The CCS integrated busbar is a type of electrical connection structure within a battery module. It perfectly integrates components such as information collection components (e.g., wire harnesses, FPCs, FFCs), plastic structural parts, and aluminum busbars into a single module. It features high integration, reliability, compact structure, and small size, which can save space and facilitate automated assembly.

The signal collection components and integration processes of the CCS integrated busbar are rapidly developing. Currently, there are various options for CCS signal collection components, including wire harnesses, PCBs, FPCs, FFCs, and FDCs, which can meet the needs of different solutions. Similarly, the integration processes also include injection molding brackets, suction molding plates, heat pressing, and PC die cutting, forming a situation where diverse technical routes are developing in parallel. Signal collection components such as FPCs, FFCs, and FDCs, compared to wire harnesses, have the advantages of being lightweight, flexible, thin, and occupying less space. They are beneficial for product integration, lightweight design, structural regularity, and better utilization of battery space, making them suitable for automated assembly and mass production, and are widely used in the fields of new energy vehicle batteries and energy storage.

Currently, CCS integrated busbars come in various forms, each with its own advantages. Application terminals can choose the best solution according to different application scenarios.

01 Wire Harness-CCS

Common Structure: Wire Harness + Collection Terminals + NTC + Conductive Aluminum Busbar + Injection/Suction Molding Bracket

     The wire harness solution is the earliest CCS integrated busbar design scheme, mainly consisting of signal collection components (such as copper and aluminum busbars), plastic structural parts, and wire harnesses. It is connected into a whole through processes such as heat pressing or riveting.

Features

➢ Integrated structure, mature process

➢ Stable and reliable signal transmission, voltage, and temperature collection both use independent wire harness connections

➢ Cost-effective

This solution can be applied in industrial and commercial energy storage, communication energy storage, home energy storage, portable energy storage, and other occasions.

02FPC-CCS

Common Structure: FPC + Nickel Tabs + Conductive Aluminum Busbar + Suction Molding Plate or PET Film Heat Pressing

The FPC solution involves mounting the signal collection components on a flexible printed circuit board (FPC), and then connecting it to the plastic structural parts through processes such as heat pressing or riveting.

Features

➢ Ultra-lightweight structure, excellent overall strength and insulation performance

➢ Stable and reliable signal transmission, voltage, and temperature collection are achieved through an integrated FPC design

➢ High degree of automation

➢ Relatively high cost

This solution can be applied in industrial and commercial energy storage, communication energy storage, home energy storage, portable energy storage, and other occasions.

03 FFC-CCS

Common Structure: FFC + Nickel Tabs + Conductive Aluminum Busbar + Suction Molding Heat Riveting or PET Film Heat Pressing

      The FFC solution involves mounting the signal collection components on a flexible flat cable (FFC), and then connecting it to the plastic structural parts through processes such as heat pressing or riveting.

Features

➢ Lightweight structure, suitable for long module collection design and cost reduction

➢ Excellent signal collection capability, stable and reliable signal output

➢ High degree of automation

This solution can be applied in industrial and commercial energy storage, communication energy storage, home energy storage, portable energy storage, and other occasions.