CN116394599A - 一种复合材料、电池箱和汽车 - Google Patents

一种复合材料、电池箱和汽车 Download PDF

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CN116394599A
CN116394599A CN202310266295.6A CN202310266295A CN116394599A CN 116394599 A CN116394599 A CN 116394599A CN 202310266295 A CN202310266295 A CN 202310266295A CN 116394599 A CN116394599 A CN 116394599A
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composite material
layer
battery box
groups
main body
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苏海亮
马莲花
展新
覃记荣
马秋香
黄国桂
陈日旺
罗可扬
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Guangxi University of Science and Technology
Dongfeng Liuzhou Motor Co Ltd
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Guangxi University of Science and Technology
Dongfeng Liuzhou Motor Co Ltd
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    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00Arrangement or mounting of electrical propulsion units
    • B60K1/04Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00Electric propulsion with power supplied within the vehicle
    • B60L50/50Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64Constructional details of batteries specially adapted for electric vehicles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22Mountings; 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
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22Mountings; 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
    • H01M50/231Mountings; 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
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249Mountings; 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/02Coating on the layer surface on fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/20Inorganic coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02Composition of the impregnated, bonded or embedded layer
    • B32B2260/021Fibrous or filamentary layer
    • B32B2260/023Two or more layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04Impregnation, embedding, or binder material
    • B32B2260/046Synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10Inorganic fibres
    • B32B2262/101Glass fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10Inorganic fibres
    • B32B2262/106Carbon fibres, e.g. graphite fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B2262/14Mixture of at least two fibres made of different materials
    • B32B2262/152Knitted fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558Impact strength, toughness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/714Inert, i.e. inert to chemical degradation, corrosion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00Electrical equipment
    • B32B2457/10Batteries
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
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Abstract

本发明公开一种复合材料、电池箱和汽车,其中,所述复合材料的各层结构由外到内依次铺设构成电池箱的下箱体,包括主体层以及两个抗氧化涂层,所述主体层包括碳纤维和玻璃纤维混杂编织的编织层;所述两个抗氧化涂层分别设于所述主体层的两侧。本发明提供的复合材料具有适合新能源汽车电池下箱体的有效抗氧化层、合理的混杂织物方式以及变厚度设计的增设加强层的特定区域能够显著提高复合材料电池下箱体的抗氧化性、抗冲击性、储能模量;降低冲击后损伤、以及改善弯曲性能增加箱体稳定性;在满足使用条件的前提下大幅降低材料成本,进一步为编织复合材料的设计及在新能源汽车上的应用提供参考方案。

