CN114407386A - 一种夹芯复合材料储能电池柜壁板的量产制备方法 - Google Patents
一种夹芯复合材料储能电池柜壁板的量产制备方法 Download PDFInfo
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Abstract
本发明公开了一种夹芯复合材料储能电池柜壁板的量产制备方法，通过使用高性能连续纤维织物及合理的结构铺层设计，达到优异的产品机械性能，通过使用快速固化阻燃树脂，实现产品的快速生产节拍以实现量产可行性，同时赋予产品阻燃性；通过使用六边形强芯毡作为夹芯材料，实现较好的夹芯层与织物层之间树脂的流动性，解决树脂在短时间内的浸润问题，提升产品质量，满足量产的快速生产节拍；六边形强芯毡在较薄的厚度下，抗压强度显著提升，提升产品结构刚度的同时满足轻量化需求；且六边形强芯毡拥有较好的柔韧性可收成卷，通过织物下料时撒粉面方向的调整，可实现夹层结构与织物的同步下料，进一步提升生产节拍，以符合量产的市场需求。
Description
技术领域
本发明属于储能电池柜壁板技术领域，具体涉及一种夹芯复合材料储能电池柜壁板的量产制备方法。
背景技术
使用新能源替代传统能源已成为主要步调，由于当前风力、光伏发电所存在的环境限制，电池储能作为最为稳定的技术必是最重要的发展方向之一。目前转载储能单元的储能机柜多采用金属壁板，导致储能站过重，一定程度上限制了储能的上限。而隔热防火作为必须满足的安全条件，需要额外增加保温防火材料，更进一步限制了空间并增加了重量。
由于天然的低导热性、可赋予阻燃性、及可一体化成型性，高性能连续纤维增强树脂基复合材料作为最优秀的减重材料之一，已广泛应用于各新能源行业中，应是储能机柜的理想材料之一。但传统的复合材料工艺由于较低的生产效率并无法满足市场需求；而当前符合量产需求的快节拍生产工艺（诸如HP-RTM、C-RTM及S-RTM）对于大尺寸的储能电池柜壁板仍面临诸多难点，例如：大尺寸的电池柜壁板需要提供足够的结构刚度及对装载电池单元的保护能力，若使用足够厚的纯层合结构则会牺牲轻量化效果，且增加材料成本；若使用较薄的常规泡沫夹芯材料来达到同样的厚度并满足轻量化效果，对于大尺寸的薄型三明治夹芯壁板结构而言，工艺过程中将面临注入的树脂是否能在较短的时间内良好地渗透并浸润纤维织物的问题，且快节拍生产工艺中使用较大的压力，夹芯材料普遍较低的抗压性能又会带来压溃的风险。
发明内容
针对上述现有技术问题的不足，本发明提供了一种适用于大尺寸夹芯复合材料储能电池柜壁板的量产制备方法，以达到快速生产节拍的效果，所制成的复合材料储能电池柜壁板能够在满足结构刚度要求的同时，兼顾防火阻燃性与轻量化，且提升了树脂与纤维织物的浸润以及芯材在成型过程中的抗压性，因此成品质量高。
为了实现上述发明目的，本发明采用以下技术方案：
一种夹芯复合材料储能电池柜壁板的量产制备方法，所述储能电池柜壁板包括上层合板、夹芯层和下层合板，采用快节拍的液体树脂成型复合材料生产工艺进行固化一体成型；
所述上层合板、下层合板均以快速固化阻燃树脂为基体材料、纤维织物为增强材料，厚度为0.5~2mm；
所述量产制备方法包括以下步骤：
步骤1，将纤维织物和夹芯层按铺叠顺序装置，裁切，得到纤维织物叠层料块和单独的夹芯层料块；
步骤2，将步骤1的纤维织物叠层料块局部加热，使各层材料连结形成连结料块；
步骤3，将步骤2中连结料块、步骤1中单独的夹芯层料块，按顺序抓取加热成为一个整体，再置于预成型模具内合模、冷压预成型，得到一个成型的预制体；
步骤4，将步骤3的预制体置入模具中，合模、锁模和抽真空，注入预热混合的阻燃树脂，注完后在保温、保模压的条件下静置，得到夹芯复合材料储能电池柜壁板。
进一步的，所述夹芯层是由耐压聚酯无纺材料所制的六边形强芯毡连接而成，其厚度为2~10mm，压缩强度为4~10MPa。
进一步的，所述纤维织物的材质选自碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维或混合纤维中的一种或几种。
进一步的，所述快节拍的液体树脂成型复合材料生产工艺包括但不限于HP-RTM、C-RTM或S-RTM。
进一步的，步骤1中的按铺叠顺序装置是指上层合板中纤维织物的撒粉面朝下，下层合板中纤维织物的撒粉面朝上。
