Battery cover for vehicle

Abstract

A battery cover for a vehicle features a multi-layer structure and reinforcing ribs designed to protect an automotive battery, thereby preventing fire spread, absorbing external impacts, and providing structural stability. The battery cover according to the present invention can satisfy requirements for fire prevention, shock absorption, and structural stability. The present invention can satisfy battery protection requirements of electric vehicles while simultaneously achieving both weight reduction and enhanced durability.

Description

Car battery cover

[0001] The present invention relates to a battery cover, and more specifically, to an automotive battery cover capable of preventing fire spread, absorbing external shocks, and providing structural stability by designing a multi-layer structure and reinforcing ribs to protect an automotive battery.

[0002] Recently, as the adoption of electric vehicles (EVs) increases in the automotive industry as a solution to environmental regulations, various issues are coming to light, with fires receiving the most attention. It has been confirmed that most of these EV fires originate in the batteries, and an analysis of the causes is currently underway.

[0003] At this time, the fire originating in the battery section spreads to the cover protecting the battery, and further spreads to the entire vehicle.

[0004] To address these issues, interest in flame-retardant battery covers is increasing, and there is a need for technology for battery covers that offer excellent flame-retardant performance and can even secure semi-flame-retardant performance.

[0005] To solve these problems, the present invention aims to provide an automotive battery cover capable of preventing fire spread, absorbing external shocks, and providing structural stability by designing a multi-layered structure and reinforcing ribs to protect the automotive battery.

[0006] A battery cover for an automobile according to the features of the present invention for achieving the above objective is,

[0007] A rectangular cover body having a flat upper surface and a lower surface partitioned by vertical and horizontal partitions to form a receiving space for a battery cell, with different lengths in the horizontal and vertical directions;

[0008] It includes one or more reinforcing ribs protruding outward from one side of the cover body at a vulnerable part indicating a structural weakness of the cover body, and

[0009] The above cover body is,

[0010] A first layer representing a fire-prevention layer that prevents fire spread at high temperatures;

[0011] A second layer representing a shock-absorbing layer that disperses external shocks; and

[0012] It may further include a third layer representing durability or structural safety.

[0013] The reinforcing rib may further include a protruding rib body of a certain shape; and a curved portion having a flat upper front surface of the rib body, extending downward from the upper front surface and gradually narrowing in width to approach one side of the battery cover.

[0014] The first layer is composed of an aluminum silicate-based ceramic composite, a heat-resistant resin, and a brominated epoxy, the second layer is composed of glass fiber reinforced polypropylene, a polyurethane foam, and talc, the third layer is composed of carbon fiber reinforced plastic, glass fiber reinforced plastic, and an epoxy resin, and the reinforcing layer may be composed of an aluminum alloy, a magnesium alloy, and a surface treatment coating agent.

[0015] With the aforementioned configuration, the present invention has the effect of enabling the battery cover to satisfy fire prevention, shock absorption, and structural stability.

[0016] The present invention can satisfy the battery protection requirements of electric vehicles and simultaneously achieve lightweighting and durability.

[0017] FIGS. 1 and FIGS. 2 are drawings showing the external appearance of a battery cover for an automobile according to an embodiment of the present invention.

[0018] FIG. 3 is a drawing showing the configuration of reinforcing ribs formed in the fifth side groove and the sixth side groove according to an embodiment of the present invention.

[0019] FIG. 4 is a drawing showing the configuration of reinforcing ribs formed in the second side groove and the fourth side groove according to an embodiment of the present invention.

[0020] FIG. 5 is a drawing showing the view from the top of a battery cover according to an embodiment of the present invention.

[0021] FIGS. 6 and FIGS. 7 are drawings showing the view from the bottom of a battery cover according to an embodiment of the present invention.

[0022] FIG. 8 is a drawing showing the layer structure constituting the cover body according to an embodiment of the present invention.

[0023] FIG. 9 is a drawing showing a method for manufacturing a battery cover according to an embodiment of the present invention.

[0024] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Identical or similar components regardless of drawing symbols are assigned the same reference number, and redundant descriptions thereof will be omitted. Furthermore, in describing the embodiments disclosed in this specification, if it is determined that a detailed description of related prior art could obscure the essence of the embodiments disclosed in this specification, such detailed description will be omitted.

[0025] Terms including ordinal numbers, such as first, second, etc., may be used to describe various components, but said components are not limited by said terms. These terms are used solely for the purpose of distinguishing one component from another.

[0026] A singular expression includes a plural expression unless the context clearly indicates otherwise.

[0027] In this application, each step described may be performed regardless of the order listed, except where it must be performed in the order listed by a particular causal relationship.

[0028] In this application, terms such as “comprising” or “having” are intended to specify the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0029] Hereinafter, the battery cover for an automobile according to the present invention will be described with reference to the attached drawings.

