CN111516318A - 一种外壳结构 - Google Patents

一种外壳结构 Download PDF

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CN111516318A
CN111516318A CN201910103115.6A CN201910103115A CN111516318A CN 111516318 A CN111516318 A CN 111516318A CN 201910103115 A CN201910103115 A CN 201910103115A CN 111516318 A CN111516318 A CN 111516318A
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layer
material layer
composite material
composite
thickness
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谢先宇
沈剑平
苍学俊
张建文
谢欢
朱顺良
沈驰
郝跃跃
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Shanghai Motor Vehicle Inspection Certification and Tech Innovation Center Co Ltd
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Shanghai Motor Vehicle Inspection Certification and Tech Innovation Center Co Ltd
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Abstract

本发明提供了一种外壳结构。该外壳结构适用于高压动力电池系统，包括隔热层、复合材料层以及电磁防护层，隔热层位于外壳结构的内侧且固定设置在复合材料层的内表面，复合材料层采用片状模压复合材料或玻璃钢材料。本发明提出的一种外壳结构材质轻，绝缘性能、机械性能、防火性能以及隔热性能良好。

Description

一种外壳结构
技术领域
本发明涉及车用动力电池系统领域，尤其涉及一种适用于高压动力电池系统的外壳结构。
背景技术
车用动力电池系统既要满足传统汽车零部件的技术要求，又要满足高压储能系统的安全要求，使得车用动力电池系统外壳必须具有良好的机械性能、高压绝缘性能、隔热性能以及防火性能等要求。目前国际上主要的车用电池系统外壳为金属外壳，同时在电池模块和外壳之间加绝缘层，并且在外壳上涂绝缘漆以达到高压绝缘的目的。该种外壳结构的缺点是：1、重量大，降低了电池系统的能量密度，增加了整车的重量；2、绝缘层和油漆破损易造成绝缘失效，从而导致高压漏电，危及乘客和驾驶员的人身安全；3、金属外壳良好的导热性不利于电池隔热性能。
发明内容
针对现有技术的上述问题，本发明提出了一种外壳结构，具有材质轻、绝缘性能、机械性能、防火性能以及隔热性能良好的特点。
具体地，本发明提出了一种外壳结构，适用于高压动力电池系统，包括隔热层、复合材料层以及电磁防护层，所述隔热层位于所述外壳结构的内侧且固定设置在所述复合材料层的内表面，所述复合材料层采用片状模压复合材料或玻璃钢材料。
根据本发明的一个实施例，所述电磁防护层嵌入所述复合材料层内或设置在所述复合材料层外。
根据本发明的一个实施例，所述电磁防护层为金属丝网，所述金属丝网嵌入所述复合材料层内。
根据本发明的一个实施例，所述金属丝网为铜网或铁丝网，其网孔形状为圆形、三角形、四边形或多边形中的任一种，对应孔面积为0.1mm2～5mm2。
根据本发明的一个实施例，设置在所述复合材料层外的所述电磁防护层包括铜层和抗石击胶材料层，所述铜层均匀覆在所述复合材料层的外表面，其厚度为0.1～0.6mm，所述抗石击胶材料层喷覆在所述铜层外，所述抗石击胶材料层为聚氯乙烯或高分子水性树脂，所述抗石击胶材料层的厚度为1～5mm。
根据本发明的一个实施例，所述隔热层以涂覆或粘接方式固定设置在所述复合材料层的内表面。
根据本发明的一个实施例，所述隔热层的厚度为0.5～5mm，所述隔热层选用玻纤、石棉、岩棉、硅酸盐、气凝胶毡及真空板中的任一种或其组合。
根据本发明的一个实施例，所述复合材料层的玻纤含量为30～50％，密度为1.3～2g/cm3，绝缘电阻值≥1012Ω。
