CN114981071A - 覆盖结构和用于制造覆盖结构的方法 - Google Patents

覆盖结构和用于制造覆盖结构的方法 Download PDF

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Publication number
CN114981071A
CN114981071A CN202180009848.9A CN202180009848A CN114981071A CN 114981071 A CN114981071 A CN 114981071A CN 202180009848 A CN202180009848 A CN 202180009848A CN 114981071 A CN114981071 A CN 114981071A
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smc
emv
layer
bonding
fire protection
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斯特凡·弗劳恩霍费尔
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Georg Fitzmaier & CoKg GmbH
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Georg Fitzmaier & CoKg GmbH
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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
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  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
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Abstract

公开了一种覆盖结构，该覆盖结构的SMC基体与两个另外的层在粘合压力机中同时被挤压和粘接。

Description

覆盖结构和用于制造覆盖结构的方法
技术领域
本发明涉及一种尤其用于电池的覆盖结构和一种用于制造这种覆盖结构的方法。
背景技术
近年来，存在用电动马达代替内燃机的趋势。一个问题在此是提供足够的电池容量。尤其在用电动马达实施的机动车中，为了确保令人满意的续驶里程必须安装具有大容量的电池。这些电池通常紧固在车辆的下底部上并且必须相应地受到保护以免受外部影响。这种被实施成具有底部通过保护的电池承载结构例如在DE 10 2011 005 403 A1和WO2018/149762 A1中公开。
在此，电池通常被容纳在一种电池盒中，通过该电池盒借助于底部通过保护相对于车道保护实际的电池。电池承载结构的朝向车身/车辆驾驶室的部分通过覆盖结构覆盖。覆盖结构必须被构造成使得该覆盖结构在电池燃烧时在一定时间(例如5分钟)内经受热量产生，使得延迟蔓延到车辆驾驶室和其他车辆部件上。
这种类型的电池盒，也称为电池壳体，在公开文件DE 10 2010 043 899 A1 中描述。在这种解决方案中，电池壳体构造有壳体盖和壳体底部，所述壳体盖相应于电池单池的外轮廓构造，所述壳体底部附接在罩形的壳体盖上。该电池壳体在已知的解决方案中由难燃的塑料制成。
这种解决方案不能经受较长的热量产生。
在文献DE 10 2013 220 778 A1中同样描述了一种由塑料制成的电池壳体，该电池壳体具有与上述电池壳体结构相同的缺点。
在非所述类型的公开文件DE 10 2009 050 787 A1中描述了一种由塑料构成的飞机构件，所述飞机构件为了改进火灾特性而被实施有包含云母的阻挡层。
已知这样的解决方案，其中，例如用作电池箱盖的覆盖结构制造为片状模制复合基体(SMC基体)，并且所需的防火保护然后通过事后粘贴防火层、例如云母板或黏结云母板来实现。此外已知的是，电磁兼容层(EMV层)被施加在SMC基体的上侧处。
这种做法需要巨大的制造技术上的耗费。
发明内容
相对于此，本发明的任务在于，提供一种覆盖结构，该覆盖结构一方面满足防火技术上的要求并且另一方面满足EMV要求，并且该覆盖结构在此能够以减小的耗费制造。本发明的另外的任务是提供一种用于制造这种覆盖结构的方法。
该任务在覆盖结构方面通过权利要求1的特征组合解决并且在方法方面通过并列权利要求7的特征组合解决。
本发明的有利的改进方案是从属权利要求的主题。
