Flat harness integration method and flat harness

Abstract

The application provides a flat harness integration method and a flat harness. The flat harness integration method comprises the following steps: determining the maximum outer diameter and the total number of wires used for connecting electrical components in a battery pack; calculating the remaining space size in the height direction of the battery pack according to the space size occupied by the electrical components; determining the height size of a protective shell according to the remaining space size, wherein the protective shell has a mounting groove, the wires comprise a plurality of wire layers, and the plurality of wire layers are arranged in the mounting groove in a stacked manner along the height direction of the mounting groove; determining the number of stacked layers of the wires according to the height size and the maximum outer diameter; determining the number of single-layer wires according to the number of stacked layers and the total number; determining the width size of the protective shell according to the maximum outer diameter of the wires and the number of single-layer wires; and mounting the wires in the protective shell with the height size and the width size. The application effectively solves the technical problem that the energy density of the battery pack is limited due to the fact that the harness in the battery pack occupies too much space in the prior art.

Description

Technical Field

[0001] This invention relates to the field of wire harness integration technology, and more specifically, to a flattened wire harness integration method and a flattened wire harness. Background Technology

[0002] With the government's vigorous promotion of new energy, electric vehicles have become the mainstream trend for the future. The power battery pack is the most important power supply component for electric vehicles. The battery pack consists of a casing, cells / modules, a battery management system, high and low voltage electrical systems, and a thermal management system. Among these, the wiring harnesses of the high-voltage or low-voltage systems serve as the transmission carriers of signals and energy within the battery pack, connecting all the components together. Therefore, the wiring harnesses are crucial in the battery pack design process.

[0003] Wiring harnesses are flexible structures and generally require brackets or cable ties for installation and fixation. Existing wiring harness brackets or cable ties have complex fixing structures, requiring the wiring harness to be fixed and clipped sequentially during installation, which is cumbersome and does not effectively protect the wiring harness. Internal wiring harnesses in battery packs typically consist of several to dozens of wires twisted together, with a circular cross-section. Engineers need to allocate space for wiring channels during battery pack layout design, resulting in wiring harness installation and fixation occupying a significant amount of internal battery pack space. However, due to increasingly higher energy density requirements for battery packs, the space available for components other than the battery cells is gradually decreasing. Therefore, providing a new wiring harness layout solution to reduce space occupation has become a pressing technical challenge in the industry. Furthermore, in the event of thermal runaway in a battery pack, the outer insulation layer of the wiring harness may fail under high temperatures or electrolyte eruption, causing the circuit's signal and energy transmission to fail, thus preventing alarms from being triggered during thermal runaway.

[0004] There is currently no effective solution to the aforementioned problems in the existing technology. Summary of the Invention

[0005] The main objective of this invention is to provide a flattened wire harness integration method and a flattened wire harness to solve the problem in the prior art where the energy density of the battery pack is limited due to the excessive space occupied by the wire harness within the battery pack.

[0006] To achieve the above objectives, according to one aspect of the present invention, a method for integrating flattened wire harnesses is provided, comprising: determining the maximum outer diameter and total number of wires for connecting electrical components within a battery pack; calculating the remaining space dimension in the height direction of the battery pack based on the space dimension occupied by the electrical components; determining the height dimension of a protective shell based on the remaining space dimension, wherein the protective shell has a mounting groove, the wires comprising multiple wire layers, the multiple wire layers being stacked within the mounting groove along the height direction of the mounting groove; determining the number of stacked wire layers based on the height dimension and the maximum outer diameter; determining the number of single-layer wires based on the number of stacked layers and the total number; determining the width dimension of the protective shell based on the maximum outer diameter of the wires and the number of single-layer wires; and installing the wires within the protective shell having the height dimension and the width dimension.

[0007] Furthermore, determining the maximum outer diameter and total number of wires used to connect electrical components within the battery pack includes: calculating the total number of wires based on the circuit system connection principle of the battery pack; determining the specifications of the wires according to the specifications of the electrical components; and determining the maximum outer diameter of the wires according to the specifications of the wires.

