The development of new energy vehicles has long been a global consensus, and the “dual carbon” strategy has become a new driving force for the development of various countries, continuously optimizing the energy structure. Automobiles continue to undergo iterative transformation towards new energy vehicles towards intelligence and electrification, and new energy vehicles maintain a high momentum. The power battery is the power source of new energy vehicles and one of the important systems of the entire vehicle. According to different connection schemes, there are mainly three technical paths for the connection between power battery modules:
The connections between individual power batteries include square, cylindrical, soft pack, and so on.
The battery modules are mainly connected through high-voltage wiring harnesses and busbars.
The connection between power batteries and external components is slightly different, mainly consisting of copper wires, aluminum wires, flat copper aluminum ribbon wires, and so on.
The power battery module connects individual battery cells in series through conductive connectors to form a power source, serving the functions of connection, fixation, and safety protection.
According to the different connection methods of battery cells and conductive busbars, they can be divided into welding, screwing, and mechanical crimping. Different connection methods not only have different manufacturing efficiencies, but also have differences in battery performance.
Laser welding, ultrasonic welding, resistance welding and other processes have high efficiency and are easy to automate production. In practical applications, welding processes are continuously optimized and improved.
Square batteries often use screw connections, which are used to secure the connection between the battery cells and the busbar with anti loosening screws, and are applied to battery systems with large individual capacities.
Mechanical crimping mainly relies on the elastic deformation of conductive components to maintain the electrical connection between the battery and the circuit, but it occupies a large space and also has an impact on energy density.
Paige Rui is a manufacturer of integrated power battery wiring harnesses. In addition, our company also provides energy storage wiring harnesses, which are widely used in various energy storage fields.