As battery energy storage systems (BESS), EV charging infrastructure, battery backup units (BBUs), and industrial power systems continued to increase in power density, engineers were challenged to deliver reliable, compact, and serviceable battery module interconnects that maximised electrical efficiency and long-term reliability.
This on-demand webinar explored the engineering considerations for designing high-current battery module connections, using the Amphenol EnergyKlip™ family of High-Power Industrial Battery Module Connectors for Energy Markets.
Through practical application examples, viewers learned how connector selection influenced electrical efficiency, thermal performance, system packaging, installation, and long-term reliability in next-generation energy systems.
The session examined key design considerations, including current carrying capability, contact resistance, temperature rise, IP67 environmental protection, touch-safe designs, and connector architectures that simplified battery module integration and maintenance. It also demonstrated how both cable and flat-flex cable (FFC) options provided the design flexibility needed to accommodate a wide range of space-constrained battery module and power distribution architectures.
Covering current ratings from 160 A to 500 A per contact, the EnergyKlip™ portfolio provided a scalable interconnect solution for battery modules, power distribution, industrial chargers, EV charging power modules, renewable energy storage, and e-mobility applications.
Key learning points included:
- Engineering challenges of grid-scale battery energy storage systems (BESS), EV charging, renewable energy, battery backup units (BBUs), and grid infrastructure.
- Best practices for designing high-power industrial battery module interconnects that optimised electrical performance, thermal management, and system reliability.
- Understanding contact resistance, current derating, temperature rise, and connector design considerations for high-current power distribution in energy storage and power systems.
- Design considerations for both cable and flat-flex cable (FFC) interconnect solutions to support a wide range of compact, space-constrained battery module and power distribution architectures.
- Designing modular, serviceable high-current power systems that simplified installation and maintenance while supporting scalable battery module designs.
- Future trends in higher power-density, long-duration energy storage (LDES), and next-generation power infrastructure, and the evolving role of high-current battery module interconnects.
Why watch this webinar?
This on-demand webinar provides practical engineering guidance on designing robust battery module interconnects for next-generation energy systems.
Hardware, electrical, power electronics, and systems engineers will gain actionable insights they can immediately apply to improve the performance, scalability, and reliability of future energy storage and power distribution designs.
Whether you are designing battery energy storage systems, EV charging equipment, renewable energy systems, utility power infrastructure, or industrial power electronics, selecting the right high-current connector can significantly impact system performance, efficiency, reliability, and total cost of ownership.
