Battery Module CCS System Technology

Through simplified design, optimized current paths, and intelligent thermal management, the integrated busbar technology in battery module CCS systems is emerging as a key innovation for reducing electric vehicle battery costs.

As lithium battery engineers, we are constantly seeking solutions to lower battery costs and enhance performance. The Cell Contact System (CCS) represents such a revolutionary technology. Its integrated design replaces traditional complex wiring harnesses, delivering a more efficient and reliable connection solution for electric vehicle battery packs.

Currently, batteries account for 40%-50% of an electric vehicle’s total cost. The CCS integrated busbar technology for battery modules reduces battery costs during initial manufacturing while extending battery life through optimized current paths and thermal management. This holds significant importance for the widespread adoption of electric vehicles.

I. Battery Module CCS Integrated Busbar: The “Neural Network System” of the Battery Pack

The battery module CCS integrated busbar serves as the critical interconnect between cells within the battery pack. It comprises signal acquisition components (FPC, PCB, FFC), plastic structural parts, and copper/aluminum busbars, forming an integrated structure through hot pressing or riveting processes.

Compared to traditional wiring harness solutions, the battery module CCS integrated busbar offers significant advantages: Part count reduced by over 50%, spatial thickness decreased by 30%, and assembly automation greatly enhanced. This integrated design not only lowers manufacturing costs but also improves battery pack reliability and energy density.

Within the battery pack, the CCS in battery modules serves a dual purpose: enabling high-voltage series/parallel connections of cells to meet voltage and capacity requirements, while simultaneously collecting voltage and temperature signals from each cell to provide critical data for the Battery Management System (BMS).

II. Technical Advantages: Why CCS is the Future Trend

Space Utilization and Weight Reduction

The slim design of CCS integrated busbars in battery modules significantly enhances space utilization within battery packs. Taking the FPC solution as an example, its thickness ranges from just 0.1 to 0.3 mm—far less than the space occupied by traditional wiring harnesses. This is crucial for boosting battery pack energy density, as every 1% increase in space utilization can translate into additional driving range.

Automated Production and Cost Control

Traditional wiring harness assembly relies on manual labor, whereas CCS integrated busbars for battery modules are suited for fully automated production, significantly improving manufacturing efficiency and consistency. With the growth in new energy vehicle sales, the CCS market for battery modules is expanding rapidly, projected to reach 39.4 billion yuan by 2025. Economies of scale will further reduce costs.

Enhanced Reliability

The CCS integrated busbar features a sealed, integrated design with excellent weather resistance, moisture resistance, and corrosion resistance. Its overcurrent protection circuitry safeguards battery cells, enhancing safety. This reliability is critical for meeting electric vehicles’ 8-10 year battery lifespan commitments.

III. Core Technical Challenges and Solutions

Large Modules and Precision Control

As battery module sizes increase, CCS components must maintain high-precision connections across larger areas. This imposes stringent demands on manufacturing processes—dimensional tolerances must be controlled within ±0.1mm.

Solutions include:

– Employing high-precision die-cutting and stamping technologies to ensure consistency even in interconnection systems exceeding 2 meters in length; Ensuring dimensional stability through precise film shrinkage control during lamination processes.

Thermal Management Challenges

Thermal runaway risks within battery packs represent a primary safety concern. Uneven current distribution within CCS components can create localized hotspots, potentially triggering thermal runaway.

Advanced thermal management solutions include: Employing liquid cooling/direct cooling combined with heat pumps to maintain battery temperatures within the optimal 15-35°C range; Optimizing current paths via U-Turn technology to prevent localized overheating.

Cell Balancing and Lifecycle Management

Cell imbalance significantly impacts battery lifespan. The CCS system within battery modules must collaborate with the BMS to ensure each cell operates at optimal conditions.

Solutions include:

– Adjusting cell states through active balancing technology;

– Precisely monitoring voltage and temperature of each cell for timely anomaly detection;

– Optimizing charge/discharge strategies to prevent overcharging and over-discharging.

IV. Innovative Technologies: Cell-PLX™ and U-Turn Design

Interplex’s Cell-PLX™ battery interconnect system represents the next generation of CCS technology. This lightweight, ultra-flat solution can be customized to help OEMs overcome battery connection challenges.

U-Turn Technology Highlights

The U-Turn design offers an innovative solution to hotspot issues by optimizing current paths. This ensures more uniform current distribution across the entire battery interconnect, preventing hotspots. This design reduces reliance on complex monitoring systems, lowering overall costs.

Precision Manufacturing Processes

Cell-PLX™ employs precision stamping technology to maintain a thin profile of 2-3mm even for large battery interconnects. High-precision die-cutting and lamination processes ensure insulation materials meet strength, temperature, and peel force requirements. Rigorous cleaning processes satisfy both aesthetic and performance standards.

V. Market Applications and Prospects

CCS integrated busbar technology has been widely adopted across mainstream electric vehicle platforms. BMW plans to utilize large cylindrical batteries in its Neue Klasse platform starting in 2025, projecting a 30% cost reduction. Stellantis Group is also developing an “intelligent battery integration system” that directly incorporates inverters and onboard chargers into the battery pack.

With the rapid expansion of the new energy vehicle market, CCS technology holds promising prospects. Global new energy vehicle sales are projected to reach 25.42 million units by 2025 and surpass 52.12 million units by 2030. This growth will create substantial market opportunities for CCS technology.

VI. Future Development Trends

Material Innovation

Next-generation CCS will adopt thinner, lighter high-performance materials to further reduce weight while ensuring safety. High-thermal-conductivity insulating materials will also enhance thermal management performance.

Integration and Intelligence

CCS will integrate more deeply with BMS to enable more precise battery state monitoring and predictive maintenance. Sensor integration will also increase, with individual CCS components potentially incorporating more functions.

Standardization and Modularization

The industry will drive unified CCS standards to reduce development costs and production complexity. Modular design will enable a single CCS platform to accommodate battery packs of varying specifications, enhancing manufacturing flexibility.

Battery module CCS integrated busbar technology is undergoing rapid development. Through integrated design, precision manufacturing processes, and intelligent thermal management, it delivers more efficient and reliable connection solutions for electric vehicle batteries. This technology not only reduces battery costs but also extends battery life by optimizing current paths and thermal management, playing a crucial role in the widespread adoption of electric vehicles.

With the continuous emergence of new materials and processes, CCS technology will continue evolving toward lighter, thinner, smarter, and more efficient designs, providing sustained technological support for the electric vehicle industry. For battery manufacturers and electric vehicle OEMs, mastering advanced CCS technology will secure a competitive edge in future markets.

By reducing battery costs and enhancing performance through technological innovation, we will collectively advance the sustainable development of the electric vehicle industry, contributing to reduced greenhouse gas emissions and improved air quality.