CN112895519B - Forming process of upper box body of composite power battery - Google Patents
Forming process of upper box body of composite power battery Download PDFInfo
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- CN112895519B CN112895519B CN202110073338.XA CN202110073338A CN112895519B CN 112895519 B CN112895519 B CN 112895519B CN 202110073338 A CN202110073338 A CN 202110073338A CN 112895519 B CN112895519 B CN 112895519B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7146—Battery-cases
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- 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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Abstract
The invention discloses a forming process of an upper box body of a composite power battery, which comprises the steps of pre-forming prepregs and material sheet layers, injection molding and hot press forming of prefabricated products and subsequent processing of the prefabricated products, wherein the epoxy SMC chopped glass fiber pre-pregs and epoxy resin-based continuous glass fiber pre-pregs which are approximately rectangular in weight and quantity are prepared according to the box body; the method comprises the steps of firstly using a plurality of epoxy resin-based continuous glass fiber prepregs to fully lay along the shape of an inner cavity of a forming lower die to form a base layer of a prefabricated product, then using epoxy SMC chopped glass fiber prepregs to stack and lay to form a thickening layer of the prefabricated product, finally using epoxy resin-based continuous glass fiber prepregs to reinforce and lay to form a reinforcing layer of the prefabricated product, and using a method of using an epoxy SMC chopped glass fiber prepreg layer and an epoxy resin-based continuous glass fiber prepreg layer to lay by using specific steps as a prefabricated product, wherein the method has the advantages of being few in laying layer number, high in strength, high in fault tolerance rate, low in cost and the like.
Description
Technical Field
The invention relates to the technical field of battery box upper cover forming, in particular to a forming process of a composite power battery upper box body.
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 upper box body of the battery in view of various advantages.
At present, the PCM process is mostly adopted in the upper box body of the composite material power battery of the new energy automobile, epoxy resin-based continuous glass fiber prepreg is mostly adopted as a raw material, the raw material is cut into preset material pieces through cutting equipment, the material pieces are accurately laid on a die or a preforming die, and the like, and after a plurality of layers are continuously laid, the product is fed into forming equipment to be heated and pressed for forming, so that a finished piece is obtained.
Therefore, the PCM process for preparing the upper battery box body in the prior art still has the following problems:
(1) When the thickness of the box body prefabricated product to be prepared is high, a large number of material sheets meeting the requirements need to be accurately prepared in advance according to the shape and the weight of the prefabricated product, so that more leftover materials are inevitably generated in the manufacturing process;
(2) Because the requirement on the size precision of a mold cavity is high, the occurrence of the bad conditions of pinholes, material shortage and the like of a product due to the slight out-of-tolerance of the mold size is easy to occur, a plurality of material sheets need to be accurately laid in the material sheet laying process, and because the material sheets are generally butt-jointed and laid in the laying process, the overpressure bad is easy to occur among the material sheets, so that the position of the material sheets can be deviated, and the fault tolerance rate is low.
Disclosure of Invention
The invention aims to provide a forming process of an upper box body of a composite power battery, and aims to solve the problems that in the prior art, material sheets need to be accurately positioned and laid, so that the operation is complicated, the period is long, and the fault-tolerant rate of laying of a plurality of material sheets is low.
In order to solve the technical problems, the invention specifically provides the following technical scheme:
a forming process of an upper box body of a composite power battery comprises the following steps:
step 100, preparing epoxy SMC chopped glass fiber prepregs and epoxy resin-based continuous glass fiber prepregs with approximate weight, quantity and shape according to a required upper box, and preparing a plurality of reinforcing sheets with corresponding approximate shapes from leftover materials in the process of preparing a plurality of epoxy resin-based continuous glass fiber prepregs;
step 200, performing layering and preforming of prepregs, namely, firstly, using a plurality of epoxy resin-based continuous glass fiber prepregs to fully lay and paste along the shape of an inner cavity of a forming lower die to form a base layer of a preform, then using epoxy SMC chopped glass fiber prepregs to carry out stacking and paving to form a thickening layer of the preform, and finally using the epoxy resin-based continuous glass fiber prepregs to carry out reinforcement and paving to form a triple reinforcing layer of the preform;
300, performing compression molding and hot-press molding on the prefabricated product, namely sleeving the prefabricated product formed by superposing and paving a plurality of tablets into a lower mold insert of a hot-press mold, and then matching the prefabricated product and a resin material through an upper mold and a lower mold of the hot-press mold, heating and pressurizing to prepare and mold the prefabricated product to obtain an upper box prefabricated component;
and 400, performing subsequent processing on the prefabricated product, namely demolding the prefabricated product subjected to hot press molding, and conveying the prefabricated product subjected to punch molding to the subsequent processing to obtain a finished product of the upper box body.
