Double-row single-interface wire harness and manufacturing method thereof

Abstract

The embodiment of the invention provides a double-row single-interface wire harness and a manufacturing method thereof, and relates to the field of battery manufacturing. The double-row single-interface wire harness comprises a plug board, a first branch assembly and a second branch assembly, the first branch assembly and the second branch assembly are connected with the plug board, the first branch assembly comprises a first branch and a fourth branch, one end of the first branch and one end of the fourth branch are connected with the plug board, and the second branch assembly is arranged between the first branch and the fourth branch. And a first crease is arranged between the first branch assembly or the second branch assembly and the plug board. The second branch assembly comprises a first connecting plate, a second connecting plate and a second branch assembly body which are connected in sequence, the first connecting plate is connected with the plug board, a second crease is arranged between the first connecting plate and the second connecting plate, a third crease is arranged between the second connecting plate and the second branch assembly body, and the second connecting plate is connected with the plug board. And the first branch assembly body and the second branch assembly body are arranged in parallel. The space of the electric appliance bin can be optimized, and the material cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of battery manufacturing, and in particular to a double-row single-interface wiring harness and a manufacturing method thereof. Background Art

[0002] With the rapid development of new energy vehicles, battery packs, as a core component, are experiencing continuous advancements in design technology. Currently, battery packs primarily utilize dual-row or multi-row modules, or integrated modules. In battery pack design, the CCS assembly is a key component connecting the battery modules to the battery management system, and its design directly impacts the performance and reliability of the battery pack.

[0003] The CCS component design generally adopts a design method of matching a row of battery packs with a row of low-voltage wiring harnesses such as FPC, FFC or FDC. This design method will lead to an increase in the number of wiring harnesses for the extension ports and complicate the wiring harness layout when there are many battery pack groups in the battery pack. Specifically, it is necessary to match and plug multiple sets of wiring harness interfaces when arranging the collection harness. The multiple strands of wiring harnesses extended from them are complicated to route in the front electrical compartment, which seriously occupies the electrical compartment space and takes up a lot of labor costs in the wiring harness layout process. Although a straight-plug design can be used to reduce the number of wiring harnesses in the lead-out section, it is still impossible to reduce the number of straight-plug boards. In addition, although there are some designs that merge multiple branches, the wiring harness designed in the current solution is too long. It is only a simple superposition design, which increases material costs and is not conducive to large-scale production. Summary of the Invention

[0004] The purpose of the present invention includes providing a double-row single-interface wiring harness and a manufacturing method thereof, which can realize that the double-row wiring harness shares one interface, reduce the number of wiring harnesses or straight plug-in boards at the lead-out end, optimize the electrical compartment space, reduce the substrate area by cutting and bending, and reduce material costs.

[0005] The embodiments of the present invention can be implemented as follows:

[0006] In a first aspect, the present invention provides a double-row single-interface wiring harness, comprising a plugboard, a first branch assembly and a second branch assembly connected to the plugboard, wherein the first branch assembly comprises a first branch and a fourth branch, one end of the first branch and the fourth branch being connected to the plugboard, and the second branch assembly being disposed between the first branch and the fourth branch;

[0007] A first fold is provided between the first branch component or the second branch component and the plug board, so that the first branch component or the second branch component can be folded 180 degrees;

[0008] The second branch component includes a first connecting plate, a second connecting plate and a second branch component body connected in sequence, the first connecting plate is connected to the plug-in plate, a second fold is provided between the first connecting plate and the second connecting plate so that the first connecting plate and the second connecting plate are folded 90 degrees, and a third fold is provided between the second connecting plate and the second branch component body so that the second connecting plate and the second branch component body are folded 90 degrees, thereby making the first branch component and the second branch component body arranged in parallel.

[0009] In an optional embodiment, a fourth fold is provided on the first branch, a fifth fold is provided on the fourth branch, the first branch is folded along the fourth fold, and the fourth branch is folded along the fifth fold to reduce the distance between the first branch and the fourth branch.