[0008] Furthermore, based on the space occupied by the electrical components, the remaining space dimension in the height direction of the battery pack is calculated, including: obtaining the overall space dimension of the battery pack, the amplitude dimension of the battery pack cover, and the reserved safety dimension; and calculating the remaining space dimension in the height direction of the battery pack based on the overall space dimension, the amplitude dimension of the battery pack cover, the reserved safety dimension, and the space occupied by the electrical components.

[0009] Furthermore, after determining the width dimension of the protective shell based on the maximum outer diameter of the conductor and the number of conductors in a single layer, the method further includes, before installing the conductor inside the protective shell which has height and width dimensions, covering the surface of the protective shell with a ceramic composite tape.

[0010] Furthermore, the sidewall of the mounting groove is provided with a groove structure for wrapping tape. After the wire is installed in the protective shell with height and width dimensions, the method further includes: fixing the wire in the mounting groove with cloth tape; fixing the protective shell with foam adhesive tape; and electrically connecting multiple mating connectors to at least a portion of the wire.

[0011] Further, the number of stacked layers of the conductor is determined based on the height dimension and the maximum outer diameter, including: calculating the quotient of the height dimension and the maximum outer diameter as a first intermediate value; and approximating the first intermediate value to obtain the number of stacked layers.

[0012] Further, the width dimension of the protective shell is determined based on the maximum outer diameter of the conductor and the number of conductors in a single layer, including: calculating the product of the maximum outer diameter of the conductor and the number of conductors in a single layer as a second intermediate value; and calculating the sum of the second intermediate value and the wall thickness of the protective shell as the width dimension.

[0013] Furthermore, the protective shell includes a head shell section, a middle shell section, and a tail shell section, with the head shell section, middle shell section, and tail shell section having different structures. After determining the width of the protective shell based on the maximum outer diameter of the conductor and the number of conductors in a single layer, the method further includes: determining the arrangement path and length of the conductors based on the circuit system connection principle of the battery pack; selecting a corresponding number of middle shell sections based on the length of the conductors; and combining the head shell section, the corresponding number of middle shell sections, and the tail shell section according to the arrangement path so that the head shell section, middle shell section, and tail shell section together form a mounting groove.

[0014] Furthermore, selecting a corresponding number of intermediate shell segments based on the length of the conductor includes: obtaining the length of a single intermediate shell segment; calculating the quotient of the length of the conductor and the length of a single intermediate shell segment to obtain the number of intermediate shell segments.

[0015] According to another aspect of the present invention, a flattened integrated wire harness is provided, which is obtained by the flattened wire harness integration method described above.

[0016] By applying the technical solution of this invention, the remaining space dimension in the height direction of the battery pack is calculated, and the height dimension of the protective shell is determined accordingly. Based on the height dimension, the maximum outer diameter of the wires, and the total number of wires, the number of overlapping layers and the number of single layers of the wires are finally determined. This allows the wire harness to be flattened and housed within the protective shell, reducing the overall height of the wire harness assembly. This fully and effectively utilizes the space in the height direction of the battery pack, avoiding the shortcomings of existing technologies that require additional space for the cylindrical wire harnesses. This improves the utilization rate of battery arrangement space and thus increases the energy density of the battery pack. The technical solution of this application effectively solves the technical problem in existing technologies where the energy density of the battery pack is limited due to the excessive space occupied by the wire harnesses within the battery pack. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0018] Figure 1 A flowchart illustrating an embodiment of the flattened wire harness integration method according to the present invention is shown;

[0019] Figure 2 A block diagram illustrating an embodiment of the circuit system connection module of the battery pack according to the present invention is shown;

[0020] Figure 3 A cross-sectional schematic diagram of a first embodiment of the flattened wire harness according to the present invention is shown;

[0021] Figure 4 A schematic diagram of a second embodiment of the flattened wire harness according to the present invention is shown;

[0022] Figure 5 A schematic diagram of the structure of a first embodiment of the protective shell according to the present invention is shown;

[0023] Figure 6 A schematic diagram of the structure of a second embodiment of the protective shell according to the present invention is shown;

[0024] Figure 7 A schematic diagram of the structure of a third embodiment of the protective shell according to the present invention is shown;

[0025] Figure 8 A flowchart illustrating an embodiment of a battery pack alarm according to the present invention is shown.

