Combined insulating plate welding process

Abstract

The invention discloses a combined insulating plate welding process. The combined insulating plate welding process specifically comprises the following steps: S1, material selection and pretreatment: (1) material selection: selecting a thin-layer polypropylene material: selecting a polypropylene film with the thickness of 0.1-1 mm; thick-layer polypropylene material: selecting a polypropylene plate with the thickness of 0.5 mm-2mm; s2, welding parameters are optimized; s3, welding process control; s4, welding post-treatment is carried out; the invention relates to the technical field of new energy. According to the combined insulating plate welding process, by optimizing material matching and the welding process, the insulating performance of the insulating plate is remarkably improved, double-layer polypropylene welding can be achieved, the material characteristics are not affected, batch production can be achieved, and the effect of improving the structural filling and insulating performance of a new energy battery pack is achieved; more reliable safety guarantee is provided for the new energy lithium battery pack, the method is not only suitable for the new energy lithium battery pack, but also can be widely applied to the fields of electric automobiles, energy storage systems, aerospace and the like, and the market potential is huge.

Description

Technical Field

[0001] The invention relates to the field of new energy technology, in particular to a combined insulation plate welding process. Background Art

[0002] New energy, also known as unconventional energy, refers to various forms of energy other than traditional energy. It is generally renewable energy developed and utilized on the basis of new technologies, such as solar energy, geothermal energy, wind energy, ocean energy, biomass energy and nuclear fusion energy. New energy vehicle batteries are new automotive batteries that use new energy technologies to reduce greenhouse gas emissions and pollution. They can be divided into two categories, namely batteries and fuel cells. Batteries are suitable for pure new energy vehicles and can be classified as lead-acid batteries and nickel-based batteries. New energy vehicle battery packs are composed of multiple batteries stacked in series. A typical battery pack has about 96 batteries. For lithium-ion batteries charged to 4.2V Such a battery pack can generate a total voltage of more than 400V, which varies slightly with the type of new energy vehicles. In pure new energy vehicles equipped with only batteries, the battery serves as the only power source for the vehicle's drive system. In hybrid vehicles equipped with traditional engines and batteries, the battery can play the role of both the main power source and the auxiliary power source for the vehicle's drive system. It can be seen that at low speeds and when starting, the battery plays the role of the main power source for the vehicle's drive system; when accelerating at full load, it plays the role of an auxiliary power source; and during normal driving or deceleration or braking, it plays the role of storing energy.

[0003] With the rapid development of new energy technologies, lithium batteries, as the main energy storage device, have increasingly higher performance and safety requirements. Although traditional insulating material molding processes, such as die-cutting processes, can meet basic insulation requirements, it is often difficult to ensure both insulation performance and structural strength when faced with complex structural requirements such as local protrusions in product design. Therefore, it is particularly important to develop an insulating plate welding process that can maintain the original properties of the material and realize complex structural design. Summary of the invention

[0004] In view of the deficiencies of the prior art, the present invention provides a combined insulating plate welding process, which solves the problems mentioned in the above background technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a combined insulation plate welding process, specifically comprising the following steps:

[0006] S1. Material selection and pretreatment:

[0007] (1) Material selection:

[0008] Thin layer polypropylene material: Choose polypropylene film with a thickness of 0.1mm-1mm;

[0009] Thick polypropylene material: Choose polypropylene sheet with a thickness of 0.5mm-2mm;

[0010] (2) Pretreatment:

[0011] Cleaning: Use anhydrous ethanol or acetone and other organic solvents to clean the surface of the material to remove impurities such as oil, dust, etc.

[0012] Drying: Place the cleaned material in a drying oven and dry it to constant weight at 50℃-80℃;

[0013] S2. Welding parameter optimization:

[0014] (1) Ultrasonic welding equipment:

[0015] Frequency: Select 15KHz ultrasonic frequency;

[0016] Power: Set the welding power to 2600W;

[0017] (2) Welding time and pressure:

[0018] Welding time: Adjust the welding time between 1S-2.6S according to the thickness of the material and the layout of the welding points. Thicker materials require longer welding time to ensure complete bonding.