[0010] In an optional embodiment, the width of the plug board is W1. Before folding, the total width of the first branch and the fourth branch is W. The sides of the first branch and the fourth branch are respectively protruded relative to the plug board. The distance from the sides of the first branch and the fourth branch to the plug board is W2, where W=W1+W2*2.

[0011] In an optional embodiment, the width of the first branch is W8, the width of the fourth branch is W9, and after folding, W≥W8+W9.

[0012] In an optional embodiment, the end of the first branch away from the fourth branch is used to connect to the bar piece, and the end of the fourth branch away from the first branch is used to connect to the bar piece. After folding, the gap between the first branch and the bar piece is W6, and the gap between the fourth branch and the bar piece is W7, wherein 0≤W6≤2mm, 0≤W7≤2mm.

[0013] In an optional embodiment, before folding, the distance that the first branch protrudes from the bar piece is W4, the distance that the fourth branch protrudes from the bar piece is W3, and the distance between the bar pieces in the single-row module is W5, where W=W4+W3+W5.

[0014] In an optional embodiment, the second branch assembly body further includes a second branch and a third branch, one end of the second branch is connected to the second connecting plate, the other end of the second branch is connected to the fifth branch, one end of the third branch is connected to the second connecting plate, and the other end of the third branch is connected to the sixth branch;

[0015] The fifth branch is connected to the second branch via a third connecting plate. A sixth fold is provided between the third connecting plate and the second branch, so that the third connecting plate and the second branch are folded 180 degrees. A seventh fold is provided between the third connecting plate and the fifth branch, so that the fifth branch and the third connecting plate are folded 180 degrees.

[0016] The sixth branch is connected to the third branch through a fourth connecting plate. An eighth fold is provided between the fourth connecting plate and the third branch so that the fourth connecting plate and the third branch are folded 180 degrees. A ninth fold is provided between the fourth connecting plate and the sixth branch so that the sixth branch and the fourth connecting plate are folded 180 degrees.

[0017] In an optional embodiment, the total length of the double-row single-interface wiring harness is L, the length of the plug board is L5, the length of the first branch is L1, the length of the fifth branch is L2, wherein L>L1+L2+L5; the length of the fourth branch is L3, the length of the sixth branch is L4, wherein L>L3+L4+L5.

[0018] In a second aspect, the present invention provides a method for manufacturing a double-row single-interface wiring harness, including the double-row single-interface wiring harness described in one of the aforementioned embodiments, the steps comprising:

[0019] S1. Cutting the features of the plug board, the first branch component and the second branch component on the wiring harness substrate;

[0020] S2, folding the first branch component and the second branch component 180 degrees in opposite directions;

[0021] S3. Fold the second branch assembly twice by 90 degrees, so that the second branch assembly body is folded to a position parallel to the first branch assembly.

[0022] In an optional embodiment, the steps further include:

[0023] S4. Bend the first branch and the fourth branch to achieve inward contraction of the first branch and the fourth branch.

[0024] The double-row single-interface wiring harness and the method for manufacturing the double-row single-interface wiring harness provided by the embodiments of the present invention have the following beneficial effects:

[0025] The double-row single-interface wiring harness of the present invention includes a plug-in board, a first branch assembly connected to the plug-in board, and a second branch assembly. The first branch assembly includes a first branch and a fourth branch. One end of the first branch and the fourth branch are connected to the plug-in board, and the second branch assembly is arranged between the first branch and the fourth branch. A first fold is provided between the first branch assembly or the second branch assembly and the plug-in board so that the first branch assembly or the second branch assembly can be folded 180 degrees. The second branch assembly includes a first connecting plate, a second connecting plate, and a second branch assembly body connected in sequence. The first connecting plate is connected to the plug-in board. A second fold is provided between the first connecting plate and the second connecting plate so that the first connecting plate and the second connecting plate can be folded 90 degrees. A third fold is provided between the second connecting plate and the second branch assembly body so that the second connecting plate and the second branch assembly body can be folded 90 degrees, thereby making the first branch assembly and the second branch assembly body arranged in parallel. By first folding the second branch assembly between the first and fourth branches 180 degrees and then continuously bending the second branch assembly 90 degrees, the second branch assembly body is arranged parallel to the first branch assembly. The first branch assembly is used to connect the first row of battery modules, and the second branch assembly body is used to connect the second row of battery modules. This invention can achieve a dual-row wiring harness sharing a single interface, reducing the number of wiring harnesses or direct plug-in boards at the lead-out end, optimizing the space in the electrical compartment, reducing the base material area through cutting and bending, and reducing material costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0027] Figure 1 A schematic diagram of the structure of a double-row, single-interface wiring harness provided by the first embodiment of the present invention after folding;

