Innovation Driver: Connector Seals Improve Design Flexibility in Battery Platforms

Integrated function: Cell-contacting architectures in modern battery packs

Connector seals open the door to a new type of cell contacting. They are based on multifunctional, modular cell connector plates for cylindrical, prismatic or pouch cells. These cell connectors are manufactured to customer specifications from nickel-plated or tin-plated copper and overmolded with elastomer. In addition to offering high levels of electrical insulation, the elastomer components meet all requirements of modern battery systems. Depending on the customer's technical specifications, it is possible to directly integrate different seals and seal geometries – such as for housing seals, cell seals or other protective features. Additional functional integrations enhance the component’s value and create a cell connector that provides not only its electrical function but also offers significant advantages in terms of assembly, installation space, robustness, damping and system integration within the battery pack.

Refined: From individual component to platform concept

The key benefit of connector seals lies in their capability for integration: Functions that were previously handled by separate components for contacting, sealing, insulation and mechanical guidance are now combined in a single concept. This reduces interfaces, shortens tolerance chains and minimizes potential failure risks. The focus has shifted from individual components to a modular platform approach in which electrical, mechanical and sealing functions are considered together right from the start. This concept covers more than just today’s lithium-ion batteries. Regardless of cell chemistry, pack architecture or application, the full range of design possibilities offered by the functional integration and new technology can be utilized. As a result, connector seals create new design options for battery developers and enable new architectures for future battery packs. A conventional cell connector solution becomes a technological platform that improves the performance of the battery pack as a whole.