CN116505179A - Carbon fiber composite material for new energy automobile body floor and battery pack cover plate - Google Patents

Carbon fiber composite material for new energy automobile body floor and battery pack cover plate Download PDF

Info

Publication number
CN116505179A
CN116505179A CN202310243103.XA CN202310243103A CN116505179A CN 116505179 A CN116505179 A CN 116505179A CN 202310243103 A CN202310243103 A CN 202310243103A CN 116505179 A CN116505179 A CN 116505179A
Authority
CN
China
Prior art keywords
carbon fiber
resin material
composite material
inner core
unidirectional tape
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202310243103.XA
Other languages
Chinese (zh)
Inventor
陆炜
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zhejiang Alai Western Australia Intelligent Equipment Technology Co ltd
Original Assignee
Zhejiang Alai Western Australia Intelligent Equipment Technology Co ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zhejiang Alai Western Australia Intelligent Equipment Technology Co ltd filed Critical Zhejiang Alai Western Australia Intelligent Equipment Technology Co ltd
Publication of CN116505179A publication Critical patent/CN116505179A/en
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H01M50/273—Lids or covers for the racks or secondary casings characterised by the material
    • H01M50/282—Lids or covers for the racks or secondary casings characterised by the material having a layered structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/071—Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/12—Compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/70—Completely encapsulating inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION 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
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/615—Heating or keeping warm
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H01M50/273—Lids or covers for the racks or secondary casings characterised by the material
    • H01M50/276—Inorganic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H01M50/273—Lids or covers for the racks or secondary casings characterised by the material
    • H01M50/278—Organic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H01M50/273—Lids or covers for the racks or secondary casings characterised by the material
    • H01M50/28—Composite material consisting of a mixture of organic and inorganic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/003—PET, i.e. poylethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
    • B29K2071/12—PPO, i.e. polyphenylene oxide; PPE, i.e. polyphenylene ether
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Transportation (AREA)
  • Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Sustainable Energy (AREA)
  • Acoustics & Sound (AREA)
  • Combustion & Propulsion (AREA)
  • Geometry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Power Engineering (AREA)
  • Battery Mounting, Suspending (AREA)
  • Reinforced Plastic Materials (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
  • Secondary Cells (AREA)
  • Battery Electrode And Active Subsutance (AREA)

Abstract

The invention provides a carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate, which adopts carbon fiber composite foaming high flame retardant molding, has a sandwich structure and can realize multiple effects of integral heat preservation, heat insulation and weight reduction of a battery pack. Specifically, the composite material can replace a metal car body structure floor to realize the functions of light weight and high strength, has the functions of integral heat preservation and heat insulation for the battery pack, and simultaneously reduces the weight of the battery pack cover plate, thereby greatly reducing the production process.