In a preferred embodiment of the present invention, in step 200, the specific steps of laying out the plurality of material sheets are:
step 201, firstly, epoxy resin based continuous glass fiber prepregs are taken to be paved along the edge position of the inner cavity of the forming lower die and tend to the central area, and the butt joint positions of the edges of the epoxy resin based continuous glass fiber prepregs are subjected to interference lap joint in the central area of the inner cavity of the forming lower die;
202, taking epoxy SMC chopped glass fiber prepreg with required weight, extending and paving the epoxy SMC chopped glass fiber prepreg to the periphery along the center of the top end of the embedded bulge of the forming lower die, bending the periphery of the epoxy SMC chopped glass fiber prepreg and then adhering the epoxy SMC chopped glass fiber prepreg to the periphery of the bulge structure of the inner cavity of the lower die;
step 203, taking a plurality of epoxy resin-based continuous glass fiber prepregs to carry out multilayer laying along the peripheral depression of the inner cavity of the lower die according to the required thickness;
204, taking a strip-shaped epoxy resin-based continuous glass fiber prepreg sheet to perform linear reinforcement laying for at least two times along the epoxy SMC chopped glass fiber prepreg sheet, wherein a plurality of linearly laid epoxy resin-based continuous glass fiber prepreg sheets are distributed symmetrically relative to the center of the epoxy SMC chopped glass fiber prepreg sheet;
and step 205, taking the strip-shaped epoxy resin-based continuous glass fiber prepreg, and linearly reinforcing and laying the strip-shaped epoxy resin-based continuous glass fiber prepreg along the bent part at the periphery of the epoxy SMC chopped glass fiber prepreg.
In a preferred embodiment of the present invention, in step 201, the requirements for overlapping a plurality of epoxy resin-based continuous glass fiber prepregs are:
the embedded part of the forming lower die is required to be paved with a plurality of epoxy resin-based continuous glass fiber prepregs in a matched interference lap joint manner, and the width and the length of the interference lap joint of the plurality of epoxy resin-based continuous glass fiber prepregs do not need to be accurately positioned.
In a preferred embodiment of the present invention, in step 202, the epoxy SMC chopped glass fiber prepreg is laid down as follows:
the epoxy SMC chopped glass fiber prepreg needs to completely cover the lap joint of a plurality of epoxy resin-based continuous glass fiber prepregs, and the edge of the periphery bending part of the epoxy SMC chopped glass fiber prepreg is positioned at any height on the periphery of the embedded bulge part of the forming die.
As a preferable scheme of the present invention, in step 204, the requirements for laying the elongated epoxy resin-based continuous glass fiber prepreg are as follows:
the staggered areas of the strip-shaped epoxy resin-based continuous glass fiber prepregs are located at the center of the convex structure of the inner cavity of the lower forming die, the strip-shaped epoxy resin-based continuous glass fiber prepregs are directly paved on any opposite sides of the convex structure of the inner cavity of the lower forming die, and two ends of the strip-shaped epoxy resin-based continuous glass fiber prepregs are respectively located at any height on the opposite sides of the convex structure of the inner cavity of the lower forming die.
In a preferred embodiment of the present invention, in step 100, the epoxy resin-based continuous glass fiber prepreg and the epoxy SMC chopped glass fiber prepreg have a compression ratio of:
and the compression amount of the epoxy resin-based continuous glass fiber prepreg is within 50 percent of that of the epoxy SMC chopped glass fiber prepreg.
As a preferable aspect of the present invention, in step 300, the temperatures of the hot-pressing upper and lower molds are:
the hot-pressing upper die temperature is as follows: 145-155 ℃, and the temperature of the hot-pressing lower die is as follows: 125-135 ℃.
As a preferable aspect of the present invention, in step 300, the molding pressure of the hot-pressing upper and lower molds is:
the unit area pressure of the hot-pressing upper die and the unit area pressure of the hot-pressing lower die are more than 3.5MPa.
