Battery Connectors Solutions Product Roundup  

This week’s Product Roundup highlights battery connectors from leading connector manufacturers and suppliers.

Battery connectors

Amphenol’s SurLok Plus connector available from PEI Genesis is a field installable alternative to common compression lugs. Features include IP67 protection, touch-proof, and RoHS compliance, and RADSOK contact technology. It is designed to support electric and hybrid electric vehicles and is used in battery packs, AC to DC or DC to DC converters, and motor control units.

Hypertac Green Connect contact technology from Smiths Interconnect offers a lead-free and beryllium-free high power contact solution with unparalleled low contact resistance. The lower contact resistance of the Hypertac Green Connect hyperboloid contact reduces heat build-up, allowing the contacts to handle far greater current in smaller contact assemblies without adversely affecting temperature rise. An improved crimp design of the socket increases the contact area between the contact body and the multi-stranded cable.

The WP12 Series compact battery board-to-board (FPC) connector from JAE supports 15A of current, which is 1.25 times higher than its predecessor, the WP10 Series, while having the same pitch and stacking height. The WP12 series achieves further miniaturization, excellent mating operability, and higher extraction force compared to the WP11 Series.

Weidmuller USA now offers a 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. The functionality of these systems relies upon the critical connection to the battery modules.

The Industrial Battery Connector (IBC) from Anderson Power features a patent-pending modular design with an innovative contact cartridge, enabling easy assembly and quick contact repair or replacement. Engineered for harsh environments, the IBC offers contact temperature sensing to prevent overheating and delivers exceptional moisture and debris resistance with its industry-first IP68-rated accessory kit. The IBC is rated from 70 to 450A, available in three sizes (80, 160, and 320), and meets DIN VDE 0623-589 and EN1175-2020 standards. It is available in standard plug/receptacle or exclusive panel-mount configurations and supports up to 10 signal wires for excellent battery monitoring capabilities.

Amphenol Communications Solutions replaceable battery connectors meet new laws and requirements for safe batteries and sustainability. Consumers will be able to remove and replace the portable batteries in their electronic products at any time of the life cycle. This will extend the life of these products before their final disposal, will encourage re-use, and will contribute to the reduction of post-consumer waste. Amphenol FCI Basics battery connectors consist of spring and blade types, available in 2.0/2.5/3.0/3.6/4.6mm pitch, with 2 to 10 positions supporting up to 10A. These connectors have been widely adopted across applications like smart home devices, e-cigarettes, household appliances medical devices, and rugged handhelds.

Kyocera AVX’s 9155-020 series battery connectors have been used in a wide range of applications such as hearing aids, portable medical devices, and handheld scanners. Designed with reliability in mind, these connectors feature gold-plated beryllium copper contacts on a 1.27 mm pitch, are rated up to 3 amps per contact, and can handle up to 15,000 mating cycles.

Adam Tech’s ESF/ESM Series energy storage connectors provide a critical link between battery modules. This link ensures safe and reliable connections in energy storage systems, such as electric vehicle charging, renewable energy devices, and both industrial and consumer energy storage. The series is composed of various mated pairs, offered in both orange and black. Various voltage ratings, current ratings, and wire gauges are supported, making this series compatible with a wide range of applications. Compatible dust covers are available to provide additional protection.

Battery Pole Cable Assemblies from Phoenix Contact feature a rotatable design, touch protection, and mechanical coding. The connectors provide a high degree of flexibility and safety when it comes to connecting battery poles. They can be rotated 360° making them ideal for flexible cable outlets. The battery connection is protected against polarity reversal by mechanical coding. The various color versions facilitate identification of battery poles. Touch-protected battery poles, even when not plugged in, allow for safe installation. Device connection technologies offer flexible installation options.

Schaltbau’s Eddicy LV charging connector series offers robust high-power charging connectors with a new optimized main contact system. The solid power contacts can carry high currents with minimal self-heating, have extremely low contact resistance, and noticeably reduced contact forces for a significantly longer service life. All LV connectors meet the requirements of EN 1175 and DIN VDE 0623-589 for high current carrying capacity. They enable active energy and battery management that optimizes the current flow and increases battery lifespan. Thanks to their modularity, Schaltbau charging connectors can be individually configured. Additional pilot contacts are available for battery management. Pilot contacts and adapters are also available to allow air to pass through during the charging process or to fill the battery with demineralized water.

Designing connectors for batteries and fuel cells requires a balance between mechanical, electrical, and thermal properties. Automakers and battery pack manufacturers need to find low-profile connectors that meet stringent requirements, with low resistance at the individual contact points to reduce power loss and heat. TE Connectivity (TE) offers a full catalog of high-voltage cell and module connectivity, switching, and battery management system connector innovations that improve power-to-weight ratios, enhance safety, and enable overall state-of-health monitoring over the course of the car’s lifetime.

Charging inlet assemblies from Amphenol Pcd include the Combined Charging System (CCS) inlets (type 1 and type 2) and North American Charging System (NACS). They enable faster and safe DC charging for aerospace applications across all regions. Each charging inlet assembly can be supplied as a complete cable assembly to meet the requirements of the application.

Amphenol’s 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 feature 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 flat cable variations to accommodate a wide range of system designs.

Like this article? Check out our other Product Roundup, Product News, and Connector Industry News features and our 2024 and 2025 Article Archives.

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