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Cell contacting system for pouch cells

ENNOVI’s pouch cell contacting system (CCS) is an innovative design solution that supports large assemblies, measuring over 2m in length. Optimized for manufacturability, ENNOVI-CellConnect-Pouch prioritizes cost-effectiveness, faster manufacturing cycle times, and accommodates scale-up production as needed.

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Applications

Like all ENNOVI components, ENNOVI-CellConnect-Pouch is suitable for numerous applications. It integrates seamlessly into any organized system and can be customized to meet your specifications.

  • Battery pack

Focused Market

Emerging market

How it works

  1. Dielectric layer
  2. Frame
  3. Traces
  4. Current collector

Simplify CCS complexity

Designing pouch CCS presents several challenges, primarily due to the need to balance cost, performance, and mechanical requirements. EV and battery makers are constantly seeking new innovations that can maintain or improve performance while lowering costs, and provide reliable mechanical support for the battery cells, all while addressing safety and longevity concerns.

Advanced lamination technology

ENNOVI-CellConnect-Pouch utilizes ENNOVI’s proven lamination technology, which ensures structural integrity and durability. Low-voltage signals are added on one side of the lamination, thereby reducing material used and resulting in a thinner solution.

Supports fast gas release

Pre-cut material with good electrical insulation properties and temperature stability, featuring optional gas vent cutouts.

Cost-efficient

Our proven technology, combined with knowledge in CCS, vertically integrated production, and precision processes, helps lower costs, simplify logistics, and reduce development time.

Technical specifications​

  • Material
  • Mechanical
  • Performance
ParameterTypical Value RangeRemarks
Current CollectorsAL1000 Series
Dielectric LayersPET, PI, PENFor cold and hot lamination
Battery Cell HolderPPA, PC/ABS, Nylon 6, PA66, PBT
Surface Treatment of Current CollectorNickel plating optionFor anti-corrosion and selective plating for welding purposes
Flammability RatingUL 94 V-0
ParameterTypical Value RangeRemarks
Battery Cell TypesPouchIncluding blade cells, cell terminals on top or side of cells
Current Collector Sizes (Length)100mm – 2500mm
Current Collector Thickness0.8mm – 3.0mmCoining process for variable collector thickness
Cell Terminal Thickness0.25mm – 1.0mmCoining or multi-layer designs possible
Cell Terminal Positional Tolerance:±0.127mmFor parts <1000mm long
±0.2mmFor parts between 1000mm – 2500mm long
Dielectric Layer Thickness0.1mm – 0.2mmPressure-sensitive and thermal-activated adhesives; adhesive free lamination
ParameterTypical Value RangeRemarks
Battery Module Voltage12 – 800V and higher
Battery Module Capacity50 – 400ADepending on vehicle application and module or pack design
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, 50VAvailable with FPC, FDC or FFC
Temperature Sensing4.7kΩ at 25°C, thermistor placement
Overload Condition<200% for 10s without degradation
*ALL SPECIFICATION VALUES INDICATED HEREIN ARE WITHIN TYPICAL VALUE RANGE; ACTUAL SPECIFICATIONS DEPEND ON END APPLICATIONS AND REQUIREMENTS

Thinner, lighter, and tougher

Moving away from conventional CCS designs that use bulky plastic trays, ENNOVI-CellConnect-Pouch utilizes advanced lamination technology to create thin and lightweight solutions that enhance electrical and thermal performance at a lower manufacturing cost. ENNOVI’s FDC is integrated at one end of the lamination, eliminating the need for two layers of insulation material.

ENNOVI-CellConnect-Pouch, cell contacting system for pouch cells

ENNOVI-CellConnect-Pouch on both sides of the pouch battery module

Exploded view of ENNOVI-CellConnect-Pouch

Close up view of the top dielectric lamination layer

Have questions about this solution?

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6 steps to innovation

Here’s how we’ll work together:

01

Enquire
Complete this form with your battery requirements and design, and we will be in touch with you.

02

Discover
We will first understand your use case and application.

03

Design

Optimize your design through simulation, prototyping, and innovation.

04

Propose

Create a proposal that addresses your challenges.

05

Contract
A clear program plan is set once the business has been awarded.

06

Production
Ramp up to full operations and delivery of the products to you.

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