[0030] FIGS. 1 and 2 are drawings showing the external appearance of a battery cover for an automobile according to an embodiment of the present invention, FIG. 3 is a drawing showing the configuration of reinforcing ribs formed in the fifth side groove and the sixth side groove according to an embodiment of the present invention, FIG. 4 is a drawing showing the configuration of reinforcing ribs formed in the second side groove and the fourth side groove according to an embodiment of the present invention, FIG. 5 is a drawing showing the view from the top of a battery cover according to an embodiment of the present invention, and FIGS. 6 and 7 are drawings showing the view from the bottom of a battery cover according to an embodiment of the present invention.

[0031] A battery cover (100) for an automobile according to an embodiment of the present invention may include a cover body (110), an extension part (111), and a reinforcing rib (120).

[0032] The battery cover (100) for an automobile can be manufactured using any one of the methods of drawing, extrusion, rolling, pressing, and CNC, and can be manufactured by injection molding using a mold.

[0033] The cover body (110) has a flat upper surface and a lower surface that is partitioned by a vertical partition (115) and a horizontal partition (116) to form a receiving space in which a battery cell (not shown) can be received. It may be a rectangular shape with different lengths in the horizontal and vertical directions, and the length in the horizontal direction may be longer than the length in the vertical direction.

[0034] The lower part of the cover body (110) may include a support structure to stably position the battery cell.

[0035] The cover body (110) may include a first extension (111a) and a second extension (111b) extending from the upper surface to both sides in the vertical direction, a third extension (111c) extending from one side in the upper surface in the horizontal direction, and a fourth extension (111d) spaced apart from the above at a certain distance.

[0036] The cover body (110) forms a first side groove (113a) that is dug to a certain depth on the side forming the first extension (111a), and a second side groove (113b) that is spaced a certain distance from the first side groove (113a).

[0037] The first side groove (113a) and the second side groove (113b) each form a reinforcing rib (120).

[0038] The cover body (110) forms a third side groove (114a) that is dug to a certain depth on the side forming the second extension (111b), and a fourth side groove (114b) that is spaced a certain distance from the third side groove (114a).

[0039] The third side groove (114a) and the fourth side groove (114b) each form a reinforcing rib (120).

[0040] The cover body (110) forms a fifth side groove (112a) that is dug to a certain depth on one side forming a third extension (111c), and a sixth side groove (112b) that is spaced a certain distance from the fifth side groove (112a).

[0041] The fifth side groove (112a) forms a pair of reinforcing ribs (120) spaced apart from each other by a certain distance.

[0042] The sixth side groove (112b) forms a pair of reinforcing ribs (120) spaced apart from each other by a certain distance.

[0043] Each reinforcing rib (120) may be installed to reinforce a weak point, which is a structural weakness of the battery cover (100). A weak point may refer to a structurally weak part of the battery cover (100) that is highly likely to be easily deformed, damaged, or cracked by external forces.

[0044] For example, weak points include areas with insufficient thickness, stress concentration, or areas subjected to continuous mechanical loads.

[0045] The reinforcing rib (120) protrudes outward from the first side groove (113a) and the second side groove (113b), the third side groove (114a) and the fourth side groove (114b), the fifth side groove (112a) and the sixth side groove (112b) to distribute the load, increase rigidity, and prevent deformation and breakage.

[0046] The reinforcing rib (120) is designed to reinforce the weak parts of the cover body (110) and is protruding outward, thereby distributing the load, increasing the rigidity of the cover body (110) to absorb external shocks, and preventing deformation.

[0047] As shown in FIGS. 3 and 4, the reinforcing rib (120) may include a protruding rib body (121) of a certain shape and a curved portion that is flat at the front top (122) of the rib body (121), extends downward from the front top (122), and gradually narrows in width so as to get closer to one side of the battery cover (100) as it goes from the front top (122) downward.

[0048] The front of the rib body (121) may form a hole (123) in the center at the lower part of the front top, and may include a first curved surface (122a) and a second curved surface (122b) in a curved shape on the left and right sides relative to the hole (123).

[0049] The first curved section (122a) and the second curved section (122b) are narrowed in width from the front upper section (122) of the rib body (121) toward the lower section so as to become closer to one side of the battery cover (100).

[0050]

[0051] FIG. 8 is a drawing showing the layer structure constituting the cover body according to an embodiment of the present invention.

[0052] A cover body (110) according to an embodiment of the present invention is a component requiring high performance and stability, and may use a composite material to prevent degradation of physical properties and to achieve flame retardancy, and may include a first layer (110a), a second layer (110b), a third layer (110c), and a reinforcing layer (130).

[0053] The first layer (110a) serves as a heat-resistant layer or fire-prevention layer that provides thermal stability at high temperatures and prevents fire spread, has a thickness of 0.5 mm to 1.5 mm, and comprises 70 to 80 weight% of an aluminum silicate-based ceramic composite, 10 to 15 weight% of a heat-resistant resin, and 10 to 15 weight% of a first additive. The fire-prevention layer protects the battery in a high-temperature environment and prevents fire from spreading into the battery.