Description

Carbon fiber composite material for new energy automobile body floor and battery pack cover plate
The present application claims priority to patent application cn202210279264.X, titled "carbon fiber composite for new energy automobile chassis structure and battery pack tray", with application day 2022, 3, 22, the entire contents of which are incorporated herein by reference.
Technical Field
The invention relates to the technical field of carbon fiber materials, in particular to a carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate.
Background
At present, the global new energy automobile floor adopts the following structural types: steel structure, aluminum alloy structure or aluminum magnesium alloy structure. Under the premise of ensuring the strength, the requirement on the weight reduction of the whole vehicle is continuously improved, and the market requirement cannot be met. Taking a battery pack cover plate with an aluminum alloy structure as an example, all new energy battery packs are processed by adopting an aluminum alloy tray in a computer numerical control manner (Computer numerical control, CNC for short). CNC processing combines with engineering plastics injection moulding battery cover, and the battery package apron is heavy and does not possess thermal-insulated function of heat preservation.
Therefore, the structure needs to be improved, so that the new energy automobile body floor and the battery pack cover plate have high strength and light weight and have the functions of heat preservation and heat insulation.
In view of this, the present invention has been made.
Disclosure of Invention
In order to overcome the technical problems as described above, the structures of the vehicle body floor and the battery pack cover plate are further improved, and development of raw materials and preparation processes of the materials is required.
The invention aims to provide a carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate, which is formed by carbon fiber composite foaming and high flame retardance, has a sandwich structure and can realize multiple effects of integral heat preservation, heat insulation and weight reduction of a battery pack.
A second object of the present invention is to provide a method for preparing the carbon fiber composite.
The third object of the invention is to provide the application of the carbon fiber composite material in the body floor of a new energy automobile and a battery pack cover plate.
In order to achieve the above purpose, the technical scheme of the invention is as follows:
the invention relates to a carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate, which comprises a shell layer prepared from carbon fibers and a resin material, and an inner core prepared from a modified resin material, wherein the shell layer forms a coating on the inner core; the resin material is a modified resin material.
Preferably, the thickness of the shell layer is 0.5-2 mm, and the thickness of the inner core is 20-100 mm.
Preferably, the modified resin material is at least one selected from the group consisting of polyethylene terephthalate (Polyethylene terephthalate, abbreviated as PET), polyphenylene ether plastic (Polyphenylene Oxide, abbreviated as PPO), polyamide Plastic (PA), and Polyether ether ketone (PEEK).
The invention also relates to a preparation method of the carbon fiber composite material, which comprises the following steps:
(1) Preparing carbon fibers and a first resin material into a thermoplastic carbon fiber unidirectional tape;
preferably, the carbon fiber is 50-65 parts by weight and the first resin material is 35-50 parts by weight.
Preferably, the first resin material is PET or PPO. The resin material is preferably the same material as the underlying core material, and this step is carried out using a continuous composite press line.
(2) And sequentially carrying out modification, granulating, supercritical carbon dioxide physical foaming and bead compression molding on the second resin material to obtain the inner core of the carbon fiber composite material.
Preferably, the second resin material is PET, PPO or PA.
Preferably, the modification is to add a chain extender and/or a toughening agent to the second resin material, the addition amount of the chain extender and/or the toughening agent being 3 to 10 mass% of the second resin material.
Preferably, after carbon dioxide supercritical physical foaming, the second resin material becomes beads, and a structural member in any shape is molded by a full-automatic molding press to obtain an inner core of the carbon fiber composite material;
preferably, EPET and/or EPPO beads are added into the beads processed by the second resin material, and a structural member with any shape is molded by a full-automatic molding press, so that an inner core of the carbon fiber composite material is obtained; the mass ratio of the second resin material to the EPET and/or EPPO beads is (3-5): 3-5.
(3) Adopting a unidirectional tape attaching process, attaching the thermoplastic carbon fiber unidirectional tape obtained in the step (1) to the surface of the inner core obtained in the step (2) in the same direction, and performing laser thermosetting on the inner core attached with the unidirectional tape to realize one-step molding, so as to obtain a first preform;
(4) Changing the attaching direction, attaching the thermoplastic carbon fiber unidirectional tape to the surface of the first preform again, and performing laser thermosetting on the first preform attached with the unidirectional tape to realize one-step molding, so as to obtain a second preform;
