CCS (Cell Contact System), also known as busbar assembly, integrates signal acquisition components (such as wire harnesses, FPC/FCC) with plastic structural elements and copper-aluminum busbars through hot-pressing or riveting processes. This system enables high-voltage series/parallel connection of battery cells while providing temperature and voltage monitoring functions. As a core component of Battery Management System (BMS), it is widely used in new energy vehicle power batteries and energy storage systems. With the rapid development of industries like new energy vehicles and energy storage, the CCS busbar market has been expanding rapidly and is expected to surpass a market value of 10 billion yuan.
Injection molding bracket is a traditional but important integration process in energy storage CCS integrated busbar, which is mainly used in structural support and component fixation of battery modules. The following is the specific application characteristics and advantages and disadvantages of injection molding bracket in energy storage CCS:
1. Composition and process of injection molding bracket
Injection-molded brackets are typically manufactured from flame-retardant materials such as PC+ABS or PA66 through injection molding. Their core function is to securely fasten signal acquisition components, copper-aluminum busbars, and other parts using hot riveting or snap-fit mechanisms, forming an integrated structure. This manufacturing process was widely adopted during the industry's early development phase and features the following characteristics:
Material characteristics: The flame retardation performance meets the safety requirements of battery modules, and needs to pass internal stress test, double 85 test (temperature 85℃, humidity 85% environment), high and low temperature impact test and other verification.
Process maturity: injection molding process is stable, high structural strength, suitable for mechanical strength requirements of high application scenarios.
2. Application advantages in energy storage scenarios
Structural stability: The heavy weight of the injection molding bracket gives it an advantage in fixed energy storage systems, especially in indoor energy storage scenarios that do not require frequent movement, and can withstand static loads during long-term operation.
Adaptability: Although the large size injection molding bracket is difficult to form, the solution of splicing partition plate (dividing the whole bracket into multiple pieces) can reduce the cost and difficulty of mold development, which is suitable for the flexible layout requirements of energy storage battery module.
3. Limitations and directions for optimization
Weight and space constraints: Injection-molded brackets are relatively heavy, which may affect the energy density and space utilization of battery packs. As a result, they are increasingly being replaced by lightweight solutions (such as hot-pressed films) in new energy vehicles. However, in the energy storage sector, where space and weight sensitivity are less critical, their disadvantages are relatively mitigated.
4. Comparison with other processes
Compared with lightweight processes such as thermoformed insulation board and hot pressed insulation film, injection molding bracket has better stability and sealing insulation performance. Therefore, injection molding bracket is often used in energy storage system for scenarios with high structural strength requirements and relatively stable environment.
The application of injection-molded brackets in energy storage CCS demonstrates the reliability advantages of traditional processes, particularly suitable for stationary energy storage scenarios. In the future, with the increasing demand for lightweight solutions, these brackets may gradually integrate with new technologies such as hot pressing and flat-plate structures to form a hybrid technical approach that meets diverse needs.
Founded in 2008, Donho Mold is a high-tech enterprise specializing in precision mold design and manufacturing, as well as integrated solutions for precision injection molding. The company's product range includes energy storage battery plastic injection-molded components, CCS integrated busbar isolation plates, injection-molded brackets, and plastic cover plates.
Energy Storage Battery CCS Integrated Busbar Injection Molding bracket manufacturer-Donho Mold
October. 16, 2025
