Lithium-Ion Battery Connector Types & Features

Categories: Lithium-ion BatteryTags: , , , Published On: May 20th, 2024By Views: 35

Choosing the Right Battery Connector for your application

Have you ever wondered how your device stays charged and ready for use? It’s all thanks to battery connectors! These tiny but powerful components play an important role in ensuring a steady supply of power to our gadgets.

Let’s explore the world of battery connectors, from the various battery connector types to their unique features, to help you understand how they keep our devices running smoothly. In addition, Saphiion will provide some expert advice on how to choose the right battery connector for your application.

Battery Connector Types

When it comes to connecting lithium-ion batteries, a variety of connectors come into play, each with its own unique features and applications. From the compact JST connectors to the heavy-duty Anderson Powerpole connectors, these connectors ensure a secure and efficient power transfer. Now, let’s explore the common types of connectors used for lithium-ion batteries, including JST, Molex, DC connectors (DC5521, DC5525), XT connectors (XT30, XT60, XT90), Deans (T-plug) connectors, Anderson Powerpole connectors, and bullet connectors. Let’s dive in and uncover the diverse world of battery connectors!

Connector TypeCurrent Ratings (General Range)
JST Connector1~3A
Molex Connector5A
DC5521 Connector3A
DC5525 Connector5A
XT30 Connectorup to 30A
XT60 Connectorup to 60A
XT90 Connectorup to 90A
Deans (T-plug) Connectorup to 40A
Anderson Powerpole Connector15A~300A

1.  Molex Connector

  • Description: Molex connectors are widely used across industries for their reliability and adaptability.
  • Current Ratings:  The current ratings of Molex connectors vary depending on the specific series, size, and configuration of the connector.
  • Features: Customization options, secure connection, available in wire-to-board, wire-to-wire, and board-to-board configurations.
  • Applications: Consumer electronics, automotive electronics, industrial automation, medical devices and healthcare equipment, telecommunications and networking, and Lighting and LED applications.

2.  JST Connector

  • Description: Compact and lightweight, JST connectors available in various sizes and configurations and it’s ideal for small-scale electronics and low-power applications.
  • Current Ratings: Current ratings vary depending on the specific JST connector type.
  • Features: Lightweight, easy assembly, secure connection, compact size.
  • Applications: Consumer electronics, portable devices.

3.  DC Connectors (DC5521, DC5525)

  • Description: DC connectors consist of a male plug and a female socket, typically with cylindrical or barrel-shaped housings. The male plug features a central pin or post (positive terminal) surrounded by a cylindrical sleeve (negative terminal), while the female socket has a corresponding receptacle.
  • Features: Standardization, polarization, locking mechanisms.
  • Applications: LED lighting, CCTV cameras, surveillance systems, routers, switches, laptops, networking equipment, power adapters, audio equipment (such as amplifiers and speakers)
  • DC5521: This connector has a 5.5mm outer diameter and a 2.1mm inner diameter, with a center pin (positive) and outer sleeve (negative) configuration. It is commonly used in various electronic devices, including LED lighting, routers, surveillance cameras, and audio equipment.
  • DC5525: Similar to DC5521 but with a 5.5mm outer diameter and a 2.5mm inner diameter. This connector is also widely used in electronic devices and is often found in laptops, monitors, and other portable electronics.

4.  XT Connectors (XT30, XT60, XT90)

  • Description: Known for their high current capacity and secure connection, XT connectors are popular in hobbyist projects and electric vehicles.
  • Current Ratings:

XT30: Typically rated for currents up to 30A;
XT60: Typically rated for currents up to 60A;
XT90: Typically rated for currents up to 90A;

  • Features: High current capacity, secure locking mechanism, available in different sizes for various applications.
  • Applications: RC(Remote Control) vehicles, electronic speed controllers (ESCs), drones, electric bicycles and scooters, electric skateboards, industrial equipment, power distribution systems, small-scale robotics projects.

5.  Anderson Powerpole Connectors

  • Description: Anderson Powerpole connectors are synonymous with high current applications, offering a genderless design and versatile configurations. They consist of housing shells that enclose spring-loaded, silver-plated contacts.
  • Current Ratings: Available in various current ratings, typically ranging from 15A to over 300A, such as 15A, 30A, 45A, 75A, 120A, 180A, 350A (for heavy-duty applications).
  • Features: High current capacity, durable construction, reliable connection, available in various sizes and configurations.
  • Applications: Amateur radio, electric vehicles, electric bikes, electric scooters, Robotics and automation, renewable energy systems, and military and aerospace applications.