preferably, in the steps (3) and (4), the unidirectional tape attaching process is a 3D braiding winding process, and the number of composite layers of the unidirectional tape on the surfaces of the inner core and the first preform is a single layer.
(5) Repeating the step (4) for 2-5 times to obtain a unidirectional tape multi-angle laminating laser thermosetting product, namely the carbon fiber composite material for the new energy automobile body floor and the battery pack cover plate, which is disclosed by the invention, and the aim of high-strength lightweight composite material parts is fulfilled.
Preferably, in the steps (4) and (5), the attaching direction of the carbon fiber unidirectional tape is changed in the order of 0 °, 45 °, and 90 ° from the horizontal direction.
After the step (5) is finished, the reserved connecting hole positions of the metal structural part and the carbon fiber inside the inner core are processed, so that the aim of connecting the integrated composite material and other metal parts is fulfilled.
The invention also relates to application of the carbon fiber composite material in manufacturing of new energy automobile body floors and battery pack cover plates.
The invention has the beneficial effects that:
the invention provides a carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate, which adopts carbon fiber composite foaming high flame retardant molding, has a sandwich structure and can realize multiple effects of integral heat preservation, heat insulation and weight reduction of a battery pack. Specifically, the composite material can replace a metal car body structure floor to realize the functions of light weight and high strength, has the functions of integral heat preservation and heat insulation for the battery pack, and simultaneously reduces the weight of the battery pack cover plate, thereby greatly reducing the production process.
Drawings
Fig. 1 is a cross-sectional view of the carbon fiber composite material of example 1.
Wherein, 1-thermoplastic carbon fiber unidirectional tape; 2-inner core.
FIG. 2 is a schematic illustration of a continuous compounding press line for making a thermoplastic carbon fiber unidirectional tape.
Wherein, 2-1 yarn placing rack; 2-2-extruder; 2-3 yarn spreading devices; 2-4 dipping die heads; 2-5 cooling and shaping rollers; 2-6 traction rollers; 2-7 winding devices.
Fig. 3 is a schematic view showing the bonding direction of the carbon fiber unidirectional tape of example 1.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It will be apparent that the described embodiments are only some, but not all, embodiments of the invention. All other embodiments, based on the examples herein, which are within the scope of the invention as defined by the claims, will be within the scope of the invention as defined by the claims.
The invention relates to a carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate, which is shown in figure 1, and comprises a shell layer prepared from carbon fibers and a modified resin material, namely a thermoplastic carbon fiber unidirectional tape 1, and an inner core 2 prepared from the resin material, wherein the shell layer forms a coating on the inner core 2.
In one embodiment of the invention, the shell layer has a thickness of 0.5 to 2mm and the core has a thickness of 20 to 100mm.
In one embodiment of the present invention, the modified resin material is selected from at least one of PET, PPO, PA.
The invention also relates to a preparation method of the carbon fiber composite material, which comprises the following steps:
(1) Preparing carbon fibers and a first resin material into a thermoplastic carbon fiber unidirectional tape;
in one embodiment of the invention, the carbon fiber is 50-65 parts by weight and the first resin material is 35-50 parts by weight.
In one embodiment of the invention, the first resin material is PET or PPO. The resin material is preferably the same material as the underlying core material, which facilitates subsequent thermoforming. This step is performed using a continuous composite press line.
As shown in fig. 2, this process is performed by a continuous composite press line known in the art, which includes a yarn feeding frame 2-1, an extruder 2-2, a yarn spreading device 2-3, an impregnation die 2-4, a cooling and shaping roller 2-5, a pulling roller 2-6, and a winding device 2-7, which are sequentially disposed. The specific process steps are as follows:
1. the carbon fibers are placed on a yarn placing frame 2-1, the yarn placing frame 2-1 is used for conveying the carbon fibers to a yarn spreading device 2-3, and a plurality of carbon fibers are tiled into a plane.
2. The first resin material is placed in an extruder 2-2 and the resin is melted under heating (the heating temperature is the melting point of the resin, typically between 150-250 c). The impregnating die heads 2-4 are provided with a plurality of grooves, the width of each groove is slightly larger than that of the carbon fiber, and the melted resin enters the grooves in the impregnating die heads 2-4.
3. Carbon fibers are sent into the dipping die heads 2-4 by the yarn spreading device 2-3, a plurality of carbon fibers in the same plane enter grooves of the dipping die heads 2-4, and liquid resin is used for dipping the carbon fibers.
4. And outputting the carbon fiber impregnated with the resin from the impregnation die head 2-4, and entering the cooling and shaping roller 2-5. And cooling the resin on the surface of the carbon fiber to form a coating layer on the carbon fiber. And cooling and shaping the carbon fibers to form the sheet.
