Cell-PLX™
Cell-PLX™ is Interplex’s customized battery interconnect system designed to your application needs. It is suitable for Lithium-ion battery cells for cylindrical, pouch and prismatic battery module designs, with robust packaging formats for high-vibration environments.
Flexibility and customization is key, and various design configurations can be explored. Cell-PLX™ is not a simplistic, off-the-shelf product; it is a tailor-made power solution that delivers what you need. Its high-precision elements seamlessly integrate into an organized system, truly delivering a reliable battery interconnect system that caters to your battery design requirements.
Unique Selling Proposition of Cell-PLX™
- Customized single/multi-layer current collector designs
- Supports various current densities and cell array configurations
- Tight-tolerance current collectors
- Laser weld/wire bond attachment options
- Robust packaging formats for high-vibration environments
- Multiple module-to-module connection options
- Seamless integration of passive and active components for safety and cell monitoring
- Quick time-to-market; vertically integrated in-house production capabilities
Markets Served
- Aerospace
- Automotive
- Commercial Transportation
- Maritime
- Personal Mobility
- Energy
- Industrial
Types of Applications
- Electric vehicles (EVs) and automotive power systems
- Maritime vessels: Electric boats, ferries
- Commercial transportation: Buses, light trucks, tractor trailers, trains, subway systems
- Personal mobility devices: Motorcycles, electric scooters, bicycles
- Energy storage: Wind, solar
Cell-PLX™ Customizable Features
Top and Bottom Current Collectors
- High-precision stamped for tight tolerances
- Single/multi-layer options
- Specific configurations to attain required outputs
- Positive and negative terminals can be formed down to cell level for laser weld or wire bond attachment
Top and Bottom Dielectric Layers
- Adhesive-backed (double/single-sided) insulation layers attached to current collectors
- Non-adhesive insulation layers can also be attached to current collectors by heat staking
Overmolded Control Board Interconnect
- Connected to current collectors’ voltage sense lines
- Overmolded lead frame interconnect into plastic insulated battery cell holder
- Provides robust connection to control board
- Geometric configurations: Right angle or straight
- Precise placement and welding of active/passive components – e.g. fuses, thermistors
Battery Cell Holder
- Customized configurations to meet your requirements
- Various plastic material options available
Control Board Connector
- Custom-designed female receptacle connects overmolded lead frame to control board
Cell-PLX™ Specifications
- Current Collectors: AL1100, C1100, Nickel
- Dielectric Layers:
– Plastic Resin: PA, PC/ABS, Nylon 6, XAREC, Noryl, Lupoy, PBT, PA66
– Thin Film: Polyimide, Nomex, Lexan, Mylar, Epoxy in various thicknesses - Lead Frame: C510 phosphor bronze, beryllium copper
- Battery Cell Holder: PPA, PC/ABS, Nylon 6, PA66, PBT
– Service temperature of plastics: <130°C - Surface Treatment of Current Collectors: Nickel plating option
– For anti-corrosion and welding purposes - Flammability Rating: UL 94 V-0
– For battery cell holder and dielectric layers
All specification values indicated herein are within a typical value range; actual specifications depend on end applications and requirements.
- Battery Cell Types: 21700, 18650, prismatic, pouch
- Battery Module Connection Types: Nut/bolt, pin/socket, customized configurations possible
- Current Collector Sizes (W x L): 100 x 100mm – 500 x 900mm
- Current Collector Thickness: 0.254 – 3mm
- Cell Terminal Thickness: 0.125 – 0.3mm
– Laser Weld: Terminal thickness <0.3mm
– Wire Bond: Various thicknesses possible - Cell Terminal Positional Tolerance: ±0.127mm
- Dielectric Layer Thickness: 0.127 – 0.3mm
– Pressure-sensitive and thermal-activated adhesive - Lead Frame Thickness: 0.64mm typical
All specification values indicated herein are within a typical value range; actual specifications depend on end applications and requirements.
- Battery Module Voltage: 12 – 120V
- Battery Module Capacity: 50 – 400Ah
- Battery Module Energy: 0.60 – 48kWh
- Module-to-module Connections: <400A, off-shelf or customized
- Current Density: <15A/mm², maintaining <60°C with cooling
- Dielectric Strength of Insulation Materials: <7.5kV/0.025mm, ASTM D149
- Dielectric Continuous Use Temperature: <220°C
- Voltage Sense Line: <2A, 50V
– Cable, flex circuit, overmolded lead frame - Temperature Sensing: 4.7kΩ at 25°C, thermistor placement
- Overload Condition: <200% for 10s without degradation
All specification values indicated herein are within a typical value range; actual specifications depend on end applications and requirements.
Our Portfolio
- Battery Interconnect Board
Battery Interconnect Board
Provides a means for electrical connections within customized battery interconnect system (Cell-PLX™) for electric vehicles. Contains multi-layer conductor and insulation layers, and a lead frame that provides robust attachment for thermal and power management interconnect board.