Custom FusionLug® for Battery Jumper


The customer needed to link lithium-ion cells to create a battery for an electric car. The links needed to be flexible and low-profile, with a custom hole pattern and a voltage monitoring tap.



Methode's flat copper braid terminated with two custom FusionLugs® provided superior electric contact and power to the battery.


Methode fabricated FusionLugs® on the ends of a flat copper braid. A sense lead was included in the termination of one lug that served as voltage tap. Two diagonal countersink holes were machined on each lug to provide a low-profile, flush surface with the mounting hardware. The lugs met the flatness specification to ensure good electric contact with their mating surface on the cell.

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