Product Introduction: 7.2V 6.5Ah Ni-MH Hybrid Battery Module for Toyota Prius G2 (2004-2009)
This high-quality Nickel-Metal Hydride (Ni-MH) battery module is a direct replacement for the individual cells found within the hybrid traction battery pack of the Toyota Prius (Generation 2, model code XW20) produced from 2004 to 2009 . These prismatic modules are the fundamental building blocks of the vehicle’s high-voltage energy storage system.
Key Specifications
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Nominal Voltage: 7.2 Volts (V)
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Nominal Capacity: 6.5 Ampere-hours (Ah)
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Nominal Energy: Approximately 45 Watt-hours (Wh)
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Physical Design: Prismatic (rectangular) form factor for efficient packing .
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Dimensions (Approx.): 19.6mm (W) x 106mm (H) x 285mm (L)
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Weight: Approximately 1,040 grams (1.04 kg) .
Technical Overview
The second-generation Toyota Prius utilizes a total of 28 of these 7.2V modules connected in series to create the complete traction battery pack, which has a total system voltage of 201.6 volts . Designed and manufactured by Panasonic EV Energy Co. (primarily in collaboration with Toyota), these modules are renowned for their durability and high power output .
Compared to the cylindrical cells used in the first generation, these prismatic modules feature improved specifications :
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Higher Specific Power: Capable of delivering up to 1,300 W/kg, which is essential for the sharp acceleration and regenerative braking demands of the hybrid system .
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Robust Cycle Life: Engineered for automotive applications, these cells are rated for a long service life, often lasting for the lifetime of the vehicle under normal driving conditions. They can withstand thousands of deep discharge cycles, with some estimates suggesting up to 10,000 cycles before capacity degrades to 80% .
Features and Benefits
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Direct OEM Replacement: This module meets the exact specifications required for the 2004-2009 Toyota Prius, ensuring perfect fitment and compatibility with the vehicle’s Battery Management System (BMS) .
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Proven Technology: Ni-MH chemistry is mature, reliable, and has a proven track record in millions of hybrid vehicles worldwide for its safety and longevity .
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Reconditioning Potential: For technicians and specialists, testing and replacing individual weak modules (like this 7.2V unit) is a cost-effective alternative to replacing the entire 201.6V battery pack, provided the remaining modules are in good health .
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Thermal Stability: Designed to operate effectively within a wide temperature range (-30°C to 55°C) and integrates seamlessly with the Prius’s factory cooling system .
Applications
This battery module is specifically designed for:
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Toyota Prius (Model NHW20) : Model Years 2004, 2005, 2006, 2007, 2008, and 2009.
Important Notes for Handling and Installation
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High-Voltage System: While a single module is only 7.2V, connecting 28 of them creates a dangerous high-voltage (201.6V) system. Only qualified technicians with proper training and safety equipment (such as insulated gloves and tools) should attempt to service the hybrid battery pack .
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Module Matching: When replacing individual modules within a pack, it is critical to use modules with similar voltage and state of health to ensure balanced performance and longevity of the entire assembly .
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Conditioning: Used or reconditioned modules should be tested and cycled to ensure they meet voltage and capacity specifications (a healthy module typically reads between 7.4V and 8.0V) before installation .
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