Description

一种复合材料、电池箱和汽车
技术领域
本发明涉及新能源汽车技术领域,特别涉及一种复合材料、电池箱和汽车。
背景技术
复合材料具有高比强度、高比模量、低密度、高疲劳极限、耐腐蚀、质量轻、可设计性好等特点,可根据不同的工作需要,设计制造出性能不同的复合材料。新能源汽车的发展要求续航里程多、车速更高等,故近年来复合材料替代金属作为主要承载结构被广泛应用。
汽车动力电池箱作为电动汽车的储能元件,常布置在车身地板底部,其底部受到异物碰撞时具有极大的危险性,可能造成车辆的自燃、爆炸等危险后果。现阶段,复合材料电池箱体主要应用的是单向碳纤维层合板结构,其纤维是空间上平行的、互不交叠的,特别容易产生层间分层失效等而导致性能降低。而且,通常情况下复合材料的铺层是整体铺层,然而电池箱体内部各处的受力情况不均。同时,碳纤维增强复合材料存在抗氧化性能差的劣势,研究表明这会直接导致纤维体的力学性能下降30%~40%。除此之外,只由单一的碳纤维增强复合材料形成层合板还存在耐冲击性较差的缺点。
发明内容
本发明的主要目的是提供一种复合材料,旨在解决现有碳纤维复合材料耐冲击性较差的缺点。
为实现上述目的,本发明提出一种复合材料,所述复合材料的各层结构由外到内依次铺设构成电池箱的下箱体,包括:
主体层,所述主体层包括碳纤维和玻璃纤维混杂编织的编织层;以及,
两个抗氧化涂层,分别设于所述主体层的两侧。
可选地,所述复合材料还包括加强层,所述加强层设于所述两个抗氧化涂层之中的外侧的抗氧化涂层和所述主体层之间,所述加强层为碳纤维和玻璃纤维混杂编织的加强编织层。
可选地,所述加强编织层为二维三轴编织的编织层。
可选地,所述编织层为二维二轴编织的编织层。
可选地,所述复合材料还包括环氧树脂,所述环氧树脂包裹所述主体层和所述加强层。
可选地,所述碳纤维的纱线为1~12K的小丝束连续纤维;和/或,
所述碳纤维的纱线宽度为1~3mm;和/或,
所述玻璃纤维的纱线密度为1000~1200tex;和/或,
所述玻璃纤维的纱线宽度为1~3mm。
可选地,所述主体层的层数为5~8层;和/或,
所述的加强层的层数为4~5层。
可选地,所述抗氧化涂层为SiC-SiO2涂层。
本发明还提出一种电池箱,所述电池箱的主体的材质包括如上所述的复合材料。
本发明还提出一种汽车,所述汽车包括如上所述的电池箱。
本发明的技术方案通过采用一种碳纤维与玻璃纤维混杂的复合材料应用于新能源汽车动力电池下箱体当中,通过抗氧化涂层、编织纤维的交联结构以及结合碳/玻混杂纤维各组分的优势制备整体结构的预成型增强体,纤维和纤维的互锁结构,使得复合材料能够有效的阻止裂纹的扩展,提高箱体的高损伤容限;合理的编织方式将碳纤维和玻璃纤维混杂,充分发挥碳纤维与玻璃纤维各自的力学性能优点,可实现较强的混杂协同效应,获得较高的抗冲击性能;解决复合材料电池箱体抗氧化性能差、层间性能低以及抗冲击性差等问题,为新能源汽车向长续航、高车速、高安全方向发展做技术积累。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图示出的结构获得其他的附图。
图1为本发明复合材料一实施例的结构示意图;
图2为图1中复合材料一实施例的加强层的结构示意图;
图3为本发明电池箱的下箱体的一实施例的结构示意图。
本发明提供的实施例附图标号说明:
标号 名称 标号 名称
1 主体层 2 主体区域
11 碳纤维 3 特定区域
12 玻璃纤维 4 吊耳
本发明目的的实现、功能特点及优点将结合实施例,参照附图做进一步说明。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
需要说明,若本发明实施例中有涉及方向性指示(诸如上、下、左、右、前、后……),则该方向性指示仅用于解释在某一特定姿态(如附图所示)下各部件之间的相对位置关系、运动情况等,如果该特定姿态发生改变时,则该方向性指示也相应地随之改变。
另外,若本发明实施例中有涉及“第一”、“第二”等的描述,则该“第一”、“第二”等的描述仅用于描述目的,而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外,全文中出现的“和/或”的含义,包括三个并列的方案,以“A和/或B”为例,包括A方案、或B方案、或A和B同时满足的方案。另外,各个实施例之间的技术方案可以相互结合,但是必须是以本领域普通技术人员能够实现为基础,当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在,也不在本发明要求的保护范围之内。
汽车动力电池箱作为电动汽车的储能元件,常布置在车身地板底部,其底部受到异物碰撞时具有极大的危险性,可能造成车辆的自燃、爆炸等危险后果。现阶段,复合材料电池箱体主要应用的是单向碳纤维层合板结构,其纤维是空间上平行的、互不交叠的,特别容易产生层间分层失效等而导致性能降低。而且,通常情况下复合材料的铺层是整体铺层,然而电池箱体内部各处的受力情况不均。同时,碳纤维增强复合材料存在抗氧化性能差的劣势,研究表明这会直接导致纤维体的力学性能下降30%~40%。除此之外,只由单一的碳纤维增强复合材料形成层合板还存在耐冲击性较差的缺点。
鉴于此,本发明提出一种复合材料,以解决现有的复合材料耐冲击性差的问题。参照图1至3,图1为本发明复合材料一实施例的结构示意图;图2为图1中复合材料一实施例的加强层的结构示意图;图3为本发明电池箱的下箱体的一实施例的结构示意图。
本发明提出一种复合材料,所述复合材料的各层结构由外到内依次铺设构成电池箱的下箱体,包括主体层1以及两个抗氧化涂层,所述主体层包括碳纤维11和玻璃纤维12混杂编织的编织层;所述两个抗氧化涂层分别设于所述主体层的两侧。
所述主体层1的两个外表面均形成抗氧化涂层,所述主体层1的外表面通过涂覆抗氧化材料,可以隔绝空气氧化,增强复合材料的抗氧化性能,延长复合材料的使用寿命;所述主体层1的碳纤维11和玻璃纤维12通过互锁的结构,使得复合材料的结构更加牢固,能够有效的阻止裂纹的扩展,提高箱体的高损伤容限;通过合理的编织方式将碳纤维11和玻璃纤维12混杂,充分发挥碳纤维11与玻璃纤维12各自的力学性能优点,可实现较强的混杂协同效应,获得较高的抗冲击性能。本发明提供的电池箱的下箱体由复合材料所制成,电池箱的下箱体由表面到内依次层叠有抗氧化涂层、主体层1和抗氧化涂层。
