• Dagong ESS

What Is Battery Module Assembly Technology?

What is Battery Module Assembly Technology?

Battery module assembly technology refers to the structural and electrical integration of individual battery cells into stable, safe, and high-performance modules. Each module typically includes battery cells, stainless steel belts, end plates, busbars, cooling components, and BMS wiring.

Modern LFP battery modules used in ESS focus on high safety, stable mechanical strength, excellent thermal performance, and long-term reliability. These features are particularly important for energy storage systems deployed in homes, factories, microgrids, and renewable energy projects.

Battery module assembly directly influences cycle life, thermal stability, energy density, and the safety performance of the entire ESS.

Types of Battery Module Assembly

• Prismatic LFP Module Assembly

Uses CTP (cell-to-pack) or cell-based module structure

High structural stability

Widely used in Dagong ESS 215kWh Air-Cooled ESS and 372kWh Liquid-Cooled ESS

• Cylindrical Cell Module Assembly

Flexible layout

Good heat conduction and airflow

Used in compact home storage solutions (5–10kWh wall-mounted batteries)

• Pouch Cell Module Assembly

Lightweight

Requires stronger mechanical protection

More common in mobility batteries than ESS

Features of Battery Module Assembly

• Mechanical Stability

Key components such as stainless steel belts, module end plates, and aluminum busbars ensure the module maintains compression stability throughout 8000+ charge cycles.

• Efficient Electrical Connection

Cell Connection Systems (CCS) and aluminum busbars reduce resistance loss and improve current carrying capacity—critical for high-voltage ESS like 5MWh Air-Cooled ESS containers.

• Thermal Management Integration

Heat dissipation plates and liquid cooling channels are integrated into modules for precise temperature control.
This technology is used in Dagong ESS 215kWh and 372kWh Liquid-Cooled ESS.

• Safety & Durability

High-voltage insulation

Fire-retardant separators

Protection films for external packaging
These ensure module reliability under long-term operation.

Applications of Battery Module Assembly in ESS

• Residential ESS

5kWh–80kWh stacked home storage

Wall-mounted 5–10kWh systems
Module assembly affects safety, cycle life, and energy efficiency.

• Commercial & Industrial ESS

100–241kWh air-cooled ESS
Precision assembly improves load stability and reduces internal resistance.

• Utility-Scale Energy Storage

3.35MWh Liquid-Cooled ESS Container

5MWh Air-Cooled ESS Container
Large-scale ESS requires ultra-stable mechanical compression, top-tier busbars, and efficient cooling plate integration.

Price of Battery Module Assembly

The price of battery module assembly varies significantly depending on materials, cell format, cooling method, protection components, and ESS system requirements. Costs should be evaluated based on project scale, energy demand, safety requirements, and long-term operating conditions. It is recommended to consult suppliers for customized technical proposals.

How to Select Battery Module Assembly Technology for Your Project?

• Determine the Cell Type (LFP recommended for ESS)
  LFP modules offer higher safety and longer cycle life for stationary energy storage.

• Choose the Cooling Method

Air-cooled for residential & C&I

Liquid-cooled for high-power industrial ESS

• Evaluate Mechanical Structure
  Look for end plates, busbars, belts, and protection films compliant with industrial standards.

• Assess Compatibility with ESS Systems
  Such as Dagong ESS 144kWh Air-Cooled ESS or 372kWh Liquid-Cooled ESS.

How Long Does Battery Module Assembly Last?

A well-assembled LFP module can achieve 8000+ cycles and 15+ years of lifespan.
Thermal management quality, structural compression, and electrical connection systems directly impact long-term durability.

The Supplier of Battery Module Assembly

High-quality suppliers provide stable mechanical components, precise busbar designs, efficient cooling interfaces, and ESS-ready module configurations. Companies like Dagong ESS integrate advanced module assembly technology into residential, commercial, and utility-scale storage systems, ensuring long-term reliability across global applications.