Freudenberg Sealing Technologies has developed a new concept for connector seals in modern battery platforms. The solution is designed to give battery developers greater design freedom when creating compact, safe and efficient battery packs.
Demand for high-performance battery systems is growing rapidly. Not only in electric vehicles, but also in mobile tools, medical technology, humanoid robots, consumer applications and industrial energy storage. At the same time, battery packs need to become smaller, more robust and more affordable. This makes their design increasingly complex.
In many battery architectures, functions such as electrical contacting, sealing, insulation and mechanical fastening are still handled separately. This results in additional components, greater tolerance risks and more assembly steps. With connector seals, Freudenberg aims to combine these functions into a single integrated concept.
The connector seals are based on modular cell connector plates for cylindrical, prismatic and pouch cells. These connectors are custom-made from nickel-plated or tin-plated copper and then overmolded with elastomer.
The elastomer not only provides electrical insulation, but can also integrate various sealing functions. Examples include housing seals, cell seals or other protective geometries. As a result, the connector is not only an electrical component, but also a part that contributes to sealing, damping, robustness and system integration.
The main benefit lies in functional integration. Where contacting, sealing, insulation and mechanical guidance were previously handled with separate components, Freudenberg combines these functions in one modular platform.
This can help reduce interfaces, shorten tolerance chains and limit potential points of failure. This gives battery developers greater freedom to design new pack architectures. The concept is also not limited to a single cell chemistry or battery type. According to Freudenberg, it can be adapted to different cell formats, pack designs and applications.
Freudenberg combines the connector seal concept with FACT, Freudenberg Adhesive Clean Technology. This technology makes it possible to permanently bond elastomer to connector surfaces that are normally difficult to bond.
An important advantage is that conventional wet-chemical pretreatment is avoided. This can make the production process more efficient and reduce dependence on bonding agents in the supply chain. At the same time, there is considerable design freedom for the connector, for example in terms of electrical conductivity, insulation, weldability and resistance to electrolytes or other battery media.
With connector seals, the focus shifts from optimizing individual components to the complete battery pack. This aligns with the development of modern battery systems, where space, weight, safety and costs are becoming increasingly interconnected.
A single component can contribute to electrical contacting, sealing, insulation and mechanical stability. Connector seals can therefore play a role in more compact and robust battery platforms for automotive and industrial applications.
Source: Freudenberg Sealing Technologies. (2026, August 18). Innovation driver: Connector seals improve design flexibility in battery platforms. https://www.fst.com/news-stories/press-releases/2026/connector-seals/
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