Battery pack CCS assembly and assembling method

Abstract

The invention discloses a battery pack CCS assembly and an assembling method.The battery pack CCS assembly comprises a plastic uptake support and a plurality of conductive aluminum bars, a first mounting unit and a second mounting unit are arranged at the two ends of the plastic uptake support respectively, each of the first mounting unit and the second mounting unit comprises a plurality of mounting subunits, and the mounting subunits are arranged at intervals; each installation subunit comprises a first groove, a second groove and a connecting column, and the first groove and the second groove are arranged in a spaced mode. The connecting column extends and is arranged between the first groove and the second groove. The plurality of conductive aluminum bars and the plurality of mounting subunits are arranged in a one-to-one correspondence manner, each conductive aluminum bar comprises a connecting end located in the middle and extension ends on the two sides, and the connecting ends are provided with connecting through holes corresponding to the connecting columns and are clamped and fixed with the connecting columns. The extension ends on the two sides correspond to the first groove and the second groove respectively, the whole plastic uptake support is light and thin, and the subunits and the conductive aluminum bars are reasonably arranged and installed, so that the number of parts is reduced, and the assembly process is simplified.

Description

Technical Field

[0001] The present invention relates to the technical field of batteries, and in particular to a battery pack CCS component and an assembly method thereof. Background Art

[0002] Conventional wire harnesses in the form of CCS aluminum bars need to be fixed to the blister bracket using a hot riveting process, and then the pressed nickel sheet is fixed to the aluminum bar by laser welding or screwed to the aluminum bar, and the pressed wire harness is fixed to the blister bracket using a cable tie. This method has the disadvantages of low production efficiency, high fixture cost, more labor, and weak screw locking.

[0003] In the conventional FPC form CCS, the pressed nickel sheet is first fixed on the FPC by automatic patching, the aluminum bar and the FPC with the sampled nickel sheet are fixed on the blister bracket by hot riveting, and finally the pressed nickel sheet is welded to the aluminum bar by laser welding. Although this method has high production efficiency and requires less labor, the equipment and fixture costs are high, the material cost is also high, and the total product cost is very high.

[0004] Regardless of whether it is a conventional wire harness form CCS or an FPC form CCS, the blister bracket is assembled on the product as part of the product, and nickel sheet is required as an intermediate medium to connect the aluminum bar and the wire harness or FPC together, which will account for about 1 / 3 of the cost of CCS. Summary of the invention

[0005] In order to overcome the above disadvantages, the object of the present invention is to provide a battery pack CCS component and an assembly method to solve the problems raised in the above background technology.

[0006] In order to achieve the above objectives, the technical solution adopted by the present invention is a battery pack CCS assembly, including a blister bracket and a plurality of conductive aluminum bars, wherein: The blister bracket is provided with a first mounting unit and a second mounting unit at both ends along the first direction, each of the first mounting unit and the second mounting unit comprises a plurality of mounting sub-units, the plurality of mounting sub-units are arranged at intervals along the second direction, each of the mounting sub-units comprises a first groove, a second groove and a connecting column, the first groove and the second groove are arranged at intervals along the second direction; the connecting column extends along the third direction and is arranged between the first groove and the second groove; The multiple conductive aluminum bars are arranged in one-to-one correspondence with the multiple installation sub-units, and each of the conductive aluminum bars is in the shape of a "F" and includes a connecting end located in the middle and extended ends on both sides. The connecting end is provided with a connecting through hole corresponding to the connecting column and is clamped and fixed to the connecting column; the extended ends on both sides are respectively arranged corresponding to the first groove and the second groove, and the first direction, the second direction and the third direction are perpendicular to each other.

[0007] Further, along the third direction, a projection of the first groove and a projection of the second groove both cover a projection of the extended end.

[0008] Furthermore, the battery pack CCS component also includes a sampling harness, which includes a summary harness and multiple branch harnesses, the summary harness extends along the second direction and is arranged between the first mounting unit and the second mounting unit; the multiple branch harnesses are arranged one-to-one corresponding to the multiple mounting sub-units, and one end of each branch harness is connected to the conductive aluminum bar, and the other end is connected to the summary harness.