本发明技术方案通过采用一种碳纤维11与玻璃纤维12混杂的复合材料应用于新能源汽车动力电池下箱体当中,通过抗氧化涂层、编织纤维的交联结构以及结合碳/玻混杂纤维各组分的优势制备整体结构的预成型增强体,充分发挥碳纤维11与玻璃纤维12各自的力学性能优点,可实现较强的混杂协同效应,获得较高的抗冲击性能,解决复合材料电池箱体抗氧化性能差、层间性能低以及抗冲击性差等问题,为新能源汽车向长续航、高车速、高安全方向发展做技术积累。
进一步地,于本实施例中,所述复合材料还包括加强层,所述加强层设于所述两个抗氧化涂层之中的外侧的抗氧化涂层和所述主体层1之间,所述加强层为碳纤维11和玻璃纤维12混杂编织的加强编织层。所述电池箱的主体区域2均由抗氧化涂层、主体层1和抗氧化涂层组成,而在特定区域3还增加有加强层,所述特定区域3为电池下箱体中电池模组固定的区域,有加强层的特定区域3在主体层1的最外层的外表面和加强层最内层的内表面形成抗氧化涂层。本发明在保证箱体一体化设计的同时根据实际电池箱内部主要承力区域进行加强,充分体现复合材料可设计性的特点为复合材料一体化设计提供方向,利用复合材料可变厚度设计的优点,在电池模组安装区域采用局部增厚,针对性地增强特定区域3的力学性能,进一步降低产品重量,降低成本,推动复合材料电池箱体产业化应用。
为了充分发挥碳纤维11与玻璃纤维12各自的力学性能,于本实施例中,请参阅图2,所述加强编织层为交织编织的方式,可以为多维多轴的方式进行编织,本发明的加强编织层采用二维三轴编织的编织层,两种不同材料的纱线通过1×1的交织方式编织形成二维三轴编织纤维布。编织时,编织角可以为30°、45°、60°等,本实施例中,为了最大限度的发挥碳纤维11和玻璃纤维12的力学性能,采用45°编织角,既美观又具有较强的力学性能。
请参阅图1,于本实施例中,所述编织层为二维二轴编织的编织层,所述编织层采用碳纤维11和玻璃纤维12两种不同材料的纱线通过1×1的交织方式编织形成二维二轴编织纤维布,编织层的编织角可以为30°、45°、60°等,本实施例中采用45°编织角,使得编织层具有较强的力学性能,耐冲击性能更优。
为了进一步增强复合材料的力学强度,于本实施例中,所述主体层1的层数为5~8层,优选为8层,主体层1的厚度达到2.64mm;所述的加强层的层数为4~5层,优选为4层,如此,加强的特定区域3由12层编织结构组成,厚度为3.96mm,本发明通过设置多层的互相交织的复合材料,使得由该材料所述制成的电池箱具有较强的抗冲击性能,同时根据电池箱体实际受力情况进行局部铺层增强设计,从而延长电池箱的使用寿命。
于本实施例中,进一步地,所述碳纤维11的纱线为1~12K的小丝束连续纤维,小丝束的碳纤维11抗拉强度更加稳定,本发明优选采用12K的小丝束连续纤维,所述碳纤维11的纱线宽度为1~3mm,优选为2mm;所述玻璃纤维12的纱线密度为1000~1200tex,优选为1200tex;所述玻璃纤维12的纱线宽度为1~3mm,优选为2mm,采用该参数的碳纤维11和玻璃纤维12具有较强的拉伸强度和力学强度,同时便于后续浸胶、固化处理。
为了方便复合材料成型,所述复合材料还包括环氧树脂,所述环氧树脂包裹所述主体层1和所述加强层,所述主体层1和所述加强层的碳纤维11和玻璃纤维12交织编织完成后,在它们的内外表面涂抗氧化涂层,最后注入环氧树脂基体,成型后组成下箱体。本发明的材料选用巨石集团1200tex/E6D17型玻璃纤维材料和中复神鹰集团12K/SYT49S型碳纤维材料,树脂为普通的环氧树脂。环氧树脂为构成混杂复合材料的基体,碳纤维11和玻璃纤维12为构成复合材料的增强材料,纤维体积含量为51.44%。所述多层碳纤维11和玻璃纤维12混杂编织复合材料电池下箱体箱体采用HP-RTM工艺成型。将编织预制体按照铺层厚度、铺层区域以及铺层次序依次浸胶、包裹、热固化、脱模和机加工,最终得到电池箱下箱体。
于本实施例中,所述抗氧化涂层为SiC-SiO2涂层,通过原位浸渍法-惰性气氛热处理在处于箱体表面的编织纤维布表面形成SiC-SiO2涂层,可以增强复合材料箱体的抗氧化性能,保证其在恶劣条件下服役的强度,所述溶胶的pH为1.5,水(H2O)、正硅酸乙酯(TEOS)、乙烯基三乙氧基硅烷(VTES)、乙醇(EtOH)的质量比为7∶7∶0.5∶11,反应温度50℃。其中,无加强层的主体区域2在主体层1的最外层的外表面和最内层的内表面形成抗氧化的SiC-SiO2涂层;有加强层的特定区域3在主体层1的最外层的外表面和加强层最内层的内表面形成抗氧化的SiC-SiO2涂层,通过设置SiC-SiO2涂层,使得复合材料具有抗氧化、耐高温的性能。
本发明还提出一种电池箱,请参阅图3,所述电池箱的主体的材质包括如上所述的复合材料,所述电池箱还包括吊耳4,所述吊耳4采用胶接的方式与所述电池箱的下箱体连接。该复合材料的具体结构参照上述实施例,由于本电池箱采用了上述所有实施例的全部技术方案,因此至少具有上述实施例的技术方案所带来的所有有益效果,在此不再一一赘述。其中,所述电池箱安装在新能源汽车的底部,内部为动力电池模组,需要满足各种使用工况要求:主要有振动、机械冲击、跌落、翻转、挤压等。采用碳纤维复合材料,可以实现轻量化;利用碳纤维复合材料结构可设计性的特点,将碳纤维11和玻璃纤维12混杂编织可以发挥各纤维的优点达到更好的性能;同时利用复合材料可变厚度设计的优点,在电池模组安装区域采用局部增厚,进一步降低产品重量,降低成本,推动复合材料电池箱体产业化应用。
进一步地,本发明还提出一种汽车,所述汽车包括如上所述的电池箱,所述电池箱使用如上所述的复合材料制成,该复合材料的具体结构参照上述实施例,由于本电池箱采用了上述所有实施例的全部技术方案,因此至少具有上述实施例的技术方案所带来的所有有益效果,在此不再一一赘述。所述汽车包括车架,所述车架上设置有如上述的碳/玻混杂纤维复合材料电池箱体,吊耳4和车架通过螺栓连接。将本发明应用在新能源汽车上,具有减重率高、续航里程高、疲劳寿命长、抗氧化性能好、抗腐蚀性能好、抗振动性能好等优点,且能够有效提高电池箱体的能量密度,有助于复合材料电池箱体批量化应用。
以上所述仅为本发明的优选实施例,并非因此限制本发明的专利范围,凡是在本发明的发明构思下,利用本发明说明书及附图内容所作的等效结构变换,或直接/间接运用在其他相关的技术领域均包括在本发明的专利保护范围内。

