Battery CCS Separator Buckle Structure for Faster Connector Assembly
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Solution Overview
Problem
The existing assembly process for battery module accessories, specifically the connection system (CCS), is cumbersome and inefficient, leading to low manufacturing efficiency due to the complexity of connecting the separator, connector, and circuit board through a hot-pressing film process.
Innovation Solution
A separator design with buckle holes and abutting portions that securely connect to a connector, allowing for simplified assembly and disassembly by engaging buckles with corresponding holes, and incorporating features like grooves, notches, and cable ties to manage wire harnesses and electrolytes, enhancing structural stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hot-pressing film process is used to connect the connector, separator, and circuit board, then the connection strength is improved, but the assembly process complexity increases and assembly efficiency decreases
Solution Approach 1:
The separator is divided into multiple functional regions: a body portion, buckles for mechanical attachment, and abutting portions for positioning. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process while maintaining connection strength.
Solution Approach 2:
The separator integrates multiple functions into a single component: it provides mechanical support, electrical insulation, structural positioning, and wire harness management. By combining these functions, the patent reduces the number of separate components and simplifies the assembly process.
2Strength
If the hot-pressing film process is used to connect the connector, separator, and circuit board, then the connection strength is improved, but the assembly efficiency decreases
Solution Approach 1:
The buckles and abutting portions are pre-formed as integral parts of the separator during manufacturing. This preliminary preparation eliminates the need for additional assembly steps during production, allowing for quick and efficient assembly while maintaining strong connections.
Solution Approach 2:
The patent replaces the thermal field-based hot-pressing process with a mechanical field-based buckling system. The buckles mechanically engage with corresponding features on the connector and circuit board, providing strong connections through mechanical interlocking rather than thermal bonding, thereby significantly improving assembly efficiency.
3Stability of the object's composition
If the separator includes multiple abutting portions and buckles, then the structural stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The separator is designed as a multi-functional component that simultaneously provides structural support, mechanical attachment (through buckles), positioning (through abutting portions), and wire harness management (through grooves and blocking portions). This universal design reduces the need for multiple separate components, simplifying manufacturing despite the increased functional integration.
Solution Approach 2:
The separator utilizes material property changes and geometric parameter variations to achieve different functions within a single component. By adjusting the shape, thickness, and configuration of different regions of the separator, the patent achieves structural stability, mechanical attachment, and wire harness management without requiring multiple separate parts.
Data Source
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AI summary
The present disclosure relates to a separator and a cells contact system (CCS). The separator is configured to install a connector. The connector includes a first side surface and a second side surface opposite to each other, and the connector is further provided with buckle holes. The separator includes a body, buckles, first abutting portions, second abutting portions, and third abutting portions. The buckles are connected to the body, and the buckles are configured to be connected to the buckle holes. The first abutting portions are connected to the body, and the first abutting portions are configured to abut against the first side surface. The second abutting portions are connected to the body, and the second abutting portions are configured to abut against the second side surface. The third abutting portions are connected to the body, and the third abutting portions are configured to abut against an edge of the connector.