Battery Pack Configurations
Discover how battery cells are connected together to create custom battery pack configurations. Our design team helps you choose the optimal configuration for your voltage, capacity, and size requirements.
How to Configure Your Battery Pack
Custom battery pack configurations determine how individual battery cells are connected together to create a complete battery pack assembly. The configuration you choose directly impacts the voltage, capacity, and physical dimensions of your final battery pack.
AceOn's design team can work with you to suggest the most suitable custom battery pack configuration depending on your size requirements as well as your electrical requirements. Our engineers will advise whether to put the battery cells in series or parallel depending on the voltage and capacity you require.
There are many different battery pack configurations that need to be considered when designing a battery pack for your end product. Below you will find the standard battery pack configurations we commonly work with.
Standard Battery Pack Configurations
B Format Configuration
Cells are welded together end to end to create a stick battery pack. Ideal for applications requiring a linear, elongated battery shape.
C Format Configuration
Single layer cells are joined next to each other to create a side by side battery pack. Perfect for flat, wide form factor requirements.
BC Format Configuration
A combination of both B and C formats. Cells are welded together on top of each other and next to each other to create a side by side stick battery pack.
Cluster Format Configuration
Cells are clustered together evenly to create a cluster battery pack. Ideal for circular or cylindrical housing applications.
Standard Format Configuration
Cells are welded side by side in both directions to create a standard battery pack. The most common configuration for rectangular enclosures.
Nested Format Configuration
Cells are welded in between the cell channels to create a nested battery pack. Maximises cell density for compact, high-capacity applications.
Why Battery Pack Configuration Matters
Voltage Requirements
Series connections increase voltage while parallel connections maintain it. Configuration determines your output voltage.
Capacity Needs
Parallel connections increase capacity (Ah). The configuration directly impacts runtime and energy storage.
Space Constraints
Different configurations fit different enclosures. We optimise cell arrangement for your available space.
Thermal Management
Cell arrangement affects heat dissipation. Proper configuration ensures safe operating temperatures.
Need a Bespoke Battery Configuration?
If you have a bespoke battery design requirement, please contact our battery experts who can assist in providing a custom configuration solution tailored to your specific application.