[0026] The above figures include the following reference numerals:

[0027] 100. Wire;

[0028] 210. First protective shell; 211. Mounting groove; 212. Cloth-based tape wrapping structure; 213. Foam adhesive tape bonding structure; 214. First limiting structure; 215. Second limiting structure; 216. Mounting and positioning structure; 220. Second protective shell; 230. Third protective shell;

[0029] 300. Foam bonding tape;

[0030] 400. First cloth-based adhesive tape; 410. Second cloth-based adhesive tape;

[0031] 510. First mating connector; 520. Second mating connector; 530. Third mating connector; 540. Fourth mating connector;

[0032] 600, Ceramic Composite Belt. Detailed Implementation

[0033] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0034] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0035] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0036] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0037] Combination Figure 1 As shown, according to a specific embodiment of the present invention, a method for integrating flattened wire harnesses is provided. The method includes: determining the maximum outer diameter and total number of wires used to connect electrical components within a battery pack; calculating the remaining space dimension in the height direction of the battery pack based on the space dimension occupied by the electrical components; determining the height dimension of a protective shell based on the remaining space dimension, wherein the protective shell has a mounting groove, the wires include multiple wire layers, and the multiple wire layers are stacked in the mounting groove along the height direction of the mounting groove; determining the number of stacked wire layers based on the height dimension and the maximum outer diameter; determining the number of single-layer wires based on the number of stacked layers and the total number; determining the width dimension of the protective shell based on the maximum outer diameter of the wires and the number of single-layer wires; and installing the wires within the protective shell having the height dimension and the width dimension.

[0038] By applying the technical solution of this invention, the remaining space dimension in the height direction of the battery pack is calculated, and the height dimension of the protective shell is determined accordingly. Based on the height dimension, the maximum outer diameter of the wires, and the total number of wires, the number of overlapping layers and the number of single layers of the wires are finally determined. This allows the wire harness to be flattened and stored within the protective shell, fully and effectively utilizing the gap in the height direction of the battery pack. This avoids the defect of prior art requiring additional space for the wire harnesses wrapped into a cylindrical shape, thereby improving the energy density of the battery pack. The technical solution of this application effectively solves the technical problem in the prior art where the energy density of the battery pack is limited due to the excessive space occupied by the wire harnesses within the battery pack.

[0039] Furthermore, determining the maximum outer diameter and total number of wires used to connect electrical components within the battery pack includes: calculating the total number of wires based on the circuit system connection principle of the battery pack; determining the specifications of the wires according to the specifications of the electrical components; and determining the maximum outer diameter of the wires according to the specifications of the wires.

[0040] Further, based on the space occupied by the electrical components, the remaining space dimension in the height direction of the battery pack is calculated, including: obtaining the overall space dimension of the battery pack, the amplitude dimension of the battery pack cover, and the reserved safety dimension; and calculating the remaining space dimension in the height direction of the battery pack based on the overall space dimension, the amplitude dimension of the battery pack cover, the reserved safety dimension, and the space dimension occupied by the electrical components. Preferably, the value obtained by subtracting the amplitude dimension of the battery pack cover, the reserved safety dimension, and the space dimension occupied by the electrical components from the overall space dimension is the median value of the remaining space dimension. The remaining space dimension should be slightly smaller than the median value of the space dimensions.

