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Cell contacting system for cylindrical cells

ENNOVI’s innovative cylindrical cell contacting system, ENNOVI-CellConnect-Round, achieves excellent current density spread. This helps extend the lifespan of battery packs by reducing the stress on individual battery cells.

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Applications

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

  • Battery pack

Focused Market

Emerging market

How it works

  1. Dielectric layer
  2. Current collector
  3. Data collection media
  4. Battery cell holder
  5. Battery cells

Optimization for Li-ion batteries

Design complexities. Assembly efficiencies. Space constraints. ENNOVI-CellConnect-Round is designed to overcome them all. We provide it with a thin, tough structure, resulting in an excellent current density spread, which ensures consistent performance and efficient, low-loss energy transfer.

Outstanding current density spread

With patented U-Turn technology, ENNOVI-CellConnect-Round ensures that current density is distributed as evenly as possible for multiple configurations.

Supports various designs

Flexibility to create designs for battery modules or new advanced cell-to-pack and cell-to-chassis configurations.

Weighs little, acts tough

Despite being especially thin, ranging from 0.17mm to 3mm, ENNOVI-CellConnect-Round is tough enough for large current collectors, up to 2.5m long.

Technical specifications​

  • Material
  • Mechanical
  • Performance
ParameterTypical Value RangeRemarks
Current CollectorsAL1000 Series, C1000 Series, Nickel​Top Mating Busbar
Dielectric LayersPET, PI​
Battery Cell HolderPPA, PC/ABS, Nylon 6, PA66, PBTService temperature of plastics ≤130°C
Surface Treatment of Current CollectorNickel plating optionFor battery cell holder and dielectric layers
Flammability RatingUL 94 V-0
ParameterTypical Value RangeRemarks
Battery Cell TypesCylindrical
Battery Module Connection TypesNut/bolt, pin/socket, custom configurations possible
Current Collector Sizes (Length)100mm – 2500mm​
Current Collector Thickness0.17 – 3.0mm
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 Thickness0.1 – 0.3mm Pressure-sensitive and thermal-activated adhesive
ParameterTypical Value RangeRemarks
Battery Module Voltage12 – 800V and higher
Battery Module Capacity50 – 400A
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 Available 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.

A U-turn to get around hot spots

EV batteries tend to develop hot spots across conventional collector plates. ENNOVI-CellConnect-Round addresses this issue with patented U-Turn technology, which yields a uniform distribution of current density. By reducing stress on individual battery cells, U-Turn helps batteries perform better, go further, and live longer.

ENNOVI-CellConnect-Round, a cell contacting system for cylindrical cells

Close-up view of the current collector

High-voltage terminal

FPC with copper traces

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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Meet ENNOVI at
The Battery Show Europe 2026

9–11 June | Stuttgart
Hall 5, Booth C40
Topic: Creating High-Performance Parts with Chemical Etching

  • Enable precise, burr-free metal components for complex designs
  • Explore chemical etching capabilities for high-precision applications
  • Understand where chemical etching fits in modern manufacturing

Schedule a Meeting

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