CN111284056A - Forming process method for upper cover of battery box - Google Patents
Forming process method for upper cover of battery box Download PDFInfo
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- CN111284056A CN111284056A CN202010382323.7A CN202010382323A CN111284056A CN 111284056 A CN111284056 A CN 111284056A CN 202010382323 A CN202010382323 A CN 202010382323A CN 111284056 A CN111284056 A CN 111284056A
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- composite material
- smc
- upper cover
- battery box
- forming
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- 238000000034 method Methods 0.000 title claims abstract description 54
- 239000002131 composite material Substances 0.000 claims abstract description 86
- 239000002994 raw material Substances 0.000 claims abstract description 14
- 239000000835 fiber Substances 0.000 claims description 32
- 239000003822 epoxy resin Substances 0.000 claims description 21
- 229920000647 polyepoxide Polymers 0.000 claims description 21
- 239000011159 matrix material Substances 0.000 claims description 15
- 238000000465 moulding Methods 0.000 claims description 10
- 238000012545 processing Methods 0.000 claims description 5
- 238000005507 spraying Methods 0.000 claims description 5
- 238000005303 weighing Methods 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 11
- 238000005516 engineering process Methods 0.000 abstract description 8
- 238000013461 design Methods 0.000 abstract description 4
- 239000000463 material Substances 0.000 abstract description 4
- 239000002184 metal Substances 0.000 abstract description 4
- 229920005989 resin Polymers 0.000 abstract description 3
- 239000011347 resin Substances 0.000 abstract description 3
- 238000012546 transfer Methods 0.000 abstract description 2
- 239000003677 Sheet moulding compound Substances 0.000 description 54
- 239000010410 layer Substances 0.000 description 10
- 239000000047 product Substances 0.000 description 8
- 238000003825 pressing Methods 0.000 description 4
- 238000011161 development Methods 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000013585 weight reducing agent Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007723 die pressing method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000012856 weighed raw material Substances 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/006—Producing casings, e.g. accumulator cases
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/10—Primary casings; Jackets or wrappings
- H01M50/147—Lids or covers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/10—Primary casings; Jackets or wrappings
- H01M50/147—Lids or covers
- H01M50/148—Lids or covers characterised by their shape
- H01M50/15—Lids or covers characterised by their shape for prismatic or rectangular cells
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
According to the forming process method of the upper cover of the battery box, the upper cover of the battery box is manufactured by adopting the composite material A and the composite material B, so that the integral forming of the upper cover structure of the battery box is realized, the weight of a new energy electric automobile is obviously reduced, and the endurance mileage is improved; the composite material B layer design can improve the strength and the fatigue resistance of the battery box; the SMC and PCM process have the same raw material resin system and high interface strength; the pre-cured SMC pre-formed structure of the composite material A is co-cured with the composite material B of the PCM process at the temperature of 150 +/-5 ℃ to form a high-strength interface layer and ensure the bonding strength; the pre-forming structure required by the PCM process is prepared by adopting the SMC process, multiple sets of metal molds required in the PCM process are replaced, the cost is reduced, and the bearing requirement on the automatic production line transfer robot is reduced; the high efficiency of SMC technology and the high strength advantage of PCM technology are combined, realize the low-cost volume production of combined material battery case upper cover.
Description
Technical Field
The invention belongs to the technical field of battery box upper cover preparation, and particularly relates to a battery box upper cover forming process method.
Background
The composite material has high specific modulus and specific strength, and meanwhile, the design and the manufacture of the structure of the composite material can be integrated, so that the composite material becomes a light-weight preferred material for the new energy electric automobile in view of various advantages. The new energy battery pack is used as a core technology of the new energy electric automobile, is a key for restricting the development and popularization of the new energy electric automobile, and the energy density of the battery pack is the most important index of the battery pack.
The use of composite materials for manufacturing electric vehicle covers is one of the most promising solutions for increasing energy density, but the high cost and high manufacturing cost of composite materials become important factors that restrict the rapid development of composite materials in the automobile industry. At present, the feasible scheme is that the composite material upper cover is prepared by adopting an SMC process through mould pressing, the SMC process has the characteristics of low raw materials, high forming efficiency, small number of moulds and the like, but the SMC process has the defects of low strength of manufactured products, easiness in cracking at stress concentration positions, requirement of certain thickness and wall thickness (generally more than 3 mm), unobvious weight reduction advantages and the like. The PCM process has the characteristics of high strength, obvious weight reduction advantage and the like, but needs a plurality of sets of forming dies, and has low forming efficiency. Therefore, the design of a special forming method of the upper cover of the battery box has very important practical significance.