[0041] Furthermore, after determining the width of the protective shell based on the maximum outer diameter of the conductor and the number of conductors in a single layer, the method further includes wrapping the surface of the protective shell with a ceramic composite tape before installing the conductors inside the protective shell, which has both height and width dimensions. This arrangement enhances the high-temperature resistance and burn protection of the protective shell, enabling it to withstand temperatures above 1000°C. In the event of thermal runaway in the battery pack, it prevents the plastic shell and wiring harness insulation from failing due to high-temperature electrolyte impact and splashing, thereby avoiding short circuits caused by exposed internal metal wires in the wiring harness coming into contact with each other. Figure 8As shown, the battery pack alarm triggering principle during thermal runaway is as follows: When thermal runaway occurs inside the battery pack, smoke or gas is generated in the initial stage. At this time, smoke sensors, pressure sensors, and other sensor devices receive these signals. When the signal value reaches the threshold (i.e., when the thermal runaway conditions meet the sensor's set value), the sensor issues a thermal runaway alarm signal. The alarm signal from the sensor is generally transmitted to the vehicle controller and other devices through the vehicle communication connector. Alternatively, the alarm signal is first transmitted to the battery management system, which, combined with other thermal runaway conditions (such as temperature, voltage, etc.), ultimately confirms a thermal runaway state. The battery management system then transmits the thermal runaway alarm signal to the vehicle controller and other devices through the vehicle communication connector. Further, the vehicle controller receives the thermal runaway alarm signal and sends it to the alarm / alarm device, which then issues an alarm sound or displays an alarm image to remind and urge the occupants to move away from the vehicle as soon as possible, providing them with escape time. Furthermore, when the vehicle controller receives a thermal runaway alarm signal, it may directly send the thermal runaway alarm signal to the alarm / warning device, or it may not send the signal directly but first send self-test or confirmation information to the battery management system. Only after confirming the thermal runaway state will it send the thermal runaway alarm signal to the alarm / warning device, preventing false alarms. When the battery pack experiences thermal runaway, it may be accompanied by arcing, fire, or cell valve ejection, which can cause high-temperature electrolyte eruption and splashing. This can damage the wiring harness insulation or its protective layer, leading to short circuits. Ultimately, the circuit system cannot transmit signals normally, and the thermal runaway alarm signal from the sensor cannot be transmitted to the alarm / warning device, posing a serious threat to the personal safety of the occupants.

[0042] In this example, the wiring harness device has a modular protective shell covered with a ceramic composite strip. This ceramic composite strip can withstand temperatures above 1000°C and prevent the plastic shell and wiring harness insulation from being damaged by the impact and splashing of high-heat electrolyte. It can protect the wiring harness in the event of thermal runaway and ensure that the thermal runaway alarm signal can be transmitted normally to the alarm / warning device, realizing the occupant reminder and urging function.

[0043] Furthermore, the sidewall of the mounting slot is provided with a groove structure for wrapping adhesive tape. After the wires are installed inside the protective housing with height and width dimensions, the method further includes: fixing the wires in the mounting slot using cloth tape; fixing the protective housing using foam adhesive tape; and electrically connecting multiple mating connectors to at least a portion of the wires. This arrangement provides further fixation and protection for the wire harness, as well as enabling information exchange and energy transfer with other components.

[0044] The number of stacked wires is determined based on the height dimension and the maximum outer diameter, including: calculating the quotient of the height dimension and the maximum outer diameter as a first intermediate value; approximating the first intermediate value to obtain the number of stacked layers. For example, if the height dimension is 9mm and the maximum outer diameter is 2mm, the calculated first intermediate value is 4.5. Rounding the first intermediate value of 4.5 down, the number of stacked layers is 4.

[0045] Further, the width dimension of the protective shell is determined based on the maximum outer diameter of the conductor and the number of conductors in a single layer, including: calculating the product of the maximum outer diameter of the conductor and the number of conductors in a single layer as a second intermediate value; and calculating the sum of the second intermediate value and the wall thickness of the protective shell as the width dimension.