根据本发明的一个实施例，所述复合材料层的厚度为2～5mm。
根据本发明的一个实施例，在所述复合材料层中添加氢氧化铝型阻燃剂或含磷型阻燃剂，以使其氧指数大于40％。
本发明提供的一种适用于高压动力电池系统的外壳结构，具有材质轻、绝缘性能、耐化学腐蚀性能、抗疲劳性能以及隔热性能良好的特点。
应当理解，本发明以上的一般性描述和以下的详细描述都是示例性和说明性的，并且旨在为如权利要求所述的本发明提供进一步的解释。
附图说明
包括附图是为提供对本发明进一步的理解，它们被收录并构成本申请的一部分，附图示出了本发明的实施例，并与本说明书一起起到解释本发明原理的作用。
附图中：
图1是本发明的一个实施例的外壳结构的截面示意图。
图2是本发明的另一个实施例的外壳结构的截面示意图。
具体实施方式
现在将详细参考本发明的优选实施例，其示例在附图中示出。在任何可能的情况下，在所有附图中将使用相同的标记来表示相同或相似的部分。此外，尽管本发明中所使用的术语是从公知公用的术语中选择的，但是本发明说明书中所提及的一些术语可能是申请人按他或她的判断来选择的，其详细含义在本文的描述的相关部分中说明。此外，要求不仅仅通过所使用的实际术语，而是还要通过每个术语所蕴含的意义来理解本发明。
图1是本发明的一个实施例的外壳结构的截面示意图。如图所示，一种外壳结构100适用于高压动力电池系统，尤其适用于电池电压范围为40～600V的电池系统。该外壳结构100包括隔热层110、复合材料层120以及电磁防护层130。隔热层110位于外壳结构100的内侧，即靠近电池系统的内部。隔热层110固定设置在复合材料层120的内表面。复合材料层120采用片状模压复合材料或玻璃钢材料。
隔热层110设置在电池系统与复合材料层120之间，以达到良好的隔热效果。复合材料层120的材质轻，具有良好的电绝缘性、耐化学腐蚀性等优点。电磁防护层130具有良好的抗电磁辐射和耐环境腐蚀性能。故，该种外壳结构100能将高能量、高压、高危险的电池系统与外界安全隔离，保护电池系统免受外界环境的损坏，防止用户高压触电，同时降低电池系统的重量，提高电池系统的能量密度。
进一步的，在图1所示的实施例中，电磁防护层130嵌入在复合材料层120内。该电磁防护层130为金属丝网。更佳地，金属丝网为铜网或铁丝网，其网孔形状为圆形、三角形、四边形或多边形中的任一种。金属丝网的单个网孔面积为0.1mm2～5mm2。该金属丝网具有良好的抗电磁辐射和耐环境腐蚀性能。
较佳地，隔热层110以涂覆或粘接方式固定设置在复合材料层120的内表面。
较佳地，隔热层110的厚度为0.5～5mm。隔热层110选用玻纤、石棉、岩棉、硅酸盐、气凝胶毡及真空板中的任一种或其组合。
较佳地，复合材料层120的玻纤含量为30～50％，密度为1.3～2g/cm3，绝缘电阻值≥1012Ω。更佳地，复合材料层120的拉伸强度为120～180MPa，拉伸模量为8～12GPa,断裂伸长率为2～3.5％，弯曲强度为200～300MPa,弯曲模量为8～9GPa，巴氏硬度为10～50HBa。
较佳地，在复合材料层120中添加氢氧化铝型阻燃剂或含磷型阻燃剂，以使其氧指数大于40％。
较佳地，复合材料层120的厚度为2～5mm。
参考图1，对实际生产过程中采用的一款外壳结构100进行具体描述。外壳结构100靠近电池系统一侧设有隔热层110，隔热层110粘接在复合材料层120上。隔热层110厚度为2mm，隔热层110的材料为气凝胶毡。复合材料层120采用片状模压复合材料，复合材料层120厚度为3mm，玻纤含量为42.65％，密度1.45g/cm3,拉伸强度134.7MPa，拉伸模量9.8GPa,断裂伸长率2.3％，弯曲强度208MPa,弯曲模量8.3GPa，巴氏硬度15HBa。绝缘电阻值5*1012Ω，在复合材料层120中添加0.3％质量百分比的氢氧化铝型阻燃剂。电磁防护层130是嵌入在复合材料层120中的金属丝网，金属丝网为铜网，网孔形状为四边形，孔面积1mm2。
图2是本发明的另一个实施例的外壳结构的截面示意图。一种外壳结构200适用于高压动力电池系统，尤其适用于电池电压范围为40～600V的电池系统。外壳结构200包括隔热层110、复合材料层120以及电磁防护层130’。隔热层110位于外壳结构100的内侧，即靠近电池系统的内部。隔热层110固定设置在复合材料层120的内表面。复合材料层120采用片状模压复合材料或玻璃钢材料。电磁防护层130’设置在复合材料层120外，该电磁防护层130’包括铜层和抗石击胶材料层。铜层均匀覆在复合材料层120的外表面，其厚度为0.1～0.6mm，抗石击胶材料层喷覆在铜层外，抗石击胶材料层为聚氯乙烯或高分子水性树脂，抗石击胶材料层的厚度为1～5mm。
