Sun.King Laminated Busbars & CCS

Manufacturing Excellence of Zhejiang Sine Power

Zhejiang Sine Power Co., Ltd. is a specialized manufacturing pillar within Sun.King Technology Group, located in Jiashan High-Tech Industrial Zone, Zhejiang Province.

The facility spans over 30,000 square meters, equipped with high-speed multi-axis CNC punching centers, automated laser cutting lines, multi-chamber ultrasonic chemical cleaning lines, and high-tonnage thermal vacuum lamination presses.

The plant's annual capacity covers millions of laminated busbars and integrated CCS assemblies.

Holding ISO 9001, IATF 16949 automotive certification, and IRIS rail transit accreditation, Sine Power houses an advanced R&D test center.

The laboratory utilizes high-frequency vector impedance analyzers to measure parasitic loop inductance, automated hipot and partial discharge stations rated to 20 kV, and environmental chambers for temperature cycling and salt spray aging.

Electromagnetic Fundamentals of Laminated Busbars

Conventional round cables or discrete flat busbars exhibit parasitic inductance ranging from tens to hundreds of nanohenries.

When high-power IGBT or SiC modules switch heavy currents (500–2000A) at extreme dI/dt slopes exceeding 5000 A/µs, trapped magnetic energy induces severe voltage spikes: U = L * dI/dt. These spikes risk exceeding semiconductor breakdown limits.

Laminated busbars resolve this by utilizing parallel planar plates separated by thin dielectric films (0.1–0.5 mm). Because current flows in opposite directions through adjacent parallel plates, the opposing electromagnetic fields cancel each other almost entirely.

This collapses overall stray inductance to single-digit nanohenries (5–15 nH), stabilizing DC-bus commutation loops.

Dielectric Insulation and Structural Integrity

Sine Power laminated busbars incorporate premium electrical-grade insulation materials possessing dielectric breakdown strengths up to 200 kV/mm: polyimide films (DuPont Kapton), aramid papers (Nomex), polyester dielectrics, and proprietary epoxy prepregs.

The assembled stack undergoes high-temperature vacuum hot pressing to eliminate microscopic air voids.

Eliminating internal voids raises the Partial Discharge Inception Voltage (PDIV) well above maximum working voltage spikes, protecting the insulation from corona erosion over decades of service. Edge perimeters are sealed with flame-retardant epoxy conforming to the UL94-V0 flammability benchmark.

Engineering Configurations for Wind and Solar Inverters

Sine Power busbars tailored for renewable power conversion are designed around high-density power module layouts and DC-link capacitor banks. Terminal connection points utilize precision-bent contact tabs or threaded press-fit stud fasteners electroplated with nickel, tin, or silver.

The custom planar architecture conforms exactly to the power stack envelope, replacing complex, error-prone wiring harnesses with a unified, vibration-resistant structural assembly.

This design streamlines assembly throughput, optimizes cooling airflow across the cabinet, and ensures uniform thermal distribution.

Architecture of Battery Cells Contact Systems (CCS)

In high-voltage EV battery packs and containerized Energy Storage Systems (ESS), hundreds of prismatic or cylindrical cells require series-parallel interconnection.

Cells Contact Systems (CCS) integrate current-carrying busbar tabs, flexible printed circuit (FPC) voltage and temperature sensing lines, and structural insulating carriers into a single drop-in component.

Installing a single pre-tested CCS harness over the battery cell array eliminates manual point-to-point wiring, enabling robotic laser welding of cell interconnect tabs in seconds.

This architecture increases battery pack manufacturing throughput more than fivefold while ensuring consistent electrical and mechanical parameters.

Comparative Analysis: Semi-Film, Full-Film, and Blister Technologies

Semi-film CCS integrates stamped metal busbars and FPC harnesses bonded onto a flexible PET carrier sheet, offering an exceptional balance of mechanical compliance, lightweight construction, and cost efficiency for commercial vehicles and ESS containers.

Full-film CCS encapsulates conductors between top and bottom hot-laminated dielectric films, achieving the absolute minimum vertical height (Z-stack) to maximize volumetric energy density in passenger EVs.

Blister CCS integrates busbars into thermoformed rigid plastic trays with precision guide channels, delivering superior crush resistance and exact laser-weld tab alignment for high-volume automated assembly.

Welding Interfaces and Bimetallic Clad Connectors

CCS interconnect tabs are fabricated from copper, aluminum, or explosively bonded copper-aluminum clad composites (Cu-Al clad).

Bimetallic clad tabs eliminate galvanic corrosion when bridging copper busbar distribution lines to the aluminum positive/negative terminal posts of prismatic battery cells.

Tab thicknesses and geometries are optimized for automated fiber laser welding or ultrasonic metal welding.

Precision stress-relief slots engineered into the tab geometry absorb cell dimensional expansion and contraction during charge-discharge cycling, protecting cell terminal seals from mechanical fatigue.

Precision Thermal Sensing and Safety Protection

To prevent and detect battery cell thermal runaway, Sine Power CCS assemblies embed miniature surface-mount NTC thermistors in direct contact with cell terminal bridge points.

FPC voltage sensing traces feature integrated narrow neck fusible links (trace fuses) that isolate sensing paths during short-circuit faults.

Automotive-grade locking connectors with Terminal Position Assurance (TPA) ensure vibration-proof signal interfaces to the Battery Management System (BMS).

All dielectric plastics and films meet UL94-V0 standards, guaranteeing zero flame propagation and low toxic smoke emission under severe thermal stress.

Quality Assurance, Dielectric Hipot, and Sensor Verification

Every completed laminated busbar and CCS assembly undergoes automated end-of-line functional screening. Quality checks include DC insulation resistance, high-voltage AC Hipot verification (up to 5–10 kV), and high-frequency partial discharge inception testing.

For CCS modules, automated automated test equipment verifies Kelvin 4-wire resistance across all power conductors, checks FPC continuity and insulation, and validates NTC resistance against calibrated temperature tables.

Test metrics are archived in the factory MES database and linked to individual laser-etched 2D DataMatrix serial codes.

Guidelines for Design Submission and Technical Inquiries

To initiate production quoting for Sine Power laminated busbars or CCS battery assemblies, submit complete 3D CAD files in STEP format (AP214/AP242) alongside 2D engineering drawings in PDF/DWG format.

Specify continuous operating currents, peak voltages, Hipot test levels, operating temperature ranges, and contact surface plating preferences.

For CCS inquiries, include the battery pack cell arrangement layout, terminal center-to-center pitch dimensions, BMS connector pinout, and preferred welding method (fiber laser or ultrasonic).

Forward technical files to zakaz@spare24.ru to initiate a Design for Manufacturing (DFM) review and commercial proposal.