6.  Deans (T-plug) Connector

  • Description: Deans connectors, also known as T-plug connectors. Deans connectors typically consist of two gold-plated connectors – one with a protruding pin and the other with a socket – to create a secure electrical connection. These connectors are renowned for their low resistance and reliable performance.
  • Current Ratings: vary depending on the specific model and configuration.
  • Features: Low resistance, secure connection, genderless design for easy assembly.
  • Applications: RC vehicles (Used in electric cars, trucks, airplanes, helicopters, and boats to connect batteries to electronic speed controllers (ESCs) and motors), power distribution systems, battery packs.

7.  Bullet Connector

  • Description: Simple yet effective, bullet connectors provide a secure and low-resistance connection, making them popular in RC vehicles and power distribution systems.
  • Current Ratings: Bullet connectors come in various sizes and current ratings, ranging from a few amps to several dozen amps, depending on the diameter and material of the connectors. Common sizes include 2mm, 3.5mm, 4mm, and 5mm.
  • Features: Easy assembly, low resistance, secure connection.
  • Applications: RC vehicles, electric motors, power distribution systems, automotive electronics.
  • 2mm Bullet = 25 Amps
  • 5mm Bullet = 50 Amps
  • 4mm Bullet = 90 Amps
  • 5mm Bullet = 120 Amps
  • 5mm Bullet = 130 Amps
  • 0mm Bullet = 150 Amps
  • 5mm Bullet = 160 Amps
  • 0mm Bullet = 200 Amps +

How to choose the right battery connector for your application?

When choosing a connector type for your lithium-ion battery system, it’s important to consider factors such as battery applications, voltage and current ratings requirements, physical size constraints, durability, and compatibility with other components in your system. Additionally, ensure that the chosen connector type complies with any relevant industry standards or regulations and proper installation and handling to maintain safety and reliability.

Key Considerations for Connector Selection

  • Voltage and Current Rating: Determine the voltage and current ratings requirements of your application. It will help you to ensure the connector can handlepower demands without overheating or degradation.
  • Connector Type:Evaluate the different types of connectors available and choose one that suits your specific needs. Consider factors such as current rating, size, and compatibility with existing components.
  • Size and Form Factor: Choose a connector that fits the physical constraints of your device or project.Ensure there is enough clearance for the connector to be securely attached without causing interference with other components.
  • Durability: Consider the environmental conditions in which the connector will be used. If your application requires connectors to withstand high temperatures, moisture, or vibration, then choose connectors with appropriate sealing and rugged construction.
  • Compatibility: Ensure compatibility between the chosen connector and other components in your system, including batteries, cables, and devices. Verify that the connector’s pin configuration and size match those of the mating connectors to prevent compatibility issues.
  • Safety Features:Look for connectors with built-in safety features like polarization and locking mechanisms to prevent accidents or damage.

If you’re unsure about which connector to choose or have specific requirements for your application, don’t hesitate to contact Saphiion to consult more details. We can offer guidance and recommendations based on our experience and expertise.

What are the electric bicycle battery connector types?

These are some of the common connector types used in e-bikes to connect battery packs to motor controllers or other electrical components, such as XT30, XT60, XT90 connectors, Anderson Powerpole connectors, Deans (T-plug) connectors, Bullet connectors, DC5525 connectors. The specific connectors used may vary depending on the e-bike manufacturer and the design of the battery pack. It is essential to ensure compatibility between the battery connector and the rest of the electrical system to ensure proper operation and safety.

Conclusion

In essence, our dive into lithium-ion battery connectors shows just how vital they are for keeping our electronic devices running smoothly. When we pick connectors that provide strong, secure connections and can handle the right amount of current and voltage, we’re protecting our devices from problems like power loss, overheating, and electrical faults. This means our gadgets can last longer and perform better, giving us peace of mind knowing they’re reliable when we need them most.

Saphiion specialize in providing tailored lithium-ion battery pack solutions to meet the unique requirements of our clients across various industries. We stand behind the quality of our lithium-ion batteries with comprehensive warranties and dedicated customer support. Our team is available to assist you with any questions or concerns you may have, ensuring a positive experience with our batteries.

Contact us at info@saphiion.com to explore the possibilities and find the suitable 18650 & 21700 customs battery packs for your needs.

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