Disclosure of Invention
In order to solve the technical problems in the prior art, the invention aims to provide a battery box upper cover forming process, wherein the battery box upper cover is obtained by co-curing an SMC preformed structure of a composite material A and a PCM preformed structure of a composite material B obtained by layering and forming.
In order to achieve the purpose and achieve the technical effect, the invention adopts the technical scheme that:
a battery box upper cover molding process method comprises the following steps:
the upper cover of the battery box is made of two composite materials through co-curing;
the adopted composite material A is a chopped fiber reinforced epoxy resin matrix composite material;
the adopted composite material B is a continuous fiber reinforced epoxy resin-based composite material;
s1, preparing an SMC pre-forming structure of the pre-cured chopped fiber reinforced epoxy resin matrix composite material on the pre-forming die by adopting an SMC process and utilizing the composite material A;
s2, demolding after semi-curing the SMC preformed structure obtained in the step S1, fixing the SMC preformed structure on a layering tool, and layering and molding the SMC preformed structure on the layering tool by adopting an uncured composite material B (continuous fiber reinforced epoxy resin matrix composite material) to obtain a PCM preformed structure;
s3, co-curing the PCM preformed structure formed by the uncured composite material B on the structure obtained in the step S1 and the SMC preformed structure obtained in the step S1 on a co-curing forming mold;
s4, processing holes and outline dimensions of the product obtained in the step S3 by laser to obtain the required upper cover of the battery box;
s1, adopting a semi-curing process to obtain an SMC pre-forming structure, wherein the curing degree is 50-60%, and then demoulding to obtain a mould of a composite material B layer; laying the composite material B on an SMC pre-forming structure in a semi-cured state to form a blank of an upper cover product of the battery box together; co-curing the mixture on the co-curing forming mold according to the step S3 to form the upper cover of the battery box;
the composite material A is a chopped fiber reinforced epoxy resin-based composite material and comprises the following components in percentage by volume: 55 plus or minus 3 percent of chopped fiber, 45 plus or minus 3 percent of epoxy resin matrix, and the fiber length of the chopped fiber is 20-30 mm; SMC sheet (SMC preformed structure), namely composite material A, the thickness of the raw material is 0.5 +/-0.05 mm;
the composite material B is a continuous fiber reinforced epoxy resin-based composite material and comprises the following components in percentage by volume: 60 +/-3% of continuous fibers, 40 +/-3% of epoxy resin matrix and 0.4 +/-0.05 mm of single layer of material thickness.
Furthermore, the adopted process is the combination of an SMC (sheet molding compound) molding process and a PCM (pulse code modulation) molding process, and the advantages of high efficiency of the SMC process and high strength of the PCM process are considered.
Further, an SMC (sheet molding compound) preformed structure of the pre-cured chopped fiber reinforced epoxy resin matrix composite material is prepared on a preformed mold by adopting an SMC (sheet molding compound) process, and the method specifically comprises the following steps:
preheating a preforming mold on a press to 100-120 ℃, weighing the chopped fiber reinforced resin matrix composite prepreg raw material according to the designed weight, adding the weighed raw material into a mold cavity, and uniformly spraying and filling;
and (3) closing the pre-forming die, pressurizing to 20 +/-2T by using the pressure of a press, maintaining the pressure and preserving the heat for 1 +/-0.1 min, and ensuring that the curing degree of the product is 50-60% to obtain the pre-cured SMC pre-forming structure of the composite material A.
Further, in step S2, the pre-cured SMC pre-formed structure is semi-cured, demolded, fixed on a layering tool, the uncured composite material B is layered according to the (0/90)/(± 45)/(0/90) angle, and then the SMC pre-formed structure with the composite material B laid thereon is placed in a PCM mold cavity, the mold temperature is 150 ± 5 ℃, the mold is closed, and the press is pressed, the pressure is 80 ± 5T; and keeping the temperature and the pressure for 5 +/-1 min to ensure that the curing degree is more than 95 percent to obtain the PCM preformed structure.
