Application of CCS Integrated Busbar Replacing Sampling Harnesses in Battery Modules-JONVER

Application of CCS Integrated Busbar Replacing Sampling Harnesses in Battery Modules

2025/4/8 10:33:33

The CCS (Cell Contact System) integrated busbar is primarily composed of signal acquisition components, plastic structural parts, copper/aluminum busbars, and other elements. It is connected into a single unit through processes such as thermal lamination or riveting. Applied in new energy vehicle and energy storage battery modules, it enables high-voltage series/parallel connections of cells, temperature sampling, and cell voltage sampling. The collected temperature and voltage data are transmitted to the BMS (Battery Management System) via signal acquisition components and connectors, making the CCS a part of the BMS.

Figure: CCS Applied in Liquid-Cooled PACK

As a critical electrical interconnection component within battery packs/modules, factors such as cell grouping methods, battery pack calibration parameters, operating environments, and requirements for internal space and weight influence the design of CCS components, manufacturing processes, and material selection. To meet diverse application demands, CCS products are continuously evolving, with upgrades to signal acquisition components and integration processes. Multiple technical approaches have emerged, including sampling solutions such as wiring harnesses, PCBs, FPCs, FFCs, FDCs, and FCCs, as well as integration solutions like injection-molded brackets, spliced structures, PET thermal laminates, and vacuum-formed isolation plates.
Previously, we introduced the CCS Integrated Busbar Technical Pathways and Signal Acquisition Components. Today, we explore CCS integration solutions.

1. Injection-Molded Bracket + Riveting Process
In the early stages of industry development, CCS products primarily adopted injection-molded brackets. Components such as brackets, signal acquisition modules, and copper/aluminum busbars were fixed via thermal riveting or snap-fit connections.

Figure: Wire Harness CCS Using Injection-Molded Bracket + Thermal Riveting

Injection-molded brackets are typically made of flame-retardant PC+ABS or PA66. The plastic parts must pass tests such as internal stress, dual 85 (85°C/85% humidity), and high/low-temperature cycling. They offer advantages like robust mechanical strength, structural stability, and mature, reliable manufacturing processes.

However, the thickness and weight of injection-molded brackets reduce the internal space utilization and energy density of battery packs. Additionally, large-sized CCS brackets face challenges in molding due to limitations in injection molding machine capacity, high mold development complexity, and equipment costs. To address this, the industry developed spliced isolation plate solutions, replacing monolithic brackets with multiple spliced support plates to reduce molding difficulty and equipment investment.
2. Vacuum-Formed Isolation Plate + Thermal Riveting
CCS vacuum-formed isolation plates are produced using flame-retardant PC films through vacuum forming and cutting. They are integrated with signal acquisition components and aluminum busbars via thermal riveting.

Figure: FPC-CCS Using Vacuum-Formed Integration

Replacing injection-molded brackets with thinner, lighter vacuum-formed plates reduces weight, improves space utilization, and offers cost advantages due to lower mold costs, reduced equipment investment, higher production efficiency, and flexibility.
However, vacuum-formed plates are relatively thin, with weaker load-bearing capacity, and may suffer from issues like dimensional shrinkage and instability.

3. Thermal Lamination with Insulating Film
The thermal lamination process for CCS integrated busbars uses PET insulating films instead of traditional isolation plates. Components such as aluminum busbars and signal acquisition modules are laminated into a thin sheet via heating and adhesion. This approach reduces product volume, weight, and part count, resulting in a thinner, more compact CCS structure with high integration, reliable insulation, and automated assembly. It aligns with industry trends toward lightweight, integrated designs and large-format modules, driving rapid adoption in recent years.

Figure: Thermal Lamination Process for CCS Integrated Busbar

Compared to injection-molded or spliced structures, thermal-laminated CCS is thinner and lighter. Relative to vacuum-formed solutions, it achieves full integration and higher structural stability. However, challenges include high equipment costs, long lamination times, lower production efficiency, and higher overall costs.

Figure: Comparison of Thermal-Laminated CCS and Vacuum-Formed CCS

4. Flat Plate Structure + Riveting
Beyond the mainstream integration methods above, new technologies are emerging to further reduce costs. For example, REPT BATTERO’s patent (filed in September 2022) describes a flat plate structure: the CCS integrated busbar uses a planar insulating support plate, with signal acquisition components and aluminum busbars fixed via rivets. This approach reduces production costs compared to injection-molded/vacuum-formed/thermal-laminated solutions.
However, this structure may not suit the vibration-intensive environments of new energy vehicle batteries. It is better suited for stationary applications like indoor energy storage systems.
Specific process details can be found in the patent documentation, and products using flat plate/rivet integration have been showcased at exhibitions.
Conclusion
The CCS (Cell Contacting System) integrates three cutting-edge processes: laser welding, ultrasonic bonding, and modular assembly. This comprehensive approach spans the entire workflow from precision processing of copper-aluminum busbars to multimodal integration, with each method offering distinct advantages in conductivity, thermal management efficiency, and scalability.

Figure 7

JONVER's newly developed CCS, custom-designed for LG, demonstrates the company's technical expertise in advanced busbar integration technologies.

Figure 8

Different CCS integration processes offer distinct advantages.End users can select the optimal integration strategy based on specific application requirements, whether prioritizing energy density (e.g., EV battery packs), thermal stability (e.g., grid-scale storage), or field adaptability (e.g., modular power systems). JONVER's proprietary multi-process compatibility framework allows hybrid configurations.

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