CN116252523A - 一种电池包下箱体复合材料底护板及制备方法 - Google Patents

一种电池包下箱体复合材料底护板及制备方法 Download PDF

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CN116252523A
CN116252523A CN202310138317.0A CN202310138317A CN116252523A CN 116252523 A CN116252523 A CN 116252523A CN 202310138317 A CN202310138317 A CN 202310138317A CN 116252523 A CN116252523 A CN 116252523A
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bottom guard
battery pack
skin
composite material
guard plate
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郭小川
田飞
杜志全
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Beijing Weisheng Composite Materials Co ltd
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Abstract

本发明公开了一种电池包下箱体复合材料底护板及制备方法，底护板与下箱体可拆卸式连接在一起，底护板包括由下至上依次设置的下蒙皮、聚氨酯复合材料芯材、加强肋、上蒙皮，本产品成型过程中上、下蒙皮、加强肋与聚氨酯复合材料芯材通过聚氨酯发泡成型制备过程自身化学反应胶连结合。本发明中取消了传统制备方法中需要二次胶接结合的方式，仅通过模具内一次发泡成型，可实现电池包下箱体结构的显著减重，提高电池包的能量密度，显著提高底护板的抗冲击性能，有效的提高对新能源汽车在诸如掠过凹坑、凸起物或者石头路面等极度复杂工况下的保护，采用的聚氨酯复合材料芯材还具有很好的保温功能，有效的维持电池包的温度恒定。

Description

一种电池包下箱体复合材料底护板及制备方法
技术领域
本发明涉及电池箱下箱体底护板技术领域，具体涉及一种电池包下箱体复合材料底护板及制备方法。
背景技术
新能源汽车在实际行驶过程中，车辆底部工况极度复杂，如掠过凹坑、凸起物或者石头路面时车辆底部极易受到撞击和剐蹭，由于安装位置在车辆底部，极具隐蔽性，给新能源汽车安全带来极大的隐患。
复合材料具有比模量、比强度高以及能够一体化结构设计、制造的特点。使用连续纤维增强树脂基复合材料设计、制造新能源汽车电池包下箱体底护板是提高电池包安全性、减轻电池包重量的重要手段，同时，其优异的低热传导系数可以有效的保护电池包内部的温度。目前市场上电池包底护板结构通常采用钣金成型，厚度在1mm左右，采用螺栓与电池包体连接，在钣金底护板与电池包体之间通常有一定厚度的泡棉。钣金底护板重量重，且厚度1mm左右对于极度复杂工况而言，防护效果一般。在实际使用过程中，为保证电池包内部环境温度以及降低车辆在使用过程中由于石子等撞击声响，通常会在钣金护板上喷涂PVC涂层，为了防止钣金生锈等问题，也会进行电泳处理。这样会较大幅度增加金属护板的成本。现有技术采用复合材料底护板的，但上、下蒙皮与芯材采用胶结方式成型，目前新能源底护板主流产品参考尺寸1800mm*1350mm，胶层厚度0.5mm，生产节拍要求一般在5min，为提高生产效率以及保证产品质量，该方案一般在蒙皮表面涂胶，涂胶面积为整个平面，但1800mm*1350mm的参考尺寸，0.5mm的胶层厚度，胶层的涂覆质量以及生产效率很难保证，生产成本很难保证。