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As technology advances, connectors are increasingly called upon to operate in harsh environments where traditional designs falter. These environments can expose connectors to extreme temperatures, chemicals, high vibration, and mechanical shocks.
It is pivotal to understand the growing demand for connectors capable of withstanding the challenges posed by harsh environments. Whether in industrial automation, automotive systems, or outdoor installations, these applications can test the limits of traditional connector designs, therefore reliability is paramount to ensure uninterrupted operation. This is where HIROSE excel with their extensive expertise in connector design and manufacturing processes which allows them to deliver robust, innovative solutions tailored to meet these demands without compromising design flexibility or performance.

This article covers some of the key considerations designers must make when specifying connectors for harsh environments and the innovative solutions available from HIROSE.

Defining Harsh Environments & Performance Requirements

A harsh environment can be characterised by several physical and chemical stressors that challenge standard connector performance:

• Extreme Temperatures: Automotive and industrial connectors often need to operate in -40°C to +125°C conditions, with some applications requiring up to +140°C tolerance.
• Ingress Protection (IP): Environments which will expose connectors to dust, moisture, and water require IP67 or higher-rated connectors. In marine or heavy industrial settings, the highest IP69K rated protection against high-pressure, high-temperature water and steam cleaning is critical.
• Chemical and UV Resistance: Connectors used outdoors must be able to withstand prolonged UV exposure, while those used in industrial systems may also require resistance to oils, solvents, and corrosive chemicals.
• Vibration and Mechanical Shocks: Applications including robotics & automotive control systems can expose connectors to vibration levels up to 50G and may require compliance with ISO 16750-3 or USCAR-2 standards. These environments necessitate connectors designed with advanced materials and engineering innovations to maintain reliability under shock and vibration conditions. Compliance with ISO 16750-3 ensures connectors can maintain electrical integrity under sinusoidal and random vibration, while shock resistance protects against impacts from heavy machinery or collisions.
• Thermal Stability: Material selection is critical for thermal stability; materials such as liquid crystal polymers (LCP) and flame-retardant resins can be employed to provide dimensional stability and electrical insulation at high temperatures.

As well as the environment the connectors will be operating in, the system designer also needs to carefully consider the performance requirements of the connectors, some key requirements include:

• Environmental Resistance: Connectors in harsh environments must not only provide robust environmental sealing, but they must also retain their performance over years of exposure.
• Mechanical Durability: Mechanical robustness is equally critical for ensuring long-term reliability of the connector and system in which it is used.
• Mating Cycles: Connectors may need to endure 5,000–10,000 mating cycles without degradation to ensure they are suitable for repeated use in test and industrial environments.
• Retention Force: The design of the connector must prevent cable disconnection under tension, retention forces exceeding 40N can be a common requirement for rugged applications.

Connector solutions from HIROSE for Harsh Environments

HIROSE’s wide portfolio of connectors include products which are designed to operate reliably under harsh conditions. By leveraging decades of expertise in connector design and manufacturing, HIROSE has developed a comprehensive range of solutions tailored to overcome the challenges posed by harsh environments. Their portfolio addresses the critical requirements of automotive, industrial, and outdoor applications with innovative features that deliver unmatched reliability, compactness, and durability. Following is a selection of HIROSE connectors that have been designed for harsh environment applications.

ZE05 Series: Compact and Robust Wire-to-Board Connectors

The ZE05 series, initially designed for automotive applications, provides a compact, low-profile solution without sacrificing reliability. With a 2 mm pitch, this miniature connector available in through hole or surface mount versions saves board space, enhancing design flexibility or reducing device size, making it suitable for various applications.

Available in right-angle and straight receptacle configurations with surface mount contacts and metal fittings, the connectors offer exceptional retention strength to withstand high vibration. The plugs accommodate AWG20 to AWG22 crimp contacts supporting currents up to 3A per contact. The polarised design ensures secure mating, and the anti-vibration ribs ensure stable connections. Tin-plated contacts resist corrosion and maintain consistent conductivity, even in challenging conditions. Operating between -40°C and 125°C, the ZE05 series meets the stringent requirements of LV214 and USCAR-2 standards. Optional retainers enhance cable pull force to around 40N, ensuring robust performance under mechanical stress.