As a preferable aspect of the present invention, in step 300, the physical properties of the resin material during the hot pressing are:
the glass transition temperature of the resin material is as follows: tg > 145 ℃, and the flame retardant rating of the resin material is: UL94-V0.
As a preferred embodiment of the present invention, in step 300, the hot-pressing upper and lower mold structures are:
the hot-pressing die is a metal die, and the upper die and the lower die of the hot-pressing die are of a hard-pressing double-sided die structure.
Compared with the prior art, the invention has the following beneficial effects:
compared with the traditional mode of using a plurality of layers of epoxy resin-based continuous glass fiber prepregs, the invention has the following beneficial effects that by using the epoxy SMC chopped glass fiber prepreg layer and the epoxy resin-based continuous glass fiber prepreg layer as the prefabricated product, the method adopts the specific steps for layering:
(1) The compression amount of the epoxy resin-based continuous glass fiber prepreg is within 50 percent of the compression amount of the epoxy SMC chopped glass fiber prepreg, so that the number of paving layers is reduced to be below 50 percent when the required wall thickness of the prefabricated product is achieved;
(2) The method has the advantages that the elongated epoxy resin-based continuous glass fiber prepreg leftover materials are used for reinforcing the peripheral sunken parts, the peripheral chamfer parts and the plurality of centrosymmetric positions on the prefabricated product of the box body, so that the strength of the prefabricated product of the box body can be effectively enhanced, the tensile strength of the prefabricated product of the box body is more than 200MPa, and the ultimate withstand voltage of the prefabricated product of the box body is more than 10Kpa;
(3) By adopting the overlapping and paving of a plurality of gelatinized epoxy resin-based continuous glass fiber prepregs and the overlapping and paving of epoxy SMC chopped glass fiber prepregs, the fault tolerance of each prepreg in the paving process is greatly improved, and the yield of the prefabricated product is improved to more than 99%;
(4) By saving the materials and improving the utilization rate and the yield of the leftover materials of the material sheet, the comprehensive manufacturing cost of the prefabricated product is reduced by more than 50 percent.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
Fig. 1 is a flowchart of the whole upper case of the battery according to the embodiment of the present invention.
Fig. 2 is a flow chart for providing a web layup according to an embodiment of the present invention.
Fig. 3 is a schematic diagram of the layup of sheets provided by an embodiment of the present invention.
Fig. 4 is a schematic illustration of reinforcing lay-ups of webs provided by an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1 to 2, the invention provides a molding process of an upper box body of a composite power battery, which comprises the following steps:
step 100, preparing epoxy SMC chopped glass fiber prepregs and epoxy resin-based continuous glass fiber prepregs with approximate weight, quantity and shape according to the required upper box, and preparing the leftover materials into a plurality of reinforcing sheets with corresponding approximate shapes in the process of preparing a plurality of epoxy resin-based continuous glass fiber prepregs.
In step 100, the epoxy resin-based continuous glass fiber prepreg and the epoxy SMC chopped glass fiber prepreg are compressed in the following ratio:
and the compression amount of the epoxy resin-based continuous glass fiber prepreg is within 50 percent of that of the epoxy SMC chopped glass fiber prepreg.
And 200, performing layering and preforming of the prepreg sheets, namely, firstly, using a plurality of epoxy resin-based continuous glass fiber prepreg sheets to be fully paved along the shape of the inner cavity of the forming lower die to form a base layer of the prefabricated product, then using epoxy SMC chopped glass fiber prepreg sheets to be overlapped and paved to form a thickening layer of the prefabricated product, and finally using epoxy resin-based continuous glass fiber prepreg sheets to be reinforced and paved to form a triple reinforcing layer of the prefabricated product.
In step 200, the specific laying steps of the plurality of material sheets are as follows:
step 201, firstly, epoxy resin based continuous glass fiber prepregs are taken to be paved along the edge position of the inner cavity of the forming lower die and tend to the central area, and the butt joint positions of the edges of the epoxy resin based continuous glass fiber prepregs are subjected to interference lap joint in the central area of the inner cavity of the forming lower die.
