Battery CCS Separator Buckle Structure for Fast Connector Assembly
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Solution Overview
Problem
The existing assembly process for battery module accessories, specifically the connection between the separator and the connector in the cells contact system (CCS), is cumbersome and inefficient, leading to low manufacturing efficiency.
Innovation Solution
A separator design with buckle holes and abutting portions that securely connect to the connector, allowing for simplified assembly and disassembly, and a CCS configuration that includes a wire harness bound by a cable tie for enhanced stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hot-pressing film process is used to connect connector, separator, and circuit board, then connection strength is improved, but assembly complexity increases and assembly efficiency decreases
Solution Approach 1:
The separator is divided into multiple functional regions: a body portion, buckle portions for connection, and abutting portions for positioning. This segmentation allows each part to perform its specific function independently, simplifying the overall assembly process while maintaining connection strength.
Solution Approach 2:
The buckle portions act as intermediary elements between the separator and the connector. These buckles engage with corresponding buckle holes in the connector, providing a simple mechanical connection that eliminates the need for complex hot-pressing processes.
2Reliability
If hot-pressing film process is used to connect components, then connection reliability is improved, but manufacturing efficiency decreases
Solution Approach 1:
The buckle portions and abutting portions are pre-formed as integral parts of the separator during separator manufacturing. This preliminary formation of connection and positioning features eliminates the need for subsequent hot-pressing operations, significantly improving manufacturing efficiency while ensuring reliable connections.
3Productivity
If simplified assembly process is used, then assembly efficiency is improved, but connection stability may worsen
Solution Approach 1:
Different regions of the separator are designed with different local qualities: the body portion provides structural support, the buckle portions provide secure mechanical connection through engagement with buckle holes, and the abutting portions provide precise positioning against the connector and circuit board. This localized functional differentiation ensures connection stability while maintaining simple assembly.
Data Source
AI summary
Provided is 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.