ZE064W Series: High-Vibration Wire-to-Wire Connectors

Designed for harsh environments, the ZE064W series provides a rugged wire-to-wire solution that excels under extreme conditions. Featuring a double-layer, 3-point spring contact design, these connectors deliver stable contact engagement even in high-vibration scenarios. The series supports wire gauges from AWG20 to AWG22 and operates across a broad temperature range of -40°C to 125°C. Its IP67/IP69K-rated construction ensures superior resistance to dust and water, making it suitable for applications in high temperature and high-moisture environments such as automotive and industrial. Key coding prevents incorrect mating when using multiple connectors in the same system. When used alongside the ZE05 series, the ZE064W complements applications requiring both wire-to-wire and wire-to-board connections, delivering seamless integration and performance. Optional retainers further enhance retention force, ensuring long-term reliability under mechanical stress.

FX26 Series: Floating Board-to-Board Connectors

HIROSE’s FX26 series addresses the challenge of maintaining electrical integrity in environments with significant vibration or misalignment. Featuring a 1 mm pitch and a clever floating design, the FX26 series offers ±0.7 mm movement in the X and Y directions and ±0.75 mm in the Z direction. This floating mechanism absorbs vibrations and assembly tolerances, preventing contact failures.

The FX26 connectors support a temperature range of -40°C to 140°C, making them ideal for demanding automotive and industrial applications. Their compact form factor enables multiple mating height combinations, providing flexibility for densely packed designs. The unique two-point contact design enhances reliability by maintaining consistent electrical connections, even under dynamic conditions. Manufactured with materials optimised for thermal stability, the FX26 series delivers reliable performance in environments with high heat and vibration.

HR41 Series: High-Current Circular Connectors

For high-power industrial applications, the HR41 series delivers advanced performance in a lightweight and durable design. Capable of handling currents up to 38A, these circular connectors are optimised for outdoor and high-power systems, including renewable energy installations and heavy machinery such as off-highway vehicles. The HR41 series employs a bayonet locking mechanism, ensuring secure and reliable connections with clear tactile feedback so the user knows the connection is made. Assembly is simplified with a design that allows cable clamping and waterproof sealing in one simultaneous step using standard crimp tools. The connector housing is built to withstand extended exposure to harsh conditions, including 2,000 hours of UV radiation, 1,500 hours of salt spray, and IP68-rated water ingress protection. An anti-loosening mechanism secures the tightening ring, preventing it from loosening during operation. Safety features include sequential pin engagement, ensuring the ground contact connects before power contacts during mating. Additionally, the housing walls provide a long creepage distance, protecting against high voltage arcing and ensuring resistance to 15kV lightning surges.

Key Applications

HIROSE’s connectors address the challenges of modern industries by providing robust solutions engineered for specific applications:

• Industrial Automation: High-speed data connectors with EMI shielding meet Industry 4.0 requirements for factory automation and machine-to-machine communication.
• Automotive Systems: Reliable connectors that withstand vibration and extreme temperatures for use in control units, engine compartments, and powertrain systems.
• Outdoor Equipment: UV and water-resistant designs support renewable energy systems, transportation infrastructure, and field-deployed machinery.

In harsh environments where traditional connectors fall short, HIROSE are delivering solutions with superior durability, electrical reliability, and design flexibility. From compact, high vibration-resistant connectors to high-current circular designs, HIROSE’s portfolio meets the demanding needs of automotive, industrial, and outdoor applications. Engineers can rely on HIROSE to push the boundaries of connector performance, enabling robust and efficient designs in even the toughest conditions.

By incorporating advanced materials, innovative mechanical designs, and compliance with international standards, HIROSE’s connectors are empowering engineers to build reliable systems for tomorrow’s challenges.

Anglia are offering customers FREE samples of the ZE05, ZE064W, FX26 and HR41 Series from HIROSE, please fill in the form below to register your interest now.