Wire-Bonded 18650 Lithium-Ion Module · 1S · 5P to 10P · Air-Cooled
Lithium Block™ GEN2
A compact, pack-ready battery module built on ultrasonic wire-bonding. Connectorized cell voltage and temperature sensing on a flex PCB, resettable sense fusing, and integrated M6 busbar threading. Engineered for repeatable assembly from prototype through production.
† 6P through 10P Power Module. 5P Power Module peak is 175 A. Energy Module max discharge: 50 to 100 A by variant. Always validate continuous vs. peak against your thermal path and duty cycle.
Energy Module Molicel M35A
Optimized for capacity and cycle life. Applications include energy storage, long-duration discharge, and range-focused electric vehicles.
| Parameter | 5P | 6P | 7P | 8P | 9P | 10P |
|---|---|---|---|---|---|---|
| Part Number | LBG2-05E | LBG2-06E | LBG2-07E | LBG2-08E | LBG2-09E | LBG2-10E |
| Capacity | 17.5 Ah | 21 Ah | 24.5 Ah | 28 Ah | 31.5 Ah | 35 Ah |
| Energy | 63 Wh | 75 Wh | 88 Wh | 100 Wh | 113 Wh | 125 Wh |
| Voltage (nom / max / min) | 3.6 V / 4.2 V / 2.5 V | |||||
| Max Charge Current | 8.5 A | 10.2 A | 11.9 A | 13.6 A | 15.3 A | 17 A |
| Max Discharge Current | 50 A | 60 A | 70 A | 80 A | 90 A | 100 A |
| Length | 119 mm | 138 mm | 157 mm | 177 mm | 196 mm | 215 mm |
| Mass | 317 g | 374 g | 431 g | 487 g | 544 g | 601 g |
Power Module Molicel P28A
Optimized for high peak discharge and fast charging. Applications include high-performance EVs, FSAE, power tools, and aerospace platforms.
| Parameter | 5P | 6P | 7P | 8P | 9P | 10P |
|---|---|---|---|---|---|---|
| Part Number | LBG2-05P | LBG2-06P | LBG2-07P | LBG2-08P | LBG2-09P | LBG2-10P |
| Capacity | 14 Ah | 16.8 Ah | 19.6 Ah | 22.4 Ah | 25.2 Ah | 28 Ah |
| Energy | 52 Wh | 62 Wh | 72 Wh | 82 Wh | 93 Wh | 103 Wh |
| Voltage (nom / max / min) | 3.6 V / 4.2 V / 2.5 V | |||||
| Std Charge / Max Charge | 14 / 30 A | 16.8 / 36 A | 19.6 / 42 A | 22.4 / 48 A | 25.2 / 54 A | 28 / 60 A |
| Max Discharge (peak) | 175 A | 210 A | 210 A | 210 A | 210 A | 210 A |
| Length | 119 mm | 138 mm | 157 mm | 177 mm | 196 mm | 215 mm |
| Mass | 317 g | 374 g | 431 g | 487 g | 544 g | 601 g |
Peak discharge values. See datasheet for continuous ratings and thermal derating curves. Wire-bond fuse rating: ~58 A/bond (Power), ~30 A/bond (Energy).
Module Overview
Electrical
- Sense Connector
- Molex Micro-Fit 3.0, 8-pin (430450812)
- Sense Fusing
- PTC resettable, 200 mA per line
- Thermistors
- 10 kΩ NTC (β 3380 K, ±0.5%)
- Thermistor Count
- 3 (5P/6P) · 4 (7P through 9P) · 5 (10P)
- HV Terminals
- M6 threaded studs, copper alloy
- Max System Voltage
- 500 Vdc (conductor spacing per IEC 60664)
Mechanical
- Cross-Section (H × W)
- 80.75 × 25.5 mm (fixed)
- Length
- 119 to 215 mm (varies by parallel count)
- Housing
- 15% glass-filled ABS, UL94 V-0 rated resin
- HV Busbar Thread
- M6 × 1 mm (module-integrated)
- Bracketing System (sold separately)
- 6061-T6 aluminum endplates, M4 threaded inserts (55 mm span, 3 to 4 Nm), 25.5 mm busbar hole spacing
Wire-Bond Technology
Every cell-to-collector connection is made with ultrasonic wire bonding, a solid-state process that creates metallurgical bonds without melting metal. No spatter, no flux, no heat damage to cells.
Built-In Fusing
Individual bonds act as fuses under overcurrent. A single bond failure doesn't propagate; the module degrades gracefully instead of failing catastrophically.
Repeatable Quality
Automated bonding with inline pull/shear testing to MIL-STD-883, statistical process control, and full traceability on every module.
