Applications of Laser Soldering in CCS Busbars

Applications of Laser Soldering in CCS Busbars

日期：2025-05-27    

Mature Application of Songsheng Optoelectronics Laser Welding Technology in CCS Busbars

With the rapid development of the new energy vehicle industry, there are increasing demands for enhanced safety and integration in battery systems. As a critical component of battery modules, CCS busbars (Cell Contact System, battery cover assembly) have become core elements ensuring efficient and stable operation of battery systems by integrating signal acquisition, circuit connections, and energy management functions. In this field, laser welding and soldering technologies have emerged as mainstream processes in CCS busbar manufacturing due to their high precision, efficiency, and non-contact processing advantages. Below, we analyze the mature applications of laser technology from perspectives including technical characteristics, application scenarios, and innovative practices.

New Energy Battery CCS Diagram

I. Composition of CCS Busbars and Laser Process Requirements

The CCS busbar assembly consists of three key components: signal collection elements (FPC/FFC/FDC, etc.), plastic structural parts, and copper/aluminum busbars. It must perform three critical functions: high-voltage series/parallel connections between battery cells, temperature/voltage signal acquisition, and fuse protection. The manufacturing challenges include:

Dissimilar material welding: achieving highly reliable connections between copper/aluminum busbars and flexible circuit boards (FDC/FPC);

Precision processing requirements: trace width and spacing must reach 0.15-0.3mm while avoiding damage to insulation layers;

Production efficiency and environmental friendliness: traditional processes consume excessive materials and cause significant pollution, necessitating green and efficient alternative solutions.

II. Application of Laser Soldering in CCS Busbars

FPC-to-nickel sheet connection: CCS busbars typically use FPC as signal collection components, and laser soldering can create robust connections between FPC and nickel sheets. Laser soldering uses laser as the energy source to act on solder material, achieving welding in the target processing area. During the welding process, the laser energy is absorbed by metal particles in the solder paste, rapidly raising the temperature to the melting point. Upon cooling and solidification, this forms secure electrical and mechanical connections that effectively solve dissimilar metal welding challenges while avoiding issues like cold solder joints, burn-through, splattering, and misalignment.

FPC pre-tinning: In CCS production processes, laser soldering can be used for FPC pre-tinning. By precisely controlling the laser's energy and duration, an appropriate amount of solder paste can be melted and evenly deposited at specified locations on the FPC, preparing for subsequent welding steps and improving welding quality and consistency.

Dual-Station Solder Paste Laser Welding Diagram

NTC Component Soldering
NTC (Negative Temperature Coefficient thermistors) serve as critical temperature-sensing elements in CCS busbars. Laser soldering enables precise attachment of NTC chips to FPCs or other circuit boards. The laser's micron-level positioning accuracy and localized heating characteristics ensure the NTC chips remain unaffected by thermal overload during welding while guaranteeing joint reliability, thereby achieving accurate temperature monitoring functionality.

FOB (Board-to-Board) Welding Applications
In CCS busbar FOB interconnections, laser soldering plays a vital role by creating robust connections between FPCs and other circuit boards/connectors. Through precise laser parameter control and welding path programming, it delivers high-quality joints in confined spaces, meeting CCS busbars' stringent electrical and mechanical performance requirements.

III. Technical Advantages & Industry Value

Songsheng Optoelectronics' laser soldering systems provide CCS busbars with multidimensional benefits:

Precision & Consistency
Controlled energy input prevents thermal damage while ensuring micron-scale joint uniformity (≤±5μm positioning repeatability).

Process Flexibility
Compatible with diverse pad geometries and materials (copper/aluminum), accommodating varied CCS design specifications.

Cost & Efficiency Optimization
Proprietary solder ball techniques and FCC solutions reduce material costs by 25% while boosting throughput by 40% versus conventional methods.

Automated Production Integration
Seamless integration with CCD inspection and fume extraction systems enables real-time quality monitoring and particulate recycling, minimizing resource waste.

Energy & Environmental Benefits
Consumable-free process with 30% higher energy efficiency than resistance soldering.

Songsheng Optoelectronics' innovative laser soldering technology provides foundational support for high-performance, cost-effective CCS busbar manufacturing. As new energy vehicles and energy storage industries expand, laser welding adoption in battery modules will continue growing exponentially.