A kind of harness CCS structure of aluminium bar and isolation board integrated molding

Abstract

The utility model discloses a kind of harness CCS structures of aluminium bar and isolating plate integrated molding, including integrated molding isolating plate and aluminium bar, the middle part of isolating plate is equipped with aluminium bar, the top of aluminium bar is equipped with harness;Harness is fastened by buckle and isolating plate and is connected.The utility model proposes a kind of harness CCS structures of aluminium bar and isolating plate integrated molding, aluminium bar is integrated with isolating plate by injection molding process, realizes structural integration, and then synchronously promotes structural strength, insulation performance and assembly efficiency, satisfies the use demand of new energy automobile battery module to high reliability, high integration.

Description

Technical Field

[0001] This utility model relates to a wire harness CCS structure, and more particularly to a wire harness CCS structure for use in battery modules where the aluminum core and separator are integrally formed, belonging to the field of new energy vehicle battery module technology. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the market has placed higher demands on the safety, integration, and long-term stability of battery modules. In the core component of the battery module—the CCS structure—traditional designs generally employ a separate mounting method for the aluminum battery and plastic separator. This method has the following significant drawbacks: 1. The assembly process is complicated: multiple processes such as fixing the aluminum bar and installing the isolation plate need to be completed separately, which not only increases labor costs but also extends the production cycle, making it difficult to adapt to the needs of large-scale automated production. 2. Low connection reliability: The split structure relies on mechanical assembly and fixation. Under complex working conditions such as vibration and impact during vehicle operation, components are prone to loosening and displacement, resulting in a decrease in electrical connection stability. 3. Insufficient insulation performance: The assembly gap between the aluminum battery and the separator may cause insulation problems. Especially after long-term use, dust and moisture can easily accumulate in the gap, increasing the risk of short circuit and threatening the overall safety of the battery module. 4. Poor consistency: Multiple assembly processes involving manual intervention can easily lead to deviations in product dimensions and connection accuracy, affecting the consistency of mass-produced products and thus restricting the stability of battery module performance.

[0003] The aforementioned problems have become key bottlenecks restricting the development of new energy vehicle battery modules towards high safety, high integration, and high efficiency. Therefore, there is an urgent need for a new CCS structure that can solve the above defects. Utility Model Content

[0004] To address the shortcomings of the aforementioned technologies, this invention provides a wire harness CCS structure in which the aluminum hub and the isolation plate are integrally formed.

[0005] To solve the above technical problems, the technical solution adopted by this utility model is: a wire harness CCS structure with an aluminum bar and a separator plate integrally formed, including an integrally formed separator plate 1 and an aluminum bar. The aluminum bar is provided in the middle of the separator plate 1, and a wire harness 5 is provided above the aluminum bar. The wire harness 5 is fastened to the separator plate by a buckle 8.

[0006] Preferably, the aluminum bar includes a connecting aluminum bar and an output aluminum bar, with the output aluminum bar provided on one side of the connecting aluminum bar.

[0007] Preferably, one end of the output aluminum bar is connected to the terminal cell of the battery module, and the other end is connected to the copper bar.

[0008] Preferably, the copper bar is disposed on the output electrode aluminum bar and is connected to the output electrode aluminum bar by welding.

[0009] Preferably, the wire harness includes nickel terminals and connectors, wherein there are multiple nickel terminals arranged at intervals on the wire harness, and the connectors are located at the ends of the wire harness.

[0010] Preferably, the nickel terminals are connected to the aluminum bar and the wires of the wire harness by crimping or welding.

[0011] Preferably, one end of the connector is connected to the wire harness via a wire, and the other end is matched and connected to the corresponding interface of the battery management system.

[0012] Preferably, there are multiple clips arranged along the installation direction of the wire harness, and the clips match the outer diameter of the wire harness and are snapped onto the outer wall of the wire harness.

[0013] Preferably, the partition plate is integrally formed with the aluminum bar through injection molding.