Further, in step S3, the co-curing pressure is 80 + -2T, and the temperature is kept for 5 + -1 min.
The invention also discloses an upper cover of the battery box.
Compared with the prior art, the invention has the beneficial effects that:
the invention discloses a battery box upper cover molding process method, which adopts composite material A and composite material B to manufacture the battery box upper cover, can realize the integral molding of the battery box upper cover structure, can obviously reduce the weight of a new energy electric automobile, and improves the endurance mileage; the composite material B layer design can improve the strength and the fatigue resistance of the battery box; the adopted SMC and PCM process have the same raw material resin system and very high interface strength; the SMC preformed structure of the pre-cured composite material A prepared by adopting the SMC process can be co-cured with the PCM preformed structure obtained by the PCM process at the temperature of 150 +/-5 ℃ to form a high-strength interface layer and ensure the bonding strength; an SMC pre-forming structure required by a PCM process is prepared by adopting an SMC process to replace a plurality of sets of pre-forming metal molds required in the PCM process, so that the manufacturing cost is reduced, the bearing requirement on a transfer robot of an automatic production line is reduced, and the input cost of the production line is reduced; in addition, the high efficiency of the SMC process and the high strength of the PCM process are combined, and the low-cost mass production of the upper cover of the composite material battery box is realized.
Drawings
FIG. 1 is an SMC preformed structure prepared by the SMC process of the battery box upper cover;
FIG. 2 is a ply preform of the battery case upper cover of the present invention;
FIG. 3 is a composite upper cover blank of the upper cover of the battery box of the present invention after co-curing;
FIG. 4 is a finished product of the battery box upper cover of the present invention after processing;
FIG. 5 is a schematic diagram of a co-curing structure of the upper cover of the battery box in FIG. 4;
wherein, 1-the upper cover main body a of the battery box; 2-battery box upper cover main body b; 3-blank of upper cover of battery box; 4-upper cover of battery box; 5-SMC layer; 6-PCM layer.
Detailed Description
The embodiments of the present invention will be described in detail with reference to the accompanying drawings so that the advantages and features of the invention can be more easily understood by those skilled in the art, and the scope of the invention will be clearly and clearly defined.
As shown in fig. 1 to 5, a battery box upper cover comprises a battery box upper cover main body a 1 and a battery box upper cover main body B2, wherein the battery box upper cover main body a 1 is a pre-cured SMC preformed structure of a composite material a with certain strength and rigidity, which is obtained by adopting the composite material a through SMC process die pressing, the battery box upper cover main body B2 is a PCM preformed structure with certain strength and rigidity, which is obtained by layering a composite material B on the SMC preformed structure of the composite material a (replacing the existing metal steel die), the battery box upper cover main body a 1 and the battery box upper cover main body B2 are co-cured to obtain a battery box upper cover blank 3, and a final product, namely the battery box upper cover 4, is obtained after processing holes and contour dimensions, and comprises an SMC layer 5 and a PCM layer 6, and a high-strength bonding interface exists between the SMC layer 5 and the PCM layer 6 on the battery box upper cover 4, the composite material A is a chopped fiber reinforced epoxy resin matrix composite material, the composite material B is a continuous fiber reinforced epoxy resin matrix composite material, the technology adopted by the invention is the combination of an SMC (sheet molding compound) mould pressing technology and a PCM (pulse code modulation) mould pressing technology, and the advantages of high efficiency of the SMC technology and high strength of the PCM technology are considered.
A battery box upper cover forming process method comprises the following steps:
s1, preparing a pre-cured SMC pre-forming structure on the pre-forming mould by adopting the composite material A;
s2, demolding after semi-curing the SMC preformed structure obtained in the step S1, fixing the SMC preformed structure on a layering tool, and layering and molding the SMC preformed structure on the layering tool by adopting an uncured composite material B to obtain a PCM preformed structure;
s3, co-curing the SMC preformed structure obtained in the step S1 and the PCM preformed structure obtained in the step S2 on a co-curing forming mold;
s4, processing holes and outline dimensions of the structure obtained in the step S3 to obtain the required upper cover 4 of the battery box;
s1, adopting a semi-curing process to obtain an SMC pre-forming structure, wherein the curing degree is 50-60%, and then demoulding to obtain a composite material B laying layer mould which is a bottom lining with a certain shape and structural strength and can replace the existing metal bottom lining in mass production; laying the composite material B on an SMC pre-forming structure in a semi-cured state to form a blank of an upper cover product of the battery box together; co-curing on the co-curing mold according to step S3 to form the desired battery case lid product.