[0028] Figure 2 A schematic structural diagram of a double-row, single-interface wiring harness provided by the first embodiment of the present invention before folding;

[0029] Figure 3 A schematic diagram of the first state structure of a double-row single-interface provided by the first embodiment of the present invention installed on a battery;

[0030] Figure 4 A schematic diagram of the second state structure of the double-row single-interface provided by the first embodiment of the present invention installed on a battery;

[0031] Figure 5A schematic structural diagram of a first state of a double-row, single-interface wiring harness folding process according to a first embodiment of the present invention;

[0032] Figure 6 A schematic structural diagram of the second state of the double-row single-interface wiring harness folding process provided by the first embodiment of the present invention;

[0033] Figure 7 A schematic structural diagram of the third state of the double-row single-interface wiring harness folding process provided by the first embodiment of the present invention;

[0034] Figure 8 A schematic structural diagram of the fourth state of the double-row single-interface wiring harness folding process provided by the first embodiment of the present invention;

[0035] Figure 9 A schematic structural diagram of the fifth state of the double-row single-interface wiring harness folding process provided by the first embodiment of the present invention;

[0036] Figure 10 A schematic diagram of the structure of a double-row, single-interface wiring harness provided by the second embodiment of the present invention after folding;

[0037] Figure 11 This is a schematic structural diagram of a double-row single-interface wiring harness provided by the second embodiment of the present invention before folding.

[0038] Icons: 100-double-row single-interface wiring harness; 10-plug-in board; 20-first branch assembly; 21-first branch; 211-fourth fold; 22-fourth branch; 221-fifth fold; 23-first fold; 30-second branch assembly; 31-first connecting plate; 311-second fold; 32-second connecting plate; 321-third fold; 33-second branch assembly body; 331-second branch; 332-third branch; 34-fifth branch; 341-third connecting plate; 342-sixth fold; 343-seventh fold; 35-sixth branch; 351-fourth connecting plate; 352-eighth fold; 353-ninth fold; 200-battery module; 201-battery piece. DETAILED DESCRIPTION

[0039] Current battery pack designs include dual-row or multi-row module assembly, or CTP integrated assembly. CCS assembly designs typically employ a row of 200 battery modules paired with a row of low-voltage wiring harnesses, such as FPC / FFC / FDC. The more battery packs arranged in the pack, the more lead-out terminals are required for the single-row low-voltage wiring harness. These terminals require wiring harnesses, which complicates wiring within the electrical compartment and significantly occupies space.

[0040] In response to the above problems, the present invention provides a double-row single-interface wiring harness 100 and a manufacturing method thereof, which can enable the double-row wiring harness to share one interface, reduce the number of wiring harnesses or straight-plug boards at the lead-out end, optimize the electrical compartment space, reduce the substrate raw material area by cutting and bending, and reduce material costs.

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0042] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are intended to fall within the scope of protection of the present invention.

[0043] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0044] In the description of the present invention, it should be noted that if the terms "upper", "lower", "inside", "outside", etc. appear, the orientation or position relationship indicated is based on the orientation or position relationship shown in the accompanying drawings, or is the orientation or position relationship in which the product of the invention is usually placed when in use. It is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be understood as a limitation on the present invention.

