In the rapid development of new energy vehicles, energy storage equipment, grid energy storage, and smart homes, Dongguan Baorui Electronics Co., Ltd., as a leading manufacturer of electronic components, is dedicated to providing high-performance battery connection system solutions. Today, we will delve into the CCS integrated busbar, a key component in modern battery systems, and explore its applications, structural composition, and production process.

CCS Integrated Busbar: A Key Connection Component in Multiple Fields

CCS integrated busbar is a core component in modern battery systems, with its main application areas including:

1. New Energy Vehicles: In the field of new energy vehicles, the CCS integrated busbar is widely used in battery modules to achieve high-voltage series and parallel connections of batteries, as well as the collection of temperature and voltage information. It provides critical data for the BMS (Battery Management System), ensuring the safe operation and high performance of vehicles.

2. Energy Storage Equipment: In the energy storage field, the CCS integrated busbar is used to centralize the energy output of energy storage devices (such as battery packs and supercapacitors) onto an integrated busbar, effectively managing and distributing energy to improve the efficiency and reliability of energy storage systems.

3. Grid Energy Storage: In grid energy storage systems, the CCS integrated busbar enables circuit connections and energy management of battery packs, enhancing the safety and stability of the system. It is an important component in the construction of smart grids.

4. Smart Homes: In the smart home field, the CCS integrated busbar is used in the battery modules of smart home devices to achieve intelligent management and control of devices, providing reliable power support for smart homes.

Structural Composition of CCS Integrated Busbar

The CCS integrated busbar mainly consists of the following components:

1. Signal Acquisition Components

These include FPC (Flexible Printed Circuit), PCB (Printed Circuit Board), and FFC (Flexible Flat Cable). These components are used to collect information such as battery temperature and voltage and transmit this information to the BMS (Battery Management System) for processing, ensuring the safe operation of the battery system.

2. Plastic Structural Components

Plastic structural components are primarily used to support and fix signal acquisition components and other parts, ensuring the stability and reliability of the entire system. They are an important part of the CCS integrated busbar.

3. Copper-Aluminum Busbars

The copper-aluminum busbars are the conductive parts of the CCS integrated busbar, used to achieve high-voltage series and parallel connections between battery cells. They have excellent conductive performance and mechanical strength, ensuring the efficient operation of the battery system.

These components are connected into a whole through processes such as heat pressing or riveting, forming a compact and efficient battery connection system. The CCS integrated busbar has the advantages of being lightweight, highly integrated, well-sealed, weather-resistant, easy to install, and highly automated. It is widely used in new energy vehicles, battery modules for energy storage, and other fields, helping to improve the performance and safety of battery systems.

Production Process of CCS Integrated Busbar

At Dongguan Baorui Electronics Co., Ltd., we adopt advanced production processes to ensure the high quality and reliability of the CCS integrated busbar. The following is our production process:

1,Film Cutting: Use a film cutting machine to cut the insulating film to the required size, producing scrap material S1. At the same time, use a cutting machine to cut the silicone board and Teflon board to the required size.
2,Film Cleaning: After cutting, remove the film from the cutting machine and visually inspect the film for uniformity, removing any substandard film.
3,Pre-Assembly: After cutting the silicone board, Teflon, and insulating film, assemble the Teflon board, silicone board, insulating film, electronic materials, aluminum sheets, and copper sheets in layers as required.
4,Pressing: Place the pre-assembled semi-finished product into a mold and use a press to heat and press at 160°C, ensuring that the insulating film, silicone board, and other materials are tightly bonded.
5,Semi-Finished Product CCD Detection: Use an appearance and visual detection device (CCD) to detect foreign objects, scratches, dents, tab defects, contamination, corrosion, pits, tab burns, and character blurring on the semi-finished product. This is a physical inspection.
6,Welding: Weld metal and plastic components, including laser welding and ultrasonic welding. Metal components are processed using laser welding, while plastic components are welded using ultrasonic welding.
7,Disassembly/Insert Temperature Sensor: Use fasteners such as rivets to assemble various purchased aluminum, copper, and plastic components, as well as temperature sensors, that have been welded and pressed.
8,Finished Product CCD Detection: After the above operations, detect foreign objects, scratches, dents, tab defects, contamination, corrosion, pits, and tab burns on the finished product.

At Dongguan Baorui Electronics Co., Ltd., we are committed to providing high-quality CCS integrated busbar solutions for new energy vehicles, energy storage equipment, grid energy storage, and smart homes. We believe that through continuous innovation and optimization of production processes, we will make greater contributions to the development of the industry.

For more information about the CCS integrated busbar, please contact Dongguan Baorui Electronics Co., Ltd., and we will be happy to serve you.