In step 201, the overlapping requirements of a plurality of epoxy resin-based continuous glass fiber prepregs are as follows:
the embedded part of the forming lower die is required to be paved with a plurality of epoxy resin-based continuous glass fiber prepregs in a matched interference lap joint manner, and the width and the length of the interference lap joint of the plurality of epoxy resin-based continuous glass fiber prepregs do not need to be accurately positioned.
Step 202, taking the epoxy SMC chopped glass fiber prepreg with the required weight, extending and paving the epoxy SMC chopped glass fiber prepreg along the center of the top end of the embedded protrusion of the forming lower die, bending the periphery of the epoxy SMC chopped glass fiber prepreg, and then adhering the epoxy SMC chopped glass fiber prepreg to the periphery of the protrusion structure of the inner cavity of the lower die.
In step 202, the epoxy SMC chopped glass fiber prepreg layup requirements are:
the epoxy SMC chopped glass fiber prepreg needs to completely cover the lap joint of a plurality of epoxy resin-based continuous glass fiber prepregs, and the edge of the periphery bending part of the epoxy SMC chopped glass fiber prepreg is positioned at any height on the periphery of the embedded bulge part of the forming die.
And 203, taking a plurality of epoxy resin-based continuous glass fiber prepregs to carry out multilayer laying along the peripheral depression of the inner cavity of the lower die according to the required thickness.
And 204, taking the long-strip-shaped epoxy resin-based continuous glass fiber prepreg to perform linear reinforcement laying for at least two times along the epoxy SMC chopped glass fiber prepreg, wherein the plurality of linearly laid epoxy resin-based continuous glass fiber prepreg sheets are distributed symmetrically relative to the center of the epoxy SMC chopped glass fiber prepreg sheet.
In step 204, the requirements for laying the elongated epoxy resin-based continuous glass fiber prepreg are as follows:
the staggered areas of the strip-shaped epoxy resin-based continuous glass fiber prepregs are located at the center of the convex structure of the inner cavity of the lower forming die, the strip-shaped epoxy resin-based continuous glass fiber prepregs are directly paved on any opposite side surfaces of the convex structure of the inner cavity of the lower forming die, and the two ends of the strip-shaped epoxy resin-based continuous glass fiber prepregs are respectively located at any heights on the opposite side surfaces of the convex structure of the inner cavity of the lower forming die.
And step 205, taking a long strip-shaped epoxy resin-based continuous glass fiber prepreg, and linearly reinforcing and laying the long strip-shaped epoxy resin-based continuous glass fiber prepreg along the bent part at the periphery of the epoxy SMC chopped glass fiber prepreg.
Step 300, performing compression molding and hot-press molding on the prefabricated product, namely sleeving the prefabricated product formed by superposing and paving a plurality of tablets into a lower mold of a hot-press mold to be embedded, matching the prefabricated product and a resin material through an upper mold and a lower mold of the hot-press mold, heating and pressurizing to prepare and mold the prefabricated product, and obtaining an upper box prefabricated component.
In step 300, the temperatures of the upper and lower molds are:
the hot-pressing upper die temperature is as follows: 145-155 ℃, and the temperature of the hot-pressing lower die is as follows: 125-135 ℃.
The unit area pressure of the hot-pressing upper die and the unit area pressure of the hot-pressing lower die are more than 3.5MPa.
The glass transition temperature of the resin material is as follows: tg > 145 ℃, and the flame retardant rating of the resin material is: UL94-V0.
The hot-pressing die is a metal die, and the upper die and the lower die of the hot-pressing die are of a hard-pressing double-sided die structure.
And 400, performing subsequent processing on the prefabricated product, namely demolding the prefabricated product subjected to hot press molding, and conveying the prefabricated product subjected to punch molding to the subsequent processing to obtain a finished product of the upper box body.
The upper box body of the battery is usually processed by adopting a hot-pressing process, a prefabricated product of the upper box body is prepared in advance, then the prefabricated product of the upper box body is put into an inner cavity of a hot-pressing lower die, and then resin materials are injected after the prefabricated product of the upper box body is combined by the hot-pressing die to carry out hot-sealing processing to obtain the prefabricated product of the upper box body.
In the prior art, in order to meet the requirements of upper boxes with different thicknesses and shapes, the raw materials of the prefabricated products mostly adopt epoxy resin-based continuous glass fiber prepreg, the raw materials are cut into preset material pieces by cutting equipment, the material pieces are accurately laid on a die or a preforming die, and the like, and after a plurality of layers are continuously laid, the product is sent into forming equipment to be heated and pressed for forming, so that the prefabricated products are manufactured.