5. The sheet is guided out by a traction roller 2-6 after being output from a cooling shaping roller 2-5, and is wound by a winding device 2-7 after being cut.
(2) And sequentially carrying out modification, granulating, supercritical carbon dioxide physical foaming and bead compression molding on the second resin material to obtain the inner core of the carbon fiber composite material.
In one embodiment of the invention, the second resin material is PET, PPO or PA.
In one embodiment of the present invention, the modification is to add a chain extender and/or a toughening agent to the second resin material in an amount of 3 to 10 mass% of the second resin material.
In one embodiment of the present invention, after carbon dioxide supercritical physical foaming, the second resin material becomes beads, and the structural member with any shape is molded by a full-automatic molding machine, so as to obtain the inner core of the carbon fiber composite material. The compression molding can obtain various required structural shapes, such as a vehicle underfloor or a battery pack cover plate, so as to realize the light weight of the components. And in the forming process, the high-strength aluminum alloy or the connecting piece of the high-strength structural steel is embedded in the middle layer of the foaming beads.
In one embodiment of the invention, EPET and/or EPPO beads are added into the beads processed by the second resin material, and the structural member with any shape is molded by a full-automatic molding machine, so that the inner core of the carbon fiber composite material is obtained. The compression molding can obtain various required structural shapes, such as a vehicle underfloor or a battery pack cover plate, so as to realize the light weight of the components. And the high-strength aluminum alloy connecting flange is embedded in the forming process.
In one embodiment of the invention, the mass ratio of the second resin material to the EPET and/or EPPO beads is (3-5): 3-5.
(3) Adopting a unidirectional tape attaching process, attaching the thermoplastic carbon fiber unidirectional tape obtained in the step (1) to the surface of the inner core obtained in the step (2) in the same direction, and performing laser thermosetting on the inner core attached with the unidirectional tape to realize one-step molding, so as to obtain a first preform;
(4) Changing the attaching direction, attaching the thermoplastic carbon fiber unidirectional tape to the surface of the first preform again, and performing laser thermosetting on the first preform attached with the unidirectional tape to realize one-step molding, so as to obtain a second preform;
in one embodiment of the present invention, in steps (3) and (4), the unidirectional tape lamination process is a 3D braiding winding process, and the number of composite layers of the unidirectional tape on the surfaces of the inner core and the first preform is a single layer.
(5) Repeating the step (4) for 2-5 times to obtain a unidirectional tape multi-angle laminating laser thermosetting product, namely the carbon fiber composite material for the new energy automobile body floor and the battery pack cover plate, which is disclosed by the invention, and the aim of high-strength lightweight composite material parts is fulfilled.
In one embodiment of the present invention, in the steps (4) and (5), the attaching direction of the carbon fiber unidirectional tape is changed in the order of 0 °, 45 °, 90 ° from the horizontal direction. As shown in fig. 3, it is assumed that the attaching direction of the first layer of unidirectional tapes is parallel to the horizontal plane, that is, the weft direction, the attaching direction of the second layer of unidirectional tapes forms an included angle of 45 ° with the weft direction, and the attaching direction of the third layer of unidirectional tapes forms an included angle of 90 ° with the weft direction. The bonding mode can improve the laying strength of the unidirectional tape.
After the step (5) is finished, the reserved connecting hole positions of the metal structural part and the carbon fiber inside the inner core are processed, so that the aim of connecting the integrated composite material and other metal parts is fulfilled.
The embodiment of the invention also relates to application of the carbon fiber composite material in manufacturing of the new energy automobile body floor and the battery pack cover plate.
Comparative example 1
The preparation method of the carbon fiber composite material for the new energy automobile body floor and the battery pack cover plate comprises the following steps:
(1) And preparing the carbon fiber and the first resin material PET into the thermoplastic carbon fiber unidirectional tape by adopting a continuous composite press production line, wherein the carbon fiber is 65 parts, and the first resin material is 35 parts.
(2) And adding a chain extender into the second resin material PET for modification, wherein the chain extender is 1, 4-Butanediol (BDO), and the addition amount is 5 mass percent of the second resin material. Then performing granulation and supercritical carbon dioxide physical foaming to obtain the beads. And (3) molding the beads into any structural member by a full-automatic molding press to obtain the inner core of the carbon fiber composite material. The compression molding can obtain various required structural shapes such as a vehicle bottom or a battery tray cover to achieve weight reduction of the component. And the high-strength aluminum alloy connecting flange is embedded in the forming process. Alternatively, a chain extender, 1, 4-Butanediol (BDO), was added to the second resin material PET in an amount of 5 mass% of the second resin material for modification. Then performing granulation and supercritical carbon dioxide physical foaming to obtain the beads. And adding EPET beads into the beads, wherein the mass ratio of the second resin material to the EPET beads is 5:3, and forming any structural member by a full-automatic molding press to obtain the inner core of the carbon fiber composite material. The compression molding can obtain various required structural shapes such as a vehicle bottom or a battery tray cover to achieve weight reduction of the component. And the high-strength aluminum alloy connecting flange is embedded in the forming process.