[0045] In addition, the terms "first", "second", etc., if used, are merely used to distinguish and describe, and should not be understood as indicating or implying relative importance.

[0046] It should be noted that, in the absence of conflict, the features in the embodiments of the present invention may be combined with each other.

[0047] In addition, for ease of understanding, the professional terms involved in the embodiments of the present invention are explained in detail in the following table:

[0048] Professional term 1: CCS, Cell contact system, integrated busbar;

[0049] Professional term 2: FPC, Flexible printed circuit, flexible circuit board;

[0050] Professional term 3: CTP, Cell to Pack, module-free power battery pack;

[0051] Professional term 4: NTC, Negative temperature codfficient, thermistor.

[0052] The overall structure, working principle and technical effects of the double-row single-interface wiring harness 100 provided by the present invention, as well as the detailed steps, implementation principles and technical effects of the corresponding manufacturing method are described in detail below through embodiments and in combination with the accompanying drawings.

[0053] First embodiment

[0054] Please refer to Figure 1 and Figure 2 An embodiment of the present invention provides a double-row, single-interface wiring harness 100, which includes a plugboard 10, a first branch assembly 20 connected to the plugboard 10, and a second branch assembly 30. The first branch assembly 20 includes a first branch 21 and a fourth branch 22, one end of each of which is connected to the plugboard 10, and the second branch assembly 30 is disposed between the first branch 21 and the fourth branch 22. A first fold 23 is provided between the first branch assembly 20 or the second branch assembly 30 and the plugboard 10, allowing the first branch assembly 20 or the second branch assembly 30 to fold 180 degrees. The second branch assembly 30 includes a first connecting plate 31, a second connecting plate 32 and a second branch assembly body 33 connected in sequence. The first connecting plate 31 is connected to the plug-in board 10. A second fold 311 is provided between the first connecting plate 31 and the second connecting plate 32 so that the first connecting plate 31 and the second connecting plate 32 are folded 90 degrees. A third fold 321 is provided between the second connecting plate 32 and the second branch assembly body 33 so that the second connecting plate 32 and the second branch assembly body 33 are folded 90 degrees, thereby making the first branch assembly 20 and the second branch assembly body 33 arranged in parallel.

[0055] It is understood that in this embodiment, the double-row single-interface wiring harness 100 is formed by cutting and bending a whole piece of substrate material. Specifically, the specific shapes of the first branch component 20 and the second branch component 30 are cut out of the substrate material and folded.

[0056] In this embodiment, the dual-row, single-interface wiring harness 100 utilizes a plug-in connector solution. The second branch assembly 30 is folded toward the back of the plugboard 10. The second connecting plate 32 is then bent upward 90 degrees, and the second branch assembly body 33 is further bent 90 degrees, ultimately placing the second branch assembly body 33 parallel to the first branch assembly 20. The first branch assembly 20 is used to connect to the first row of battery modules 200, while the second branch assembly body 33 is used to connect to the second row of battery modules 200.

[0057] It is understood that in this embodiment, the first fold 23 is perpendicular to the extension direction of the first branch component 20. The second fold 311 and the third fold 321 are respectively at 45 degrees to the extension direction of the second branch component 30, and the second fold 311 and the third fold 321 are perpendicular to each other.

[0058] Furthermore, a fourth fold 211 is provided on the first branch 21, and a fifth fold 221 is provided on the fourth branch 22. The first branch 21 is folded along the fourth fold 211, and the fourth branch 22 is folded along the fifth fold 221 to reduce the distance between the first branch 21 and the fourth branch 22.

[0059] Specifically, in this embodiment, the fourth fold 211 is two folds at an angle to the extension direction of the first branch 21, and the fifth fold 221 is two folds at an angle to the extension direction of the fourth branch 22, so that the first branch 21 and the fourth branch 22 are folded inward twice. It can be understood that since the double-row single-interface wiring harness 100 in this embodiment is manufactured by cutting and bending, the first branch 21 and the fourth branch 22 are located on both sides of the second branch assembly 30, wherein the width of the second branch assembly 30 is set to match the distance between the single-row module battery tabs 201. Then, the total width of the first branch 21 and the fourth branch 22 is greater than the distance between the single-row module battery tabs 201. In this case, the width of the first branch 21 and the fourth branch 22 needs to be reduced, that is, the first branch 21 and the fourth branch 22 are folded inward toward the gap between them.