[0009] Furthermore, each of the mounting sub-units also includes a limit block, which is arranged on one side of the first groove and the second groove along the first direction away from the edge of the blister bracket; the limit block is arranged on the same side as the connecting column, and a wire groove is provided on the top for clamping and fixing the branch wiring harness through the wire groove.

[0010] Further, the wire groove extends along the first direction, and the shape of the wire groove along the third direction is one of a straight line shape and a wavy shape.

[0011] The technical solution adopted by the present invention also includes an assembly method of a battery pack CCS assembly, using the battery pack CCS assembly described above, the assembly method includes a first welding station and a second welding station, wherein: The first welding station includes welding the branch wiring harness and the conductive aluminum bar; The second welding station includes welding the conductive aluminum bar and the battery pack; The specific steps include: S1. Provide a battery pack without CCS integrated busbar, wherein the top of the battery pack is a connection end; S2, placing the aggregated wiring harness between the first mounting unit and the second mounting unit, and placing the plurality of branch wiring harnesses in the mounting sub-units in sequence, and clamping and fixing them in the wire groove of the limit block; S3, sequentially installing a plurality of conductive aluminum bars in the first installation unit and the second installation unit of the blister bracket, wherein the connecting through holes in the conductive aluminum bars are clamped and fixed with the connecting columns in each installation sub-unit, wherein the conductive aluminum bars are located above the branch wiring harness; S4. Flip the assembled wire harness and aluminum bar blister bracket over so that the branch wire harness is located above the conductive aluminum bar, weld and fix the branch wire harness and the conductive aluminum bar in the first welding station, and perform anti-corrosion treatment; S5. Place the welded wiring harness and the blister bracket of the aluminum bar at the connection end accordingly, and weld and fix the conductive aluminum bar to the connection end in the second welding station; S6. Separate the blister bracket from the battery pack.

[0012] Furthermore, the anti-corrosion treatment includes applying glue at the welding point between the branch wiring harness and the conductive aluminum bar.

[0013] Furthermore, the welding method of the first welding station and the second welding station is ultrasonic welding.

[0014] Compared with the prior art, the battery pack CCS assembly and assembly method provided by the present invention have the following beneficial effects: The blister bracket is reused as a jig and is no longer assembled into the product as part of the product, which reduces costs. The sampling harness is directly welded to the conductive aluminum bar by ultrasonic welding, and nickel sheets are no longer used as a transfer medium, which reduces costs. A number of limit blocks and wire grooves are set on the blister bracket corresponding to the sampling harness to clamp and fix the harness. A number of connecting columns are set on the blister bracket, which cooperate with the conductive aluminum bar to form an inverted structure to better fix the aluminum bar. This solution has a simple structure and manufacturing process, uses less tools and requires less labor, and has a great cost advantage. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work, among which: Figure 1 A three-dimensional structure according to an embodiment of the present invention Figure 1 ; Figure 2 It is a partial structural schematic diagram of an embodiment of the present invention; Figure 3 A three-dimensional structure according to an embodiment of the present invention Figure 2 ; Figure 4 A flowchart of an embodiment of the present invention; In the figure: 1. Battery pack CCS components; 2. Blister bracket; 20. First mounting unit; 21. Second mounting unit; 22. Mounting subunit; 23. First groove; 24. Second groove; 25. Connecting column; 3. Conductive aluminum bar; 30. Connecting end; 31. Extended end; 4. Sampling harness; 40. Summary harness; 41. Branch harness; 5. Limit block; 50. Wire guide groove; 6. Battery pack. DETAILED DESCRIPTION

[0016] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0017] refer to Figures 1 to 3 , Figure 1 The embodiment of the present invention provides a stereoscopic Figure 1 ; Figure 2 A partial structural schematic diagram provided by an embodiment of the present invention is shown; Figure 3 The three-dimensional diagram of a battery pack CCS assembly 1 provided by an embodiment of the present invention is shown. Figure 2 .