所要求保护的覆盖结构尤其被设计用于作为电池盒壁、优选作为用于电动车辆的电池盖来使用。这种覆盖结构具有片状模塑料基体(SMC基体)。设置至少一个成型件和/或至少一个平坦的板作为防火层。为了改善电磁兼容性 (EMV)并且因此优选为了相对于车辆的其他驱动和控制/调节元件进行屏蔽，覆盖结构被实施有电磁兼容层(EMV层)。覆盖结构的制造是特别简单的，因为防火层和EMV层与基体粘接。通过三个所述构件在一个工序中在粘合压力机中的统一的粘接，协同作用是可用的。
当防火层的至少一个成型件和根据SMC基体的几何形状实施的EMV层与基体粘接时，覆盖结构的制造是特别简单的。
特别优选的是，SMC基体和EMV层和防火覆层借助反应性热熔粘接系统彼此粘接。在此，物理固化粘合剂(热塑性塑料)和化学固化粘合剂(热固性塑料)是可能的。由此提供一种特别持久的并且耐用的覆盖结构。
当然，也可以代替这种热熔粘合剂而使用其他粘合剂，例如粉末粘合剂或其他粘合剂，这些粘合剂优选事先施加在构件上或施加在粘合对的至少一个构件上并且然后通过置入粘合压力机中而被激活，以便执行粘接。如所阐述的，在置入到粘合压力机中之前，设有粘合剂的层可以被覆盖，以便避免污染物的附着或无意的粘接。
然而原则上也可以在将构件置入粘合压力机中之前才直接施加粘合剂。
尤其在汽车应用中优选的是，EMV层被施加在SMC基体的背离防火覆层的一侧上。尤其，在车辆中的覆盖结构的安装位置中，防火覆层在下部并且 EMV层在上部。
优选的是，防火覆层基本由至少一个云母板或黏结云母板和/或由至少一个云母成型件或黏结云母成型件形成。在此，防火覆层优选由多个这种板组装而成。
在特别简单构造的实施例中，EMV层被构造为部分或很大程度或完全覆盖SMC基体的铝箔或铝蒙皮。
为了简化EMV层相对于SMC基体的定位，可以设置自动对中，该自动对中由EMV层的凹入部和SMC基体的与该凹入部适配的凸出部形成。
适合于制造前述覆盖结构的粘合压力机具有上部模具和下部模具，该上部模具和下部模具的型面与待粘接的覆盖结构的大面适配。
按照根据本发明的方法，防火覆层和EMV层在一个工序中一起与SCM 基体粘接。这在粘合剂压机中进行，SMC基体、防火覆层和EMV层(改形的铝箔或铝蒙皮)被置入到该粘合压力机中。最后，通过闭合模具半部(上部模具/下部模具)，将SMC基体与防火覆层和EMV层挤压和粘接成覆盖结构。
在该方法的适合于批量制造的改进方案中，首先将防火覆层定位和固定在下部模具上。在置入防火覆层之后，将SMC基体定位在粘合压力机中。然后置入EMV层。
当防火覆层具有成型件时，下部模具具有相应的型面。
在所述方法的其他改进方案中，构造防火覆层的至少一个成型件在粘合压力机外首先预固定在SMC基体的下侧上。然后，可以将具有预固定的防火覆层的SMC基体放置到粘合压力机的下部模具上，使得根据本发明的方法的前两个步骤同时进行。最后，EMV层被放置到SMC基体的上侧上。
为了能够简单地施加预固定(例如以粘合带的形式)，特别优选的是，在粘合压力机外将防火覆层放置到以其下侧向上指向的SMC基体上并且预固定在那里。然后，具有预固定的防火覆层的SMC基体可以翻转，然后该SMC 基体被放置到粘合压力机的下部模具上。
当在SMC基体从SMC挤压模具脱模之后立即或者在施加粘合剂之后立即或者在预固定防火覆层之后立即进行挤压和粘接时，可以节省制造时间。
当挤压和粘接在空间上靠近或邻近SMC挤压模具(SMC基体在SMC挤压模具中成形)进行时，可以节省制造时间和承载工作。例如，SMC挤压模具和粘合压力机之间的距离最大为10米，优选最大为5米。
关于根据本发明的方法，SMC基体、EMV层和防火覆层也能够借助反应性的热熔粘接系统彼此粘接。在此，物理固化粘合剂(热塑性塑料)和化学固化粘合剂(热固性塑料)是可能的。由此提供一种特别持久的并且耐用的覆盖结构。如所实施的，也可以使用其他粘合剂。
附图说明
下面借助于示意图更详细阐述本发明的优选的实施例。示出了：
图1以分解图示出在粘合压力机中挤压和粘接之前的根据本发明的覆盖结构；
图2以透视图示出图1中的根据本发明粘接和挤压的覆盖结构的大部分；并且
图3示出图2中的覆盖结构的横截面的截取部分。
具体实施方式
图1示出具有上部模具2和下部模具4的粘合压力机1的原理性构造，所述上部模具和下部模具在根据图1的图示中彼此移开。在下部模具4上(并且相应地也在上部模具2中)构造有型面6，这些型面在闭合状态中挤压和粘接覆盖结构38的三个部件32、12、36。在所示的实施例中，覆盖结构38用作电动车辆的电池盖。
这些型面6相应于该覆盖结构38的几何形状构造为3D面。在所示的实施例中，下部模具4的型面6在图1中的右侧区域中向上、朝向上部模具2 凸起，从而构造凸出部8。在模具上部2中设置有相应的(未示出的)凹入部，从而在粘合压力机1闭合时将导气罩粘接，该导气罩在经安装状态中覆盖电动车辆的部件、例如油箱或类似物。