[0060] Specifically, in this embodiment, the width of the plugboard 10 is W1, and before folding, the total width of the first branch 21 and the fourth branch 22 is W. It is understood that the total width of the substrate is W. The side edges of the first branch 21 and the fourth branch 22 are respectively protruded relative to the plugboard 10. The distance from the side edges of the first branch 21 and the fourth branch 22 to the plugboard 10 is W2, where W=W1+W2*2. It is understood that the side edges of the first branch 21 and the fourth branch 22 are respectively protruded relative to the plugboard 10, widening the total width of the substrate to ensure that the low-voltage wiring harness has sufficient distance to run.

[0061] Please refer to Figure 3, the width of the first branch 21 is W8, and the width of the fourth branch 22 is W9. After folding, W≥W8+W9. It is understood that after folding, a gap is left between the first branch 21 and the fourth branch 22 to prevent interference between the first branch 21 and the fourth branch 22 during folding.

[0062] Furthermore, the end of the first branch 21 away from the fourth branch 22 is used to connect the bar 201, and the end of the fourth branch 22 away from the first branch 21 is used to connect the bar 201. It can be understood that in this embodiment, both sides of the first branch assembly 20 are used to connect the bar 201. The bar 201 of the single-row module battery is located on both sides of the first branch assembly 20. When the first branch 21 and the fourth branch 22 are folded, the gap between the first branch 21 and the bar 201 is W6, and the gap between the fourth branch 22 and the bar 201 is W7, where 0≤W6≤2mm and 0≤W7≤2mm. It can be understood that by setting W6 and W7, an installation gap can be reserved between the first branch 21 and the fourth branch 22 and the bar 201.

[0063] Please refer to Figure 4 Before folding, both the first branch 21 and the fourth branch 22 protrude beyond the tab 201. The first branch 21 protrudes from the tab 201 by a distance W4, and the fourth branch 22 protrudes from the tab 201 by a distance W3. The distance between the tabs 201 in a single-row module is W5. It should be understood that W5 refers to the distance between the tabs 201 on both sides of the first branch assembly 20. Here, W = W4 + W3 + W5.

[0064] Please continue to refer to Figure 1 and Figure 2 In this embodiment, the second branch assembly body 33 further includes a second branch 331 and a third branch 332. One end of the second branch 331 is connected to the second connecting plate 32, and the other end of the second branch 331 is connected to the fifth branch 34. One end of the third branch 332 is connected to the second connecting plate 32, and the other end of the third branch 332 is connected to the sixth branch 35.

[0065] It will be appreciated that, in this embodiment, before the substrate is cut, the length of the first branch component 20 is shorter than that of the second branch component 30. After the second branch component 30 is bent, the length of the second branch component body 33 is shorter than that of the first branch component 20. To increase the length of the second branch component body 33, in this embodiment, a fifth branch 34 is added at one end of the second branch 331, and a sixth branch 35 is added at one end of the third branch 332. Before folding, the fifth branch 34 is located as an extension of the first branch 21, and the sixth branch 35 is located as an extension of the fourth branch 22. After folding, the fifth branch 34 is located as an extension of the second branch 331, and the sixth branch 35 is located as an extension of the third branch 332. By setting the fifth branch 34 on the extended path of the first branch 21 and the sixth branch 35 on the extended path of the fourth branch 22, the substrate can be fully utilized and the utilization rate of the substrate can be improved. That is, in this embodiment, before cutting, the substrate adopts a rectangular structure to reduce waste from cutting the substrate.