[0018] like Figures 1 to 3 As shown, the technical solution adopted by the present invention is a battery pack CCS component 1, including a blister bracket 2 and a plurality of conductive aluminum bars 3, wherein: The blister bracket 2 is along the first direction ( Figure 1 The first mounting unit 20 and the second mounting unit 21 are respectively provided at both ends of the first mounting unit 20 and the second mounting unit 21, and each of the first mounting unit 20 and the second mounting unit 21 includes a plurality of mounting sub-units 22. The plurality of mounting sub-units 22 are arranged along the second direction ( Figure 1 Each mounting subunit 22 includes a first groove 23, a second groove 24 and a connecting post 25. The first groove 23 and the second groove 24 are arranged at intervals along the second direction. The connecting post 25 is arranged along the third direction ( Figure 1 The first groove 23 and the second groove 24 extend in the Z direction.

[0019] Multiple conductive aluminum bars 3 are arranged one by one with multiple mounting sub-units 22. Each conductive aluminum bar 3 is in a "F" shape, including a connecting end 30 located in the middle and extended ends 31 on both sides. The connecting end 30 is provided with a connecting through hole corresponding to the connecting column 25 and is clamped and fixed with the connecting column 25. The extended ends 31 on both sides are respectively arranged corresponding to the first groove 23 and the second groove 24, and the first direction, the second direction and the third direction are perpendicular to each other.

[0020] The battery pack CCS assembly 1 provided in the present application has a main body made of a blister bracket 2, on which a plurality of mounting subunits 22 are arranged, each of which includes a groove and a connecting column 25, and corresponds to and is fixed to the conductive aluminum bar 3 one by one, thereby reducing the number of parts, simplifying the assembly process, and improving production efficiency. The blister bracket 2 is thin and light as a whole, and by rationally arranging the mounting subunits 22 and the conductive aluminum bar 3, the space utilization is further optimized, which helps to improve the energy density and overall performance of the battery pack 6.

[0021] Specifically, the first installation unit 20 is provided with a separate first groove 23, a second groove 24, a connecting column 25 and a portion of the conductive aluminum bar 3 at both ends along the first direction, which are used as the positive and negative electrode connecting terminals 30 of the battery pack 6.

[0022] In some embodiments, reference Figures 1 to 3 Along the third direction, the projection of the first groove 23 and the projection of the second groove 24 both cover the projection of the extension end 31 .

[0023] Exemplarily, the design of the groove projection covering the projection of the extended end 31 ensures that the extended end 31 of the conductive aluminum bar 3 can completely fall into the first groove 23 and the second groove 24, which facilitates the subsequent welding of the conductive aluminum bar 3 and the branch wiring harness 41, as well as the separation of the blister bracket 2.

[0024] In some embodiments, reference Figures 1 to 3 The battery pack CCS assembly 1 also includes a sampling harness 4, which includes a summary harness 40 and a plurality of branch harnesses 41. The summary harness 40 extends along the second direction and is arranged between the first mounting unit 20 and the second mounting unit 21. The plurality of branch harnesses 41 are arranged one by one with the plurality of mounting subunits 22, and one end of each branch harness 41 is connected to the conductive aluminum bar 3, and the other end is connected to the summary harness 40.

[0025] For example, by designing the sampling harness 4 as a collective harness 40 and a plurality of branch harnesses 41, and integrating them with the conductive aluminum bar 3 and the mounting subunit 22, the number and complexity of the harnesses are reduced, and the overall integration is improved. In some embodiments, reference Figures 1 to 3 Each mounting subunit 22 further includes a stopper 5, which is disposed on a side of the first groove 23 and the second groove 24 away from the edge of the blister bracket 2 along the first direction. The stopper 5 is disposed on the same side as the connecting column 25, and a wire groove 50 is disposed on the top thereof, which is used for clamping and fixing the branch wire harness 41 through the wire groove 50.

[0026] For example, in a traditional CCS assembly, loose wiring harness or poor contact may cause a short circuit or unstable signal acquisition, affecting the safety of the battery pack 6. By setting a wire groove 50 on the top of the limit block 5, the branch wiring harness 41 can be more effectively combed and fixed, making the wiring harness layout more regular and reducing interference between the wiring harnesses.