现有技术采用了泡沫芯材与预浸料模压一体成型方式，预浸料模压工艺是通过对预浸料上下表面加热、加压，后实现预浸料表面的树脂二次流动，进而充分浸润纤维，得到性能良好的复合材料板材，但因目前预浸料的成型温度在140℃左右，成型压力300吨/平米，选用的泡沫会在成型过程中压溃，由于泡沫芯材是在上、下蒙皮的中间，在一体化成型过程中，由于泡沫芯材的压溃，很难保证上、下蒙皮成型过程中所需的压力，进而很难保证成型后的蒙皮质量。底护板由于在使用过程中，经常会溅到污水或污泥，受到腐蚀影响使用寿命。
发明内容
基于背景技术存在的问题，本发明提供了一种电池包下箱体复合材料底护板及制备方法。本发明通过泡沫芯材发泡过程实现上、下蒙皮、加强肋、泡沫芯材胶结成一个整体，克服了上、下蒙皮、加强肋、泡沫芯材单独加工，然后胶结的工序、成本增加问题，克服了泡沫芯材与预浸料模压一体成型方式的由于泡沫芯材在成型过程中压溃，蒙皮的成型质量不能保证，底护板由于在使用过程中，经常会溅到污水或污泥，受到腐蚀影响使用寿命的问题。在保证电池包底部安全的同时，又增加了电池包的保温性能，有助于提高电池的续航里程。
本发明通过以下技术方案实施：
一种电池包下箱体复合材料底护板，底护板与下箱体可拆卸式连接在一起；底护板包括由下至上依次设置的下蒙皮、聚氨酯复合材料芯材、加强肋和上蒙皮；其中，上蒙皮、下蒙皮、加强肋通过聚氨酯复合材料芯材发泡成型制备过程中发泡胶连结合成整体。
进一步地，底护板同时包括上、下蒙皮、加强肋和聚氨酯复合材料芯材，或包括下蒙皮、加强肋和聚氨酯复合材料芯材，或包括下蒙皮和聚氨酯复合材料芯材，或包括上、下蒙皮和聚氨酯复合材料芯材。
进一步地，上、下蒙皮为连续纤维复合材料，连续纤维复合材料由连续纤维和基体树脂通过高压HP-RTM工艺、湿法模压WCM工艺或者预浸料模压PCM工艺制得。
进一步地，连续纤维为玻璃纤维、玄武岩纤维、芳纶纤维、碳纤维中的一种或几种组合；基体树脂为环氧树脂、聚氨酯树脂、酚醛树脂中的一种。
进一步地，上、下蒙皮的厚度为1-3mm。
进一步地，聚氨酯复合材料芯材的密度为150kg/m3-1000kg/m3，纤维质量含量为0-40％，厚度为1-10mm。
进一步地，加强肋是由连续纤维复合材料通过拉挤工艺制得，加强肋的厚度为3-10mm，宽度为3-10mm。
一种电池包下箱体复合材料底护板的制备方法，包括以下步骤：
S1、采用连续纤维和基体树脂制备蒙皮和加强肋；
S2、蒙皮和加强肋表面采用异丙醇擦拭处理，并将加强肋组合成网格状；
S3、将下蒙皮放置在模具的下模中，将由加强肋组成的网格状结构安装到下蒙皮上；
S4、将聚氨酯与长切玻璃纤维丝的混合物喷射到网格空隙内；
S5、将上蒙皮固定到模具的上模中，合上模具；
S6、将步骤S5所得模具保压加热固化，即得复合材料底护板半成品；
S7、采用激光/雕刻机/CNC等方式在S6步骤所得复合材料底护板半成品的上蒙皮上加工若干装配孔，即得复合材料底护板。
进一步地，步骤S4中可采用LFI、SRIM、RIM、聚氨酯喷涂工艺将混合物喷射到网格空隙内。
进一步地，步骤S6中保压加热固化条件为：固化温度50±5℃，保温时间3-60min，保压压力100-200吨。
进一步地，模具内部设置预埋管道，通过模具实时温控系统控制加热固化温度。
进一步地，模具实时温控系统，其包含PLC控制器、控制按钮、温度检测模块、温控模块；
其中温度检测模块包含温度传感器和转换模块一，温度检测模块与PLC控制器输入接口相连接；
温控模块包含转换模块二、流量比例阀、预埋管道和水泵控制模块，温控模块与PLC控制器输出接口相连接；
打开控制按钮，设定模具工作温度和对流换热系数W，其系数计算如下：
Figure BDA0004086746990000041