[0066] Specifically, the fifth branch 34 is connected to the second branch 331 through the third connecting plate 341, and a sixth fold 342 is provided between the third connecting plate 341 and the second branch 331 so that the third connecting plate 341 and the second branch 331 are folded 180 degrees. A seventh fold 343 is provided between the third connecting plate 341 and the fifth branch 34 so that the fifth branch 34 and the third connecting plate 341 are folded 180 degrees.

[0067] The sixth branch 35 is connected to the third branch 332 through the fourth connecting plate 351. An eighth fold 352 is provided between the fourth connecting plate 351 and the third branch 332 so that the fourth connecting plate 351 and the third branch 332 are folded 180 degrees. A ninth fold 353 is provided between the fourth connecting plate 351 and the sixth branch 35 so that the sixth branch 35 and the fourth connecting plate 351 are folded 180 degrees.

[0068] In this embodiment, the total length of the double-row, single-interface wiring harness 100 is L, the length of the plugboard 10 is L5, the length of the first branch 21 is L1, and the length of the fifth branch 34 is L2, where L> L1+L2+L5; the length of the fourth branch 22 is L3, and the length of the sixth branch 35 is L4, where L> L3+L4+L5. It will be understood that the total length of the double-row, single-interface wiring harness 100 refers to the total length of the substrate before cutting. It will be understood that in this embodiment, before cutting, a gap is provided between the first branch 21 and the fifth branch 34, and a gap is provided between the fourth branch 22 and the sixth branch 35 to meet design requirements.

[0069] Please refer to Figure 1 、 Figure 2 and Figure 5-Figure 9The forming principle and process of the double-row single-interface wiring harness 100 provided in this embodiment are as follows:

[0070] By cutting the base material, the shape features of the plug board 10, the first branch component 20 and the second branch component 30 are formed, and folds are engraved thereon.

[0071] The second branch assembly 30 is folded downward 180 degrees along the first fold line 23 .

[0072] The second connecting plate 32 and the second branch assembly body 33 are folded upward 90 degrees along the second fold line 311 .

[0073] The second branch assembly body 33 is folded rightward 90 degrees along the third fold line 321 so that the second branch assembly body 33 is arranged parallel to the first branch assembly 20 .

[0074] Along the sixth fold 342 and the seventh fold 343, the fifth branch 34 at the tail end of the second branch 331 is folded inward so that the fifth branch 34 is flush with the second branch 331; along the eighth fold 352 and the ninth fold 353, the sixth branch 35 at the tail end of the third branch 332 is folded inward so that the sixth branch 35 is flush with the third branch 332, thereby extending the second branch component body 33.

[0075] Along the fourth fold 211, fold the first branch 21 on both sides toward the fourth branch 22, and shrink the first branch 21 inward to ensure that the outer side of the first branch 21 does not exceed the bar 201; along the fifth fold 221, fold the fourth branch 22 on both sides toward the first branch 21, and shrink the fourth branch 22 inward to ensure that the outer side of the fourth branch 22 does not exceed the bar 201.

[0076] Second embodiment

[0077] Please refer to Figure 10 and Figure 11 The present invention provides another embodiment of a dual-row, single-interface wiring harness 100. Its general structure is the same as the first embodiment described above, except that, in this embodiment, the dual-row, single-interface wiring harness 100 utilizes a direct plug-in solution. In this embodiment, the position of the first fold 23 is different; it is located on the first branch assembly 20. By folding the first branch assembly 20 downward, the specific position of the plugboard 10 is changed. The remaining structure is the same as the first embodiment described above and will not be further described here.

[0078] Third embodiment

[0079] Please refer to Figure 5-Figure 11 The present invention also provides a method for manufacturing a double-row single-interface wiring harness 100, the steps of which include:

[0080] S1. Cut and form features of the plug board 10, the first branch component 20 and the second branch component 30 on the wiring harness substrate.

[0081] Specifically, the shape features of the plug board 10, the first branch component 20 and the second branch component 30 are formed by cutting the base material, and folds are engraved thereon.

[0082] S2. Fold the first branch assembly 20 and the second branch assembly 30 degrees in opposite directions.