Claims (10)

1.一种复合材料,所述复合材料的各层结构由外到内依次铺设构成电池箱的下箱体,其特征在于,包括:
主体层,所述主体层包括碳纤维和玻璃纤维混杂编织的编织层;以及,
两个抗氧化涂层,分别设于所述主体层的两侧。
2.如权利要求1所述的复合材料,其特征在于,所述复合材料还包括加强层,所述加强层设于所述两个抗氧化涂层之中的外侧的抗氧化涂层和所述主体层之间,所述加强层为碳纤维和玻璃纤维混杂编织的加强编织层。
3.如权利要求2所述的复合材料,其特征在于,所述加强编织层为二维三轴编织的编织层。
4.如权利要求1所述的复合材料,其特征在于,所述编织层为二维二轴编织的编织层。
5.如权利要求2所述的复合材料,其特征在于,所述复合材料还包括环氧树脂,所述环氧树脂包裹所述主体层和所述加强层。
6.如权利要求1所述的复合材料,其特征在于,所述碳纤维的纱线为1~12K的小丝束连续纤维;和/或,
所述碳纤维的纱线宽度为1~3mm;和/或,
所述玻璃纤维的纱线密度为1000~1200tex;和/或,
所述玻璃纤维的纱线宽度为1~3mm。
7.如权利要求2所述的复合材料,其特征在于,所述主体层的层数为5~8层;和/或,
所述的加强层的层数为4~5层。
8.如权利要求1所述的复合材料,其特征在于,所述抗氧化涂层为SiC-SiO2涂层。
9.一种电池箱,其特征在于,所述电池箱的主体的材质包括如权利要求1至8任一项所述的复合材料。
10.一种汽车,其特征在于,所述汽车包括如权利要求9所述的电池箱。
CN202310266295.6A 2023-03-17 2023-03-17 一种复合材料、电池箱和汽车 Pending CN116394599A (zh)

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