CN107933005A - 一种具有冲击防护功能的复合材料电池壳及制备工艺 - Google Patents
一种具有冲击防护功能的复合材料电池壳及制备工艺 Download PDFInfo
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Abstract
本发明涉及一种具有冲击防护功能的复合材料电池壳及制备工艺，包括：电池壳外壳体、夹芯芯材、电池壳内壳体、电池壳盖和吊耳；电池壳内壳体包括电池壳内壳体内底板和电池壳内壳体内侧面板；电池壳外壳体、夹芯芯材和电池壳内壳体通过胶粘连接，电池壳外壳体和电池壳盖通过吊耳螺栓连接；电池壳夹芯芯材的存在可以显著提高复合材料电池壳的抗冲击性和防穿透性能。
Description
技术领域
本发明涉及一种具有冲击防护功能的复合材料电池壳及制备工艺，具体涉及一种由复合材料制造的底部及侧壁由夹层结构及能量吸收材料构成的电池壳。
背景技术
汽车的轻量化设计对于汽车产业及交通运输行业实现节能减排，绿色发展意义重大，是该产业持续发展的必经之路。电池组总成在电动汽车整备质量中占比可达30％，因而电池壳轻量化设计对整车轻量化十分重要。复合材料由于其轻量化、高比刚、高比强，冲击吸能特性良好等优势，在汽车零部件设计的应用逐渐广泛。目前已有的复合材料电池壳多为热固性复合材料，且大多仅考虑静态承载性能。复合材料具有良好的动态吸能特性，可用于电池壳承受外来物冲击或吸收整车碰撞时车体变形能量，增强电池总成的碰撞安全性。夹层板结构一方面可提高箱型容器壁的弯曲刚度，从而提升电池壳静态刚度；另一方面夹层板结构也使电池壳具有良好的冲击吸能效果。
专利CN 206040716 U提出了一种划分为很多小区域的电池壳，可以提高电池运行效率和寿命，但是其单层结构很容易压溃，导致电池受损。
CN 105501041 A将电池壳集成在地盘总成上，提高了空间利用率，但是其电池壳本身结构并未考虑冲击防护。
CN 200880000807.8提出了一种由螺纹连接的电池壳，其主要侧重点在于螺栓的布置方式，未考虑电池壳本身的抗冲击性能。
因此，本发明提出的采用夹芯芯材提高电池壳抗冲击性具有必要性。
发明内容
本发明技术解决问题：克服现有技术的不足，提供一种具有冲击防护功能的复合材料电池壳及制备工艺，提高电池壳的冲击防护性能，解决现有复合材料电池壳的批量生产困难问题，以及使用模压法和拉挤工艺生产复合材料电池壳部件的方法。本发明实施简单，制作方便，能超大批量生产，大幅降低制作成本。使得复合材料电池壳在电动汽车制造中得到更为广泛的应用，从而实现轻量化目标。
为实现上述技术目的，达到上述技术效果，本发明通过以下技术方案实现：
本发明中所用的复合材料为短纤维增强复合材料、长纤维增强复合材料和连续纤维增强复合材料，纤维种类，包括短纤维、长纤维和连续纤维可以为碳纤维、玻璃纤维。基体的选择可以多样化，包括聚丙烯，聚丁烯等。
本发明所述的吊耳材料可以为前述复合材料。
本发明所述的电池壳内壳体可以通过模压工艺成型。即先通过模压成型工艺制备的复合材料平板，然后通过锁嵌方法组成电池壳内壳体，锁嵌方法即先开槽，再通过开的槽互相拼接的方法，如图7。
