A Comprehensive Guide to CCS Integrated Busbars for EV Battery Packs
What is CCS on a Battery?
CCS, short for Cells Contact System, refers to an integrated busbar system that combines conductive busbars, control circuits (such as voltage and temperature sensors), and other components into a single modular unit. It plays a critical role in the internal electrical architecture of battery modules.
By consolidating multiple functions into one system, CCS enhances the integration, reliability, and safety of battery systems. It also helps reduce assembly complexity, save space, lower production costs, and simplify maintenance.
Advantages of CCS Busbar for EV Battery Packs
- High Integration: Multiple functions are integrated into one module, reducing the number of components and wiring complexity.
- Enhanced Reliability: The integrated design improves system stability and reduces failure rates.
- Lightweight Design: With compact architecture and lightweight materials, CCS helps lower overall vehicle weight and improve energy efficiency.
- Improved Production Efficiency: Simplified assembly processes and high automation levels reduce labor costs and improve manufacturing throughput.
- Ease of Maintenance: Modular design allows for easier maintenance and component replacement, reducing downtime and service costs.
CCS Structure and Classifications
CCS systems vary based on the type of signal acquisition component used, and include several solutions such as wire harnesses, PCB, FPC, FFC, FDC, and FCC. Various integration techniques are employed, including injection-molded brackets, vacuum-formed plates, hot pressing, and die-cut PET films. The industry currently sees multiple technical paths coexisting and evolving.
Common Materials Used in CCS Include:
- Hot-pressed insulation film
- Aluminum busbars
- Vacuum-formed trays
- Injection-molded structural brackets
- PCB/FPC/FFC signal acquisition components
| Type | Signal Acquisition Component | Common Integration Techniques |
| Wire Harness | Traditional Wiring Harness | Injection-molded bracket; Thermal riveting process with vacuum-formed tray (blister riveting process) |
| PCB | Printed Circuit Board | Hot pressing process; Thermal riveting process with vacuum-formed tray (blister riveting process) |
| FPC | Flexible Printed Circuit | |
| FFC | Flexible Flat Cable | |
| FDC | Flexible Die-cut Circuit | |
| FCC | FFC connected with FPC or FDC |
Overview of CCS Variants for EV Batteries
Each CCS implementation offers unique benefits depending on the application scenario:
1. Wire Harness Solution
Structure: Wire harness + acquisition terminals + NTC sensors + aluminum busbar + injection/vacuum-formed bracket
Features: Cost-effective and stable signal transmission, but with lower automation potential.
2. PCB Solution
Structure: PCB + nickel strips + aluminum busbar + hot pressing with PET film or vacuum thermal riveting
Features: Lightweight, high automation, and excellent signal integrity.
3. FPC Solution
Structure: FPC + nickel strips + aluminum busbar + hot pressing with PET film or vacuum-formed plate
Features: Ultra-lightweight with high automation and stable signal transmission, though with higher costs.
4. FFC Solution
Structure: FFC + nickel strips + aluminum busbar + PET film hot pressing or vacuum thermal riveting
Features: Lightweight, low cost, high automation—ideal for long-format battery modules.
5. FDC Solution
Structure: Die-cut flexible circuits using rotary die technology
Features: Fewer processing steps, low cost, and suitable for mass production.
6. FCC Solution
Structure: FFC as the main body with soldered FPC or FDC branches through window openings
Features: An emerging cost-effective solution still under evaluation and testing.
Key Considerations for CCS Design and Manufacturing
1. Material Selection & Integration Process
The choice of conductive (copper, aluminum) and insulating materials, as well as integration techniques like hot pressing and riveting, greatly impacts performance, safety, and durability.
2. Automation & Manufacturing Efficiency
High levels of automation are essential for scale and cost control. However, due to differing requirements across battery and vehicle manufacturers, semi-automated processes may offer better return on investment at lower volumes.
3. Signal Transmission Reliability
Ensuring stable and accurate transmission of voltage and temperature data is crucial. PCB and FPC solutions perform well in this regard but come at a higher cost.
4. Lightweight Design & Cost Control
As electrification continues to grow, CCS must balance performance, weight reduction, and affordability. FFC and FDC solutions offer promising trade-offs, but continuous optimization is necessary.
5. Safety & Protection Features
CCS must provide overcurrent protection, corrosion resistance, and thermal stability. Design considerations must include cell-level protection to ensure safe operation under extreme conditions.
6. Thermal Management
Proper heat dissipation and thermal balance within the battery pack are vital. CCS design must support efficient thermal management through material selection and structural layout.
7. Quality Control & Testing
Rigorous quality assurance is key to reliable CCS performance. This includes testing electrical performance, mechanical durability, and environmental adaptability to ensure consistent results across operating conditions.
8. Market Competition & Innovation
With growing competition, CCS manufacturers must innovate in process technologies, improve product quality, and reduce costs to stay competitive.
Our CCS Technology for EV Battery Packs
Our intelligent integrated CCS technology, featuring a fully integrated design that replaces the traditional complex approach of “wiring harness + BMS + temperature sensors.” By integrating multiple cell state detection components directly into the system, we achieve a streamlined, intelligent solution.
Starting from the battery cell level, our CCS system establishes a multidimensional safety architecture—combining active and passive protection mechanisms and system-level thermal runaway risk management. Centered on real user needs, our solution delivers smarter, safer, and more reliable battery management—putting safety at the core.
Cost-Effective
Standardized integrated systems enhance quality and production efficiency, significantly improving PACK assembly speed while reducing overall costs. The use of standardized components greatly simplifies the assembly process.
Ultimate Safety
Superior insulation and high-voltage withstand capability reduce the risk of accidents. The design minimizes common issues associated with traditional sampling harnesses, such as insulation failure, aging, breakage, and short circuits.
Highly Integrated
Combines sampling harnesses, aluminum busbars, temperature sensors, as well as internal PACK components like air pressure sensors, explosion-proof valves, electrolyte leakage detection, and BMS acquisition boards—offering a comprehensive and highly reliable active safety solution.
- Discover our tailored EV battery solution here: https://brogenevsolution.com/ev-battery/
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