Product Description

The Battery Cell Contact System (CCS) with Integrated Busbar is a key electrical and signal interface inside lithium battery modules. It integrates conductive busbars, voltage and temperature sensing circuits, insulation layers, and structural components into a compact module.

The CCS performs several critical functions:

• High-voltage cell series and parallel interconnection

• Voltage sampling for each cell

• Temperature sensing via NTC sensors

• Overcurrent protection through integrated fuse structures

With its integrated design, the CCS offers:

• High structural integration

• Reduced wiring complexity

• Improved reliability

• Compact module layout

• Compatibility with automated assembly

This makes it a standard solution for modern battery packs used in energy storage systems and electric vehicles.

Features of the CCS with Integrated Busbar

This CCS solution integrates aluminum busbars, signal acquisition components, insulation materials, and mechanical support structures into a compact assembly. The integrated design minimizes discrete wiring, optimizes internal space utilization, and supports high integration levels required by modern ESS battery modules. The product is highly customizable and can be adapted to different module sizes, cell arrangements, and BMS interfaces.

CCS Signal Collection Types

To meet different performance, weight, automation, and cost requirements, CCS systems are available in several signal collection configurations.

1. FPC-Based CCS (Flexible Printed Circuit)

Typical Structure:

FPC + nickel tabs + aluminum busbar + thermoformed or heat-pressed insulation

Features:

· Ultra-lightweight structure

· Excellent flexibility and insulation performance

· Integrated voltage and temperature sensing

· High automation compatibility

· Higher cost compared to wire harness or FDC solutions

Typical Use:

High-performance ESS or EV battery modules requiring lightweight design.

2. FCC Hybrid CCS (Flexible Cable + Die-Cut Circuit)

Typical Structure:

FFC main cable + windowed soldered FPC or FDC branches

Features:

• Hybrid signal collection structure

• Voltage sampling without nickel tabs

• Direct ultrasonic welding to aluminum busbars

• Reduced material cost

• Optimized manufacturing process

Typical Use: 

Next-generation battery modules and cost-optimized high-volume projects.

3. PCB-Based CCS (Rigid Printed Circuit Board)                                              

Typical Structure:

PCB + nickel tabs + aluminum busbar + thermoformed or heat-pressed insulation

Features:

• Integrated signal acquisition design

• Lightweight and compact structure

• Stable and reliable signal transmission

• High automation compatibility

Typical Use:

Battery modules requiring high integration and automated assembly.

4. FDC-Based CCS (Flexible Die-Cut Circuit)

Typical Structure:

Die-cut flexible circuit + aluminum busbar

Features:

• Simplified manufacturing process

• About 30% lower process cost compared to FPC

• Shorter production cycle

• Environmentally friendly process

• Suitable for high-volume production

Typical Use:

Mass-production ESS battery modules focusing on cost efficiency.

5. FFC-Based CCS (Flexible Flat Cable)

Typical Structure:

FFC + nickel tabs + aluminum busbar + thermoformed or heat-pressed insulation

Features:

• Lightweight structure

• Suitable for long battery modules

• Stable signal transmission

• High automation compatibility

• Cost-reduction potential compared to FPC

Typical Use:

Large or elongated battery module designs with cost optimization goals.

6. Wire Harness CCS

Typical Structure:

Wire harness + sampling terminals + NTC + aluminum busbar + molded or thermoformed support

Features:

• Mature and widely used technology

• Stable and reliable signal transmission

• Separate wiring for voltage and temperature sensing

• Cost-effective solution

• Lower automation level compared to integrated circuit solutions

Typical Use:

Cost-sensitive ESS modules and conventional battery pack designs.

Applications in Energy Storage Systems

The CCS with Integrated Busbar is widely used in:

• Commercial and industrial energy storage systems

• Containerized ESS solutions

• Grid-scale lithium battery systems

• Electric vehicle battery packs

• High-capacity modular battery systems

By ensuring reliable electrical connections and accurate signal feedback to the BMS, the CCS improves system safety, assembly efficiency, and long-term operational stability.

Price of the Battery Cell Contact System (CCS)

The price of a CCS with Integrated Busbar depends on several factors, including signal collection type, busbar material, module size, design complexity, and order quantity.

Pricing is typically quoted under EXW, FOB, or CIF terms based on project requirements. For accurate pricing, it is recommended to consult the manufacturer with detailed technical specifications.

Manufacturer Information

Dagong ESS provides customized Battery Cell Contact System (CCS) solutions designed for modern energy storage battery modules. With experience in both ESS systems and battery structural components, Dagong ESS supports multiple CCS architectures to match different performance, automation, and cost targets.

For projects requiring tailored CCS designs, technical drawings and system requirements can be provided for engineering evaluation.

If you are interested in the Battery Cell Contact System (CCS) with Integrated Busbar and would like more technical details or a customized solution, please feel free to contact Dagong ESS.

Item	Specification
Product Type	Battery Cell Contact System (CCS) with Integrated Busbar
Application	Energy Storage Systems (ESS)
Busbar Material	Aluminum / Copper (optional)
Signal Collection	FPC /FCC / PCB / FDC / FFC / Wire Harness
Voltage Sampling	Supported
Temperature Sampling	Supported
Overcurrent Protection	Optional (FIC or fuse structure)
Insulation Material	PET / PI / Engineering plastics
Customization Support	Yes
Assembly Method	Manual or automated assembly

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