Battery Pack Wiring Harness Layout With Flat High-Voltage Routing
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Solution Overview
Problem
The challenge of arranging high-voltage and low-voltage wiring harnesses in the limited space of a new energy vehicle battery pack is exacerbated by the large diameter of high-voltage wiring harnesses, which limits bending radius and requires physical isolation to avoid signal interference.
Innovation Solution
A battery pack structure incorporating a flexible wiring harness connected to a low-voltage protective sleeve and a flat rigid wiring harness connected to a high-voltage protective sleeve, fixed by a mounting bracket, allowing for physical isolation and transitioning the high-voltage wiring harness from a circular to a flat shape, with features like fuse grooves and telescoping sections for protection and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional circular high-voltage wiring harness is used, then the wiring harness can be easily manufactured and installed, but the large diameter limits the bending radius and occupies excessive space in the battery pack
Solution Approach 1:
The patent transforms the high-voltage wiring harness from a traditional circular cross-section to a flat rectangular cross-section. This dimensional change allows the wiring harness to be arranged more efficiently in the limited battery pack space, reducing the volume occupied while maintaining electrical performance. The flat structure enables better space utilization without significantly increasing manufacturing complexity.
Solution Approach 2:
The patent changes the geometric parameters of the wiring harness by transitioning from a circular to a flat configuration. This parameter change reduces the bending radius and cross-sectional area, allowing the wiring harness to fit into tighter spaces within the battery pack while maintaining ease of installation and connection.
2Reliability
If physical isolation between high-voltage and low-voltage wiring harnesses is implemented, then signal interference is avoided, but the arrangement space in the battery pack is further reduced
Solution Approach 1:
The patent integrates the high-voltage and low-voltage wiring harnesses into a single combined harness structure with flat geometry. This merging approach maintains the necessary electrical isolation between high-voltage and low-voltage circuits while reducing the overall space required compared to separate circular harnesses. The combined structure allows for optimized routing and reduced packaging volume.
3Quantity of substance
If the high-voltage wiring harness is made flat and rigid, then the volumetric energy density of the battery pack is improved, but the flexibility and adaptability of the wiring harness is reduced
Solution Approach 1:
The patent divides the high-voltage wiring harness into multiple flat rigid sections that are electrically connected. Each section maintains a rigid flat structure for space efficiency, while the segmentation allows the overall harness to adapt to different routing requirements. The modular segmented structure enables better space utilization while providing the necessary flexibility for installation and connection.
Data Source
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AI summary
Disclosed by the present disclosure is a battery pack structure, including a housing, and a battery module and a wiring harness assembly which are disposed in the housing, in which the wiring harness assembly includes a flexible wiring harness, a flat rigid wiring harness, at least one high-voltage protective sleeve, at least one low-voltage protective sleeve, and a mounting bracket for mounting the high-voltage protective sleeve and the low-voltage protective sleeve to the housing. The battery pack structure of the present disclosure can fix the high-voltage protective sleeve and the low-voltage protective sleeve through the mounting bracket, thereby achieving a physical isolation between the high-voltage wiring harness and the low-voltage wiring harness. Meanwhile, the wiring harness assembly of the present disclosure includes a flexible wiring harness connected to the low-voltage protective sleeve, and a flat rigid wiring harness connected to the high-voltage protective sleeve. The arrangement of the flat rigid wiring harness achieves the transition of the high-voltage wiring harness from an external circular shape to a flat shape, solves the problem that the high-voltage wiring harness is difficult to be bent and arranged inside the battery pack due to the excessive diameter, and furthermore, the arrangement of the flat rigid wiring harness can effectively improve the volumetric energy density of the battery pack.