even for high-volume consumer EVSE programs.
Trusted by leading automotive OEMs, Tier-1 suppliers and EVSE brands across more than 100 countries worldwide.
SANCO HV junction boxes and EV charging components hold comprehensive international certifications — underpinning global market access and customer confidence.
Explore our extended portfolio of high-voltage junction boxes, EV connectors, and related charging system components — engineered for portable, Mode 2, and fixed EVSE applications worldwide.