[0046] Furthermore, the protective shell includes a head shell section, a middle shell section, and a tail shell section. The head shell section, middle shell section, and tail shell section have different structures. After determining the width of the protective shell based on the maximum outer diameter of the conductor and the number of conductors in a single layer, the method further includes: determining the arrangement path and length of the conductors based on the circuit system connection principle of the battery pack; selecting a corresponding number of middle shell sections according to the conductor length; and combining the head shell section, the corresponding number of middle shell sections, and the tail shell section according to the arrangement path so that the head shell section, middle shell section, and tail shell section together form a mounting groove. In other words, by dividing the protective shell into several modular shell sections, engineers can combine different numbers and specifications of modular protective shells (i.e., head shell section, middle shell section, and tail shell section) according to the wiring harness assembly arrangement requirements (i.e., the arrangement path and length) to achieve the expected design requirements.

[0047] Furthermore, selecting a corresponding number of intermediate shell segments based on the length of the conductor includes: obtaining the length of a single intermediate shell segment; calculating the quotient of the length of the conductor and the length of a single intermediate shell segment to obtain the number of intermediate shell segments.

[0048] In an optional embodiment, the flattened wire harness integration method includes:

[0049] Step S1: Design a low-voltage topology based on the internal electrical component layout of the battery pack (including cells / modules, battery management system, battery disconnection unit, vehicle communication connector, water temperature sensor, pressure sensor, smoke sensor, etc.), as the input for the low-voltage circuit system connection principle design. For example... Figure 2 As shown, the battery management system is connected to the vehicle communication connector, the battery management system is connected to the battery disconnection unit, the battery management system is connected to the battery cells / modules, the battery management system is connected to sensors, etc., the sensors are connected to the vehicle communication connector (optionally, the two can not be connected, and information can be transmitted through the battery management system), and the battery disconnection unit is connected to the vehicle communication connector.

[0050] Step S2: Based on the connection principle of the low-voltage circuit system, calculate the number of wires used in each low-voltage circuit. The number of wires used in the main circuit is n (in this embodiment, 45 wires are used as an example; other branch circuits are not counted). Select appropriate wire specifications according to the specifications of the connected electrical components, and determine the wire specification m (in this embodiment, 0.5mm²). 2 (Taking the national standard conductor specifications as an example). Based on the specifications of the selected conductor, determine the maximum outer diameter d of each conductor (in this example, the maximum outer diameter is 2mm). Finally, confirm the harness layout path and the number of conductors in each path, see [reference needed]. Figure 4 As shown.

[0051] Step S3: Calculate the remaining space dimension of the battery pack in the Z-direction (i.e., the height direction) based on the space allocated to other electrical components inside the battery pack. Calculate the maximum outer envelope height dimension k of the wiring harness integration device (i.e., the protective shell) based on the amplitude dimension of the battery pack cover and the reserved safety dimension (the maximum outer envelope height dimension refers to the maximum physical entity height dimension). In this example, k is 8mm.

[0052] Step S4: Based on the number of conductors n (45 conductors in this embodiment), the maximum outer diameter of each conductor (2mm), and the single-sided wall thickness of the modular housing (1.5mm in this embodiment), calculate the number of stacked layers of conductors. The stacking layer number in the height direction is calculated as (kl) / 2, i.e., (8-1.5) / 2 = 3.25, rounded down (3 in this embodiment), meaning a total of three layers of conductors are arranged. The total number of conductors is 45, with 15 conductors arranged in each layer. The final calculation confirms that the maximum outer envelope width h of the wire harness integration device (i.e., the protective housing) is 34mm (h = 31mm + 2 * 1.5mm). Figure 3 As shown, the final wire arrangement is 3*15.

