Power Battery Pack Cable-CCS

Honflex Electronics offers the Power Battery Pack Cable-CCS, a battery connection and management component that integrates traditional cables (wires, terminals, connectors) with busbars, plastic structural parts, and temperature sensors into a single modular unit. Unlike FPC-based CCS solutions, our Cable-CCS supports full customization. Through modular and integrated design, it systematically upgrades the previously scattered and disorganized sensing harnesses, serving as a key foundational module for battery safety monitoring, state assessment, and performance optimization.

Product Overview

The Power Battery Pack Cable-CCS combines conventional automotive-grade wiring harnesses with isolation boards, busbars, and sensing elements to form a pre-assembled, ready-to-install connection system. Because core welding and connections within the module are completed prior to final assembly, the integration of dozens or even hundreds of discrete assembly points into a few modular components significantly simplifies the production process. This approach reduces rework rates caused by on‑site welding defects or poor assembly.

The integrated structural design effectively resolves issues commonly associated with traditional wiring, such as messy layouts, interference between cables, and wear against other components. By securing wires neatly within plastic brackets, the Cable-CCS improves space utilization and facilitates subsequent maintenance. Furthermore, based on mature automotive wiring processes, the supply chain is well established and raw material costs are transparent. This makes the Cable-CCS an ideal choice for manufacturers seeking a stable upgrade path without transitioning to newer FPC-based processes.

Modular plastic structural components provide unified insulation protection and mechanical fixation for cables and connection points, enhancing the system‘s resistance to vibration and impact, thereby ensuring operational safety.

Structure and Key Features

1. Modular Integrated Design  

Scattered independent voltage sampling lines and temperature sensor lines are consolidated into an orderly wiring harness assembly using connectors and terminals. This fundamentally changes the traditional assembly method of “first laying scattered wires, then connecting terminals”, creating standardized functional units.

2. Reliable Busbar-to-Cell Connections  

Connections between busbars and battery terminals are typically achieved via laser welding. Within the CCS, these connections are realized through crimping, soldering, or integration inside the connector, ensuring overall structural stability and preventing loosening of individual wires.

3. Adaptability for Automated Assembly  

Traditional loose-wire wiring relies heavily on manual assembly. In contrast, the Power Battery Pack Cable-CCS is integrated into a module with a regular shape and clearly defined interfaces, enabling compatibility with higher degrees of automated assembly processes.

4. Hybrid Integration Options  

According to customer design requirements, the Cable-CCS can be combined with FPC or PCBA to form hybrid solutions. Options include “harness + isolation board” or “FPC + vacuum‑formed / harness” configurations, meeting diverse cost, performance, and space constraints.

Technical Specifications

| Parameter | Details |

|-----------|---------|

| Voltage acquisition accuracy | Error within ±5 mV |

| Insulation resistance | > 100 MΩ |

| Contact resistance | Micro‑ohm (µΩ) level |

| Vibration and shock tolerance | Passes rigorous mechanical vibration and shock tests (simulating vehicle operation) |

| Operating temperature range | -40°C to +125°C (or wider) |

| Sealing and protection rating | Meets IP67 |

| Flame retardant rating | Complies with UL94 V‑0 |

| Welding strength | Meets tensile and peel strength standards |

Application Scenarios

The Power Battery Pack Cable-CCS is particularly suitable for:

- Projects sensitive to cost and process transitions, especially battery packs with mature wiring supply systems – requiring minimal changes to improve efficiency and reliability.  

- Medium‑to‑large scale battery modules and energy storage systems.  

- Commercial vehicles and stationary energy storage applications, where the Cable-CCS can serve as part of a composite solution (“harness + FPC” or “harness + PCBA”), leveraging its advantages in high‑current transmission and specific connection types.

Our Value and Commitment

Honflex understands the balancing challenge that the electric battery industry faces among efficiency, reliability, and cost. Based on mature automotive electrical connection technology, our Cable-CCS delivers proven value. Our commitment extends beyond providing high‑quality modules that meet group standards such as the “Technical Requirements for New Energy Battery Connection System (CCS) Components”. We offer comprehensive service capabilities covering structural design, wiring process engineering, automated assembly integration, and full testing validation. We are a reliable partner on your upgrade path for battery pack design and manufacturing.

For further technical discussion on Cable-CCS or comparisons with alternative technologies, please feel free to contact us:

Terry Ding (VP)  

Tel: +86 18750290300  

Email: rding@hon-flex.com

Rick Wang (Business Manager)  

Tel: +86 15959382432  

Email: yhwang@hon-flex.com

Website: http://www.hongflex.com