[0083] Specifically, the second branch assembly 30 is folded downward 180 degrees along the first fold line 23 .

[0084] S3 , fold the second branch assembly 30 twice by 90 degrees, and fold the second branch assembly body 33 to a position parallel to the first branch assembly 20 .

[0085] Specifically, the second connecting plate 32 and the second branch assembly body 33 are folded upward 90 degrees along the second fold 311 , and the second branch assembly body 33 is folded rightward 90 degrees along the third fold 321 so that the second branch assembly body 33 is arranged parallel to the first branch assembly 20 .

[0086] S4. Bend the first branch 21 and the fourth branch 22 to shrink the first branch 21 and the fourth branch 22 inward.

[0087] Specifically, along the fourth fold 211, the first branch 21 is folded on both sides toward the fourth branch 22, and the first branch 21 is retracted to ensure that the outer side of the first branch 21 does not exceed the bar 201; along the fifth fold 221, the fourth branch 22 is folded on both sides toward the first branch 21, and the fourth branch 22 is retracted to ensure that the outer side of the fourth branch 22 does not exceed the bar 201.

[0088] S5. Bend the fifth branch 34 and the sixth branch 35 to extend the second branch assembly body 33.

[0089] Specifically, along the sixth fold 342 and the seventh fold 343, the fifth branch 34 at the tail end of the second branch 331 is folded inward so that the fifth branch 34 is flush with the second branch 331; along the eighth fold 352 and the ninth fold 353, the sixth branch 35 at the tail end of the third branch 332 is folded inward so that the sixth branch 35 is flush with the third branch 332, thereby extending the second branch component body 33.

[0090] The double-row single-interface wiring harness 100 and the method for manufacturing the double-row single-interface wiring harness 100 provided by the embodiments of the present invention have the following beneficial effects:

[0091] The double-row, single-interface wiring harness 100 of the present invention includes a plugboard 10, a first branch assembly 20 connected to the plugboard 10, and a second branch assembly 30. The first branch assembly 20 includes a first branch 21 and a fourth branch 22, one end of each of which is connected to the plugboard 10. The second branch assembly 30 is disposed between the first branch 21 and the fourth branch 22. A first fold 23 is provided between the first branch assembly 20 or the second branch assembly 30 and the plugboard 10 to enable the first branch assembly 20 or the second branch assembly 30 to be folded 180 degrees. The second branch assembly 30 includes a first connecting plate 31, a second connecting plate 32, and a second branch assembly body 33, which are sequentially connected. The first connecting plate 31 is connected to the plug board 10. A second fold 311 is provided between the first connecting plate 31 and the second connecting plate 32, allowing the first connecting plate 31 and the second connecting plate 32 to bend 90 degrees. A third fold 321 is provided between the second connecting plate 32 and the second branch assembly body 33, allowing the second connecting plate 32 and the second branch assembly body 33 to bend 90 degrees, thereby arranging the first branch assembly 20 and the second branch assembly body 33 in parallel. The second branch assembly 30 is first folded 180 degrees between the first branch 21 and the fourth branch 22, and then further bent 90 degrees, so that the second branch assembly body 33 is arranged parallel to the first branch assembly 20. The first branch assembly 20 is used to connect to the first row of battery modules 200, and the second branch assembly body 33 is used to connect to the second row of battery modules 200. The present invention can realize that two rows of wiring harnesses share one interface, reduce the number of wiring harnesses or straight plug-in boards at the lead-out end, optimize the space of the electrical compartment, reduce the base material area by cutting and bending, and reduce material costs.

[0092] The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with this technical field within the technical scope disclosed by the present invention should be covered by the scope of protection of the present invention.