[0053] Step S5: Based on the maximum outer envelope height k (8mm) and width h (34mm) of the wire harness integration device, combined with the wire harness routing length and the surrounding structural environment, determine the quantity and type of modular housing (i.e., head housing segment, middle housing segment, and tail housing segment) to realize the design of the modular housing.

[0054] Step S6: Install the wires in the modular housing (i.e., protective housing) at predetermined positions. The modular housing is covered with ceramic composite tape. The wires are wrapped and fixed using cloth tape, and foam adhesive tape is installed at predetermined positions, along with mating connectors to secure the wires, ultimately achieving a flattened wire harness integration design. This embodiment uses the low-voltage wire harness of a battery pack as an example; the same integration method applies to the high-voltage wire harness of the battery pack.

[0055] It should be noted that the flattened wire harness integration method in the above embodiments can be stored in a computer-readable storage medium, such as the memory of an industrial robot. The process robot generates control commands based on the above flattened wire harness integration method and controls the execution components to automatically integrate the wire harness within the battery pack.

[0056] In another alternative embodiment, this application also provides a wire harness integration device. For example... Figure 4 As shown, the wire harness integration device comprises several wires 100 (45 wires in this example), several first protective shells 210, second protective shells 220, and third protective shells 230, several foam adhesive tapes 300, several first cloth adhesive tapes 400, several second cloth adhesive tapes 410, first mating connectors 510, second mating connectors 520, third mating connectors 530, and fourth mating connectors 540. Various protective shells have wire grooves (i.e., mounting grooves) for placing the wires. Ceramic composite tape is wrapped around the exterior of various protective shells. The protective shells have groove structures for wrapping and fixing the internal wire harness with cloth adhesive tape. The mating connectors connect to the wire harness for information and energy exchange with electrical components. The wires 100 (45 wires in this example, 0.5mm² national standard wire specification) are used to realize the transmission of low-voltage signals and energy between electrical components. The first protective shell 210, the second protective shell 220, and the third protective shell 230 all have internal grooves for placing the wires 100. The lower outer surface of each of the three types of protective shells has an adhesive area for attaching foam adhesive tape 300. Ceramic composite tape is wrapped around the outer surface of each of the three types of protective shells. Grooves are provided in the outer sidewalls of each of the three types of protective shells for attaching the first cloth-based adhesive tape 400 and the second cloth-based adhesive tape 410 to secure the wires 100.

[0057] The first mating connector 510 is fixedly mounted on the second protective shell 220 (or can be fixed on the battery pack mounting panel) and connected to the wire 100. The first mating connector 510 is used to mate with the vehicle-side communication connector to realize the information and energy exchange function between the battery and the vehicle.

[0058] The second mating connector 520 can be fixedly mounted on the modular protective housing or exist as a standalone wiring harness branch. The second mating connector 520 connects to a portion of the wires in the wire 100. The second mating connector 520 is used to interface with the BMS (Battery Management System) to achieve signal and energy exchange.

[0059] The third mating connector 530 can be fixedly installed on the modular protective housing or exist as a separate wiring harness branch. The third mating connector 530 connects to some of the wires in the wire 100. It also interfaces with sensors (such as pressure sensors, temperature sensors, smoke sensors, etc.) to achieve signal and energy interaction. Upon receiving a thermal runaway signal, the third mating connector 530 processes the signal (or not) through the battery management system and then sends it to the vehicle controller via the first mating connector 510. This transmits the thermal runaway hazard information to the vehicle occupants via an alarm to provide a safety warning.

[0060] The fourth mating connector 540 can be fixedly mounted on the modular protective housing or exist as a standalone wiring harness branch. The fourth mating connector 540 connects to a portion of the wires in the wire 100 and is used to mate with the BDU (Battery Disconnect Unit) to achieve signal and energy exchange.

[0061] In a preferred embodiment, this application also provides a modular protective shell, such as... Figures 5 to 7 As shown, the modular protective shell includes several protective shell segments located at different positions, which can be divided into a first protective shell 210 at the front end (i.e., the head shell segment), a second protective shell 220 at the rear end (i.e., the tail shell segment), and a third protective shell 230 in the middle (i.e., the middle shell segment). This embodiment only lists three types of modular protective shells; other types of modular protective shells can be designed according to requirements.