外壳结构200与图1中的外壳机构100基本相同，在电池系统与复合材料层120之间设置隔热层110，以达到良好的隔热效果。复合材料层120的材质轻，具有良好的电绝缘性、耐化学腐蚀性等优点。外壳结构200的电磁防护层130’具有良好的抗电磁辐射和耐环境腐蚀性能。故，外壳结构200与外壳结构100一样能将高能量、高压、高危险的电池系统与外界安全隔离，保护电池系统免受外界环境的损坏，防止用户高压触电，同时降低电池系统的重量，提高电池系统的能量密度。
较佳地，隔热层110的厚度为0.5～5mm。隔热层110选用玻纤、石棉、岩棉、硅酸盐、气凝胶毡及真空板中的任一种或其组合。
较佳地，复合材料层120的玻纤含量为30～50％，密度为1.3～2g/cm3，绝缘电阻值≥1012Ω。更佳地，复合材料层120的拉伸强度120～180MPa，拉伸模量8～12GPa,断裂伸长率2～3.5％，弯曲强度200～300MPa,弯曲模量8～9GPa，巴氏硬度10～50HBa。
参考图2，对实际生产过程中采用的一款外壳结构200进行具体描述。外壳结构200靠近电池系统一侧设有隔热层110，隔热层110粘接在复合材料层120上。隔热层110厚度为3mm，隔热层110材料为石棉。中间的复合材料层120采用片状模压复合材料制成，复合材料层120的厚度为3mm，玻纤含量为42.65％，密度1.45g/cm3,拉伸强度134.7MPa，拉伸模量9.8GPa,断裂伸长率2.3％，弯曲强度208MPa，弯曲模量8.3GPa，巴氏硬度15HBa。绝缘电阻值5*1012Ω，在复合材料层120中添加0.3％质量百分比的氢氧化铝型阻燃剂。电磁防护层130’采用在复合材料外层120均匀的敷铜，敷铜层厚度0.3mm，再在敷铜层外面喷抗石击胶形成抗石击胶材料层，其中抗石击胶材料为聚氯乙烯，厚度为3mm。
参考图2，对实际生产过程中采用的另一款外壳结构200进行具体描述。外壳结构200靠近电池系统一侧设有隔热层110，隔热层110涂覆在复合材料层120上。隔热层110厚度为1mm，隔热层110材料为硅酸盐。中间的复合材料层120采用玻璃钢材料制成，复合材料层120厚度为3mm，玻纤含量为46.15％，密度1.76g/cm3,拉伸强度164.3MPa，拉伸模量11.5GPa,断裂伸长率3.2％，弯曲强度281MPa，弯曲模量8.5GPa，巴氏硬度33HBa。绝缘电阻值6*1012Ω，在复合材料层120中添加0.3％质量百分比的氢氧化铝型阻燃剂。电磁防护层130’采用在复合材料外层120均匀的敷铜，敷铜层厚度0.4mm，再在敷铜层外面喷抗石击胶形成抗石击胶材料层，其中抗石击胶材料为聚氯乙烯，厚度为3mm。
本发明提供的一种适用于高压动力电池系统的外壳结构，具有高机械强度、良好的电、电磁、热隔离功能，既可以安全保护电池系统免受环境的损坏，又可以保护使用者免受高压触电危险，同时整个外壳材料选用非金属轻量化复合材料，可提高电池系统的能量密度。外壳机构的主要特点如下：
1、轻量化。
模压复合材料或玻璃钢材料的密度小于1.8g/cm3，相比传统的金属外壳，可以大大降低外壳整体重量，从而提高电池系统的能量密度。
2.高性能。
a)隔热性能，设有隔热层，另外复合材料层本身也有较好的隔热性能，而传统的金属外壳隔热性能差；
b)电绝缘性能，复合材料层具有优秀的电绝缘性能，绝缘电阻值≥1012Ω，这对于电池系统的高压安全保护至关重要，而在实际应用中一般在金属外壳表面涂覆绝缘漆，但存在使用过程中绝缘漆受到破坏脱落发生高压触电的风险；
c)电磁防护层可以达到金属外壳的防电磁功能，而一般非金属外壳不具备该功能；
d)高阻燃性，模压复合材料或玻璃钢材料本身有较好的阻燃性，同时在该复合材料中加入氢氧化铝型或含磷型阻燃剂，能大大提高外壳结构的阻燃性能，产品氧指数大于40％，这对车用电池系统非常重要，而一般其他非金属电池外壳很难达到要求；
e)高机械性能，模压复合材料或玻璃钢材料具有高强度、抗疲劳、长寿命的特点；
f)耐腐蚀性，能够很好的耐受环境的腐蚀和影响，而金属电池外壳往往易发生腐蚀，性能降低。
本发明提供的外壳结构能够对电池系统内外部环境起到良好的机械、电、电磁、热、火隔离的作用，轻质高强，降低电池系统的重量，从而提高电池系统的能量密度，进而提升新能源汽车的整车性能。
本领域技术人员可显见，可对本发明的上述示例性实施例进行各种修改和变型而不偏离本发明的精神和范围。因此，旨在使本发明覆盖落在所附权利要求书及其等效技术方案范围内的对本发明的修改和变型。