[0014] This invention proposes a wire harness CCS structure in which the aluminum busbar and the separator are integrally formed. The aluminum busbar and the separator are integrated through injection molding to achieve structural integration, thereby simultaneously improving structural strength, insulation performance and assembly efficiency, and meeting the high reliability and high integration requirements of new energy vehicle battery modules.

[0015] This wiring harness CCS structure effectively improves production efficiency and product consistency by using an integrated injection molding process to form the aluminum busbar and the separator plate, combined with an automated production process. At the same time, it enhances structural stability and electrical performance reliability, making it suitable for various power battery packs and other scenarios that require efficient and reliable electrical connections. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0017] Figure 2 for Figure 1 A schematic diagram of the three-dimensional structure.

[0018] In the diagram: 1. Isolation plate; 2. Connecting aluminum bar; 3. Output aluminum bar; 4. Copper bar; 5. Wire harness; 6. Nickel terminal; 7. Connector; 8. Clip. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0020] Example like Figure 1 , Figure 2The diagram shows a CCS (Computer-on-Chip) structure for a wire harness, comprising an integrally molded partition plate 1 and an aluminum bar. The aluminum bar is located in the middle of the partition plate 1, and a wire harness 5 is located above the aluminum bar. The wire harness 5 is fastened to the partition plate via a clip 8. The partition plate 1 is integrally molded with the aluminum bar using an injection molding process.

[0021] Among them, the isolation plate 1 is made of high-strength insulating materials (such as modified PA66, PPO, etc.), and is directly integrally formed with the connecting aluminum bar 2 and the output pole aluminum bar 3 through precision injection molding process, without the need for subsequent assembly; this design can eliminate the assembly gap between components, which not only improves the overall structural strength, but also ensures excellent insulation performance and effectively blocks the risk of electrical short circuit.

[0022] An aluminum bar is located in the middle of the separator plate 1, and a wire harness 5 is located above the aluminum bar. The aluminum bar includes a connecting aluminum bar 2 and an output aluminum bar 3, with the output aluminum bar 3 located on one side of the connecting aluminum bar 2. One end of the output aluminum bar 3 is connected to the terminal cell of the battery module, and the other end is connected to a copper bar 4. The copper bar 4 is mounted on the output aluminum bar 3 and is welded to the output aluminum bar 3.

[0023] The connecting aluminum bar 2 is made of high-conductivity pure aluminum or aluminum alloy material and is tightly integrated with the separator plate 1 during the injection molding process. Its main function is to connect multiple cells in the battery module to realize the current conduction between the cells. Compared with the traditional separate assembly, the one-piece molding design can avoid the aluminum bar from loosening and ensure the stability of current conduction.

[0024] The output electrode aluminum bar 3 is made of high conductivity aluminum material. One end of it is connected to the terminal cell of the battery module, and the other end is reliably connected to the copper bar 4. As a transition component for the transmission of cell current to the outside, its integrated structure with the isolation plate 1 can reduce connection nodes, reduce contact resistance, and improve power transmission efficiency.

[0025] The copper bar 4 is made of high-purity electrolytic copper material and is fixed to the output electrode aluminum bar 3 by welding or bolt connection. As the connection carrier between the cell output end and the external circuit of the battery (such as inverter and controller), it has excellent conductivity and corrosion resistance, and can ensure stable transmission of large current.

[0026] The wire harness 5 is securely connected to the isolation plate via clips 8. There are multiple clips 8 arranged along the installation direction of the wire harness, and the clips 8 match the outer diameter of the wire harness 5 and are snapped onto the outer wall of the wire harness.

[0027] The wiring harness 5 includes nickel terminals 6 and connectors 7. Multiple nickel terminals 6 are arranged at intervals on the wiring harness, and connectors 7 are located at the ends of the wiring harness. The nickel terminals 6 are connected to the aluminum battery and the wires of the wiring harness 5 respectively by crimping or soldering. One end of the connector 7 is connected to the wiring harness 5 via a wire, and the other end is matched and connected to the corresponding interface of the battery management system.