According to the invention, the epoxy SMC chopped glass fiber prepreg layer and the epoxy resin-based continuous glass fiber prepreg layer are used as the prefabricated product of the upper box body in a layering manner by using specific steps, and compared with the traditional manner of using multiple layers of epoxy resin-based continuous glass fiber prepregs, the prefabricated product has the effects of reducing the layering number, improving the strength of the prefabricated product of the upper box body, improving the fault tolerance rate of the prefabricated product formed by paving and pasting the sheets, reducing the comprehensive cost and the like.
According to the steps, the prefabricated product which is similar to the prefabricated product which is paved by single stacking can be paved by means of overlapping, triple reinforcing and the like of the epoxy resin-based continuous glass fiber prepreg layer and the epoxy SMC chopped glass fiber prepreg layer, so that the prefabricated product still has the effect.
As shown in fig. 3, the principle of improving the fault tolerance of the preform by laying the sheets is that, in the drawing, the epoxy resin based continuous glass fiber prepregs 2 are aligned and inwardly laid along the edge of the convex structure of the inner cavity of the lower molding die 1, and at this time, the inner side edge portions of the epoxy resin based continuous glass fiber prepregs 2 are vertically overlapped at the center of the convex portion of the inner cavity of the lower molding die 1, and the inner cavity structure of the lower molding die can be completely covered only after the epoxy resin based continuous glass fiber prepregs 2 are overlapped and laid.
And then extending and paving the epoxy SMC chopped glass fiber prepreg 3 along the central part of the inner cavity convex structure of the lower forming die 1 to the periphery until the upper surface of the inner cavity convex structure of the lower forming die 1 is fully paved, bending redundant parts and paving the bent parts on the peripheral side surfaces of the inner cavity convex structure of the lower forming die 1, wherein the length and the size of the bent parts of the epoxy SMC chopped glass fiber prepreg, which are paved on the peripheral side surfaces of the inner cavity convex structure of the lower forming die 1, are not limited, and only needs to ensure that a plurality of epoxy resin-based continuous glass fiber prepregs 2 and the epoxy chopped glass fiber prepregs 3 are matched and paved to approximately accord with the approximate weight of the needed SMC prefabricated product frame structure.
Therefore, the requirements on the accuracy of the shape and the weight of the epoxy resin-based continuous glass fiber prepreg 2 are low, accurate cutting is not required to be carried out in advance according to the shape and the weight of the required prefabrication, and the efficiency of processing the prefabricated product is greatly improved.
By adopting the overlapping and paving of a plurality of fuzzy epoxy resin-based continuous glass fiber prepregs and the overlapping and paving of epoxy SMC chopped glass fiber prepregs, the fault tolerance rate of each prepreg in the paving process is greatly improved, and the yield of the prefabricated product is improved to more than 99%.
In addition, since the compression amount of the epoxy SMC chopped glass fiber prepreg 3 is more than 200% of the compression amount of the epoxy resin-based continuous glass fiber prepreg 2, the epoxy SMC chopped glass fiber prepreg is used as most of the region of the cavity bulge structure of the cover forming lower die 1, so that the paving amount of the epoxy resin-based continuous glass fiber prepreg 2 can be greatly reduced, and the paving layer number is reduced to below 50% when the required wall thickness of the preform is achieved.
As shown in FIG. 4, the principle of the strength improvement of the upper box body prefabricated member is that after a plurality of epoxy resin-based continuous glass fiber prepregs 2 and epoxy SMC chopped glass fiber prepregs 3 are matched and laid, the concave reinforcing continuous prepregs 4 are laid on the peripheral concave positions of the convex structures in the inner cavity of the lower molding die 1 according to the thickness and the weight of the required prefabricated member structure, and are used for reinforcing the periphery of the prefabricated member once.
And then selecting a proper amount of axis-reinforced continuous prepregs 5 according to design requirements, and paving and pasting the axis-reinforced continuous prepregs 5 towards different directions along the center position of the top end of the convex structure of the inner cavity of the lower forming die 1, so that staggered points of the axis-reinforced continuous prepregs 5 are positioned at the center position of the top end of the convex structure of the inner cavity of the lower forming die 1, and the included angles of the axis-reinforced continuous prepregs 5 are the same, and the included angles are used for double reinforcement of the top end of the preform.
