CN116373401A - 一种电池包底护板及其制备方法 - Google Patents

一种电池包底护板及其制备方法 Download PDF

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CN116373401A
CN116373401A CN202310204191.2A CN202310204191A CN116373401A CN 116373401 A CN116373401 A CN 116373401A CN 202310204191 A CN202310204191 A CN 202310204191A CN 116373401 A CN116373401 A CN 116373401A
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battery pack
bottom guard
pack bottom
continuous fiber
resin
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吕金泽
丁江平
王宇超
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Ningbo Xintai Machinery Co Ltd
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    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
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    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/231—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks having a layered structure
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    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
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Abstract

本发明属于电动车汽车零部件领域，具体涉及一种电池包底护板及其制备方法。所述的电池包底护板由上到下依次包括上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层，其中低密度闭孔泡沫芯层中设有预埋件。电池包底护板通过将上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层通过树脂传递模塑成型工艺制得，树脂传递模塑成型工艺所用的树脂为热固性树脂。本发明电池包底护板可在厚度增加的情况下，实现减重约30～50％，同时保证电池包底护板的强度、刚性以及耐腐蚀性，并且不需要额外再进行表面处理，就可以保证底护板的耐疲劳性能，提高电池包底护板的使用寿命长。

Description

一种电池包底护板及其制备方法
技术领域
本发明属于电动车汽车零部件领域，具体涉及一种电池包底护板及其制备方法。
背景技术
随着电动汽车的高速发展，针对电动汽车的创新需求也在不断增加。电动汽车的续航里程最为主要的性能之一，而电动汽车的零部件的重量又是觉得续航里程的重要因素之一。电池包底护板是电动汽车区别于传统燃油汽车而独有的零部件。一方面汽车电池底护板可以保护电池包免受石子冲击和地面磕碰，另一方面电池底护板较大的覆盖面积可以在一定程度上防止雨水溅入电池包的线束插接件上。目前的电动汽车的电池底护板通常由钢板冲压成形，再经过电泳工艺来防止锈蚀。
目前新能源汽车底护板以钢或铝合金为主，这种底护板强度足够高，但是金属结构重量大，易腐蚀，一方面会增加整车能耗，另一方面为了避免腐蚀问题，需要对金属件进行表面处理，增加了成本；对于钢制底护板，还要增加价格较高的PVC涂层进行表面防冲击保护；同时，车辆行驶中遇到石子飞溅冲击会产生较大噪声。另外，还有一些产品使用复合材料或塑料包覆金属板，达到减少腐蚀的目的，但其重量与噪声的问题仍然存在。
现有技术中虽有提供夹芯结构的底护板，但仍存在不少问题。如中国专利(公开号CN111933861B/CN213483883U)公开的电池包下箱体连续纤维泡沫底护板结构及制备方法，其方案选用了泡沫夹心预浸料共固化方案，产品抗冲击性，降噪性，耐腐蚀性，兼具减重优势，但是其选用了材料成本较高的预浸料，该预浸料需要在-18℃下保存，保质期只有6个月，并且需要使用模压工艺，其产品不易进行纤维层的局部厚度补强，并且不适用于结构复杂或产品尺寸较大的零件，大大限制了该底护板的应用。其方案中预埋弓型件也增加了模压成型的复杂程度。
又如中国专利申请文件(公开号CN112009041A1)公开的一种电池包下箱体复合材料蜂窝夹层底护板，该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、网格状蜂窝芯材和上蒙皮，下蒙皮和上蒙皮分别与网格状蜂窝芯材胶接，通过网格状蜂窝芯材保证底护板的刚度。然而该夹层底护板需要在真空固化炉中进行固化，真空固化炉中需要加压加热，并且需要真空袋等辅助材料，工艺时间长，成本高。且上下蒙皮采用模压工艺，模压环境参数预示必然使用热固性材料，热固性材料易脆，还不可回收。