SMC基体32以及防火覆层12和EMV层36置入到打开的粘合压力机1 中。在所示的实施例中，防火覆层12多件式地由云母板12a、12b、12c构造，这些云母板首先被放置到型面6上。在此，云母板12c覆盖构成导气罩的凸出部8。云母板12a、12b、12c根据型面6或待成型的覆盖结构38的轮廓来构造。两个云母板12a、12b与云母板12c具有距离。云母板12a、12b、12c在覆盖结构38的安装状态下覆盖所述覆盖结构38的在产生热量时被危害的区域和电动车辆的处于其上方的构件。
首先借助喷枪将粘合剂施加到云母板12a、12b、12c和EMV层36上。
在批量制造中，优选借助于机器人在纺丝喷涂中进行粘合剂施加。
在置入云母板12a、12b、12c之后，SMC基体32置入到粘合压力机1中，该SMC基体例如由纤维垫、纤维织物(Faserflies)或类似物构成，该纤维垫、纤维织物或类似物被塑料基质、例如聚酯树脂或乙烯基酯树脂包围。在应用根据本发明的方法之前，如此形成的SMC坯件在被加热至改形/熔化温度的SMC 挤压模具中熔化，使得SMC坯件可以被改形成SMC基体32的预定几何形状并且在硬化/脱模之后保持该3D几何形状。
备选地，云母板12a、12b、12c在粘合压力机外首先借助于粘合带预固定在SMC基体32的下侧上。为了能够简单地安设这些云母板，在粘合压力机1 外将云母板12a、12b、12c放置到以其(在安装位置中的)下侧向上指向的 SMC基体32上。然后SMC基体32与预固定的云母板12a、12b、12c翻转并且放置到粘合压力机1的下部模具4上。
在批量制造中，经涂覆的云母板12a、12b、12c定位并固定在下部模具4 上。
为了改善电磁兼容性(EMV)，在SMC基体32上在背离防火覆层12的大面上(在图1中上方)粘接EMV层36。在所示的实施例中，这个EMV层 36由铝箔/铝蒙皮构成，铝箔/铝蒙皮在应用根据本发明的方法之前在改形模具中根据SMC基体32的3D几何形状来成形。
为了简化EMV层36相对于SMC基体32的定位，设置自动对中，该自动对中在所示的实施例中由EMV层36的凹入部和SMC基体32的与该凹入部适配的凸出部形成。当EMV层36下降到SMC基体32上时，凸出部形状配合地埋入凹入部中，由此得出两个部件彼此间的(预先)定位。
最后，在唯一的工序中，SMC基体32一方面与防火覆层12并且另一方面与EMV层36借助于反应性的热熔粘接系统和粘合压力机1挤压并且粘接，使得在该工序之后构造根据图2的覆盖结构38，该覆盖结构朝向电动车辆的车辆驾驶室设有EMV层36并且朝向电池设有防火覆层12。
图3示出具有处于上面(根据图3的视图)的EMV层36的完成粘接的覆盖结构38的层结构，该EMV层通过粘接缝隙40的粘合剂平面地与SMC 基体32连接。该SMC基体通过另外的粘接缝隙40的粘合剂与云母板12a、 12b、12c连接。在此，可以使用物理固化粘合剂(热塑性塑料)和化学固化粘合剂(热固性塑料)。因此确保了覆盖结构38的均匀的层结构，所述层结构在EMV问题、耐火性和机械强度方面被优化。
以这种方式，也能够制造适用于大电池容量的形状稳定的并且满足防火规定的覆盖结构38，所述覆盖结构能够具有明显大于1m2的面积。
公开了一种覆盖结构38，该覆盖结构的SMC基体32与两个另外的层12、 36在粘合压力机1中同时被挤压和粘接。
附图标记列表
1 粘合压力机
2 上部模具
4 下部模具
6 型面
8 凸出部
12 防火覆层
12a 云母板
12b 云母板
12c 云母板
32 SMC基体
36 EMV层
38 覆盖结构
40 粘接缝隙。
权利要求书(按照条约第19条的修改)
1.一种用于制造覆盖结构(38)的方法，所述覆盖结构尤其用于电动车辆的电池，所述方法具有步骤：
-将防火覆层(12)置入到粘合压力机(1)中，
-将SMC基体(32)置入到所述粘合压力机(1)中，
-将EMV层(36)置入到所述粘合压力机(1)中，以及
-借助于所述粘合压力机(1)将所述SMC基体(32)与所述防火覆层(12)和所述EMV层(36)粘接。
2.根据权利要求1所述的方法，其中，所述步骤以所述顺序进行。
3.根据权利要求1所述的方法，其中，首先将所述防火覆层(12)预固定在所述SMC基体(32)上。
4.根据权利要求1至3中任一项所述的方法，其中，所述SMC基体(32)和所述EMV层(36)和所述防火覆层(12)借助于施加到粘合对的至少一个构件上的粘合剂、如粉末粘合剂或者借助于反应性的热熔粘接系统彼此粘接。
5.根据权利要求4所述的方法，其中，在所述粘合压力机(1)中的粘接之前所述粘合剂施加到粘合压力机(1)上或者以一定的时间间隔施加到粘合压力机上。
6.根据权利要求1至5中任一项所述的方法，其中，在所述SMC基体从所述SMC挤压模具(32)脱模之后立即进行所述挤压或者在施加所述粘合剂之后立即进行所述挤压或者在预固定所述防火覆层(12)之后立即进行所述挤压。
7.根据权利要求1至6中任一项所述的方法，其中，所述挤压在空间上靠近或邻近SMC挤压模具进行，SMC基体(32)在所述SMC挤压模具中成形。