In step S1, the SMC pre-form structure is prepared by:
s11, cutting the continuous fibers into chopped fibers with a certain length, directly spraying the chopped fibers into an epoxy resin matrix, and uniformly mixing to obtain a prepreg raw material of the composite material A;
s12, preheating a pre-forming die on a press to 100-120 ℃, weighing the composite material A prepreg raw material according to the designed weight, adding the composite material A prepreg raw material into a cavity of the pre-forming die, and uniformly spraying and filling;
and S13, closing the die of the pre-forming die, pressurizing to 20 +/-2T by using a press, maintaining the pressure and the temperature for 1 +/-0.1 min, and ensuring that the curing degree of the product is 50-60% to obtain the pre-forming structure of the SMC of the pre-cured composite material A.
The composite material A is a chopped fiber reinforced epoxy resin-based composite material and comprises the following components in percentage by volume: 55 plus or minus 3 percent of chopped fiber, 45 plus or minus 3 percent of epoxy resin matrix, 20 to 30mm of fiber length of the chopped fiber and 0.5 plus or minus 0.05mm of thickness of the raw material of the composite material A.
In the step S2, demolding the pre-molded SMC structure of the pre-cured composite material A, fixing the pre-molded SMC structure on a layering tool, layering the uncured composite material B at an angle of (0/90)/(+/-45)/(0/90), then placing the pre-molded SMC structure paved with the composite material B into a PCM mold cavity, setting the mold temperature at 150 +/-5 ℃, closing the mold, pressing by a press, keeping the pressure at 80 +/-5T, keeping the temperature and the pressure for 5 +/-1 min, ensuring that the curing degree is more than 95%, and layering and molding to obtain the PCM pre-molded structure.
The composite material B is a continuous fiber reinforced epoxy resin-based composite material and comprises the following components in percentage by volume: 60 +/-3% of continuous fibers, 40 +/-3% of epoxy resin matrix and 0.4 +/-0.05 mm of single-layer thickness of the raw material of the composite material B.
In step S3, co-curing pressure is 80 + -2T, and heat preservation is carried out for 5 + -1 min.
And step S1, semi-curing a part of the SMC pre-forming structure, then demolding to form a composite material B laying mold, co-curing the part of the raw material and the composite material B together on the PCM process mold to form a whole, and serving as a part of the composite material upper cover as both a mold and a material.
The composite material a and the composite material B of the present invention are prepared by the prior art, and are not described herein again.
The parts of the invention not described in detail can be realized by adopting the prior art, and are not described in detail herein.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes performed by the present specification and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (5)
1. A battery box upper cover forming process method is characterized by comprising the following steps:
s1, preparing a pre-cured SMC pre-forming structure on the pre-forming mould by adopting the composite material A;
s2, demolding after semi-curing the SMC preformed structure obtained in the step S1, fixing the SMC preformed structure on a layering tool, and layering and molding the SMC preformed structure on the layering tool by adopting an uncured composite material B to obtain a PCM preformed structure;
s3, co-curing the SMC preformed structure obtained in the step S1 and the PCM preformed structure obtained in the step S2 on a co-curing forming mold;
s4, processing holes and outline dimensions of the structure obtained in the step S3 to obtain the required upper cover of the battery box;
s1, adopting a semi-curing process to obtain an SMC pre-forming structure, wherein the curing degree is 50-60%, and then demoulding to obtain a mould of a composite material B layer; laying the composite material B on an SMC pre-forming structure in a semi-cured state to form a blank of an upper cover product of the battery box together; co-curing the mixture on the co-curing forming mold according to the step S3 to form the upper cover of the battery box;
the composite material A is a chopped fiber reinforced epoxy resin-based composite material and comprises the following components in percentage by volume: 55 plus or minus 3 percent of chopped fiber, 45 plus or minus 3 percent of epoxy resin matrix, and the fiber length of the chopped fiber is 20-30 mm;
the composite material B is a continuous fiber reinforced epoxy resin-based composite material and comprises the following components in percentage by volume: 60 +/-3% of continuous fibers and 40 +/-3% of epoxy resin matrix.
