CCS Isolation Plate Vacuum Forming for Faster Battery Assembly
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Solution Overview
Problem
Traditional production processes for isolation plates in CCS components involve long mold development cycles and high costs due to injection molding, leading to low production efficiency and yield rates.
Innovation Solution
The use of vacuum formed plastic pieces for isolation plates in CCS components, which reduces mold development time and enhances production efficiency, allowing for cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding is used to manufacture isolation plates, then the structural integrity and precision are improved, but the mold development cycle is extended and production costs increase
Solution Approach 1:
The patent employs disposable isolation plates made from plastic materials that are discarded after a single use during battery assembly. These single-use plates eliminate the need for expensive, long-lasting molds while maintaining sufficient functional performance for the isolation task, directly reducing mold development time and costs.
Solution Approach 2:
The patent changes the material parameter from traditional metal or durable plastic requiring injection molding to thin-gauge plastic sheets suitable for vacuum forming. This parameter change enables a shift from mold-intensive manufacturing to a simpler forming process, reducing development cycle while maintaining isolation effectiveness.
2Manufacturing precision
If injection molding is used to manufacture isolation plates, then the manufacturing precision is improved, but the production efficiency is reduced
Solution Approach 1:
The disposable nature of the isolation plates allows for rapid production using vacuum forming technology. Multiple plates can be formed simultaneously from large sheets, and the simple forming process requires no complex mold assembly or disassembly, significantly increasing production throughput compared to injection molding.
Solution Approach 2:
The patent extracts the essential function of isolation from the complex injection molding process. By using simple vacuum forming of thin plastic sheets, the core isolation function is achieved without the time-consuming mold preparation, injection, cooling, and ejection cycles required by traditional methods.
3Strength
If injection molding is used to manufacture isolation plates, then the structural integrity is improved, but the production cost is increased
Solution Approach 1:
The disposable isolation plates are designed to perform their isolation function for a single assembly operation. The low cost of thin plastic sheets and vacuum forming eliminates the need for expensive injection molds, tooling, and associated setup costs, making the overall production cost significantly lower despite using simpler materials.
Solution Approach 2:
The patent changes the manufacturing approach from high-capital injection molding to low-capital vacuum forming. This parameter change in the manufacturing process, combined with using thin-gauge plastic materials, dramatically reduces equipment investment, tooling costs, and per-unit production costs while maintaining sufficient structural integrity for the application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly improves production efficiency and reduces costs by shortening the mold development cycle and increasing yield rates in CCS component production.
Implementation Method 1
the isolation plate is a vacuum formed plastic piece
Data Source
AI summary
A CCS component, a battery with the same, and an electric apparatus are disclosed. The CCS component includes: an isolation plate, where the isolation plate is a vacuum formed plastic piece, and a side surface of the isolation plate in thickness direction is a first surface; and connecting pieces, where the connecting pieces are connected to the isolation plate and arranged on a side on which the first surface of the isolation plate is located, and the connecting piece is configured to electrically connect an electrode pole of a battery cell. According to the CCS component application, the isolation plate and the connecting pieces are provided, and the isolation plate is provided as a vacuum formed plastic piece, which can give a high production efficiency of the isolation plates, thereby greatly improving the production efficiency of the CCS components and reducing the production costs of the CCS components.