Modular Harness Isolation Plate Assembly for Accurate Busbar Welding
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Solution Overview
Problem
The increasing size of battery modules due to higher energy density requirements leads to low production efficiency and reduced positioning accuracy in the hot-pressing process of harness isolation plate assemblies, resulting in decreased welding accuracy between electrode leads and busbars.
Innovation Solution
The harness isolation plate assembly is composed of small, independently processed isolation units connected through a connecting assembly, which improves positioning accuracy and enhances the rigidity and reliability of the assembly, preventing short circuits and facilitating precise connection of busbars to electrode leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the harness isolation plate assembly is made as a large integral structure to meet increasing energy density requirements, then the energy density of the battery module is improved, but the production efficiency of the harness isolation plate assembly decreases
Solution Approach 1:
The harness isolation plate assembly is divided into multiple isolation units that can be independently processed and then assembled. Each isolation unit corresponds to one or more battery cells and can be manufactured separately using hot-pressing technology, avoiding the need to produce one large integral structure. This segmentation maintains high energy density while improving production efficiency through parallel manufacturing and reduced molding complexity.
2Quantity of substance
If the harness isolation plate assembly is made as a large integral structure, then the energy density is improved, but the positioning accuracy of components in the hot-pressing process decreases
Solution Approach 1:
By dividing the assembly into smaller isolation units, each unit can be positioned and molded with higher precision. The smaller size of individual units allows for better control of component placement and hot-pressing parameters, improving positioning accuracy while still achieving high energy density through the integrated assembly of multiple precision units.
3Quantity of substance
If the harness isolation plate assembly is made as a large integral structure, then the energy density is improved, but the welding accuracy between electrode leads and busbars decreases
Solution Approach 1:
Each isolation unit contains the busbars and electrode leads for its corresponding battery cells, allowing welding operations to be performed on smaller, more manageable components. This segmentation enables better positioning and more accurate welding connections compared to attempting to weld within a single large integral structure, while the overall energy density is maintained through the compact arrangement of multiple units.
Data Source
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AI summary
The present application relates to a harness isolation plate assembly, a battery module, a battery pack and a device. The harness isolation plate assembly includes a plurality of isolation units comprising busbars and insulating films connecting the busbars; a connecting assembly through which the adjacent isolation units are connected. In the present application, the harness isolation plate assembly includes a plurality of separate isolation units. Upon molding, each isolation unit can be processed independently. Moreover, a size of each isolation unit is small, thus reducing processing difficulty. Furthermore, it is easy to control a location of each busbar, such that locating accuracy of the busbars is improved so as to enhance connecting reliability between the busbars and an electrode lead. Meanwhile, in each isolation unit, the busbars are connected through the insulating films, such that a risk of short circuit for the busbars is low. In addition, adjacent isolation units are connected through the connecting assembly, thus forming a complete harness isolation plate assembly and improving rigidity of the harness isolation plate assembly to facilitate connection of the busbars to the electrode lead.