mak terminal & connector overview, 20-feb-20091 high power terminals & connectors mak8 &...
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MAK Terminal & Connector Overview, 20-Feb-2009 1
High Power Terminals & Connectors MAK8 & MAK12
MAK Terminal & Connector Overview, 20-Feb-2009 2
Power Terminals Application Range
MAK Terminal & Connector Overview, 20-Feb-2009 3
Product Line-Up
MAK8 Crimp MAK8 Sonic Weld MAK12 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009 4
Product Line-Up
Female Terminal Male Terminal
MAK8 Crimp Product currently not available
MAK8 Sonic Weld Product currently not available
Can be installed short term
MAK12 Crimp None, product not planned None, product not planned
MAK12 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009 5
Product Outline
Terminal Comment
MAK8 Crimp 2.5 – 16.0mm²
Sn and Ag plating
For Cu wire only
For sealed & unsealed applications
MAK8 Sonic Weld Max. 25.0mm² (Cu wire)
Max. 27.0mm² (Al wire)
Sn and Ag plating
For Cu and Ag wire
For sealed & unsealed applications
MAK12 Sonic Weld Max. 35.0mm² (Cu wire)
Max. 42.0mm² (Al wire)
Sn and Ag plating
For Cu and Ag wire
For sealed & unsealed applications
MAK Terminal & Connector Overview, 20-Feb-2009 6
Available Connectors MAK8 Crimp
MAK8, 1-way
direct connection to PowerFuse
(13679)
MAK8, 2-way
direct connection to PowerFuse
(13676)
MAK8, 6-way
power feed and fuse connection into junction box
(13478)
MAK8, 2-way
connector to EPS
(19060)
MAK8, 3-way
power feed into engine junction box
(19028)
MAK8, 1-way
direct connection to PowerFuse
(18610)
MAK8 + MAK48, 4-way
direct connection to cooling fan
(18943)
MAK Terminal & Connector Overview, 20-Feb-2009 7
Available Connectors MAK8 Crimp
MAK8, 1-way
direct connection to PowerFuse
(13679)
MAK8, 2-way
direct connection to PowerFuse
(13676)
MAK8, 6-way
power feed and fuse connection into junction box
(13478)
MAK8, 2-way
connector to EPS
(19060)
MAK8, 3-way
power feed into engine junction box
(19028)
MAK8, 1-way
direct connection to PowerFuse
(18610)
MAK8 + MAK48, 4-way
direct connection to cooling fan
(18943)
MAK Terminal & Connector Overview, 20-Feb-2009 8
Available Connectors MAK12 Sonic Weld
MAK12, 1-way, 90°
power supply into central junction box
(13693)
MAK12, 1-way
direct connection to PowerFuse
(17959)
MAK12/MAS12, 1-way
inline to PTC heater
(17968/17973)
MAK12, 1-way
'clip-in‘ connector for sealed fusebox
(17956)
MAK12 + MAK28, 4-way
inline connection for 1kW cooling fan
(17969/17988)
MAK12/MAS12, 1-way
inline connection for EPS
(17161/17164)
MAK12, 2-way
direct connection to EPS (standard AK interface)
(17999)
MAK12 + MAK28, 5-way, 90°
direct connection on capacitor
(17265)
MAK Terminal & Connector Overview, 20-Feb-2009 9
Available Connectors MAK12 Sonic Weld
MAK12, 1-way, 90°
power supply into central junction box
(13693)
MAK12, 1-way
direct connection to PowerFuse
(17959)
MAK12/MAS12, 1-way, 90° and straight
inline to PTC heater
(17968/17973)
MAK12, 1-way
'clip-in‘ connector for sealed fusebox
(17956)
MAK12 + MAK28, 4-way
inline connection for 1kW cooling fan
(17969/17988)
MAK12/MAS12, 1-way
inline connection for EPS
(17161/17164)
MAK12, 2-way
direct connection to EPS (standard AK interface)
(17999)
MAK12 + MAK28, 5-way, 90° & straight
direct connection on capacitor
(17265)
MAK Terminal & Connector Overview, 20-Feb-2009 10
MAK12 Application Example
Power supply to central junction box replaced eyelet terminal with direction connection
elimination of bolt and nut weight saving
elimination of screwing operation process improvement
elimination of screwing operation deletion of power tools from assembly line
optimised wire routing package space improvement
MAK Terminal & Connector Overview, 20-Feb-2009 11
MAK8 Application Example
5151 pieces pieces
1* Housing
1* Busbar
16* Bolts
17* Nuts
8* Fuses
8* Eyelets
8* Screwing operation
at harness plant
9* Screwing operation at vehicle plant
1919 pieces pieces
1* Housing
1* Busbar/Powerfuse
2* Bolts
2* Nuts
1* Eyelets
7* Terminals
5* Connectors
2* Screwing operation
5* Mating operation at vehicle plant
Example: Pre-Fuse box for passenger vehicle, mounted direct on battery (in production)
MAK Terminal & Connector Overview, 20-Feb-2009 12
Terminal Electrical Performance
Derating Curves - LEAR MAK Power Terminals
0
50
100
150
200
250
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Temperature / °C
Cu
rren
t /
A
MAK8 Crimp 16mm² MAK8 Sonic Weld 25mm² MAK12 Sonic Weld 35mm²
all parts with Ag surface finish and maximum applicable wire size
* MAK8 Sonic Weld, preliminary derating, from prototype parts
MAK Terminal & Connector Overview, 20-Feb-2009 13
Terminal Performance Summary
Outstanding electrical performance and mechanical robustness
Sonic weld version offers additional harness routing flexibility
MAK8 Crimp MAK8 Sonic Weld MAK12 Sonic Weld
Applicable Wire Size 2.5 - 16.0mm² 2.5 - 25.0mm² 6.0 - 35.0mm²
Contact Resistance < 1mOhm < 1mOhm < 1mOhm
Maximum Rating 120A @ 80°C, 16mm², Ag finish 130A @ 80°C, 25mm², Ag finish 190A @ 80°C, 35mm², Ag finish
Derating 100A @ 80°C, 16mm², Ag finish 110A @ 80°C, 25mm², Ag finish 160A @ 80°C, 35mm², Ag finish
-40°C … +130°C, Sn finish -40°C … +130°C, Sn finish -40°C … +130°C, Sn finish
-40°C … +150°C, Ag finish -40°C … +150°C, Ag finish -40°C … +150°C, Ag finish
< 25N on first insertion < 25N on first insertion < 40N on first insertion
< 20N on second insertion < 20N on second insertion < 35N on second insertion
10 for Sn finish 10 for Sn finish 10 for Sn finish
50 for Ag finish 50 for Ag finish 50 for Ag finish
Terminal Retention to Housing > 120N > 120N > 120N
derating preliminary, taken from prototype parts
Lear Power Terminals, Performance Summary
Operating Temperature
Terminal Mating Effort
Mating Cycles
MAK Terminal & Connector Overview, 20-Feb-2009 14
Terminal Drawings: MAK8 Crimp
MAK Terminal & Connector Overview, 20-Feb-2009 15
Terminal Drawings: MAK8 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009 16
Terminal Drawings: MAK12 Sonic Weld
MAK Terminal & Connector Overview, 20-Feb-2009 17
Terminal Drawings: MAS12 Sonic Weld