(3) And (3) compounding the thermoplastic carbon fiber unidirectional tape obtained in the step (1) on the surface of the inner core obtained in the step (2) by adopting a 3D braiding winding process, wherein the number of compounding layers is a single layer, and then performing laser thermosetting to realize one-step molding.
The carbon fiber composite material prepared in comparative example 1 was subjected to performance test, and the results are shown in table 1:
TABLE 1
Example 1
The steps (1) and (2) of the preparation method of the carbon fiber composite material for the new energy automobile body floor and the battery pack cover plate are the same as those of comparative example 1, and the preparation process of the step (3) and the following steps is as follows:
(3) Adopting a unidirectional tape laminating process, laminating the thermoplastic carbon fiber unidirectional tape obtained in the step (1) on the surface of the inner core obtained in the step (2) in the same direction, wherein the laminating direction is a horizontal direction, the laminating layer number is a single layer, and then performing laser thermosetting on the inner core laminated with the unidirectional tape to realize one-step molding, so as to obtain a first prefabricated product;
(4) Changing the bonding direction, bonding the carbon fiber unidirectional tape on the surface of the first preform again, forming an included angle of 45 degrees between the bonding direction and the horizontal direction, wherein the bonding layer number is a single layer, and performing laser thermosetting on the first preform bonded with the unidirectional tape to realize one-step molding to obtain a second preform;
(5) Changing the laminating direction, laminating the carbon fiber unidirectional tape again on the surface of the second prefabricated product, forming an included angle of 90 degrees between the laminating direction and the horizontal direction, forming a single laminating layer number, and performing laser thermosetting on the second prefabricated product of the laminating unidirectional tape to realize one-step forming, so as to obtain a finished product.
Comparative example 2
The steps (1) to (2) of the preparation method of the carbon fiber composite material for the new energy automobile body floor and the battery pack cover plate are the same as those of the embodiment 1, and the preparation process of the step (3) and the following steps is as follows:
(3) Adopting a unidirectional tape laminating process, laminating the carbon fiber unidirectional tape obtained in the step (1) on the surface of the inner core obtained in the step (2) in the same direction, wherein the laminating direction is a horizontal direction, the laminating layer number is a single layer, and then performing laser thermosetting on the inner core laminated with the unidirectional tape to realize one-step molding, so as to obtain a first prefabricated product;
(4) Attaching the carbon fiber unidirectional tape to the surface of the first prefabricated product again, wherein the attaching direction is the horizontal direction, the attaching layer number is a single layer, and then performing laser thermosetting on the first prefabricated product attached with the unidirectional tape to realize one-step molding, so as to obtain a second prefabricated product;
(5) And (3) attaching the carbon fiber unidirectional tape to the surface of the second prefabricated product again, wherein the attaching direction is the horizontal direction, the attaching layer number is a single layer, and then performing laser thermosetting on the second prefabricated product attached with the unidirectional tape to realize one-step molding, so as to obtain a finished product.
The carbon fiber composite materials prepared in example 1 and comparative example 2 were subjected to performance test, and the results are shown in table 2:
TABLE 2
Content of test Direction (°) Unit (B) Test results
Example 1 Charpy impact Perpendicular to the surface N/A 230.00
Comparative example 1 Charpy impact Perpendicular to the surface N/A 140.00
Comparative example 2 Charpy impact Perpendicular to the surface N/A 170.00
As is clear from table 2, in comparative example 1, a single-layer carbon fiber unidirectional tape was bonded to the surface of the foamed core, and the strength thereof was good. Comparative example 2 further attached a unidirectional tape to the surface and the strength continued to increase. On the premise of unchanged bonding layer number, the bonding direction of the unidirectional tapes of different layers is changed in the embodiment 1, and the strength is improved obviously.
The foregoing is merely illustrative of the present invention, and the present invention is not limited thereto, and any person skilled in the art will readily recognize that variations or substitutions are within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims (10)