进一步的，步骤1中，上层合板、下层合板为分别的纤维织物叠层料块。
进一步的，步骤2中，上层合板、下层合板为分别的连结料块。
进一步的，步骤3中是将料块按下层合板、夹芯层、上层合板的顺序抓取至已预热的平台上进行加热成为一个整体，所述夹芯层的尺寸小于上层合板和下层合板。
进一步的，步骤4中模具温度为70℃~150℃，注入树脂的压力为30~150bar，静置时间不超过6min。
本发明的一种夹芯复合材料储能电池柜壁板的量产制备方法，其结构包括上层合板、下层合板与夹芯层，使用包括但不限于HP-RTM、C-RTM及湿法模压的快节拍的液体树脂成型复合材料生产工艺固化一体成型。夹芯层由耐压聚酯无纺材料所制的边长约3mm的六边形强芯毡连接而成，厚度为2~10mm，其压缩强度可达4~10MPa（ISO 844，10%应变下），对比传统泡沫夹芯材料的压缩强度仅为0.4~3MPa；层合板为高性能连续纤维织物增强树脂基复合材料，其纤维种类包括碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维、混合纤维等，各层合板的厚度范围为0.5~2mm；采用快速固化阻燃树脂浸润成型模具中的纤维织物、夹芯层强芯毡的六边形通道及夹芯层与织物的界面，在一定温度和压力下实现固化成型达到所述各层的一体成型。其中高性能连续纤维织物作为增强材料主要提供结构强度；树脂作为基体并提供阻燃性；六边形强芯毡，边与边的连接与常规的毡一致，可透树脂，故作为通道以提升树脂的流动性，六边形内不透树脂，故作为替代传统泡沫的夹芯材料提供厚度/刚度，同时具备一定的柔韧性可收成卷，因此可在量产的自动化下料线上与连续纤维一起展卷下料，并且在备料时调整纤维织物撒粉面的朝向，使所有织物撒粉面的朝向始终面向夹芯层。
本发明通过使用高性能连续纤维织物及合理的结构铺层设计，可达到最优化产品机械性能；通过使用匹配的快速固化阻燃树脂体系，可实现产品的快速生产节拍以实现量产可行性，同时赋予产品阻燃性；通过使用六边形强芯毡作为夹芯材料，在提升结构刚度的同时满足产品轻量化，同体积的六边形强芯毡在树脂固化后的重量只有同体积的玻纤复合材料的25%~35%。针对大尺寸薄型三明治夹层壁板的快节拍生产中存在的问题，通过使用六边形强芯毡实现较好的夹芯层与织物层之间树脂的流动性，从而解决树脂在较短时间内的浸润问题，提升产品质量的同时满足量产的快速生产节拍；同时，六边形强芯毡较好的抗压强度，尤其在较薄的厚度下，提升更为显著；此外，由于六边形强芯毡拥有较好的柔韧性可收成卷，通过织物下料时撒粉面方向的调整，可实现夹层结构与织物的同步下料，进一步提升生产节拍，以符合量产的市场需求。
具体实施方式
以下实施例进一步说明本发明的内容，但不应理解为对本发明的限制。在不背离本发明精神和实质的情况下，对本发明方法、步骤或条件所作的修改或替换，均属于本发明的范围。实施例中未注明具体条件的实验方法及未说明配方的试剂均为按照本领域常规条件。
实施例1
一种夹芯复合材料储能电池柜壁板，由上层合板、下层合板与夹芯层组成；
夹芯层是由耐压聚酯无纺材料所制的数个小六边形强芯毡连接而成一整张材料，小六边形强芯毡呈蜂窝状排列，六边形的边与边之间可透树脂，不同于常规的三明治夹芯结构所选用的硬质泡沫（如PU、PVC、PET、PMI及巴沙木等），所述六边形强芯毡拥有良好的柔韧性可收成卷，其厚度为2~10mm，压缩强度为4~10MPa；
上层合板、下层合板为高性能连续纤维织物增强树脂基复合材料，厚度为0.5~2mm；
其纤维种类包括碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维、混合纤维等，连续纤维织物为单面撒粉织物，在高温下拥有黏性；
以快速固化阻燃树脂作为基体材料，本实施例中采用环氧快速固化树脂；
夹芯复合材料储能电池柜壁板的工艺制备方法包括以下步骤：
S1：备料：将上述上层合板、下层合板的连续纤维织物及六边形强芯毡按制定的铺叠顺序装置在料卷辊上，其中上层合板纤维织物的撒粉面朝下，下层合板纤维织物的撒粉面朝上；
S2：叠层及裁切：将料卷辊上纤维织物在展料台上进行对齐、展料和叠放，而后裁切为料块，上层合板、下层合板为分别的纤维织物叠层料块，六边形强芯毡直接裁切为单独的夹芯层料块；