本发明所述的夹芯芯材板为一种以筋条结构或波纹板组合而成的结构。在夹芯芯材中可以使用填充物添加(即本发明提出的夹芯芯材为多孔结构，可以在空隙处填充材料以作增强，但亦可不添加)：填充物选自聚氨酯泡沫、石墨、橡胶、石膏、聚苯乙烯泡沫、活性炭或碳黑。用于充实夹芯芯材内部空间，进一步提升夹层结构的静态弯曲刚度及冲击吸能性能。
本发明中电池壳盖不作为主要承载部件，为复合材料单层结构板可同样通过LFT-D模压工艺生产。电池壳盖与电池壳壳体通过外缘翻边螺栓连接，方便拆卸与维护。
在电池壳外壳体外缘翻边下端，分布有与车身连接用的耳片。耳片可为热塑或热固性复合材料，通过机械连接的方法与电池壳壳体连接，以保证耳片的连接强度。
本发明与现有技术相比的优点在于：
(1)目前电池壳还是以金属，特别是铝材料为主，本发明采取复合材料体现了轻量化；夹芯芯材的应用有助于提高电池壳的抗冲击性和防穿透性。
(2)采用纤维增强复合材料生产电池壳，在保证性能的前提下显著降低了电池壳的质量，有利于汽车的轻量化。
(3)采取复合材料生产电池壳，性能良好，且符合当今材料可回收、环保的生产要求。
(4)基于复合材料成型技术，设计出整体结构。利用模压工艺生产电池壳部件，自动化程度提高，提高生产效率，成本较低。利用拉挤工艺生产筋条、波纹板等部件，生产效率极高，且制品性能优良。
(5)本发明所提出的电池壳结构具有较好的可设计性。可以根据实际工况及轻量化要求灵活改变夹芯芯材或考虑增减夹芯芯材填充物。
(6)本发明提出的电池壳的夹芯设计可以有效缓减外部冲击对电池壳内电池的破坏。
附图说明
图1为电池壳爆炸图，图中标号分别代表：1.电池壳盖；2.吊耳；3.夹芯芯材；4.电池壳外壳体；5.电池壳内壳体内底板；6.电池壳内壳体内侧面板，包括线段所指的两块面板以及这两块面板对面的两块面板，因构图所限无法用线段指出电池壳内壳体内侧面板总共为四块，包括标号6的两条线段所指的两块面板以及这两块面板对面的两块面板；电池壳内壳体包括5所指的电池壳内壳体内底板和6所指的四块电池壳内壳体内侧面板；
图2(a)为组装完成的电池壳去除电池壳盖的三维图；
图2(b)为组装完成的电池壳去除电池壳外壳体的三维图；
图3为夹芯芯材和电池壳内壳体的布置方式；(a)(b)(c)(d)分别代表去除电池壳盖，电池壳外壳体和电池壳内壳体内底板的模型的正视图，侧视图，俯视图和等轴测图。6代表电池壳内壳体内侧面板，3代表夹芯芯材。如图所示，四块电池壳内壳体内侧面板通过锁嵌法组装在一起；
图4为其中一层格栅夹芯图，(a)(b)(c)(d)分别为一层格栅夹芯的俯视图，侧视图，正视图和等轴测图。如图4所示，此格栅夹芯由筋条锁嵌拼装而成。此格栅夹芯也可以被替换为波纹板等夹芯芯材；
图5为吊耳的零件示意图。9代表用于和车身连接的吊耳螺栓孔，10代表用于和电池壳外壳体连接的吊耳螺栓孔；
图6为模压示意图。11为上模，12为待模压的材料，13为下模。上模沿着箭头方向合模即可模压产品；
图7展示了锁嵌工艺的示意图。按照设计在筋条上开槽，互相组合即可组装完成一个夹芯芯材；
图8为吊耳在电池壳外壳体上的按照示意，14为在电池壳外壳体4的相应位置上打螺栓孔；
图9为电池壳翻边上的螺栓孔位置示意图，15为在电池壳外壳体翻边和电池盖翻边的适当位置打螺栓孔；