[0019] Pressure: Apply appropriate pressure to promote close contact between materials and mutual penetration of molecular chains;

[0020] (3) Welding point layout:

[0021] Adopting a dot matrix layout, according to the needs of product design, set a reasonable number and position of welding points on the material, and the welding points should be evenly distributed to ensure that the insulation board has uniform mechanical properties and insulation properties after welding;

[0022] S3. Welding process control:

[0023] (1) Temperature monitoring:

[0024] During the welding process, a temperature sensor is used to monitor the temperature of the welding area in real time;

[0025] (2) Welding quality inspection:

[0026] Use tear test, peel test and insulation resistance test methods to test the quality of the insulation board after welding to ensure that the welding points are firm, free of cracks and pores, and meet the insulation performance requirements;

[0027] S4. Post-welding treatment:

[0028] (1) Repair and cleaning:

[0029] Remove defects such as flash and burrs produced during welding, and use tools such as sandpaper or grindstone to trim them. At the same time, clean the welding area again to ensure that there is no residue;

[0030] (2) Performance test:

[0031] Carry out comprehensive performance tests on the welded insulation boards.

[0032] Preferably, in S1(2), the drying is to remove residual solvent and moisture.

[0033] Preferably, in S2(1), an ultrasonic frequency of 15KHz is selected, which is suitable for welding polypropylene materials and can generate sufficient vibration energy to destroy the molecular bonds on the surface of the material and recombine them. The welding power is set to 2600W to ensure sufficient energy input while avoiding overheating that causes material melting or degradation.

[0034] Preferably, in S2(2), the pressure should be adjusted according to the thickness of the material and the performance of the welding equipment.

[0035] Preferably, in S3(1), the welding parameters and cooling method are adjusted to ensure that the welding temperature does not exceed the thermoplastic temperature range of the material to avoid melting or degradation of the material.

[0036] Preferably, in S4(2), the performance tests include tensile strength, elongation at break, insulation resistance, voltage resistance, puncture resistance, etc., to ensure that the product meets the design requirements and usage conditions.

[0037] Beneficial Effects

[0038] The present invention provides a combined insulating plate welding process. Compared with the prior art, it has the following beneficial effects: the combined insulating plate welding process specifically includes the following steps: S1, material selection and pretreatment; S2, welding parameter optimization; S3, welding process control; S4, welding post-processing; by optimizing material matching and welding process, the insulation performance of the insulating plate is significantly improved, double-layer polypropylene welding can be achieved without affecting material properties, batch production can be achieved, the structural filling and insulation performance of new energy battery packs are improved, and a more reliable safety guarantee is provided for new energy lithium battery packs. It is not only suitable for new energy lithium battery packs, but also can be widely used in electric vehicles, energy storage systems, aerospace and other fields, with huge market potential. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a flow chart of the steps of the present invention. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] See also Figure 1 The present invention provides a technical solution: a combined insulating plate welding process, specifically comprising the following steps:

[0042] S1. Material selection and pretreatment:

[0043] (1) Material selection:

[0044] Thin layer polypropylene material: Choose polypropylene film with a thickness of 0.1mm-1mm;

[0045] Thick polypropylene material: Choose polypropylene sheet with a thickness of 0.5mm-2mm;

[0046] (2) Pretreatment:

[0047] Cleaning: Use anhydrous ethanol or acetone and other organic solvents to clean the surface of the material to remove impurities such as oil, dust, etc.

[0048] Drying: Place the cleaned material in a drying oven and dry it to constant weight at 50℃-80℃;

[0049] S2. Welding parameter optimization:

[0050] (1) Ultrasonic welding equipment:

[0051] Frequency: Select 15KHz ultrasonic frequency;

[0052] Power: Set the welding power to 2600W;

[0053] (2) Welding time and pressure:

[0054] Welding time: Adjust the welding time between 1S-2.6S according to the thickness of the material and the layout of the welding points. Thicker materials require longer welding time to ensure complete bonding.

[0055] Pressure: Apply appropriate pressure to promote close contact between materials and mutual penetration of molecular chains;

[0056] (3) Welding point layout:

[0057] Adopting a dot matrix layout, according to the needs of product design, set a reasonable number and position of welding points on the material, and the welding points should be evenly distributed to ensure that the insulation board has uniform mechanical properties and insulation properties after welding;

[0058] S3. Welding process control:

[0059] (1) Temperature monitoring:

[0060] During the welding process, a temperature sensor is used to monitor the temperature of the welding area in real time;

[0061] (2) Welding quality inspection:

[0062] Use tear test, peel test and insulation resistance test methods to test the quality of the insulation board after welding to ensure that the welding points are firm, free of cracks and pores, and meet the insulation performance requirements;

[0063] S4. Post-welding treatment:

[0064] (1) Repair and cleaning:

[0065] Remove defects such as flash and burrs produced during welding, and use tools such as sandpaper or grindstone to trim them. At the same time, clean the welding area again to ensure that there is no residue;

[0066] (2) Performance test:

[0067] Carry out comprehensive performance tests on the welded insulation boards.

[0068] In the present invention, in S1(2), drying is to remove residual solvent and moisture.

