I-PEX High-Temperature Connector Products

Electric power is becoming mainstream due to technological innovations in automated driving and the growing use of environmentally friendly electric vehicles (EVs). In order to cope with the increased electronics used in automobiles, automotive developers must address high-speed data transmission, and high-current and high-voltage situations while reducing the size and weight of components and saving space.

In addition, the increased number of modules installed means increased heat generated due to high currents. It also means increased heat generation density inside the housing of the modules, so the use of heat resistant components is ever more important.

I-PEX has a large lineup of general-purpose connectors rated at 85°C and products designed for consumer devices, but to address requirements in the automotive field, we have developed a number of products that can handle high temperatures, from 105°C to 125°C. And, we will continue to add to our line-up of connectors that operate reliably in high temperature environments.

Matrix of high-temperature resistance recommended connectors

Product type	Micro-Coaxial Connectors				RF / Coaxial Connectors
Product Name	CABLINE^®-VS II	CABLINE^®-CA II	CABLINE^®-CA II PLUS	CABLINE^®-UM	MHF^®-TI

Heat resistance	105℃	105℃	105℃	105℃	105℃
Pitch	0.5 mm	0.4 mm	0.4 mm	0.4 mm	-
Height (MAX)	1.2 mm	1.1 mm	1.2 mm	2.35 mm	3.65 mm
Depth	6.7 mm	6.2 mm	6.7 mm	5.0 mm	-

Product type	FPC/FFC Connectors
Product Name	MINIFLEX^® 5-BFN II	MINIFLEX^® 5-BFN II LK	MINIFLEX^® 5-FF	EVAFLEX^® 5-VS	EVAFLEX^®5-SE-G VT	EVAFLEX^® 5-SE

Heat resistance	125℃	125℃	125℃＊	105℃	125℃	FFC：85℃ FPC：125℃
Pitch	0.5 mm	0.5 mm	0.5 mm	0.5 mm	0.5 mm	0.5 mm
Height (MAX)	1.1 mm	1.1 mm	2.75 mm	2.0 mm	6.9 mm	2.7 mm
Depth	3.5 mm	4.0 mm	7.2 mm	4.97 mm	4.1 mm	6.1 mm

Product type	Power Connectors / Terminals
Product Name	ISH®				AP-10	AP-TSS10, AP-LT10
Type	Horizontal	Horizontal Type-Hybrid	Vertical	Wire to Wire	Vertical	Vertical

Heat resistance	125℃	125℃	125℃	125℃	105℃	125℃
Pitch	2.0 mm	Signal: 2.0 mm Power: 3.8 mm	2.0 mm	2.0 mm	-	-
Height (MAX)	(1 row) 7.4 mm (2 rows) 10.9 mm	13.6 mm	20.75 mm	(1 row) 8.0 mm (2 rows) 11.7 mm	13.6 ~ 16.1 mm 16.1 ~ 23.1 mm	8.0 mm

(*Only Specified Products)

Features of I-PEX high-temperature connectors

I-PEX has designed high-temperature connectors by making full use of our vast experience, so that they can be used safely even in severe environments where high temperatures and long hours of operation are anticipated.

1) Material Selection

I-PEX selects materials with excellent workability, dielectric properties, and thermal conductivity, as well as stress relaxation characteristics that stabilize spring characteristics even in high-temperature use environments, and materials that can ensure consistent contact. Most of our products are made of phosphor bronze contact material, but we also use Corson alloy for high-temperature products, which is a stronger material without sacrificing the high electrical and thermal conductivity inherent in copper.

2) Design

To obtain stable electrical contact, a certain level of contact pressure is required between mutual contacts. The contacts are made of a metal material and are designed in a spring shape. We focus on designing connectors that make good use of spring characteristics so that they can return to their original position and maintain contact force even during connector insertion, removal operations and stress relaxation.
Typical example: EVAFLEX^® 5-SE-GVT

The contact shape has sufficient deflection (height) to maintain contact pressure even after stress relaxation.

3) Reliability Test

I-PEX is equipped with the following facilities for mechanical performance and environmental testing, as well as conducting reliability testing.

Reliability Test Facilities

Double Chamber Incubator Operating Temperature Range：-40℃~ 150℃	Rapid-Rate Thermal Cycle Chamber Operating Temperature Range：-65℃～200℃
Compound Environment Test (Constant temperature and humidity chamber equipment) Operating Temperature Range: -40℃～ 150℃	Compound Environment Test (vibration machine)

Reliability test for high-temperature products

I-PEX conducts the following reliability tests on high-temperature products.

Test Item		Testing Method		Measurements
Mechanical Performance	Vibration	3 mutually perpendicular directions 2 hours for each direction for a total of 6 hours		Contact resistance Electrical discontinuity Appearance
	Shock	Max. G:50 G Direction: 6 mutually perpendicular directions Cycle: 3cycles for each direction		Contact resistance Electrical discontinuity Appearance
Environmental Performance
	Heat Cycling	Standard Test	High Temp Test	Contact resistance Appearance
		Temp : -10 ⇔ 85℃ Time : 30mins cycle	Temp -55 ⇔ +125℃ Time : 30mins cycle (Transition 5mins. MAX) No. of cycle : 100 cycle
	High Temp Life	Standard Test	High Temp Resistance	Contact resistance Appearance
		Temp : 85 ℃±2 ℃ Duration : 250 hours	Temp : 125℃±2℃ Duration : 1000 hours
	Humidity (Steady State)	Temp : 40±2 ℃ Humidity : 90~95% RH Duration : 240 hours		Contact resistance Insulation resistance Electric withstanding voltage Appearance
	Humidity Cycling)	Temp-10～+65℃ Humidity : 90~98 % RH, Cycle : 10 cycle （240 hours）		Contact resistance Insulation resistance Electric withstanding voltage Appearance
	Salt Water Spray	Temp : 35±2℃、 Salt water density 5±1 % [by weight] Duration : 48 hours		Contact resistance Appearance
	H2S Gas	Temp : 40±2℃ Humidity : 80±5 % RH Gas : H2s 3±1 ppm Duration : 96 hours		Contact resistance Appearance

(Only Specified Products)

In addition, we will propose more effective test items and measures to meet the customer's requirements for their desired conditions. For connectors that require a high level of reliability, please contact us for information on the appropriate product for your application.