Battery Pack CCS Hybrid Structure for Warp-Resistant Connections
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Solution Overview
Problem
Existing battery packs face issues with the reliability of electrical connections between the electrode structure and the electrical connection plate, leading to potential warping, deformation, and increased risk of electric sparks.
Innovation Solution
A battery pack design incorporating a vacuum-molded member as the main mounting structure and an injection molded member as an auxiliary structure, with a connection structure that reduces warping and deformation, ensuring a more reliable electrical connection and enhanced safety through the use of reinforcement portions and specific assembly methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a vacuum-molded member is used as the main mounting structure, then warping and deformation are reduced, but structural stiffness is insufficient compared to injection molded members
Solution Approach 1:
The patent combines a vacuum-molded member (main mounting structure) with an injection molded member (auxiliary mounting structure) to create a hybrid structure. The injection molded member provides additional structural stiffness while the vacuum-molded member maintains warping resistance, resolving the contradiction between these two properties.
2Device complexity
If the electrical connection plate is mounted on the vacuum-molded member, then the mounting structure is simplified, but the electrical connection plate is prone to bending and deformation
Solution Approach 1:
The patent merges the vacuum-molded member and injection molded member into a combined mounting structure that supports the electrical connection plate. This hybrid structure provides both simplified mounting (from the vacuum-molded member) and enhanced stability (from the injection molded member's higher stiffness).
Solution Approach 2:
The patent uses a composite mounting structure combining two different molding techniques (vacuum molding and injection molding) to create a structure with optimized properties for both ease of manufacture and structural stability.
3Reliability
If the electrical connection plate is prone to bending, then virtual electrical connections occur, but increasing structural support adds complexity
Solution Approach 1:
The patent combines two mounting structures (vacuum-molded and injection molded) to provide adequate structural support for the electrical connection plate, preventing bending and virtual connections while maintaining reasonable complexity through the use of complementary manufacturing techniques.
Data Source
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AI summary
Battery pack and manufacturing method are provided. Battery pack includes cells contact system (CCS) assembly and cell assembly. CCS assembly includes injection molded member, vacuum-molded member, electrical connection plate, wiring harness. Injection molded member is connected to vacuum-molded member. Part of electrical connection plate is connected to injection molded member. Electrical connection plate is connected to vacuum-molded member. Wiring harness is connected to injection molded member, and further connected to electrical connection plate. Cell assembly includes battery cells electrically connected to electrical connection plate. Structural stiffness of injection molded member is greater than vacuum-molded member. Connection between injection molded member and vacuum-molded member reduces possibility of warping and deformation. Electrical connection plate mounted on vacuum-molded member is less prone to bending and deformation, and electrical connection plate is less prone to virtual electrical connection with cell. Electrical connection between electrical connector and cell has higher degree of operational reliability.