[0062] like Figure 5 As shown, the first protective shell 210 is provided with a mounting groove 211 for placing the wire 100, a cloth tape winding structure 212, a foam adhesive tape bonding structure 213, a first limiting structure 214, and a second limiting structure 215. The first limiting structure 214 is used to limit and position the modular protective shells, and the second limiting structure 215 is used to limit and position the modular protective shells themselves. The surface of the first protective shell 210 is covered with a ceramic composite tape 600.

[0063] like Figure 6 As shown, the second protective shell 220 is provided with a mounting groove 211 for placing the wire 100, a cloth tape winding structure 212, a foam adhesive tape bonding structure 213, a first limiting structure 214, a second limiting structure 215, and a mounting positioning structure 216 for connecting with the first mating connector 510. The surface of the second protective shell 220 is covered with a ceramic composite tape 600.

[0064] like Figure 7As shown, the third protective shell 230 is provided with an installation groove 211 for placing the wire 100, a cloth tape winding structure 212, a foam adhesive tape bonding structure 213, a first limiting structure 214, and a second limiting structure 215. The surface of the third protective shell 230 is covered with a ceramic composite tape 600. Through the modular protective shell and special structural design (including positioning, anti-misalignment, fixing, wire groove and other structural features), the wire harness device is easy to install, and the physical protection of the wire harness is strengthened to improve wear resistance.

[0065] A modular protective housing assembly typically consists of one first protective housing 210, one second protective housing 220, and several third protective housings 230. The overall length is determined by the number of third protective housings 230, meaning the unit length dimension of each third protective housing 230 is t. The total length of the wire harness protective housing is equal to the sum of the lengths of a single first protective housing 210, a single second protective housing 220, and the lengths t of n third protective housings 230. In this embodiment, the wires 100 are arranged in 3 rows and 15 columns; however, the arrangement of the wires 100 and the specifications of the protective housing can be arbitrarily configured according to specific circumstances.

[0066] The first protective shell 210 and the second protective shell 220 serve as the beginning and end protection components of the conductor 100 and can be designed according to actual needs. The middle third protective shell 230 serves as a wire harness length unit and can be selected according to the total length requirements of the wire harness arrangement. Compared with the overall protective shell design, the slender plastic shell is prone to bending deformation and bending damage.

[0067] As can be seen from the above description, the embodiments of the present invention achieve the following technical effects:

[0068] The technical solution of this application proposes a flattened wire harness integration method and a flattened wire harness, which can effectively solve the problems existing in the prior art and optimize the existing wire harness in terms of fixing, assembly, maintenance, and protection. By coating the surface of the protective shell with ceramic composite tape, it can withstand high temperatures of over 1000℃ and prevent electrolyte impact and splashing from causing failure of the plastic shell and wire harness insulation layer, ensuring normal transmission of circuit signals and avoiding phenomena such as failure to trigger alarms in the event of thermal runaway. The wire harness is flattened and protected by combining multiple modular shells. The flattened wire harness integration method in the above embodiments calculates the height of the wire harness to be arranged and makes reasonable use of the idle space in the Z-axis height inside the battery pack to achieve the purpose of arranging the wire harness. The integrated wire harness device composed of protective shell, cloth tape, and mating connectors has the advantage of high assembly efficiency and can improve the battery pack production efficiency. Compared with the flexibility of wire harnesses, the integrated wire harness device can realize mechanized assembly, and its replacement and maintenance operations are simple and convenient, without the need for additional auxiliary parts. A design scheme with fewer components can achieve cost reduction and weight reduction, ultimately increasing battery energy density.