And finally, paving and pasting the bent reinforced continuous prepreg 6 along the bent part on the epoxy SMC chopped glass fiber prepreg 3 until the bent reinforced continuous prepreg 6 forms a rectangular ring around the epoxy SMC chopped glass fiber prepreg 3, and sequentially improving the triple reinforcement of the bent part of the preform.
By using the elongated epoxy resin-based continuous glass fiber prepreg leftover materials to carry out triple reinforcement on the peripheral sunken parts, the peripheral chamfer parts and a plurality of centrosymmetric positions on the prefabricated product of the box body, the strength of the prefabricated product of the box body can be effectively enhanced, so that the tensile strength of the prefabricated product of the box body is more than 200MPa, and the ultimate withstand voltage is more than 10Kpa.
Because the cutting mode of the epoxy resin based continuous glass fiber prepreg 2 and the epoxy SMC chopped glass fiber prepreg 3 is rough cutting, a plurality of strip-shaped epoxy SMC chopped glass fiber prepregs can be left, and the epoxy SMC chopped glass fiber prepregs can be secondarily cut into a plurality of concave reinforced continuous prepregs, axial reinforced continuous prepregs and bent reinforced continuous prepregs in the subsequent process, so that the utilization rate of excess materials is improved.
In conclusion, the comprehensive manufacturing cost of the prefabricated product is reduced by more than 50% by saving the materials, and improving the utilization rate and the yield of the leftover materials of the material sheet.
The above embodiments are only exemplary embodiments of the present application, and are not intended to limit the present application, and the protection scope of the present application is defined by the claims. Various modifications and equivalents may be made by those skilled in the art within the spirit and scope of the present application and such modifications and equivalents should also be considered to be within the scope of the present application.
Claims (6)
1. A forming process of an upper box body of a composite power battery is characterized by comprising the following steps:
step 100, preparing epoxy SMC chopped glass fiber prepregs and epoxy resin-based continuous glass fiber prepregs with approximate weight, quantity and shape according to a required upper box, and preparing a plurality of reinforcing sheets with corresponding approximate shapes from leftover materials in the process of preparing a plurality of epoxy resin-based continuous glass fiber prepregs;
step 200, performing layering and preforming of prepregs, namely, firstly, using a plurality of epoxy resin-based continuous glass fiber prepregs to fully lay and paste along the shape of an inner cavity of a forming lower die to form a base layer of a preform, then using epoxy SMC chopped glass fiber prepregs to carry out stacking and paving to form a thickening layer of the preform, and finally using the epoxy resin-based continuous glass fiber prepregs to carry out reinforcement and paving to form a triple reinforcing layer of the preform;
300, performing compression molding and hot-press molding on the prefabricated product, namely sleeving the prefabricated product formed by superposing and paving a plurality of tablets into a lower mold insert of a hot-press mold, and then matching the prefabricated product and a resin material through an upper mold and a lower mold of the hot-press mold, heating and pressurizing to prepare and mold the prefabricated product to obtain an upper box prefabricated component;
step 400, performing subsequent processing on the prefabricated product, namely demolding the prefabricated product subjected to hot press molding, and conveying the prefabricated product subjected to punch molding to subsequent processing to obtain a finished product of the upper box body;
in step 200, the specific laying steps of the plurality of material sheets are as follows:
step 201, firstly, epoxy resin based continuous glass fiber prepregs are taken to be paved along the edge position of the inner cavity of the forming lower die and tend to the central area, and the butt joints of the edges of the epoxy resin based continuous glass fiber prepregs are subjected to interference lap joint in the central area of the inner cavity of the forming lower die, wherein the lap joint requirements of the epoxy resin based continuous glass fiber prepregs are as follows:
the multiple epoxy resin-based continuous glass fiber prepregs need to be fully paved in the embedded part of the forming lower die in a matched interference lap joint manner, and the width and the length of the multiple epoxy resin-based continuous glass fiber prepregs in the interference lap joint manner do not need to be accurately positioned;
