CCS Busbar Assembly With Positioning Plates for Long Battery Modules
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Solution Overview
Problem
Conventional plastic brackets used in CCS assemblies for battery modules are inadequate due to high mold costs, processing accuracy issues, and dimensional chain matching difficulties, especially as battery module lengths increase.
Innovation Solution
The CCS assembly integrates an insulating film with a busbar group, including output bars, connecting bars, and positioning plates, which are connected to the insulating film to reduce production costs and enhance structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic brackets are used to integrate output bars and connecting bars, then integration is achieved, but mold costs increase and processing accuracy becomes difficult to control
Solution Approach 1:
The patent divides the conventional integrated plastic bracket into separate components: positioning plates and support plates. These modular elements can be independently manufactured and assembled, avoiding the need for a single large plastic bracket that is difficult to mold with high precision. The segmentation allows each component to be produced with standard mold sizes and easier quality control.
Solution Approach 2:
The patent combines metal positioning plates with plastic support plates to create a hybrid support structure. This merging of different materials leverages the dimensional stability and strength of metal with the cost-effectiveness and ease of shaping of plastic, achieving both integration capability and manufacturing precision without relying on a single expensive plastic bracket.
2Adaptability or versatility
If plastic brackets with increased length are used to accommodate longer battery modules, then integration needs are met, but mold costs increase and dimensional chain matching becomes difficult
Solution Approach 1:
Instead of using a single long plastic bracket that requires a complex large-size mold, the patent segments the support structure into multiple smaller positioning plates and support plates distributed along the battery module. Each plate can be manufactured with simple, standard molds, significantly reducing mold complexity and cost while still providing comprehensive support for the longer module.
Solution Approach 2:
The patent transitions from a single-dimensional long bracket to a multi-dimensional arrangement of distributed plates. By spreading the support function across multiple discrete elements in space, the design achieves the necessary adaptability for longer modules without requiring a single complex large-scale component, thus simplifying the manufacturing mold requirements.
3Ease of manufacture
If conventional plastic brackets are used, then integration is achieved, but structural strength and stiffness are insufficient for transportation and processing
Solution Approach 1:
The patent creates a composite structure by combining metal positioning plates with plastic support plates. The metal plates provide the necessary structural strength and stiffness for transportation and processing, while the plastic plates provide support and integration functionality. This composite approach overcomes the weakness of pure plastic brackets while maintaining their integration advantages.
Solution Approach 2:
By segmenting the support structure into discrete metal and plastic plates rather than using a single plastic bracket, the design allows strategic placement of metal reinforcement elements at critical locations. This segmented approach enables the structure to achieve high strength-to-weight ratio and sufficient stiffness for handling while maintaining ease of manufacture through modular assembly.
Data Source
AI summary
The present disclosure provides a CCS assembly and a battery module. The CCS assembly includes an insulating film and a busbar group. The busbar group includes two output bars, connecting bars, and two positioning plates. The two output bars are correspondingly arranged at two ends of the battery module in a length direction. The connecting bars are arranged between the two output bars. At the same end of the battery module in the length direction, the output bar is at least partially supported by the positioning plate, and the positioning plate extends toward the connecting bar adjacent to the output bar. The insulating film is disposed on one side of the busbar group facing battery cells of the battery module. The busbar group is connected to the insulating film.