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