1. A carbon fiber composite material for a new energy automobile body floor and a battery pack cover plate, which is characterized in that the composite material comprises a shell layer prepared from carbon fibers and a resin material, and an inner core prepared from the resin material, wherein the shell layer forms a coating on the inner core; the resin material is a modified resin material.
2. The composite material of claim 1, wherein the shell layer has a thickness of 0.5 to 2mm and the inner core has a thickness of 20 to 100mm.
3. The composite material of claim 1, wherein the modified resin material is selected from at least one of PET, PPO, PA, PEEK.
4. A method of producing a carbon fiber composite material according to any one of claims 1 to 3, comprising the steps of:
(1) Preparing carbon fibers and a first resin material into a thermoplastic carbon fiber unidirectional tape;
(2) Sequentially modifying, granulating, carbon dioxide supercritical physical foaming and bead compression molding the second resin material to obtain an inner core of the carbon fiber composite material;
(3) Adopting a unidirectional tape attaching process, attaching the thermoplastic carbon fiber unidirectional tape obtained in the step (1) to the surface of the inner core obtained in the step (2) in the same direction, and performing laser thermosetting on the inner core attached with the unidirectional tape to realize one-step molding, so as to obtain a first preform;
(4) Changing the attaching direction, attaching the thermoplastic carbon fiber unidirectional tape to the surface of the first preform again, and performing laser thermosetting on the first preform attached with the unidirectional tape to realize one-step molding, so as to obtain a second preform;
(5) Repeating the step (4) for 2-5 times to obtain the carbon fiber composite material for the new energy automobile body floor and the battery pack cover plate.
5. The method according to claim 4, wherein in the step (1), the carbon fiber is 50 to 65 parts by weight and the first resin material is 35 to 50 parts by weight.
6. The method of claim 4, wherein in step (1), the first resin material is PET or PPO, and the first resin material is preferably the same material as the underlying core material, and step (1) is performed using a continuous compounding press line.
7. The method of claim 4, wherein in step (2), the second resin material is PET, PPO, or PA.
8. The method according to claim 4, wherein in the step (2), the modification is to add a chain extender and/or a toughening agent to the second resin material, the addition amount of the chain extender and/or the toughening agent being 3 to 10 mass% of the second resin material;
and/or, forming the second resin material into beads after supercritical carbon dioxide physical foaming, and forming structural members in any shape through a full-automatic molding press to obtain an inner core of the carbon fiber composite material;
or, EPET and/or EPPO beads are added into the beads processed by the second resin material, and a structural member with any shape is molded by a full-automatic molding press, so that an inner core of the carbon fiber composite material is obtained; the mass ratio of the second resin material to EPET and/or EPPO beads is (3-5): 3-5.
9. The method according to claim 4, wherein in steps (3) and (4), the unidirectional tape lamination process is a 3D braiding winding process, and the number of composite layers of the unidirectional tape on the surfaces of the inner core and the first preform is a single layer;
and/or, in the steps (4) and (5), changing the attaching direction of the carbon fiber unidirectional tape according to the sequence of forming 0 degree, 45 degrees and 90 degrees with the horizontal direction.
10. Use of the carbon fiber composite material prepared by the method of any one of claims 1 to 3 or any one of claims 4 to 9 in manufacturing new energy automobile body floors and battery pack covers.
CN202310243103.XA 2022-03-22 2023-03-14 Carbon fiber composite material for new energy automobile body floor and battery pack cover plate Pending CN116505179A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN202210279264X 2022-03-22
CN202210279264.XA CN114374038A (en) 2022-03-22 2022-03-22 Carbon fiber composite material for new energy automobile chassis structure and battery pack tray