其中，m为预埋管道直径,V为流体的流速，c为流体的比热容，ρ为流体密度，ν为流体运动粘度。
温度检测模块中的温度传感器将检测温度通过转换模块一将所测的温度模拟量转换成数字量，温度检测模块将所测温度数字量传送到PLC控制器，PID计算程序启动，通过所测温度与设定工作温度之间差值计算出温控模块中流量比例阀的开度，将数字信号通过PLC控制器输出继电器传送到温控模块中的转换模块二，转换成电流信号再传送到流量比例阀，控制阀门的大小，从而达到控制流体流量，精准控制模具温度。
本发明的有益效果：
(1)本发明的底护板包括由下至上依次设置的下蒙皮、聚氨酯复合材料芯材、加强肋、上蒙皮，上、下蒙皮、加强肋与聚氨酯复合材料芯材通过聚氨酯复合材成型制备过程胶结。本发明提供的电池包下箱体底护板及制备方法，取消了传统制备方法中需要二次胶接结合的方式，仅通过模具内一次发泡成型，可实现电池包下箱体结构的显著减重，提高电池包的能量密度，显著提高底护板的抗冲击性能，有效的提高对新能源汽车在诸如掠过凹坑、凸起物或者石头路面等极度复杂工况下的保护，采用的聚氨酯复合材料芯材还具有很好的保温功能，有效的维持电池包的温度恒定。
(2)本发明中在模具内部设置预埋管道，往管道内通过一定温度的流体来控制模具的温度，相较于烘房加热大大降低了热损失和生产成本。同时本申请中通过模具实时温控系统避免了传统管道加热模具温度调节滞后期长的问题，实现精准控制模具温度，避免因温度分布不均匀影响聚氨酯复合材料发泡成型的反应速度和反应均匀性。
附图说明
附图用来提供对本发明的进一步解释，并且构成说明书的一部分，与本发明的实施例一起用于解释本发明，并不构成对本发明的限制。在附图中：
图1为本发明的下蒙皮结构示意图；
图2为本发明的加强肋结构示意图；
图3为本发明的聚氨酯复合材料芯材示意图；
图4为本发明的上蒙皮结构示意图；
图5为本发明的底护板结构示意图；
图6为本发明的底护板横截面示意图；
图7为本发明中清洁结构的示意图；
图8为本发明中第一圆盘和第二圆盘的连接示意图；
其中，1-下蒙皮；2-聚氨酯复合材料芯材；3-上蒙皮；4-装配孔；5-加强肋，6-动力箱，7-电机，8-第一转轴，9-第一圆盘，10-第二圆盘，11-转杆，12-连杆，13-移动杆，14-固定块，15-撞击块，16-凸柱，17-固定板，18-弹簧，19-开口，20-第二转轴，21-刷筒，22-齿轮，23-齿条，24-清洁液储存箱，25-排液管，26-喷嘴，27-输液管，28-驱动泵，29-电磁阀，30-常闭开关，31-保护罩。
具体实施方式
下面结合具体实施例对本发明的技术方案做进一步的详述，但本发明的保护范围并不仅限于以下实施例。
在本发明实施例中环氧树脂为双酚A型128，固化剂为双氰胺100S；
聚氨酯由异氰酸酯、聚醚多元醇和发泡剂制备而得。
实施例1
如图1-6所示，一种电池包下箱体复合材料底护板，包括：
用于提供底护板结构强度的上蒙皮3、下蒙皮1，上、下蒙皮的厚度为1mm±0.1mm；
用于提供高刚度结构的聚氨酯复合材料芯材，密度为350kg/m3，纤维质量为20％，厚度6mm。
一种电池包下箱体复合材料底护板的制备方法，包括以下步骤：
S1、采用WCM工艺制备复合材料上蒙皮3和下蒙皮1，上、下蒙皮的厚度为1mm±0.1mm，所用的连续纤维包括玻璃纤维、玄武岩纤维、碳纤维，基体树脂为环氧树脂，锁模压力1000T，固化温度80℃，保温时间4min，上蒙皮3和下蒙皮1表面采用异丙醇擦拭处理；
S2、采用拉挤工艺制备厚度5㎜，宽度6㎜的加强肋5，加强肋5表面采用异丙醇擦拭处理，后按图纸在加强肋中加工深度
Figure BDA0004086746990000061
宽度/>
Figure BDA0004086746990000062
的切口，后按图纸组合成网格状；
S3、将下蒙皮1放置模具内，将由加强肋5组成的网格状结构安装到下蒙皮1上；
S4、采用LFI工艺将聚氨酯与长切玻璃纤维丝的混合物喷射到网格空隙内；
S5、将上蒙皮3放置在加强肋5组成的网格上，合上模具；
S6、将步骤S5所得模具保压加热固化，固化温度50℃，保温时间6min，保压压力150吨，聚氨酯复合材料芯材的厚度为6mm，即得复合材料底护板半成品；
S7、采用激光在复合材料底护板半成品的上蒙皮3上加工若干个装配孔4，得到聚氨酯复合材料夹层结构的电池包下箱体底护板。
实施例2
在本发明制备方法中的模具内部设置预埋管道，通过模具实时温控系统控制加热固化温度。
本发明中，预埋管直径为14mm，流体选择85℃热水。
模具实时温控系统，其包含PLC控制器、控制按钮、温度检测模块、温控模块；
其中温度检测模块包含温度传感器和转换模块一，温度检测模块与PLC控制器输入接口相连接；
温控模块包含转换模块二、流量比例阀、预埋管道和水泵控制模块，温控模块与PLC控制器输出接口相连接；
打开控制按钮，设定模具工作温度和对流换热系数W，其系数计算如下：
Figure BDA0004086746990000071
其中，m为预埋管道直径14mm，V为流体的流速0.24m/s，c为流体的比热容4202J(kg·℃)，ρ为流体密度968.6Kg/m3，ν为流体运动粘度0.346×10-6m2/s。
温度检测模块中的温度传感器将检测温度通过转换模块一将所测的温度模拟量转换成数字量，温度检测模块将所测温度数字量传送到PLC控制器，PID计算程序启动，通过所测温度与设定工作温度之间差值计算出温控模块中流量比例阀的开度，将数字信号通过PLC控制器输出继电器传送到温控模块中的转换模块二，转换成电流信号再传送到流量比例阀，控制阀门的大小，从而达到控制流体流量，精准控制模具温度。
上述发明有益效果：该模具温控系统能实时对模具温度进行监控，及时发现温度变化，随即调节流体流量大小，实现对模具温度的精准控制，取代了人工操作比例阀，不仅提高效率同时保证了产品质量的可靠性。
实施例3
在实施例1的基础上，如图7-8所示，下蒙皮1一侧设置有动力箱6，动力箱6与下箱体连接，动力箱6内壁上设置有电机7，电机7输出轴与第一转轴8一端连接，第一转轴8另一端穿过第一圆盘9与第二圆盘10连接，第一转轴8与第一圆盘9转动连接，第一圆盘9的直径大于第二圆盘10的直径，第二圆盘10的周向外壁上设置有沿径向延伸的转杆11，第一圆盘9的周向外壁与连杆12一端连接，连杆12另一端与移动杆13一端转动连接，移动杆13另一端穿过固定块14与撞击块15连接，移动杆13与固定块14滑动连接，固定块14与动力箱6内壁连接，连杆12上设置有凸柱16，转杆11能与凸柱16接触，移动杆13上设置有固定板17，固定板17位于固定块14和撞击块15之间，移动杆13上套设有弹簧18，弹簧18一端与固定块14连接，弹簧18另一端与固定板17连接，动力箱6靠近下蒙皮1一侧的外壁上设置有开口19，第二转轴20穿过移动杆13，并与移动杆13转动连接，第二转轴20一端穿过开口19与刷筒21连接，第二转轴20另一端与齿轮22连接，动力箱6内壁上设置有齿条23，齿轮22与齿条23啮合，动力箱6内设置有清洁液储存箱24，动力箱6外壁上设置有排液管25，排液管25上设置有若干喷嘴26，喷嘴26朝向刷筒21，清洁液储存箱24与排液管25通过输液管27连通，输液管27上设置有驱动泵28和电磁阀29，清洁液储存箱24外壁上设置有常闭开关30，撞击块15朝向常闭开关30，常闭开关30与电磁阀29电性连接，动力箱6外壁上设置有保护罩31，刷筒21和排液管25位于保护罩31内。
