Freudenberg Connector Seal Concept Enhances Battery Pack Integration

Freudenberg Develops Customer-Specific Connector Seal Concept

Freudenberg Sealing Technologies has developed a Freudenberg connector seal concept designed to improve design flexibility and system integration in modern battery packs. The customer-specific approach combines several critical functions within a single sealing concept, addressing the increasingly integrated architecture of battery systems. The solution is based on modular cell connector plates that can be adapted for cylindrical, prismatic and pouch battery cells. By combining electrical contacting, insulation, sealing and mechanical functions, the concept is intended to simplify system design while reducing the number of interfaces and associated tolerance chains.

Modular Connector Plates Integrate Multiple Functions

The connector plates developed by Freudenberg Sealing Technologies are manufactured according to customer specifications using nickel-plated or tin-plated copper and are subsequently overmolded with elastomer. This modular construction allows the connector solution to accommodate different battery cell formats while integrating electrical and mechanical requirements into one component concept. Combining these functions can reduce interfaces within the battery pack architecture, which in turn can limit tolerance accumulation and potential failure risks. The approach supports greater flexibility for battery pack designers while maintaining the required contacting, insulation and sealing functions.

FACT Technology Supports Resource-Conserving Production

The concept also incorporates Freudenberg Adhesive Clean Technology, known as FACT, to establish permanent bonding between the elastomer and connector surfaces without conventional wet-chemical pretreatment. According to Freudenberg Sealing Technologies, this bonding approach supports a more resource-conserving manufacturing process while reducing dependence on conventional bonding agents. Eliminating the need for wet-chemical pretreatment can simplify the production process and reduce the materials associated with bonding preparation. The combination of modular connector construction and FACT therefore addresses both battery-system integration requirements and manufacturing considerations.

Frequently Asked Questions

What is the Freudenberg connector seal concept?
The Freudenberg connector seal concept is a customer-specific solution that integrates electrical contacting, insulation, sealing and mechanical functions for modern battery packs. It uses modular cell connector plates designed for cylindrical, prismatic and pouch cells, with copper materials overmolded using elastomer. By consolidating several functions into one concept, the solution can reduce interfaces, tolerance chains and potential failure risks. The approach is intended to give battery designers greater flexibility while supporting system integration across different battery cell formats and configurations.

What manufacturing technology does the concept use?
The connector seal concept uses Freudenberg Adhesive Clean Technology, or FACT, to permanently bond elastomer to connector surfaces without conventional wet-chemical pretreatment. This approach supports a resource-conserving manufacturing process and reduces dependence on bonding agents. The connector plates themselves are produced from nickel-plated or tin-plated copper according to customer requirements and then overmolded with elastomer. This combination enables the electrical, insulation, sealing and mechanical functions to be integrated into a single component concept for battery applications.