Publications (1)

Publication Number Publication Date
CN116505179A true CN116505179A (en) 2023-07-28

Family

ID=81145469

Family Applications (2)

Application Number Title Priority Date Filing Date
CN202210279264.XA Pending CN114374038A (en) 2022-03-22 2022-03-22 Carbon fiber composite material for new energy automobile chassis structure and battery pack tray
CN202310243103.XA Pending CN116505179A (en) 2022-03-22 2023-03-14 Carbon fiber composite material for new energy automobile body floor and battery pack cover plate

Family Applications Before (1)

Application Number Title Priority Date Filing Date
CN202210279264.XA Pending CN114374038A (en) 2022-03-22 2022-03-22 Carbon fiber composite material for new energy automobile chassis structure and battery pack tray

Country Status (1)

Country Link
CN (2) CN114374038A (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114953518A (en) * 2022-06-02 2022-08-30 贵州翰凯斯智能技术有限公司 Automobile chassis and processing method thereof

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105038116B (en) * 2015-08-26 2017-04-05 江南大学 A kind of deep cross-linked structure carbon fiber reinforced phenol formaldehyde resin base frication material and preparation method thereof
DE102017106289B4 (en) * 2017-03-23 2019-09-12 Vibracoustic Gmbh bearing bush
CN109867908B (en) * 2017-12-05 2021-09-03 广州金发碳纤维新材料发展有限公司 Manufacturing method of high-fluidity carbon fiber reinforced sheet die-pressing material
CN109054337A (en) * 2018-06-06 2018-12-21 广东奔迪新材料科技有限公司 A kind of formula of Noryl expanded bead, preparation method and applications
CN113105714B (en) * 2021-03-12 2022-07-05 航天材料及工艺研究所 Continuous high-thermal-conductivity asphalt-based carbon fiber reinforced epoxy resin composite material and preparation method thereof
CN113512228A (en) * 2021-05-31 2021-10-19 江苏中科聚合新材料产业技术研究院有限公司 General polyester high-power expanded bead and preparation method thereof
CN114006116A (en) * 2021-09-28 2022-02-01 上海瓴荣材料科技有限公司 Thermoplastic composite sandwich battery box tray and manufacturing method thereof
CN113980336B (en) * 2021-11-09 2022-12-13 江西盛汇光学科技协同创新有限公司 Foaming type diffusion plate film and manufacturing method thereof

Also Published As

Publication number Publication date
CN114374038A (en) 2022-04-19

Similar Documents

Publication Publication Date Title
KR20150089051A (en) Method for producing a structural component, particularly for a vehicle body
EP2554348B1 (en) Method for laminating fiber-reinforced thermoplastic resin prepreg
JP6085798B2 (en) COMPOSITE MATERIAL FOR 3D SHAPE FORMING AND ITS MANUFACTURING METHOD
CN111730876A (en) Forming process of upper cover of composite battery box
KR102065845B1 (en) Apparatus for Manufacturing Thermoplastic Fiber Reinforced Composite Material Using Continuous Compression Molding
EP3549741B1 (en) Method for manufacturing fiber-reinforced resin molded article
KR20090099215A (en) Process of preparing continuous fiber reinforced thermoplastic composite with high strength
US20110033655A1 (en) Energy saving honeycomb having enhanced strength
CN116505179A (en) Carbon fiber composite material for new energy automobile body floor and battery pack cover plate
KR101945560B1 (en) front end module carrier using continuous fiber reinforced thermoplastics and method of manufacturing
CN108183181A (en) Manufacturing method of electric vehicle battery pack and battery pack
US20210197519A1 (en) Method for producing a planar composite component and composite component produced thereby
CN106273989A (en) The shaped device of a kind of fiber reinforced thermolplastic composite material plate and forming method thereof
KR102307989B1 (en) Fiber reinforced composite material having a hollow section and method for manufacturing the same
CN106739245A (en) Electronic product casing and its manufacture method
CN112976701A (en) Honeycomb panel, manufacturing method thereof, vehicle body panel and vehicle
WO2020122260A1 (en) Production method for fiber-reinforced resin molded article
KR102333834B1 (en) Lightweight composite material applied with thermoplastic foam and its manufacturing method
KR100768824B1 (en) Equipment for the production of multilayer extruded sheet and multilayer extruded sheet
CN1775507A (en) Thermal forming method for PMI foam laminated structure
CN114055807B (en) Method for forming composite material part, formed part and aircraft
KR101421951B1 (en) Side insulator and manufacturing method thereof
KR101396818B1 (en) Thin type thermoplastics complex materials with reinforced insulation surface of substrates
US20230015015A1 (en) Method for manufacturing thermoplastic fiber-reinforced resin molded article
US20210370624A1 (en) Method for producing a thermoplastically deformable, fiber-reinforced flat semi-finished product

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination