Automotive
Figure 3: Expanded views of MX80 in-line pin and socket connectors. (Source: JAE Electronics)
to match customer demands for automotive technological advancements. JAE developed the MX80 Series of automotive in-line pin and socket connectors that correspond to wire sizes of 0.13 to 1.0 mm2
and have an operating
temperature range of -40°C to +125°C. Starting with the terminals inside the connectors, engineers evaluated multiple aspects, including spring geometry, current handling, mechanical locking, wire size range, crimp optimization, damage prevention, test probe access, installation and removal, wide operating temperature, sealing, and vibration performance. After defining those requirements, the JAE team approached the actual connector design, including moulding, materials selection, and assembly. Utilizing the company's experience in manufacturing high-quality miniaturized connectors, they set about developing a compact connector with high performance that could meet exacting requirements for water resistance, high currents, and high reliability.
Connector series reconciles retention force and miniaturization JAE developed two prototype design versions, one of which was focused on ultimate miniaturization, and the second on addressing the reduced retention force resulting from miniaturization. Following these efforts, JAE developed a unique design with a retainer installed in front of the
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rubber seal to improve retention. The new design ensures proper harness assembly and terminal retention, and it meets the IPX7 water ingress protection rating to resist water depths of 1 metre for 30 minutes. Also available is a 4-position IPX9K version, capable of withstanding high-temperature, high-pressure water jets. JAE provides 2, 3, and 4-position in- line pin and socket versions of the MX80 connectors. A 6-position version is available only as a socket-type connector. For added reliability and to prevent incomplete assembly, the connectors incorporate a terminal position assurance (TPA) feature on the housings to detect incomplete terminal insertion. There is also a clear audible click to aid in confirming complete mating. The MX80 series is suitable for a wide variety of automotive and transportation vehicle applications, including:
Mirrors and glazing: door mirrors, roof systems, electrochromic glass, and glazing modules
Lighting: front and rear bumper, fog light, reversing light, stop lamp, license plate illumination, indicator, puddle lamp, and ambient lighting
Sensor: parking, brake pedal, camera, keyless entry module, tire pressure, and fluid reservoir
Audio: speaker (anti-rattle and large wire size) and microphone
Others: suspension, tailgate, doors, and bonnet switch
Among JAE’s component portfolio are the 2-pin MX80B02PZ1A (Figure 1) in-line connector and MX80A02SZ1B (Figure 2) socket connector. Also available are the 3-pin MX80B03PZ1A in-line and MX80A03SZ1B socket connectors; the 4-pin MX80B04PZ1A in-line and MX80B04PZ1B socket connectors; and the 6-pin MX80A06SZ1A socket connector. IPX9K-rated connectors are available in 4-pin MX80D04PZ1A in-line and MX80E04SZ1A socket formats. The JAE MX80 Series are compact, waterproof in-line connectors with an extensive range of power-carrying capabilities, depending on the wire size chosen: 0.75 ~ 1.0 mm2 and 0.13 ~ 0.22 mm2
, 0.3 ~ 0.5 mm2 . With a 0.13 mm2
,
wire size, 2-pin connectors are rated at 4.2 A, 3-pin at 3.7 A, and 4-pin at 3.6 A. With 0.35 mm2
10.3 A, 10.0 A, and 9.5 A.
The connectors are environmentally tested to the USCAR-2 V2 performance standard for automotive electrical connector systems and the LV214 (severity 3) connector test standard. They feature the ISO/JASO/EWCAP/VDA standard 0.64 mm tab size, are compatible with 2.54 mm pitch pin contacts, and incorporate an integrated bracket on pin housings to support chassis fastening vehicle clips. Rear covers, housings, and front
wire size, those ratings are,
respectively, 7.1 A, 6.4 A, and 5.4 A, and for 1.0 mm2
wire, the respective ratings are Conclusion
Motor vehicle manufacturers want to add more electronics-enhanced features and functions into existing spaces. Product designers who can leverage a new breed of more compact and efficient connectors will be able to deliver smaller components with greater performance, providing manufacturers with more flexibility to meet market demands.
https://www.digikey.co.uk/ Components in Electronics July/August 2024 23
retainers (Figure 3) are moulded from polybutylene terephthalate and glass fibre (PBT-GF10) material. Seals are silicon rubber. JAE offers contacts (sold separately and not integrated at the time of delivery), including the MX80S08K3F1, made with copper alloy material and a tin plating finish. Dummy plugs to seal off unused cavities are available both in IPX7 (MX80A000XD1) and IPX9K (MX60A000XD2) rated versions. JAE also offers an MX81 Series of non- waterproof compact connectors, suitable for connecting in-vehicle electronic devices such as ECUs and sensors. The MX81 connectors, including the MX81A002SF1, utilize the same socket terminals as the MX80 Series of waterproof connectors. This enables utilization of the same terminals and crimp tools for a broad range of waterproof and non-waterproof areas of the vehicle.
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