[0027] In some embodiments, the wire groove 50 extends along the first direction, and the shape of the wire groove 50 along the third direction is one of a straight line shape and a wavy shape.

[0028] refer to Figure 4 , Figure 4 The flowchart of the assembly method of the battery pack CCS component 1 is as follows: like Figures 1 to 4 As shown, the technical solution adopted by the present invention also includes an assembly method of a battery pack CCS assembly 1, using the battery pack CCS assembly 1 described in the above multiple embodiments, the assembly method includes a first welding station and a second welding station, wherein: The first welding station includes welding the branch wire harness 41 and the conductive aluminum bar 3 .

[0029] The second welding station includes welding the conductive aluminum bar 3 and the battery pack 6 .

[0030] The specific steps include: S1. Provide a battery pack 6 without CCS integrated busbar assembly, wherein the top of the battery pack 6 is a connection terminal 30 .

[0031] S2. Place the aggregated wiring harness 40 between the first mounting unit 20 and the second mounting unit 21, and place the plurality of branch wiring harnesses 41 in the mounting sub-units 22 in sequence, and fix them in the wire groove 50 of the limit block 5 by clamping.

[0032] S3. Install multiple conductive aluminum bars 3 in the first installation unit 20 and the second installation unit 21 of the blister bracket 2 in sequence, and the connecting through holes in the conductive aluminum bars 3 are clamped and fixed with the connecting columns 25 in each installation sub-unit 22, wherein the conductive aluminum bars 3 are located above the branch wiring harness 41.

[0033] S4. Turn over the assembled wire harness and aluminum bar blister bracket 2 until the branch wire harness 41 is located above the conductive aluminum bar 3, weld and fix the branch wire harness 41 to the conductive aluminum bar 3 in the first welding station, and perform anti-corrosion treatment.

[0034] S5. Place the welded wiring harness and the aluminum bar blister bracket 2 correspondingly at the connection end 30, and weld and fix the conductive aluminum bar 3 to the connection end 30 in the second welding station.

[0035] S6, separating the blister bracket 2 from the battery pack 6.

[0036] Exemplarily, after the conductive aluminum bar 3 is welded and fixed to the connecting end 30, the blister bracket 2 is no longer assembled to the product as part of the product, but is used as a reusable jig, thereby reducing the cost required for the battery pack CCS assembly 1. The sampling harness 4 is directly welded to the conductive aluminum bar 3 by ultrasonic welding, and nickel sheets are no longer used as a transfer medium, reducing costs. A plurality of limit blocks 5 and wire grooves 50 are provided on the blister bracket 2 corresponding to the sampling harness 4 to clamp and fix the harness. A plurality of connecting columns 25 are provided on the blister bracket 2, which cooperate with the conductive aluminum bar 3 to form an inverted structure to better fix the aluminum bar. This solution has a simple structure and manufacturing process, uses less tools and jigs, requires less labor, and has a great advantage in cost.

[0037] In some embodiments, the anti-corrosion treatment includes applying glue to the welding points between the branch wiring harness 41 and the conductive aluminum bar 3 .

[0038] For example, the welding parts of traditional CCS components are prone to electrochemical corrosion due to humid or salinized environments, which affects the reliability and safety of the connection. By applying glue at the welding parts, a sealing protective layer is formed to effectively isolate the corrosive environment such as moisture and salinization, and significantly improve the corrosion resistance of the welding parts. Gluing is a common technical means in the prior art, and spot welding adhesives are often used as adhesives for spot welding processes.

[0039] In some embodiments, the welding method of the first welding station and the second welding station is ultrasonic welding.

[0040] For example, ultrasonic welding achieves material fusion through high-frequency vibration, and the welding point is firm and reliable. Compared with traditional welding methods, ultrasonic welding does not require preheating and can directly weld the materials, saving preheating time. It is usually completed within a few milliseconds to a few seconds, with a fast welding speed, which is suitable for large-scale production. In addition, during the welding process, ultrasonic energy causes the welding part to melt and form a connection under the action of local vibration and friction, reducing the heat-affected zone, which is conducive to maintaining the stable performance of battery materials.