[0069] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0070] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0071] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0072] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for integrating flattened wire harnesses, characterized in that, include: Determine the maximum outer diameter and total number of wires used to connect the electrical components within the battery pack; Based on the space occupied by the electrical components, calculate the remaining space in the height direction of the battery pack, wherein the space occupied by the electrical components is the space inside the battery pack for the arrangement of other electrical components excluding wires; The height of the protective shell is determined based on the remaining space dimensions. The protective shell has a mounting groove, and the wire includes multiple wire layers, which are stacked in the mounting groove along the height direction. The number of stacked layers of the conductor is determined based on the height dimension and the maximum outer diameter; The number of conductors in a single layer is determined based on the number of stacked layers and the total number; The width of the protective shell is determined based on the maximum outer diameter of the conductor and the number of conductors in a single layer; The wire is installed inside the protective housing having the height and width dimensions.

2. The method according to claim 1, characterized in that, Determining the maximum outer diameter and total number of wires used to connect electrical components within the battery pack includes: Based on the circuit system connection principle of the battery pack, the total number of wires is calculated; The specifications of the wires are determined according to the specifications of the electrical components; The maximum outer diameter of the conductor is determined according to the conductor's specifications.

3. The method according to claim 1, characterized in that, Based on the space occupied by the electrical components, calculate the remaining space in the height direction of the battery pack, including: Obtain the overall spatial dimensions of the battery pack, the amplitude of the battery pack cover, and the reserved safety dimensions; The remaining space dimension in the height direction of the battery pack is calculated based on the overall space dimension, the amplitude dimension of the battery pack cover, the reserved safety dimension, and the space dimension occupied by the electrical components.

4. The method according to claim 1, characterized in that, After determining the width dimension of the protective shell based on the maximum outer diameter of the conductor and the number of conductors in a single layer, before installing the conductor inside the protective shell having the height dimension and the width dimension, the method further includes: The ceramic composite tape is wrapped around the surface of the protective shell.

5. The method according to claim 1, characterized in that, The mounting groove has a groove structure for wrapping tape on its side wall. After the wire is installed in the protective shell having the height and width dimensions, the method further includes: The wire is fixed in the mounting groove using cloth tape; The protective shell is secured using foam adhesive tape; Multiple mating connectors are electrically connected to at least a portion of the wires.

6. The method according to claim 1, characterized in that, Determining the number of stacked layers of the conductor based on the height dimension and the maximum outer diameter includes: The quotient of the height dimension and the maximum outer diameter is calculated as a first intermediate value; The number of stacking layers is obtained by approximating the first intermediate value.

7. The method according to claim 1, characterized in that, The width dimension of the protective shell is determined based on the maximum outer diameter of the conductor and the number of conductors in a single layer, including: The product of the maximum outer diameter of the conductor and the number of conductors in a single layer is calculated as the second intermediate value; The width dimension is calculated by summing the second intermediate value and the wall thickness of the protective shell.

8. The method according to claim 1, characterized in that, The protective shell includes a head shell section, a middle shell section, and a tail shell section, with the head shell section, the middle shell section, and the tail shell section having different structures. After determining the width of the protective shell based on the maximum outer diameter of the conductor and the number of conductors in a single layer, the method further includes: Based on the circuit system connection principle of the battery pack, the arrangement path and length of the wires are determined; Select the corresponding number of intermediate shell segments according to the length of the conductor; The head housing segment, the corresponding number of intermediate housing segments, and the tail housing segment are combined according to the arrangement path so that the head housing segment, the intermediate housing segment, and the tail housing segment together form the mounting groove.

9. The method according to claim 8, characterized in that, The number of intermediate shell segments is selected according to the length of the conductor, including: Obtain the length of a single intermediate shell segment; The number of intermediate shell segments is obtained by calculating the quotient of the length of the conductor and the length of a single intermediate shell segment.

10. A flattened integrated wire harness, characterized in that, The flattened integrated wire harness is obtained by the flattened wire harness integration method according to any one of claims 1 to 9.

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