step 202, taking epoxy SMC chopped glass fiber prepreg with required weight, extending and paving the epoxy SMC chopped glass fiber prepreg to the periphery along the center of the top end of the embedded bulge of the forming lower die, bending the periphery of the epoxy SMC chopped glass fiber prepreg and then adhering the epoxy SMC chopped glass fiber prepreg to the periphery of the bulge structure of the inner cavity of the lower die, wherein the paving requirement of the epoxy SMC chopped glass fiber prepreg is as follows:
the epoxy SMC chopped glass fiber prepreg sheet needs to completely cover the lap joint of a plurality of epoxy resin-based continuous glass fiber prepreg sheets, and the edge of the peripheral bending part of the epoxy SMC chopped glass fiber prepreg sheet is positioned at any height on the periphery of the embedded convex part of the forming die;
step 203, taking a plurality of epoxy resin-based continuous glass fiber prepregs to carry out multilayer laying along the peripheral depression of the inner cavity of the lower die according to the required thickness;
204, taking the strip-shaped epoxy resin-based continuous glass fiber prepreg to perform linear reinforcement laying for at least two times along the epoxy SMC chopped glass fiber prepreg, wherein the plurality of linearly laid epoxy resin-based continuous glass fiber prepregs are distributed symmetrically relative to the center of the epoxy SMC chopped glass fiber prepreg, and the requirements for laying the strip-shaped epoxy resin-based continuous glass fiber prepreg are as follows:
the staggered areas of the strip-shaped epoxy resin-based continuous glass fiber prepregs are positioned at the central position of the convex structure of the inner cavity of the lower forming die, the strip-shaped epoxy resin-based continuous glass fiber prepregs are paved and pasted right opposite to any opposite side surface of the convex structure of the inner cavity of the lower forming die, and two ends of the strip-shaped epoxy resin-based continuous glass fiber prepregs are respectively positioned at any height on the opposite side surfaces of the convex structure of the inner cavity of the lower forming die;
and step 205, taking the strip-shaped epoxy resin-based continuous glass fiber prepreg, and linearly reinforcing and laying the strip-shaped epoxy resin-based continuous glass fiber prepreg along the bent part at the periphery of the epoxy SMC chopped glass fiber prepreg.
2. The forming process of the upper box body of the composite type power battery as claimed in claim 1, wherein in step 100, the compression ratio of the epoxy resin-based continuous glass fiber prepreg to the epoxy SMC chopped glass fiber prepreg is as follows:
and the compression amount of the epoxy resin-based continuous glass fiber prepreg is within 50 percent of that of the epoxy SMC chopped glass fiber prepreg.
3. The molding process of the upper box body of the composite power battery according to claim 1, wherein in step 300, the temperatures of the hot-pressing upper and lower molds are respectively:
the hot-pressing upper die temperature is as follows: 145-155 ℃, and the temperature of the hot-pressing lower die is as follows: 125-135 ℃.
4. The forming process of the upper box body of the composite power battery as claimed in claim 1, wherein in step 300, the forming pressure of the hot-pressing upper and lower dies is:
the unit area pressure of the hot-pressing upper die and the unit area pressure of the hot-pressing lower die are more than 3.5MPa.
5. The forming process of the upper box body of the composite power battery as claimed in claim 1, wherein in step 300, the physical properties of the resin material in the hot pressing process are as follows:
the glass transition temperature of the resin material is as follows: tg > 145 ℃, and the flame retardant rating of the resin material is: UL94-V0.
6. The molding process of the upper box body of the composite power battery according to claim 1, wherein in step 300, the hot-pressing upper and lower mold structures are as follows:
the hot-pressing die is a metal die, and an upper die and a lower die of the hot-pressing die adopt a hard-pressing double-sided die structure.
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| CN109353031A (en) * | 2018-11-19 | 2019-02-19 | 苏州银禧新能源复合材料有限公司 | The preparation method of battery box cover |
| CN111730876A (en) * | 2020-07-10 | 2020-10-02 | 苏州银禧新能源复合材料有限公司 | Forming process of upper cover of composite battery box |
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| CN109353031A (en) * | 2018-11-19 | 2019-02-19 | 苏州银禧新能源复合材料有限公司 | The preparation method of battery box cover |
| CN111730876A (en) * | 2020-07-10 | 2020-10-02 | 苏州银禧新能源复合材料有限公司 | Forming process of upper cover of composite battery box |
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