[0041] The above description is only an implementation mode of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly used in other related technical fields, should be included in the protection scope of the present invention.

Claims

1. A battery pack CCS assembly, characterized in that: It includes a blister bracket and a plurality of conductive aluminum bars, wherein: The blister bracket is provided with a first mounting unit and a second mounting unit at both ends along the first direction, each of the first mounting unit and the second mounting unit comprises a plurality of mounting sub-units, the plurality of mounting sub-units are arranged at intervals along the second direction, each of the mounting sub-units comprises a first groove, a second groove and a connecting column, the first groove and the second groove are arranged at intervals along the second direction; the connecting column extends along the third direction and is arranged between the first groove and the second groove; The multiple conductive aluminum bars are arranged in one-to-one correspondence with the multiple installation sub-units, and each of the conductive aluminum bars is in the shape of a "F" and includes a connecting end located in the middle and extended ends on both sides. The connecting end is provided with a connecting through hole corresponding to the connecting column and is clamped and fixed to the connecting column; the extended ends on both sides are respectively arranged corresponding to the first groove and the second groove, and the first direction, the second direction and the third direction are perpendicular to each other.

2. The battery pack CCS assembly according to claim 1, characterized in that: Along the third direction, a projection of the first groove and a projection of the second groove both cover a projection of the extended end.

3. The battery pack CCS assembly according to claim 1, characterized in that: It also includes a sampling harness, which includes a summary harness and multiple branch harnesses. The summary harness extends along the second direction and is arranged between the first mounting unit and the second mounting unit. The multiple branch harnesses are arranged in a one-to-one correspondence with the multiple mounting sub-units, and one end of each branch harness is connected to the conductive aluminum bar, and the other end is connected to the summary harness.

4. The battery pack CCS assembly according to claim 3, characterized in that: Each of the mounting sub-units also includes a limit block, which is arranged on one side of the first groove and the second groove away from the edge of the blister bracket along the first direction; the limit block is arranged on the same side as the connecting column, and a wire groove is provided on the top for clamping and fixing the branch wiring harness through the wire groove.

5. The battery pack CCS assembly according to claim 4, characterized in that: The wire groove extends along the first direction, and the shape of the wire groove along the third direction is one of a straight line shape and a wavy shape.

6. A method for assembling a battery pack CCS assembly, characterized in that: Using the battery pack CCS assembly as claimed in claims 1 to 5, the assembly method includes a first welding station and a second welding station, wherein: The first welding station includes welding the branch wiring harness and the conductive aluminum bar; The second welding station includes welding the conductive aluminum bar and the battery pack; The specific steps include: S1. Provide a battery pack without CCS integrated busbar, wherein the top of the battery pack is a connection end; S2, placing the aggregated wiring harness between the first mounting unit and the second mounting unit, and placing the plurality of branch wiring harnesses in the mounting sub-units in sequence, and clamping and fixing them in the wire groove of the limit block; S3, sequentially installing a plurality of conductive aluminum bars in the first installation unit and the second installation unit of the blister bracket, wherein the connecting through holes in the conductive aluminum bars are clamped and fixed with the connecting columns in each installation sub-unit, wherein the conductive aluminum bars are located above the branch wiring harness; S4. Flip the assembled wire harness and aluminum bar blister bracket over so that the branch wire harness is located above the conductive aluminum bar, weld and fix the branch wire harness and the conductive aluminum bar in the first welding station, and perform anti-corrosion treatment; S5. Place the welded wiring harness and the blister bracket of the aluminum bar at the connection end accordingly, and weld and fix the conductive aluminum bar to the connection end in the second welding station; S6. Separate the blister bracket from the battery pack.

7. The assembly method according to claim 6, characterized in that: The anti-corrosion treatment includes applying glue at the welding point between the branch wiring harness and the conductive aluminum bar.

8. The assembly method according to claim 6, characterized in that: The welding method of the first welding station and the second welding station is ultrasonic welding.

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