Claims (13)

1.一种覆盖结构，尤其用于电动车辆的电池，所述覆盖结构具有SMC基体(32)，所述SMC基体(32)设有防火覆层(12)和EMV层(36)，其特征在于，所述防火覆层(12)和所述SMC基体(32)和所述EMV层(36)在工序中优选借助于粘合压力机(1)彼此粘接。
2.根据权利要求1所述的覆盖结构，其中，所述防火覆层(12)由至少一个成型件和/或由至少一个平坦的板形成。
3.根据前述权利要求中任一项所述的覆盖结构，其中，所述SMC基体(32)和所述EMV层(36)和所述防火覆层(12)借助粘合剂、例如粉末粘合剂或反应性的热熔粘接系统彼此粘接。
4.根据前述权利要求中任一项所述的覆盖结构，其中，所述EMV层(36)布置在所述SMC基体(32)的背离所述防火覆层(12)的大面上。
5.根据前述权利要求中任一项所述的覆盖结构，其中，所述防火覆层(12)是至少一个云母板(12a、12b、12c)。
6.根据前述权利要求中任一项所述的覆盖结构，其中，所述EMV层(36)是铝箔或铝蒙皮。
7.一种用于制造覆盖结构(38)的方法，所述覆盖结构尤其用于电动车辆的电池，所述方法具有步骤：
-将防火覆层(12)置入到粘合压力机(1)中，
-将SMC基体(32)置入到所述粘合压力机(1)中，
-将EMV层(36)置入到所述粘合压力机(1)中，以及
-借助于所述粘合压力机(1)将所述SMC基体(32)与所述防火覆层(12)和所述EMV层(36)粘接。
8.根据权利要求7所述的方法，其中，所述步骤以所述顺序进行。
9.根据权利要求7所述的方法，其中，首先将所述防火覆层(12)预固定在所述SMC基体(32)上。
10.根据权利要求7至9中任一项所述的方法，其中，所述SMC基体(32)和所述EMV层(36)和所述防火覆层(12)借助于施加到粘合对的至少一个构件上的粘合剂、如粉末粘合剂或者借助于反应性的热熔粘接系统彼此粘接。
11.根据权利要求10所述的方法，其中，在所述粘合压力机(1)中的粘接之前所述粘合剂施加到粘合压力机(1)上或者以一定的时间间隔施加到粘合压力机上。
12.根据权利要求7至11中任一项所述的方法，其中，在所述SMC基体从所述SMC挤压模具(32)脱模之后立即进行所述挤压或者在施加所述粘合剂之后立即进行所述挤压或者在预固定所述防火覆层(12)之后立即进行所述挤压。
13.根据权利要求7至12中任一项所述的方法，其中，所述挤压在空间上靠近或邻近SMC挤压模具进行，SMC基体(32)在所述SMC挤压模具中成形。
CN202180009848.9A 2020-02-04 2021-01-26 覆盖结构和用于制造覆盖结构的方法 Pending CN114981071A (zh)

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