Battery Connector Product Roundup
This week’s Product Roundup highlights battery connectors from leading connector manufacturers and suppliers.
Battery connectors
The KYOCERA AVX 9155 family of battery connectors is designed with reliable and robust gold-plated beryllium copper contacts, reduced assembly time, and assembly process flexibility in mind. These connectors are offered in two to eight positions, contact pitches from 1.27 to 4 mm, contact deflection forces from 30 to 260 grams, parallel, stacking, right angle, and perpendicular mating directions, with up to 50,000 mating cycles, and up to 5 amps per contact in a 1-piece or 2-piece board-to-board solution (depending on the series). Comprising both horizontal and vertical options, these robust connectors are suited for board-to-board connections as well as battery pack integration. KYOCERA AVX has a wide range of battery connectors and can customize products to support various application needs.
TE Connectivity’s high durability direct-to-PCB battery terminals are designed to address ergonomic low mating force, high current capability, and reliable performance through repeated mating cycles. With performance proven to last through 10,000 mating cycles, the multi-point contact terminal features rounded contact edges for low insertion force (LIF) and a large contact surface area for a reliable connection and excellent low-level contact resistance (LLCR). They are available in a 20A power version and a 5A signal version and can be assembled in custom housings according to application requirements. TE can also develop customized terminals with different electrical and mechanical ratings. Applications include e-mobility, power tools, lawn tools, and appliances.
Smith Interconnect’s Hypertac Green Connect contact technology offers a lead-free and beryllium-free high power contact solution. Its low contact resistance reduces heat build-up allowing the contacts to handle far greater current in smaller contact assemblies without adversely affecting temperature rise. The improved crimp design of the socket offers an increased contact area between the contact body and the multi-stranded cable.
The DW series from JAE are high-power connectors for battery management systems, including power and signal hybrid solutions in a single housing and cable solution for battery daisy-chaining in small-scale storage. The hybrid connectors come with a wide range of misalignment floating ideal for blind mating, with output capacity up to 500A.
Bourns modular contacts from Avnet are off-the-shelf interconnect devices that can be used in cellular telephones, PDAs, laptop computers, portable medical and test equipment — anywhere a rechargeable battery pack is required. Because they can be used as either compression or sliding modular contacts, they can function as connectors for many other non-battery related applications.
Amphenol Communications Solutions’ new EnergyKlip product series utilizes existing and trusted Amphenol high-current contact technology designed for energy markets. EnergyKlip EK350 connectors are rated for up to 350A per contact and features a built-in IP67 seal to ensure protection from harsh environments. EnergyKlip EK350 is an ideal product for battery module interconnects within an energy storage system (ESS). EK350 also features a robust latching system to ensure a reliable connection while mated. This power connector comes in both cable and flex busbar variations to accommodate a wide range of system designs.
Hirose’s high-power hybrid FPC-to-board connectors support up to 15A in a space-saving housing that reduces the PCB mounting space by up to 40%. The BM50 series is designed for mobile devices with built-in battery or USB connections, contributing to a significant reduction of both the space used inside the device and the size of customers’ end products. In addition, the BM50 connector offers superior design flexibility. Using an FPC to connect the USB to the PCB, the USB can be placed anywhere within the end product’s design.
Amphenol LTW provides two essential solutions for effective pressure management: the Pressure Relief Vent and the Over-Pressure Relief Vent. These vents play a crucial role in equalizing internal-external pressure, emphasizing both operational safety and equipment longevity, and enabling devices to thrive in challenging environments. The spring-loaded type and rectangular type Over-Pressure Relief Vents function to prevent sudden heat/pressure rise of a battery module that leads to an explosion. The Pressure Relief Vent facilitates controlled pressure release within safe operating limits, specifically designed to equalize the internal and external pressure. This not only prevents heat accumulation from electronic components but also reduces the need for bulkier housings and seals. Both vents feature hydrophobic/oleophobic membranes effectively excluding water or oil and minimizing condensation. This design ensures comprehensive protection and reliability across various industrial applications.
Weidmuller USA offers advanced battery connectors as part of its full suite of energy storage products to cover the power, data, and signaling needs required in a wide array of battery energy storage system (BESS) applications including battery storage, connectors and power conversion, HVAC/fire control, surge protection, combiner boxes, and marshalling boxes. Battery connectors are critical components that facilitate the transfer of electrical energy between the battery cells and the application, allowing the connection of the battery modules in just a few simple steps. They come in a variety of sizes to cater to different usages in many industry sectors. Weidmuller USA’s battery connectors for BESS applications are engineered to handle high currents, allowing for efficient energy transfer and reduced power losses. They are designed to withstand harsh environmental conditions and are user-friendly with mechanisms that prevent accidental disconnections. The contact is made of copper alloy finished with silver and approved according to UL 4128 to warrant the best electrical contact with more than 100 operations of mechanical connection and disconnection (without load). On the wiring side, options for conductor cross-sections from 10mm² to 95mm² are available. Color coded connectors (orange = positive; black = negative) are on both the connector and the mated busbar connection. Connectors are key coded on both sides to alleviate the possibility of user error. A locking mechanism fastens the plug and the socket.
A battery module system regulates the charging and discharging of the battery, preventing damage to the module cells and ensuring overall management of the lifetime capabilities of the battery. A One27 1.27 mm SMT connector from ept has the endurance, high tolerance compensation, and signal integrity for connections within a battery system. An enormous “Z” direction tolerance of 1.5 mm, which supports board-to-board (mezzanine) distances ranging from 8 mm up to 20.5 mm, is possible. Choosing the optional cable assembly variant of the One27 connector allows for enormous tolerances. Ept offers the three different cables options for the female IDC: PVC cables, high temperature cables, and environmentally-friendly and fire-rated halogen-free solid wire cables with LSZH sheathing. One27s have a 1.4 A current rating, and 12 – 80 pins. They are capable of 500 mating cycles and are packaged in tape-and-reel format.
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