Battery Module Connector (Flexible Busbar)

Flexible busbar connector for PHEV battery modules

Contents
Battery Module Connector (Flexible Busbar)

Flexible module-to-module connection

The Battery Module Connector (Flexible Busbar) links cell modules in PHEV battery architectures. Its customized, compact design provides a flexible and robust connection. The assembly accommodates module assembly tolerances and includes touch protection.

Orange protective housing, flexible copper busbar and connector components

Assembly and production

The connector is designed for automated robot assembly and mass production. The flexible conductor accommodates differences in the positions of adjacent battery modules.

High-voltage performance and automated assembly

The Lear Battery Module Connector supports module-to-module power transmission with a current capacity of 170 A and a working voltage of 400 V. A dielectric strength of more than 3,500 V and an IPXXB protection rating support safe operation within high-voltage battery systems. The connector is designed for operating temperatures from -40°C to +120°C.

Copper conductive components and flame-retardant, glass-fiber-reinforced plastic provide a combination of electrical performance, mechanical strength and thermal resistance. The design is suitable for mass production and automated robotic assembly, supporting repeatable installation in high-volume battery manufacturing.

Key technical features and benefits:

  • Current-carrying capacity of 170 A
  • Working voltage of 400 V
  • Dielectric strength greater than 3,500 V
  • IPXXB protection rating
  • Operating temperature range from -40°C to +120°C
  • V-0 flammability rating according to TL 1011-A
  • Copper conductive components
  • Flame-retardant PK GF30 FR  (polyketone) plastic components
  • Designed for automated robotic assembly
  • Suitable for high-volume production
  • Repeatable module-to-module installation

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