Highly Reliable Connector that Prevents Electric Shock to Workers, Short Circuit due to Dust Adhesion and Meets Automotive Quality Standards
ZH05 Series Wire-to-Board Connector for Electric Shock Prevention
Ideal for Battery Electric Vehicles (BEV) and Hybrid Electric Vehicles (HEV/PHEV).
Against the backdrop of stricter environmental regulations around the world, HEV, PHEV, BEV, FCV and other vehicles that use electric motors, known as “New Energy Vehicles,” are spreading at a faster pace. Along with this trend, the role of automotive electrical components including connectors has become more important than ever as vehicle electrification advances.
The automotive connector ZH05 Series is designed to withstand temperatures of up to 125°C and has high vibration resistance. In addition, it is designed to prevent short circuits caused by dust adhesion and electric shocks to workers. This automotive connector can be used for a wide range of automotive electronic components such as automotive batteries, automotive chargers, and various ECUs.
Usage in Automotive Battery
|Rated Voltage||60V AC|
|Operating Temperature|| -40 to + 125°C
(Includes the temperature rise by current flow.)
|Contact Resistance||10mΩ Max. (1A DC)|
|Insulation Resistance||100MΩ Min. (500V DC)|
|Withstanding Voltage||1,000V AC for 1 min.|
|Mating Durability||30 times|
0.2-0.35SQ, Outer diameter 1.4mm Max. (FLRY)
No. of Pos.
Mass Production: 16, 20pos.
Under Development: 12pos.
Under Planning: 24pos.
A Female contact is used for the board-side connector, and the contact is surrounded by resin to prevent short circuit and electric shock.
A wire-to-board connector with rod-shaped, protruding male contacts on the board-side is typically used to connect the live parts that monitor the on-board battery voltage, etc. However, in the case of conventional connectors, there is a short circuit hazard due to dust sticking between adjacent contacts and a risk of electric shock when an worker touches a contact during insertion and removal work.
The ZH05 uses a box-shaped female contact for the board-side connector. By physically surrounding the contact with resin to insulate, Hirose has achieved an innovative electric shock prevention design.
22.9mm Narrow Width for 050 Tab Size Contributes to Space Reduction (For 16pos.)
In order to increase battery module capacity the connector is often installed on the side of the module. In such designs the mating surface of the connector must be turned sideways to prevent water intrusion from the top surface due to condensation. However, this results in problems with strength because the module case has to be reduced to accommodate the width of the connector. The ZH05 has a width of 22.9mm (16pos.), which is the amongst the smallest for 050 tab sizes, and helps to improve battery reliability and capacity by minimizing the impact on the case.
|No. of Pos.||12||16||20|
|Dimension A (mm)||18.9||22.9||26.9|
Hirose’s original, patent-pending design is potting (resin encapsulation) compatible. Potting processing makes ZH05 safe to use even in an environment where condensation easily forms.
Withstands Continuous Vibration During Engine Operation and Driving
The female contact has a double-layered spring design for higher contact force than a single spring and suppresses the influence of vibration from the outside. In addition, three contact points are provided for each line on the top and bottom to maintain stable contact even under continuous vibration.
Increase the contact force and prevents vibration from outside.
Withstands severe vibration due to improved contact reliability.
Comparison with Internal Connection Connector for Automotive Battery ZE05 Series
The ZE05 Series is slightly wider than the ZH05 Series, but is lower profile and shorter in depth, so you can choose the connector that best suits your needs.
|Contact||0.5 size, Tin Plated||0.5 size, Tin Plated|
|Rated Current||5A (Single pin power supply),
2A (All pins power supply)
|5A (Single pin power supply),
2A (All pins power supply)
|No. of Pos. (Currently in Mass Production)||16, 20pos. (Double-row)||2, 4 (Single-row)
5, 8, 12, 16, 20, 24 (Double-row)
|Electric Shock Prevention||✔||-|
Applications (Use Case)