2. The method of claim 1, wherein in step S1, the SMC pre-formed structure is prepared by:
s11, cutting the continuous fibers into chopped fibers with a certain length, directly spraying the chopped fibers into an epoxy resin matrix, and uniformly mixing to obtain a prepreg raw material of the composite material A;
s12, preheating a pre-forming die on a press to 100-120 ℃, weighing the composite material A prepreg raw material according to the designed weight, adding the composite material A prepreg raw material into a cavity of the pre-forming die, and uniformly spraying and filling;
and S13, closing the die of the pre-forming die, pressurizing to 20 +/-2T by using a press, maintaining the pressure and the temperature for 1 +/-0.1 min, and ensuring that the curing degree of the product is 50-60% to obtain the pre-forming structure of the SMC of the pre-cured composite material A.
3. The method of claim 1, wherein in step S2, the pre-cured SMC preform structure is demolded and fixed on a layering tool, the uncured composite material B is layered according to an angle of (0/90)/(± 45)/(0/90), and then the SMC preform structure with the composite material B is placed in a PCM mold cavity, the mold temperature is 150 ± 5 ℃, the mold is closed, the press is pressed, the pressure is 80 ± 5T, the temperature and pressure are kept for 5 ± 1min, the curing degree is ensured to be more than 95%, and the PCM preform structure is obtained by layering and molding.
4. The method of claim 1, wherein in step S3, the co-curing pressure is 80 ± 2T, and the temperature is maintained for 5 ± 1 min.
5. The method as claimed in claim 1, wherein in step S4, the holes and the contour are processed by laser.
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| CN202010382323.7A CN111284056B (en) | 2020-05-08 | 2020-05-08 | Forming process method for upper cover of battery box |
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| CN202010382323.7A CN111284056B (en) | 2020-05-08 | 2020-05-08 | Forming process method for upper cover of battery box |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112849066A (en) * | 2020-12-28 | 2021-05-28 | 山东格瑞德集团有限公司 | Novel composite anti-collision beam and preparation method thereof |
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| CN102059833A (en) * | 2010-10-27 | 2011-05-18 | 航天材料及工艺研究所 | Combined fiber reinforced water-blown polyurethane hard foam composite board, production method and production equipment thereof |
| JP2012125497A (en) * | 2010-12-17 | 2012-07-05 | Kose Corp | Inner tray for compact container |
| CN106007519A (en) * | 2016-05-23 | 2016-10-12 | 苏州思创源博电子科技有限公司 | Preparation method of compound carbon fiber heat-insulation material |
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2020
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006111832A (en) * | 2004-10-09 | 2006-04-27 | Yasuo Wakabayashi | Covered film composition of naturally hardenable type electroconductive polyurethane prepolymer, and antifouling apparatus by using it |
| CN102059833A (en) * | 2010-10-27 | 2011-05-18 | 航天材料及工艺研究所 | Combined fiber reinforced water-blown polyurethane hard foam composite board, production method and production equipment thereof |
| JP2012125497A (en) * | 2010-12-17 | 2012-07-05 | Kose Corp | Inner tray for compact container |
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Address after: 215124 Building 2, Fumin phase III, No.818 Wusong Road, Guoxiang street, Wuzhong Economic Development Zone, Suzhou City, Jiangsu Province Patentee after: Suzhou kangben New Energy Technology Co.,Ltd. Address before: 215124 Building 2, Fumin phase III, No.818 Wusong Road, Guoxiang street, Wuzhong Economic Development Zone, Suzhou City, Jiangsu Province Patentee before: SUZHOU YINXI NEW ENERGY COMPOSITE MATERIALS Co.,Ltd. |
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Effective date of registration: 20221130 Address after: No. 9 Yongxing Avenue, Shangxing Town, Liyang City, Changzhou City, Jiangsu Province, 213000 Patentee after: Liyang kangben composite material Co.,Ltd. Address before: 215124 Building 2, Fumin phase III, No.818 Wusong Road, Guoxiang street, Wuzhong Economic Development Zone, Suzhou City, Jiangsu Province Patentee before: Suzhou kangben New Energy Technology Co.,Ltd. |