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.
Gallery
Cell-PLX™ Battery Interconnect System
Cell-PLX™ Features
Cell-PLX™ Features
Cell-PLX™ Cell Holder with Dielectric Layer Between Current Collectors
Overmolded Control Board Interconnect
Overmolded Lead Frame
Alternating Current Collectors and Dielectric Layers with Overmolded Control Board Interconnect
Cell-PLX™ is Customizable to Various Module Sizes and Configurations for EV Applications
Positive and Negative Terminals of Reduced Thickness are Formed for Cell Attachment
Laser Welding of Current Collectors to Overmolded Lead Frame
Heat Staking Dielectric Layers and Current Collectors to Overmolded Control Board Interconnect
Customized I/O Connectors for Battery Management Systems (BMS)
Assembled Cell-PLX™ with Aluminum Current Collectors
Assembled Cell-PLX™ with Copper Current Collectors