As more and more battery modules are placed under the vehicle, larger cross-sectional wire harnesses or conductors need to be installed and routed around and under the passenger compartment. Therefore, the body structure must not only be insulated from cables and conductors, but must also safely dissipate the temperature rise that occurs in the wiring harness during fast charging.
Back to the technical challenges of the connection process, the ultrasonic metal welding process, as an efficient solid-phase connection process, has the advantages of short welding time, low internal resistance of the joint, and high mechanical strength, especially suitable for high-voltage connector systems. Welding of wire harness to wire harness or wire harness to terminal. However, the use of ultrasonic welding of high-voltage wire harnesses with large cross-sectional areas (≥50mm2) requires the use of very high-power equipment, and at the same time, the mechanical strength of the welded wire harnesses and connectors during use must be guaranteed.