Quick Takeaways
- This new CCS architecture cuts battery pack weight and complexity while improving safety.
- Leoni’s fuse-integrated bond wire approach targets scalable, cost-efficient EV battery production.
Leoni Cell Connecting System for High-Voltage Batteries was introduced as a new solution designed to electrically link battery cells with either lateral terminals or terminals positioned on the top of the cell. The development targets modern electric vehicle battery packs that demand compact, reliable, and lightweight interconnection technologies.
The Leoni Cell Connecting System for High-Voltage Batteries uses advanced bond wire technology to replace conventional surface-mounted device melting fuses. This approach delivers the same protective fuse function while improving electrical reliability and significantly reducing both component weight and overall system cost, which are critical factors for large-scale EV battery production.
How Leoni Cell Connecting System for High-Voltage Batteries works
The core of the Leoni Cell Connecting System for High-Voltage Batteries is its bond wire design, which acts as an electrical conductor and a protective fuse at the same time. This dual function removes the need for separate fuse components and simplifies the electrical architecture of the battery module.
Key technical advantages include:
Integrated monitoring and mechanical stability
To ensure safe operation, the Leoni Cell Connecting System for High-Voltage Batteries integrates temperature sensors directly into the system. These sensors enable continuous thermal monitoring of the battery cells, supporting early detection of overheating and helping protect the entire high-voltage battery pack.
The CCS is mounted within a dedicated mechanical frame that provides strong physical support for all electrical connections. This structure not only improves durability under vibration and thermal cycling but also simplifies assembly, allowing faster and more consistent battery module production.
Flexible and sustainable design features
Leoni has also added flexible pinning options at the ECU connector, allowing the system to be adapted to different battery management and vehicle architectures without redesigning the entire CCS. This flexibility makes the solution suitable for multiple EV platforms and battery layouts.
Sustainability is another core element of the Leoni Cell Connecting System for High-Voltage Batteries. Parts of the system are produced using additive manufacturing, which reduces material waste, supports more efficient production processes, and enables rapid design optimization for future battery generations.
By combining fuse protection, thermal sensing, mechanical stability, and adaptable connectivity in a single integrated solution, Leoni’s CCS supports safer, lighter, and more cost-effective high-voltage battery systems for next-generation electric vehicles.
The Leoni Cell Connecting System for High-Voltage Batteries uses advanced bond wire technology to replace conventional surface-mounted device melting fuses. This approach delivers the same protective fuse function while improving electrical reliability and significantly reducing both component weight and overall system cost, which are critical factors for large-scale EV battery production.
How Leoni Cell Connecting System for High-Voltage Batteries works
The core of the Leoni Cell Connecting System for High-Voltage Batteries is its bond wire design, which acts as an electrical conductor and a protective fuse at the same time. This dual function removes the need for separate fuse components and simplifies the electrical architecture of the battery module.
Key technical advantages include:
- Bond wires that safely interrupt current during fault conditions
- Fewer discrete electronic parts compared with SMD fuse layouts
- Lower material usage, contributing to reduced weight
- Higher reliability through fewer soldered joints
Integrated monitoring and mechanical stability
To ensure safe operation, the Leoni Cell Connecting System for High-Voltage Batteries integrates temperature sensors directly into the system. These sensors enable continuous thermal monitoring of the battery cells, supporting early detection of overheating and helping protect the entire high-voltage battery pack.
The CCS is mounted within a dedicated mechanical frame that provides strong physical support for all electrical connections. This structure not only improves durability under vibration and thermal cycling but also simplifies assembly, allowing faster and more consistent battery module production.
Flexible and sustainable design features
Leoni has also added flexible pinning options at the ECU connector, allowing the system to be adapted to different battery management and vehicle architectures without redesigning the entire CCS. This flexibility makes the solution suitable for multiple EV platforms and battery layouts.
Sustainability is another core element of the Leoni Cell Connecting System for High-Voltage Batteries. Parts of the system are produced using additive manufacturing, which reduces material waste, supports more efficient production processes, and enables rapid design optimization for future battery generations.
By combining fuse protection, thermal sensing, mechanical stability, and adaptable connectivity in a single integrated solution, Leoni’s CCS supports safer, lighter, and more cost-effective high-voltage battery systems for next-generation electric vehicles.
Company Press Release
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