[0069] In the present invention, in S2(1), an ultrasonic frequency of 15KHz is selected, which is suitable for welding polypropylene materials and can generate sufficient vibration energy to destroy the molecular bonds on the surface of the material and recombine them. The welding power is set to 2600W to ensure sufficient energy input while avoiding overheating that causes material melting or degradation.

[0070] In the present invention, in S2(2), the pressure should be adjusted according to the thickness of the material and the performance of the welding equipment.

[0071] In the present invention, in S3(1), by adjusting the welding parameters and cooling method, it is ensured that the welding temperature does not exceed the thermoplastic temperature range of the material to avoid melting or degradation of the material.

[0072] In the present invention, in S4(2), the performance tests include tensile strength, elongation at break, insulation resistance, voltage resistance, puncture resistance, etc., to ensure that the product meets the design requirements and usage conditions.

[0073] Specifically, there is a step of mass production and quality control in the later stage, as follows:

[0074] Automated production line:

[0075] An automated production line is used for mass production, including material transportation, cutting, welding, post-processing and other processes. The automated control system enables precise control and efficient operation of the production process.

[0076] Quality Control System:

[0077] We have established a complete quality control system, including raw material inspection, process control, finished product inspection, etc., and adopted advanced testing equipment and methods to ensure the consistency and stability of product quality.

[0078] Specifically, in addition to polypropylene materials, the welding process can also be expanded to other materials, such as polycarbonate (PC), polyethylene (PE), polyvinyl chloride (PVC) and metals. By adjusting the welding parameters and process conditions, effective combination of different materials can be achieved.

[0079] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0080] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0081] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A combined insulating plate welding process, characterized in that: The specific steps include: S1. Material selection and pretreatment: (1) Material selection: Thin layer polypropylene material: Choose polypropylene film with a thickness of 0.1mm-1mm; Thick polypropylene material: Choose polypropylene sheet with a thickness of 0.5mm-2mm; (2) Pretreatment: Cleaning: Use anhydrous ethanol or acetone and other organic solvents to clean the surface of the material to remove impurities such as oil, dust, etc. Drying: Place the cleaned material in a drying oven and dry it at 50℃-80℃ to constant weight; S2. Welding parameter optimization: (1) Ultrasonic welding equipment: Frequency: Select 15KHz ultrasonic frequency; Power: Set the welding power to 2600W; (2) Welding time and pressure: Welding time: Adjust the welding time between 1S-2.6S according to the thickness of the material and the layout of the welding points. Thicker materials require longer welding time to ensure complete bonding. Pressure: Apply appropriate pressure to promote close contact between materials and mutual penetration of molecular chains; (3) Welding point layout: Adopting a dot matrix layout, according to the needs of product design, set a reasonable number and position of welding points on the material, and the welding points should be evenly distributed to ensure that the insulation board has uniform mechanical properties and insulation properties after welding; S3. Welding process control: (1) Temperature monitoring: During the welding process, a temperature sensor is used to monitor the temperature of the welding area in real time; (2) Welding quality inspection: Use tear test, peel test and insulation resistance test methods to test the quality of the insulation board after welding to ensure that the welding points are firm, free of cracks and pores, and meet the insulation performance requirements; S4. Post-welding treatment: (1) Repair and cleaning: Remove defects such as flash and burrs produced during welding, and use tools such as sandpaper or grindstone to trim them. At the same time, clean the welding area again to ensure that there is no residue; (2) Performance test: Carry out comprehensive performance tests on the welded insulation boards.

2. A combined insulating plate welding process according to claim 1, characterized in that: In S1(2), the drying is to remove the residual solvent and moisture.

3. A combined insulating plate welding process according to claim 1, characterized in that: In S2(1), an ultrasonic frequency of 15KHz is selected, which is suitable for welding polypropylene materials and can generate sufficient vibration energy to destroy the molecular bonds on the surface of the material and recombine them. The welding power is set to 2600W to ensure sufficient energy input while avoiding overheating that causes melting or degradation of the material.

4. A combined insulating plate welding process according to claim 1, characterized in that: In S2(2), the pressure should be adjusted according to the thickness of the material and the performance of the welding equipment.

5. A combined insulating plate welding process according to claim 1, characterized in that: In S3(1), the welding parameters and cooling method are adjusted to ensure that the welding temperature does not exceed the thermoplastic temperature range of the material to avoid melting or degradation of the material.

6. A combined insulating plate welding process according to claim 1, characterized in that: In S4(2), the performance tests include tensile strength, elongation at break, insulation resistance, voltage resistance, puncture resistance, etc., to ensure that the product meets the design requirements and usage conditions.

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