S3：料块连结：将裁切好的纤维织物叠层料块用局部加热的方式使料块中的各层材料连结为一个可抓取的整体，上层压板、下层压板为分别的连结料块；
S4：预成型：将上述的料块按下层合板、夹芯层、上层合板的顺序抓取至已预热的平台上进行加热，夹芯层的尺寸小于上层合板和下层合板，置于层合板中间的位置，温度达到织物上撒粉材料的熔融温度使其黏结为一个整体，随后将其抓取至预成型模具内而后合模并进行冷压预成型，再将成型的预制体抓取至预成型工装上并对余边进行裁剪；
S5：放置预制体：将预制体置入温度为70℃~150℃的恒温压机模具中；
S6：高压注射：依次进行合模、锁模和抽真空，并注入按比例充分预热混合的环氧树脂、固化剂及内脱模剂，质量配比为100：（10~33）：（1~4），混合的温度为40℃~80℃，其注射压力为30~150bar；
S7：固化：待上述注射的树脂充模完成后则保持≤6min的时间以待树脂固化；
S8：上述步骤完成后进行冷却和顶出，并取出完成的储能电池柜壁板产品。
上述步骤均可选择自动化生产以最大程度的实现去人工化操作，从而缩短生产节拍，大幅度提高了生产效率，同时也提升了生产的稳定性和产品质量。上述S1-S8为一个件的生产节拍，时间为≤12min。
Claims (9)
1.一种夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：
所述储能电池柜壁板包括上层合板、夹芯层和下层合板，采用快节拍的液体树脂成型复合材料生产工艺进行固化一体成型；
所述上层合板、下层合板均以快速固化阻燃树脂为基体材料、纤维织物为增强材料，厚度为0.5~2mm；
所述量产制备方法包括以下步骤：
步骤1，将纤维织物和夹芯层按铺叠顺序装置，裁切，得到纤维织物叠层料块和单独的夹芯层料块；
步骤2，将步骤1的纤维织物叠层料块局部加热，使各层材料连结形成连结料块；
步骤3，将步骤2中连结料块、步骤1中单独的夹芯层料块，按顺序抓取加热成为一个整体，再置于预成型模具内合模、冷压预成型，得到一个成型的预制体；
步骤4，将步骤3的预制体置入模具中，合模、锁模和抽真空，注入预热混合的阻燃树脂，注完后在保温、保模压的条件下静置，得到夹芯复合材料储能电池柜壁板。
2.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：所述夹芯层是由耐压聚酯无纺材料所制的六边形强芯毡连接而成，厚度为2~10mm，压缩强度为4~10MPa。
3.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：所述纤维织物的材质选自碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维或混合纤维中的一种或几种。
4.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：所述快节拍的液体树脂成型复合材料生产工艺包括但不限于HP-RTM、C-RTM或S-RTM。
5.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：步骤1中，上层合板中纤维织物的撒粉面朝下，下层合板中纤维织物的撒粉面朝上。
6.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：步骤1中，上层合板、下层合板为分别的纤维织物叠层料块。
7.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：步骤2中，上层合板、下层合板为分别的连结料块。
8.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：步骤3中是将料块按下层合板、夹芯层、上层合板的顺序抓取至已预热的平台上进行加热成为一个整体，所述夹芯层的尺寸小于上层合板和下层合板。
9.根据权利要求1所述的夹芯复合材料储能电池柜壁板的量产制备方法，其特征在于：步骤4中模具温度为70℃~150℃，注入树脂的压力为30~150bar，静置时间不超过6min。
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