Low Resistance
Wire bonds produce consistently low-resistance connections with excellent fatigue life under thermal cycling and vibration.
What Changed in GEN2
GEN2 adds a flex PCB and connectorized interface that GEN1 doesn't have. If you're designing a new pack, start here.
Connectorized Cell Telemetry
Cell voltage and temperature sensing runs on a flex PCB mounted directly against the cells, terminating in a single 8-pin Molex connector. Cleaner data, faster harness assembly, fewer failure points than flying leads.
Resettable Sense Fusing
PTC fuses on every voltage sense line protect the monitoring circuit without requiring service to replace blown fuses. The sense path resets automatically after a fault clears.
HV Busbar Mounting
Integrated M6 threaded inserts on the module for direct busbar attachment. Rigid, repeatable connections without floating nuts or adhesive-mounted hardware.
IPC Class II PCB
The GEN2 board is manufactured and inspected to IPC Class II standards with creepage/clearance per IEC 60664.
Integration & Accessories
BMS Compatibility
Works with any BMS supporting individual cell voltage monitoring and 10 kΩ NTC inputs. Fully compatible with Orion BMS products, available from EVolve.
Included
Each module ships with a mating Molex 43025-0800 LV connector and 43030-0007 crimp contacts.
Available Separately
Custom busbars, bracketing/mounting system, cooling blocks for fan mounting, and M4/M6 fastener kits.
Safety & Compliance
| Standard | Scope | Level |
|---|---|---|
| UN 38.3 | Transport safety | Module level, test report available |
| IEC 62133 | Cell safety | Cell level, manufacturer certified |
| UL94 V-0 | Housing flammability | Resin rating (thickness-dependent) |
| IEC 60664 | Conductor spacing | Module, designed to standard |
| IPC Class II | PCB manufacture | Module, GEN2 flex PCB |
| UL 1973 / IEC 62619 / ISO 12405 | System-level | Pack integration required |
System-level certifications (UL 1973, IEC 62619, ISO 12405) are achieved at the pack or vehicle level and are the responsibility of the system integrator. RoHS compliant. No REACH SVHCs. Responsible mineral sourcing.
Downloads
CAD Models (STEP)
Frequently Asked Questions
What cells does the Lithium Block GEN2 use?
Energy Modules use the Molicel M35A (3.6 V nominal, 3.5 Ah per cell). Power Modules use the Molicel P28A (3.6 V nominal, 2.8 Ah per cell). All cells are procured directly from the manufacturer and individually tested before integration.
What is the difference between Energy and Power modules?
Energy Modules maximize capacity and cycle life, delivering up to 35 Ah and 125 Wh with max discharge up to 100 A. Power Modules maximize discharge rate, reaching up to 210 A peak with fast-charge support up to 60 A. Both share identical housing dimensions at each parallel count, so you can swap module types without changing your mechanical design.
What is wire bonding and why does it matter?
Ultrasonic wire bonding creates solid-state metallurgical bonds between cells without melting metal. Each bond acts as an individual fuse under overcurrent, so a single bond failure doesn't cascade into a catastrophic event. The process also produces lower thermal stress on cells during manufacturing, consistently low connection resistance, and is fully automated with inline quality testing to MIL-STD-883.
What BMS is compatible with the Lithium Block GEN2?
Any BMS that supports individual cell voltage monitoring and 10 kΩ NTC thermistor inputs will work. The GEN2 sense harness terminates in a Molex Micro-Fit 3.0 connector (8-pin). Orion BMS products are fully compatible and available directly from EVolve.
What is the maximum system voltage?
The module supports pack architectures up to 500 Vdc. Conductor spacing on the PCB and within the housing is designed to IEC 60664 requirements. The module is intended for segmented pack designs where series strings build up to the target system voltage.
What accessories are available?
Each module includes a mating LV connector and crimp contacts. Sold separately: custom busbars (sized per configuration), a bracketing and mounting system for multi-module stacks, cooling blocks for fan integration, and M4/M6 fastener kits.
Does the Lithium Block GEN2 have safety certifications?
Cells are IEC 62133 certified. Modules are tested to UN 38.3 for transport safety; test reports are available on request. The housing resin carries a UL94 V-0 flammability rating (thickness-dependent, per supplier datasheet). System-level certifications (UL 1973, IEC 62619, ISO 12405) are achieved at the pack or vehicle level by the integrator.
Designed & Manufactured in Boulder, CO
EVolve Battery Systems has been engineering and building custom lithium-ion packs for over 10 years. Straight pricing, reliable lead times, and real integration support.
Phone: (720) 414-5502 · Email: info@evolvebattery.us