发明内容
本发明的发明目的在于针对现有技术存在的上述问题，提供一种比强度高、比刚度高、比重小、耐高温、抗疲劳、吸水率低的电池包底护板。
为实现上述发明目的，本发明通过如下方案实现：一种电池包底护板，所述的电池包底护板由上到下依次包括上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层，其中低密度闭孔泡沫芯层中设有预埋件。
本发明电池包底护板采用在上、下蒙皮连续纤维层之家设置低密度闭孔泡沫芯层，并在低密度闭孔泡沫芯层中设置预埋件，上、下面层采用比强度高、比刚度高的连续纤维，中间层具有比重小、耐高温、抗压强度高、比强度高、抗疲劳、吸水率低等优点采用闭孔泡沫芯材。相比于当前主流的钢、铝合金底护板，本发明电池包底护板可在厚度增加的情况下，实现减重约30～50％，同时保证电池包底护板的强度、刚性以及耐腐蚀性，并且不需要额外再进行表面处理，就可以保证底护板的耐疲劳性能，提高电池包底护板的使用寿命长。且本发明低密度闭孔泡沫芯层中设有预埋件，预埋件提供与电池包连接的安装孔，由于两者的连接螺栓初始扭矩较大，现有技术中的泡沫无法承载。另外本发明电池包底护板选用低密度闭孔泡沫芯，与蜂窝夹层结构相比能够适应更高的共固化温度和压力，加快生产节奏。同时进一步使面层受压均匀，提高力学性能，还能避免出现像蜂窝芯壁成型时受压导致的纤维弯曲和富树脂现象。
作为优选，所述的电池包底护板通过将上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层通过树脂传递模塑成型工艺制得，树脂传递模塑成型工艺所用的树脂为热固性树脂。
本发明电池包底护板采用成本更低、更环保的树脂传递模塑成型工艺(RTM)，该工艺自动化程度高，可根据性能要求进行纤维层的择向增强、局部增强、混杂增强及预埋结构，可制备大尺寸复杂结构，满足多种型号底护板的需求，且本发明使用热固性树脂，相比于热塑性复合材料，热固性树脂不溶于有机溶剂，在提高电池包底护板耐热性的同时也提高耐机油性，进而提高本发明电池包底护板的尺寸精度、表面质量、机械性能以及表面光洁度。
进一步优选，所述的上蒙皮连续纤维层、下蒙皮连续纤维层中的纤维包括由玻璃纤维、碳纤维、玄武岩纤维中一种或多种制成的单向布、纤维毡、编织布。
进一步优选，所述的低密度闭孔泡沫芯层中的芯材为泡沫、轻质木材、钢板中的一种或多种。
更进一步优选，所述的泡沫包括PVC、PEI、PMI、PET中一种或多种。
更进一步优选，所述的泡沫的密度为110±5g/cm3，厚度为7.8-8.2mm。
作为优选，所述的预埋件贯穿低密度闭孔泡沫芯层。
进一步优选，所述的预埋件包括铝合金、不锈钢中的一种或多种。
作为优选，所述的树脂传递模塑成型工艺包括高压树脂传递模塑成型工艺(HP-RTM)、真空辅助树脂传递注塑成型工艺(VARTM)中的一种或多种。
进一步优选，所述的热固性树脂包括环氧树脂、不饱和聚酯树脂、乙烯基树脂、酚醛树脂中的一种或多种。
进一步优选，树脂传递模塑成型工艺中的注射压力注射压力6-10Mpa，注射时间0.3-3min；注射进行固化处理，固化温度120±5℃，固化时间1-5min。
本发明还提供一种上述电池包底护板的制备方法，所述的制备方法包括如下步骤：
将下蒙皮连续纤维在预制成型模具上铺贴，得下蒙皮连续纤维层；
再将低密度闭孔泡沫芯置于下蒙皮连续纤维层上，并将预埋件埋设于低密度闭孔泡沫芯的代打孔位置，得低密度闭孔泡沫芯层；
然后将上蒙皮连续纤维铺贴到低密度闭孔泡沫芯层上表面，得预制体；
将预制体放置于成型模具中，通过树脂传递模塑成型工艺注入树脂并固化成电池包底护板半成品，脱模后对半成品机加工在电池包底护板上得到用于连接电池包的底护板螺栓连接孔，得本发明电池包底护板。
在上述制备方法中，下蒙皮连续纤维层铺层顺序为(0°/90°)6，纤维面密度为600g/m2，单层厚度为0.26-0.28mm。
在上述制备方法中，上蒙皮连续纤维层铺层顺序为(0°/90°)6，纤维面密度为600g/m2，单层厚度为0.26-0.28mm。
在上述制备方法中，树脂传递模塑成型工艺中注射压力注射压力6-10Mpa，注射时间0.3-3min；注射进行固化处理，固化温度120±5℃，固化时间1-5min。
与现有技术相比，本发明具有如下优点：
1.本发明电池包底护板采用在上、下蒙皮连续纤维层之家设置低密度闭孔泡沫芯层，并在低密度闭孔泡沫芯层中设置预埋件，相比钢、铝合金底护板，本发明电池包底护板可在厚度增加的情况下，实现减重约30～50％，同时保证电池包底护板的强度、刚性以及耐腐蚀性，并且不需要额外再进行表面处理，就可以保证底护板的耐疲劳性能，提高电池包底护板的使用寿命长。
2.本发明电池包底护板采用树脂传递模塑成型工艺(RTM)，该工艺自动化程度高，可根据性能要求进行纤维层的择向增强、局部增强、混杂增强及预埋结构，可制备大尺寸复杂结构，满足多种型号底护板的需求，且本发明使用热固性树脂，相比于热塑性复合材料，热固性树脂不溶于有机溶剂，在提高电池包底护板耐热性的同时也提高耐机油性，进而提高本发明电池包底护板的尺寸精度、表面质量、机械性能以及表面光洁度。
附图说明
图1是本发明中电池包底护板的结构爆炸示意图。
图2是本发明中电池包底护板的预制体示意图。
图3为本发明的成型示意图。
图4为本发明的产品示意图。
图中，1、上蒙皮连续纤维层；2、低密度闭孔泡沫芯层；3、下蒙皮连续纤维层；4、预埋件；5、预制体；6、预制成型模具；7、注射机的混合头；8、成型模具；9、螺栓连接孔；10、电池包底护板。
具体实施方式
如图1所示，本发明电池包底护板，由上到下依次包括上蒙皮连续纤维层1、低密度闭孔泡沫芯层2、下蒙皮连续纤维层3，其中低密度闭孔泡沫芯层中设有预埋件4。
图2、图3分别为本发明中电池包底护板的预制体示意图和成型示意图。将预制体5放入预制成型模具6中，通过注射机的混合头7将树脂注入成型模具8中，取出后即可得到图4中含有用于连接电池包的螺栓连接孔9的电池包底护板10。
上蒙皮连续纤维层、下蒙皮连续纤维层中的纤维包括由玻璃纤维、碳纤维、玄武岩纤维中一种或多种制成的单向布、纤维毡、编织布。
作为优选，低密度闭孔泡沫芯层中的芯材为泡沫、轻质木材、钢板中的一种或多种。
进一步优选，泡沫包括PVC、PEI、PMI，PET中一种或多种。
作为优选，预埋件贯穿低密度闭孔泡沫芯层。
进一步优选，预埋件包括铝合金、不锈钢中的一种或多种。
实施例1
.一种电池包底护板通过如下方法制得：
将下蒙皮连续纤维所需要的六层编织布依次在预制成型模具上按(0°/90°)6铺层角度铺贴，得下蒙皮连续纤维层；
再将密度为110±5g/cm3，厚度为7.8-8.2mm的低密度闭孔PVC泡沫芯置于下蒙皮连续纤维层上，并将尺寸50*50*8mm的6061-T6铝合金预埋件埋设于低密度闭孔泡沫芯的待打孔位置，得预埋件贯穿低密度闭孔泡沫芯层；
然后将上蒙皮连续纤维所需要的六层编织布依次按(0°/90°)6铺层角度铺贴到低密度闭孔泡沫芯层上表面，得预制体；
上蒙皮连续纤维层、下蒙皮连续纤维层中的纤维为由玻璃纤维制成的单向布，铺层顺序均为(0°/90°)6，纤维面密度均为600g/m2，单层厚度均为0.26-0.28mm。
将预制体放置于成型模具中，合模后进行抽真空，将环氧树脂、固化剂、内脱模剂三者按照质量比100：40：0.8混合的混合液注入模具，其比重为50％，注射压力6-10Mpa，注射时间0.3-3min；注射结束后将模具完全闭合，合模压力3000t，闭合过程中模具进一步挤压注射环氧树脂；最后在120±5℃下固化1-5min固化成取出电池包底护板半成品，脱模后对半成品机加工在电池包底护板上得到用于连接电池包的底护板螺栓连接孔，得由上到下依次包括上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层的电池包底护板。
实施例2
.一种电池包底护板通过如下方法制得：
将下蒙皮连续纤维在预制成型模具上铺贴，得下蒙皮连续纤维层；
再将密度为110±5g/cm3，厚度为7.8-8.2mm的低密度闭孔PEI泡沫芯置于下蒙皮连续纤维层上，并将不锈钢预埋件埋设于低密度闭孔泡沫芯的待打孔位置，得预埋件贯穿低密度闭孔泡沫芯层；
然后将上蒙皮连续纤维铺贴到低密度闭孔泡沫芯层上表面，得预制体；
上蒙皮连续纤维层、下蒙皮连续纤维层中的纤维为由碳纤维制成的单向布，铺层顺序均为(0°/90°)6，纤维面密度均为600g/m2，单层厚度均为0.26-0.28mm。
将预制体放置于成型模具中，合模后进行抽真空，将酚醛树脂、固化剂、内脱模剂三者按照质量比100：40：0.8混合的混合液注入模具，其比重为50％，注射压力6-10Mpa，注射时间0.3-3min；注射结束后将模具完全闭合，合模压力3000t，闭合过程中模具进一步挤压注射环氧树脂；最后在120±5℃下固化1-5min固化成取出电池包底护板半成品，脱模后对半成品机加工在电池包底护板上得到用于连接电池包的底护板螺栓连接孔，得由上到下依次包括上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层的电池包底护板。
实施例3
一种电池包底护板通过如下方法制得：
将下蒙皮连续纤维在预制成型模具上铺贴，得下蒙皮连续纤维层；
再将密度为110±5g/cm3，厚度为7.8-8.2mm的低密度闭孔PMI泡沫芯置于下蒙皮连续纤维层上，并将6061铝合金预埋件埋设于低密度闭孔泡沫芯的待打孔位置，得预埋件贯穿低密度闭孔泡沫芯层；
然后将上蒙皮连续纤维铺贴到低密度闭孔泡沫芯层上表面，得预制体；
上蒙皮连续纤维层、下蒙皮连续纤维层中的纤维为由玄武岩纤维制成的编织布，铺层顺序均为(0°/90°)6，纤维面密度均为600g/m2，单层厚度均为0.26-0.28mm。
将预制体放置于成型模具中，合模后进行抽真空，将环氧树脂、固化剂、内脱模剂三者按照质量比100：40：0.8混合的混合液注入模具，其比重为50％，注射压力6-10Mpa，注射时间0.3-3min；注射结束后将模具完全闭合，合模压力3000t，闭合过程中模具进一步挤压注射环氧树脂；最后在120±5℃下固化1-5min固化成取出电池包底护板半成品，脱模后对半成品机加工在电池包底护板上得到用于连接电池包的底护板螺栓连接孔，得由上到下依次包括上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层的电池包底护板。
取实施例1-3制得的电池包底护板进行如下性能测试，测试结果：阻燃等级满足；吸水性小于0.1％；纤维含量可达50％；耐石子冲击满足SAEJ400-2002标准；高温高湿结构无分层，开裂等现象，结构完好；高低温冲击后结构无分层开裂，结构完好；耐酸、碱、机油测试，不发糊，不起泡，无剥离、分层软化等现象；铆钉螺栓等紧固件承载能力满足，经过GB/T31467.3-2015振动测试后，无开裂或裂纹的迹象，紧固件不松动；底部球击测试通过，满足120J冲击；热变形温度满足150℃。
以上为本发明所述的具体实施方式，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

1.一种电池包底护板，其特征在于，所述的电池包底护板由上到下依次包括上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层，其中低密度闭孔泡沫芯层中设有预埋件。
2.根据权利要求1所述的电池包底护板，其特征在于，所述的电池包底护板通过将上蒙皮连续纤维层、低密度闭孔泡沫芯层、下蒙皮连续纤维层通过树脂传递模塑成型工艺制得，树脂传递模塑成型工艺所用的树脂为热固性树脂。
3.根据权利要求1或2所述的电池包底护板，其特征在于，所述的上蒙皮连续纤维层、下蒙皮连续纤维层中的纤维包括由玻璃纤维、碳纤维、玄武岩纤维中一种或多种制成的单向布、纤维毡、编织布。
4.根据权利要求1或2所述的电池包底护板，其特征在于，所述的低密度闭孔泡沫芯层中的芯材为泡沫、轻质木材、钢板中的一种或多种。
5.根据权利要求4所述的电池包底护板，其特征在于，所述的泡沫包括PVC、PEI、PMI、PET中一种或多种。
6.根据权利要求1所述的电池包底护板，其特征在于，所述的预埋件贯穿低密度闭孔泡沫芯层。
7.根据权利要求1或6所述的电池包底护板，其特征在于，所述的预埋件包括铝合金、不锈钢中的一种或多种。
8.根据权利要求2所述的电池包底护板，其特征在于，所述的树脂传递模塑成型工艺包括高压树脂传递模塑成型工艺(HP-RTM)、真空辅助树脂传递注塑成型工艺(VARTM)中的一种或多种。
9.根据权利要求2或8所述的电池包底护板，其特征在于，所述的热固性树脂包括环氧树脂、不饱和聚酯树脂、乙烯基树脂、酚醛树脂中的一种或多种。
10.根据权利要求2所述的电池包底护板，其特征在于，树脂传递模塑成型工艺中的注射压力注射压力6-10Mpa，注射时间0.3-3min；注射进行固化处理，固化温度120±5℃，固化时间1-5min。
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CN116872531A (zh) * 2023-09-07 2023-10-13 北京爱思达航天科技有限公司 一种复合材料底板一体化成型模具及方法
CN117134056A (zh) * 2023-10-26 2023-11-28 杭州卡涞复合材料科技有限公司 多材料复合动力电池下箱体

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116872531A (zh) * 2023-09-07 2023-10-13 北京爱思达航天科技有限公司 一种复合材料底板一体化成型模具及方法
CN117134056A (zh) * 2023-10-26 2023-11-28 杭州卡涞复合材料科技有限公司 多材料复合动力电池下箱体

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