Hirose has announced commercial availability of its ZE150HV Series high-voltage wire-to-board connector, designed for electric vehicle (EV) and hybrid electric vehicle (HEV) powertrains. The connector features a 4.5mm pitch, meaning the spacing between individual pins, and supports 1000V AC/DC, 10A per pin, with an operating temperature range up to 125°C.
Engineered to meet IEC 60664 standards, an international standard governing insulation coordination in electrical equipment, covering both pollution degree 2 (a rating for how much contamination the connector can tolerate) and operation at altitudes up to 6,000 meters, the ZE150HV combines reliable electrical performance with mechanical stability. It's built from heat-resistant, RoHS2-compliant materials, meaning it meets restrictions on hazardous substances, and is designed for long-term reliability in harsh conditions, helping extend service life and reduce waste from damage or the need for rework.
The connector was named a CES Innovation Awards 2026 Honoree in the Vehicle Tech & Advanced Mobility category, recognized for three design innovations addressing key challenges in high-voltage systems that make power connections safer and more reliable in extreme environments.
First, achieving a 1000V rating traditionally requires a standard spacing of 6.8mm between pins to prevent electrical arcing. The ZE150HV uses a patented design that reduces this required spacing by placing proprietary ribs between the contacts, allowing Hirose to shrink the overall connector size and support more compact powertrain and high-voltage system designs.
Second, the ZE150HV's terminal uses a three-point contact structure designed to maintain a stable electrical connection even under vibration. A double-spring design increases contact pressure, strengthening the connection and keeping it stable in environments prone to significant movement, such as near EV motors and inverters, ensuring the electrical connection stays consistent even under harsh vibration.
Third, a robust housing paired with a built-in connector position assurance (CPA) mechanism helps prevent the connector from being only partially mated, reducing the risk of electrical arcing or exposed live connections, a particularly important safety consideration in high-voltage systems.
Pete Lais, assistant vice president of product management for Hirose Electric Americas, said the award-winning ZE150HV Series was built for next-generation high-voltage automotive systems, combining a compact footprint with reliable high-voltage performance and clear visual guidance during installation for fast, confident assembly. He said its space-saving design supports clean wire routing and flexible placement, even in tightly packed powertrain assemblies.