Claims (10)

1.一种外壳结构，适用于高压动力电池系统，包括隔热层、复合材料层以及电磁防护层，所述隔热层位于所述外壳结构的内侧且固定设置在所述复合材料层的内表面，所述复合材料层采用片状模压复合材料或玻璃钢材料。
2.如权利要求1所述的外壳结构，其特征在于，所述电磁防护层嵌入所述复合材料层内或设置在所述复合材料层外。
3.如权利要求2所述的外壳结构，其特征在于，所述电磁防护层为金属丝网，所述金属丝网嵌入所述复合材料层内。
4.如权利要求3所述的外壳结构，其特征在于，所述金属丝网为铜网或铁丝网，其网孔形状为圆形、三角形、四边形或多边形中的任一种，对应孔面积为0.1mm2～5mm2。
5.如权利要求2所述的外壳结构，其特征在于，设置在所述复合材料层外的所述电磁防护层包括铜层和抗石击胶材料层，所述铜层均匀覆在所述复合材料层的外表面，其厚度0.1～0.6mm，所述抗石击胶材料层喷覆在所述铜层外，所述抗石击胶材料层为聚氯乙烯或高分子水性树脂，所述抗石击胶材料层的厚度为1～5mm。
6.如权利要求1所述的外壳结构，其特征在于，所述隔热层以涂覆或粘接方式固定设置在所述复合材料层的内表面。
7.如权利要求1所述的外壳结构，其特征在于，所述隔热层的厚度为0.5～5mm，所述隔热层选用玻纤、石棉、岩棉、硅酸盐、气凝胶毡及真空板中的任一种或其组合。
8.如权利要求1所述的外壳结构，其特征在于，所述复合材料层的玻纤含量为30～50％，密度为1.3～2g/cm3，绝缘电阻值≥1012Ω。
9.如权利要求8所述的外壳结构，其特征在于，所述复合材料层的厚度为2～5mm。
10.如权利要求8所述的外壳结构，其特征在于，在所述复合材料层中添加氢氧化铝型阻燃剂或含磷型阻燃剂，以使其氧指数大于40％。
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