2023/07/03
Variations of Products Supporting High Voltages
The MY05 Series, which is currently under development for mass production, is a compact connector with a rated voltage of 1,000 V(DC). The operating temperature range is between minus 40 degrees and plus 125 degrees.
PCB Headers in both right-angle and straight orientations will become available.
In addition, two types of sockets; with and without CPA will become available. The CPA type guarantees correct mating position by fixing the lock after mating.
To add further product variation, MY05 connectors can support either JAE’s MX80 terminal or other terminals*, both widely used 0.63/0.64mm terminal systems, thus offering four variants within the planned lineup. With this variety, the tier-1s can select MY05 with confidence, knowing that the OEMs preferred terminal system will be supported.
Terminal plating in both Silver and Tin plating types will be available.
The number of contacts per connector planned will be 6, 10, 14, and 18.
Addressing BCU Connector Challenges
When developing low voltage connector systems, Engineers have always considered factors such as contact resistance and dielectric insulation between terminals, but high voltage connectors call for additional, careful considerations. At high voltages, factors such as creepage and clearance distances come into play. Conditions such as operating voltage, the environment and the type of materials used means that terminal separation calculations are vital. The IEC specification provides a basis of these calculations and unless carefully followed, high voltages and short insulation distances can lead to short circuits and other problems.
With the absence of suitable connector solutions in the market, connecting EV battery packs to BCU has been challenging and led to the use of far less than satisfactory solutions being adopted. For example, by using high-voltage connectors from industrial machinery or home appliances being used with pins removed. Alternatively, by using existing low-voltage connectors, but to meet the creepage and clearance distance requirements, some terminal cavities have remained empty. An extremely inefficient solution from the geometric size viewpoint. For high-voltage connectors, such as those for industrial machinery and home appliances, the maximum voltage remains limited and suited to 600V battery packs.
For some time, there has been a market gap for automotive connectors that offer both full compliance with the IEC requirements and genuine suitability for harsher automotive environments & specifications. For this reason JAE developed MY05, a connectors series compatible of the 800V - 1,000V specifications necessary for the future EV market. The new design addressed the realization of high-voltage compatibility coupled with miniaturization.
In the development of this series, JAE adopted a structure with separation ribs between the terminals for the purpose of reducing the size of the product while ensuring the insulation distance between the terminals. The result is a product that not only addresses miniaturization, but fully conforms to the creepage & clearances distance requirement defined within the IEC design standard.
Achieving the Highest Industry Specifications
The specifications of the MY05 series are as follows: The rated voltage is DC 1,000 V and the withstand voltage is DC 4,800 V. It is compatible with the extremely stringent OEM specifications such as LV215 and USCAR 37.
In addition, the distance between terminals conforms to the IEC60664 standard. The dimensions are 50.5 mm wide × 15 mm high (10 position).
The product size may be slightly larger than that of competing products, but in terms of performance such as the withstand voltage and the distance between terminals, it complies better with IEC standards and meets the highest standards for preventing fires caused by high-voltage short circuits in connectors.
JAE has already started shipping the first MY05 samples of the angle and socket type with 10way. Meanwhile, mass production will begin in 2024.
JAE has been offers a wide range of connectors for EV battery packs. In addition to high-voltage connectors for BMS, it has commercialized connectors for the cell module connection and the BMU connection.
It can meet customer needs with the product lineup having low profile, lightweight, and wide range of pin counts.
MY05 Series Product Information Document Download
After completing the form on the right, you can download MY05 series custom development process detailed documentation (PDFs).
Subject to change without notice. Errors and omission excepted.