上述发明有益效果：当需要对电池包下箱体上的底护板清理时，启动电机7，带动第二圆盘10及转杆11旋转，转杆11与凸柱16接触，就带动连杆12旋转，当连杆12旋转180度后，在弹簧18的弹性力拉动下，连杆12加速旋转180度，就使得移动杆13左右往复移动，向右移动的速度要远大于向左移动的速度，由于弹簧的存在，使得移动杆13会在右端极限位置产生振动，移动杆13带动第二转轴20左右往复移动，通过齿轮22与齿条23啮合，第二转轴20还不断正反转交替旋转，相应的，刷筒21向左移动，并同时旋转，对下蒙皮1表面进行清洁，之后，向右加速移动，并同时反向旋转，对下蒙皮1表面再次清洁，减少污物对底护板的腐蚀，提高底护板的使用寿命，当移动到最右端时会产生短暂振动，抖落刷筒21上的污水之后，撞击块15与常闭开关30相撞，打开电磁阀29，就使得输液管27开启，对刷筒21喷洒清洁液，撞击块15远离常闭开关30后，就停止喷洒，从而起到节约清洁液的作用。
最后应说明的是：以上所述实施例仅表达了本发明的几种实施方式，并不用以限制本发明创造，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，所作的任何修改、等同替换、改进等，均应包含在本发明创造的保护范围之内。因此，本发明专利的保护范围应以所附权利要求为准。

Claims (10)

1.一种电池包下箱体复合材料底护板，其特征在于，底护板与下箱体可拆卸式连接在一起；底护板包括由下至上依次设置的下蒙皮、聚氨酯复合材料芯材、加强肋和上蒙皮；其中，上蒙皮、下蒙皮、加强肋通过聚氨酯复合材料芯材发泡成型制备过程中发泡胶连结合成整体。
2.根据权利要求1中一种电池包下箱体复合材料底护板，其特征在于，底护板同时包括上、下蒙皮、加强肋和聚氨酯复合材料芯材，或包括下蒙皮、加强肋和聚氨酯复合材料芯材，或包括下蒙皮和聚氨酯复合材料芯材，或包括上、下蒙皮和聚氨酯复合材料芯材。
3.根据权利要求1或2中一种电池包下箱体复合材料底护板，其特征在于，上、下蒙皮为连续纤维复合材料，连续纤维复合材料由连续纤维和基体树脂通过高压HP-RTM工艺、湿法模压WCM工艺或者预浸料模压PCM工艺制得。
4.根据权利要求3中一种电池包下箱体复合材料底护板，其特征在于，连续纤维为玻璃纤维、玄武岩纤维、芳纶纤维、碳纤维中的一种或几种组合；基体树脂为环氧树脂、聚氨酯树脂、酚醛树脂中的一种。
5.根据权利要求1中一种电池包下箱体复合材料底护板，其特征在于，上、下蒙皮的厚度为1-3mm。
6.根据权利要求1中一种电池包下箱体复合材料底护板，其特征在于，聚氨酯复合材料芯材的密度为150kg/m3-1000kg/m3，纤维质量含量为0-40％，厚度为1-10mm。
7.根据权利要求1中一种电池包下箱体复合材料底护板，其特征在于，加强肋是由连续纤维复合材料通过拉挤工艺制得，加强肋的厚度为3-10mm，宽度为3-10mm。
8.根据权利要求1-7中任一电池包下箱体复合材料底护板的制备方法，其特征在于，包括以下步骤：
S1、采用连续纤维和基体树脂制备蒙皮和加强肋；
S2、蒙皮和加强肋表面采用异丙醇擦拭处理，并将加强肋组合成网格状；
S3、将下蒙皮放置在模具的下模中，将由加强肋组成的网格状结构安装到下蒙皮上；
S4、将聚氨酯与长切玻璃纤维丝的混合物喷射到网格空隙内；
S5、将上蒙皮固定到模具的上模中，合上模具；
S6、将步骤S5所得模具保压加热固化，即得复合材料底护板半成品；
S7、采用激光/雕刻机/CNC等方式在S6步骤所得复合材料底护板半成品的上蒙皮上加工若干装配孔，即得复合材料底护板。
9.根据权利要求8中一种电池包下箱体复合材料底护板的制备方法，其特征在于，步骤S4中可采用LFI、SRIM、RIM、聚氨酯喷涂工艺将混合物喷射到网格空隙内。
10.根据权利要求8中一种电池包下箱体复合材料底护板的制备方法，其特征在于，步骤S6中保压加热固化条件为：固化温度50±5℃，保温时间3-60min，保压压力100-200吨。
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