Claims

1. A double-row single-interface wiring harness, characterized in that: The circuit comprises a plug board, a first branch assembly and a second branch assembly connected to the plug board, wherein the first branch assembly includes a first branch and a fourth branch, one end of the first branch and the fourth branch are connected to the plug board, and the second branch assembly is arranged between the first branch and the fourth branch; A first fold is provided between the first branch component or the second branch component and the plug board, so that the first branch component or the second branch component can be folded 180 degrees; The second branch component includes a first connecting plate, a second connecting plate and a second branch component body connected in sequence, the first connecting plate is connected to the plug-in plate, a second fold is provided between the first connecting plate and the second connecting plate so that the first connecting plate and the second connecting plate are folded 90 degrees, and a third fold is provided between the second connecting plate and the second branch component body so that the second connecting plate and the second branch component body are folded 90 degrees, thereby making the first branch component and the second branch component body arranged in parallel.

2. The double-row single-interface wiring harness according to claim 1, characterized in that: The first branch is provided with a fourth fold, the fourth branch is provided with a fifth fold, the first branch is folded along the fourth fold, and the fourth branch is folded along the fifth fold to reduce the distance between the first branch and the fourth branch.

3. The double-row single-interface wiring harness according to claim 2, characterized in that: The width of the plug board is W1. Before folding, the total width of the first branch and the fourth branch is W. The sides of the first branch and the fourth branch are respectively protruded relative to the plug board. The distance from the sides of the first branch and the fourth branch to the plug board is W2, where W=W1+W2*2*2.

4. The double-row single-interface wiring harness according to claim 3, characterized in that: The width of the first branch is W8, the width of the fourth branch is W9, and after folding, W≥W8+W9.

5. The double-row single-interface wiring harness according to claim 2, characterized in that: The end of the first branch away from the fourth branch is used to connect to the bar, and the end of the fourth branch away from the first branch is used to connect to the bar. After folding, the gap between the first branch and the bar is W6, and the gap between the fourth branch and the bar is W7, where 0≤W6≤2mm, 0≤W7≤2mm.

6. The double-row single-interface wiring harness according to claim 5, characterized in that: Before folding, the distance that the first branch protrudes from the bar piece is W4, the distance that the fourth branch protrudes from the bar piece is W3, and the distance between the bar pieces in the single-row module is W5, where W=W4+W3+W5.

7. The double-row single-interface wiring harness according to claim 1, characterized in that: The second branch assembly body further includes a second branch and a third branch, one end of the second branch is connected to the second connecting plate, the other end of the second branch is connected to the fifth branch, one end of the third branch is connected to the second connecting plate, and the other end of the third branch is connected to the sixth branch; The fifth branch is connected to the second branch via a third connecting plate. A sixth fold is provided between the third connecting plate and the second branch, so that the third connecting plate and the second branch are folded 180 degrees. A seventh fold is provided between the third connecting plate and the fifth branch, so that the fifth branch and the third connecting plate are folded 180 degrees. The sixth branch is connected to the third branch through a fourth connecting plate. An eighth fold is provided between the fourth connecting plate and the third branch so that the fourth connecting plate and the third branch are folded 180 degrees. A ninth fold is provided between the fourth connecting plate and the sixth branch so that the sixth branch and the fourth connecting plate are folded 180 degrees.

8. The double-row single-interface wiring harness according to claim 7, characterized in that: The total length of the double-row single-interface wiring harness is L, the length of the plug-in board is L5, the length of the first branch is L1, the length of the fifth branch is L2, wherein L>L1+L2+L5; the length of the fourth branch is L3, the length of the sixth branch is L4, wherein L>L3+L4+L5.

9. A method for manufacturing a double-row single-interface wiring harness, characterized in that: The double-row single-interface wiring harness according to any one of claims 1 to 8 comprises the following steps: S1. Cutting the features of the plug board, the first branch component and the second branch component on the wiring harness substrate; S2, folding the first branch component and the second branch component 180 degrees in opposite directions; S3. Fold the second branch assembly twice by 90 degrees, so that the second branch assembly body is folded to a position parallel to the first branch assembly.

10. The method for manufacturing a double-row single-interface wiring harness according to claim 9, characterized in that: The steps also include: S4. Bend the first branch and the fourth branch to achieve inward contraction of the first branch and the fourth branch.

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