图10(a)为电池壳外壳体俯视图，图10(b)为电池壳盖俯视图；16所指的四块区域为电池壳外壳体翻边，17为电池壳盖翻边。
具体实施方式
下面结合说明书附图详细说明本发明。
如图1所示，本发明的复合材料电池壳包括电池壳外壳体4，电池壳内壳体内底板5，电池壳内壳体内侧面板6，夹芯芯材3，电池壳盖1，吊耳2。电池壳外壳体4、夹芯芯材3、电池壳内壳体通过胶结法连接在一起。吊耳2采用复合材料，通过螺栓连接的方式固定在电池壳外壳体4上。
如图7所示，本发明一种由复合材料制造的含有底部及侧壁夹层结构的电池壳结构制备工艺具体如下：
步骤一：使用模压工艺生产复合材料电池壳内壳体，可先通过模压工艺制造复合材料平板，再通过平板的嵌锁组装制造电池壳内壳体。如图7所示，首先按照设计在平板的适当位置开槽，相互锁嵌的平板的槽口互相对准扣合，即可把多块平板组成一个结构。
步骤二：制备夹芯芯材和固定夹芯芯材。
通过拉挤工艺生产筋条或波纹板；通过模压法生产电池壳内壳体。然后通过锁嵌结构或者在合适的排布方式组成夹芯芯材，然后通过胶粘工艺将夹芯芯材和电池壳内外壳体连接在一起。
步骤三：通过LFT-D模压法生产电池壳盖，如图6所示，首先选择适合电池壳盖的模具，把待模压的材料放置在下模上，然后上模沿图中箭头向下运动，上下模闭合，就可把材料压制成所需要的形状。模具闭合一段时间后上模向上运动开模，即可取出制件。
步骤四：连接吊耳2，将模压工艺制成的复合材料吊耳与电池壳外壳体4通过螺栓连接等方式进行机械连接。如图8所示，首先确定吊耳2在电池壳外壳体上4的固定位置，然后根据吊耳螺栓孔的位置在电池壳外壳体4的相应位置上打螺栓孔14。最后在螺栓孔14中装配上螺栓即可完成吊耳和电池壳外壳体4的连接。
步骤五：如图9所示，在电池壳外壳体翻边和电池盖翻边的适当位置打螺栓孔15，在螺栓孔15中装配螺栓即可完成电池壳外壳体4和电池壳盖的连接。
提供以上实施例仅仅是为了描述本发明的目的，而并非要限制本发明的范围。本发明的范围由所附权利要求限定。不脱离本发明的精神和原理而做出的各种等同替换和修改，均应涵盖在本发明的范围之内。
Claims (2)
1.一种具有冲击防护功能的复合材料电池壳，其特征在于：包括电池壳外壳体、夹芯芯材、电池壳内壳体、电池壳盖和吊耳；电池壳内壳体包括电池壳内壳体内底板和电池壳内壳体内侧面板；电池壳外壳体、夹芯芯材和电池壳内壳体通过胶粘连接，电池壳外壳体和电池壳盖通过吊耳螺栓连接；电池壳夹芯芯材的存在可以显著提高复合材料电池壳的抗冲击性和防穿透性能。
2.一种具有冲击防护功能的复合材料电池壳制备工艺，其特征在于：步骤如下：
(1)使用模压法生产电池壳外壳体；
(2)制备夹芯芯材：通过拉挤工艺生产筋条或波纹板，再组装成夹芯芯材；
(3)使用LFT-D生产工艺生产电池壳盖；
(4)使用模压或拉挤法快速制备吊耳，并与电池壳外壳体通过螺栓连接；
(5)使用模压法生产电池壳内壳体，将筋条芯子装配于电池壳内壳体各面上，将芯子和电池壳内板插入电池壳外壳中；
(6)通过热塑性复合材料的熔融焊接对装配连接点加固；
(7)在电池壳的夹芯芯材空隙中填充聚氨酯泡沫，石墨，橡胶填充物，以进一步提升夹芯芯材力学性能。
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