High-Voltage Interlock (HVIL) Safety Terminals for Electric Vehicle Battery Systems

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High-Voltage Interlock (HVIL) Safety Terminals for Electric Vehicle Battery Systems

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Product Description

Basic Specifications

Model NO.

DJ-F05-11

Processing

Shaping Metal

Material

Phosphor Bronze (C5191)

Mould Type

Multistep Progressive Dies

Surface

Gold Over Nickel Plating

Tolerance

0.02mm

Voltage Rating

48V DC

Insulation

High-Temp PPS/Peek

Current Capacity

1-5A

Temp Range

-40°C to +180°C

Resistance

< 10 MΩ

Certification

IATF 16949, ISO 26262

Intelligent HVIL Safety Terminals

Safety is paramount in electric vehicle design. High-Voltage Interlock Loop (HVIL) terminals are the critical safety sentinels for modern EV battery systems. They provide the essential low-voltage signal circuit that ensures all high-voltage connections are secure before power is enabled, preventing electrical hazards and ensuring operator safety.

Parameter	Specification
Rated Current	2 A
Rated Voltage	48 V DC
Contact Resistance	≤ 8 mΩ
Dielectric Strength	1000 V AC/minute
Operation Temperature	-40°C to +125°C
Contact Material	C5191 Phosphor Bronze
Housing Material	PA66, 30% Glass Filled
Flame Rating	UL94 V-0

🛡️ Precision Safety Engineering

Dedicated Safety Function Specifically engineered to complete and monitor the HVIL circuit-a mandatory safety feature in all EVs that disables high-voltage power if any connection is loose.
Signal Integrity Assurance Constructed from high-reliability phosphor bronze with selective gold plating to maintain a flawless signal connection for the Vehicle Control Unit (VCU).
Foolproof Design Features a unique polarized and keyed housing design that prevents incorrect mating, guaranteeing system integrity.

❄️ Reliability in Harsh Environments

Vibration Resistant Precision-made contact design provides high retention force and exceptional performance under constant automotive vibration.
High-Temperature Resilience Glass-filled nylon housing maintains structural integrity near battery packs and powertrains.

⚙️ Compliance and Customization

Global Standards Designed to comply with international automotive safety standards (ISO 6469-3, LV215).
Automated Assembly Designed for seamless integration with automated harness manufacturing processes.
Tailored Configurations Customization available in plating thickness, housing color, and wire seal types.

Critical Applications

EV Battery Pack Modules

Power Distribution Units (PDUs)

DC-DC Converter Connections

Electric Motor Housings

High-Voltage Cable Connectors

Manufacturing Excellence

Precision Engineering Utilizing precision stamping and injection molding technologies to ensure micron-level accuracy.
100% Automated Testing Automated electrical testing and optical inspection to verify dimensions and performance.
Dependable Supply Flexible order quantities and full traceability to support global production lines.

Quality Certificates

Frequently Asked Questions

What is the primary function of HVIL terminals?

HVIL (High-Voltage Interlock Loop) terminals act as a safety circuit that monitors the connection status of high-voltage components. If a connection is broken, the system immediately signals to disable high-voltage power.

Which materials are used for superior conductivity?

We use High-Performance Phosphor Bronze (C5191) with gold plating over a nickel underplate to ensure maximum signal integrity and corrosion resistance.

Are these terminals suitable for high-vibration environments?

Yes, the terminals are specifically engineered with high retention force contacts to maintain stability under constant automotive vibrations.

What is the operating temperature range?

Our HVIL terminals are designed to operate reliably in extreme conditions ranging from -40°C to +125°C, with some components rated up to +180°C.

Can the terminals be customized for specific vehicle designs?

Absolutely. We offer customization for terminal plating thickness, housing colors, keying/polarization, and wire gauge compatibility to meet specific OEM requirements.

Do these products meet international automotive standards?

Yes, our manufacturing process is IATF 16949 certified, and the products comply with global standards such as ISO 6469-3 and LV215.

Product Detail

High-Voltage Interlock (HVIL) Safety Terminals for Electric Vehicle Battery Systems

Product Description

Basic Specifications