[0028] Among them, the wiring harness 5 is composed of multiple strands of tin-plated copper wire, nickel terminals 6, connectors 7 and NTC temperature sensors and other auxiliary materials; its core function is to collect the voltage and temperature signals of each cell in real time, and provide accurate status monitoring data for the battery management system (BMS).

[0029] The nickel terminal 6 is made of high-purity nickel material. It is connected to the aluminum bar (connecting aluminum bar 2 / output aluminum bar 3), the wire of the wire harness 5 and the NTC temperature sensor by crimping or welding. As a transition conductive component, it can effectively reduce the contact resistance and electrochemical corrosion risk between different metals (aluminum, copper) and ensure stable transmission of signals and current.

[0030] Connector 7 uses a waterproof, high and low temperature resistant engineering plastic shell and gold-plated terminals. One end of it is connected to the wire of wire harness 5, and the other end is matched with the corresponding interface of the battery management system (BMS). It has anti-reverse insertion and anti-loosening design, and can reliably transmit voltage and temperature acquisition signals, adapting to the complex working environment of new energy vehicles.

[0031] The buckle 8 is a raised structure integrally formed during the injection molding of the isolation plate 1, and is distributed on the installation path of the wire harness 5. Its shape matches the outer diameter of the wire harness 5, which can accurately position and fix the cable, prevent the wire harness from shifting or wearing in a vibration environment, and ensure the continuity and reliability of signal acquisition.

[0032] Preferably, the buckle 8 includes two opposing locking blocks that are symmetrical about the wire harness. Each locking block includes a vertical plate integrally formed with the isolation plate. The side of the vertical plate facing the wire harness has a protrusion that is inclined toward the center of the wire harness. The wire harness is locked onto the isolation plate by the two locking blocks.

[0033] The purpose of this utility model is to provide a wire harness CCS structure in which the aluminum busbar and the separator are integrally formed. The separator is integrally formed with the aluminum busbar and the wire harness through injection molding, which saves assembly steps and is suitable for large-scale automated production. It improves the reliability of the connection between components and the stability of electrical connection. It further enhances the insulation between the aluminum busbar and the separator, while enhancing product consistency and ensuring the stability of battery module performance.

[0034] The above embodiments are not intended to limit the present utility model, nor is the present utility model limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present utility model are also within the protection scope of the present utility model.

Claims

1. A wire harness CCS structure integrally formed with an aluminum busbar and a separator plate, characterized in that: It includes an integrally formed isolation plate (1) and an aluminum bar. The isolation plate (1) has an aluminum bar in the middle and a wire harness (5) above the aluminum bar. The wire harness (5) is fastened to the isolation plate by a buckle (8).

2. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 1, characterized in that: The aluminum bar includes a connecting aluminum bar (2) and an output aluminum bar (3), and the output aluminum bar (3) is provided on one side of the connecting aluminum bar (2).

3. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 2, characterized in that: One end of the output aluminum bar (3) is connected to the terminal cell of the battery module, and the other end is connected to the copper bar (4).

4. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 3, characterized in that: The copper bar (4) is disposed on the output electrode aluminum bar (3) and is connected to the output electrode aluminum bar (3) by welding.

5. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 1, characterized in that: The wire harness (5) includes nickel terminals (6) and connectors (7). There are multiple nickel terminals (6) arranged at intervals on the wire harness, and the connectors (7) are located at the ends of the wire harness.

6. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 5, characterized in that: The nickel terminal (6) is connected to the conductors of the aluminum bar and the wire harness (5) by crimping or welding.

7. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 5, characterized in that: One end of the connector (7) is connected to the wire harness (5) via a wire, and the other end is matched and connected to the corresponding interface of the battery management system.

8. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 1, characterized in that: The buckles (8) are multiple and arranged along the installation direction of the wire harness. The buckles (8) match the outer diameter of the wire harness (5) and are snapped onto the outer wall of the wire harness.

9. The wire harness CCS structure integrally formed with the aluminum busbar and the separator plate according to claim 1, characterized in that: The isolation plate (1) is integrally formed with the aluminum bar through injection molding.

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