[0054] The thickness of the first layer (110a) is configured to be 0.5 mm to 1.5 mm to strike a balance between preventing fire spread and minimizing weight. If it is too thick, the total weight of the battery cover (100) increases, and if it is too thin, the heat resistance performance may be reduced.

[0055] The heat-resistant resin may be polyimide resin, etc., and the first additive may be a flame-retardant material, such as brominated epoxy, inorganic flame retardant, etc.

[0056] The first layer (110a) is made of a material with low thermal conductivity so that it does not deform even at high temperatures.

[0057] The second layer (110b) has high flexibility and resilience and serves as a shock-absorbing layer that effectively disperses external shocks, has a thickness of 2 mm to 5 mm, and comprises 50 to 70 weight% of glass fiber reinforced polypropylene, 20 to 30 weight% of a polyurethane foam layer, and 10 to 20 weight% of a second additive.

[0058] The second layer (110b) can serve to disperse external impacts and reduce the load transmitted to the battery cell. The second layer (110b) is composed of a polyurethane foam with high flexibility and resilience and glass fiber reinforced polypropylene.

[0059] The thickness of the second layer (110b) is configured to be 2 mm to 5 mm, making it the thickest layer among all layers of the battery cover (100). This is because a certain thickness is required to effectively perform the shock absorption function.

[0060] The second layer (110b) can have an optimal thickness set by considering the distance at which the impact is dispersed and the deformation characteristics of the impact-absorbing material.

[0061] The second additive may include an inorganic filler that improves resistance to thermal deformation and stability. The inorganic filler includes talc or microsilica.

[0062] The third layer (110c) provides structural strength and serves as a durable or structural safety layer that withstands external pressure or stress, has a thickness of 1 mm to 3 mm, and comprises 70 to 80 weight% carbon fiber reinforced plastic, 15 to 20 weight% glass fiber reinforced plastic, and 5 to 10 weight% third additive.

[0063] The thickness of the third layer (110c) is 1 mm to 3 mm, which secures the rigidity of the battery cover (100) and serves to maintain structural stability even under external pressure or long-term stress.

[0064] The third layer (110c) can provide sufficient structural stability even with a relatively thin thickness thanks to the high rigidity of the carbon fiber reinforced plastic.

[0065] The third additive may be a resin-based binder, for example, epoxy resin, polyurethane, etc.

[0066] The reinforcing layer (130) serves as an outer layer for external protection of the battery cover (100), has a thickness of 0.8 mm to 2 mm, and comprises 50 to 70 weight% of aluminum alloy, 20 to 30 weight% of magnesium alloy or high-strength stainless steel, and 10 to 20 weight% of surface treatment coating agent.

[0067] The thickness of the reinforcing layer (130) is configured to be 0.8 mm to 2 mm to protect the battery cover (100) from the external environment and to provide corrosion resistance and durability.

[0068] Preferably, the battery cover (100) of the present invention may comprise a first layer (110a) of a fire-prevention layer composed of an aluminum silicate-based ceramic composite (75 wt%), a heat-resistant resin (12 wt%), and a brominated epoxy (13 wt%), a second layer (110b) of a shock-absorbing layer composed of glass fiber reinforced polypropylene (60 wt%), a polyurethane foam (25 wt%), and talc (15 wt%), a third layer (110c) of a structural safety layer composed of carbon fiber reinforced plastic (75 wt%), glass fiber reinforced plastic (18 wt%), and an epoxy resin (7 wt%), and a reinforcing layer (130) of an outer layer composed of an aluminum alloy (60 wt%), a magnesium alloy (25 wt%), and a surface treatment coating agent (15 wt%).

[0069] The first layer (110a), second layer (110b), third layer (110c) and reinforcing layer (130) may have different required thicknesses depending on the physical role of each layer. For example, the shock-absorbing layer is designed to be thick considering deformation and resilience, and the fire-resistant layer is designed to be thin considering heat resistance and weight balance.

[0070] The first layer (110a), second layer (110b), third layer (110c) and reinforcing layer (130) provide strong bonding strength using an interlayer bonding material and can maintain robust adhesive performance even under temperature changes and vibrations. The bonding material may be one of epoxy adhesive, polyurethane adhesive, silicone adhesive, or flame-retardant adhesive.

[0071] This automotive battery cover (100) can satisfy the requirements for battery protection of an electric vehicle while also satisfying lightweight, heat resistance, and durability.

[0072]

[0073] FIG. 9 is a drawing showing a method for manufacturing a battery cover according to an embodiment of the present invention.

[0074] The method for manufacturing a battery cover (100) follows the following procedure to homogeneously mix and mold the composite material of each layer.

[0075] Aluminum silicate, heat-resistant resin, and brominated epoxy are heated to 120°C in a high-temperature stirrer to produce a uniform mixture.

[0076] Glass fiber reinforced polypropylene and polyurethane foam are mixed in a separate mixer at 80°C for 10 minutes to prepare the shock-absorbing layer material.

[0077] Carbon fiber and glass fiber reinforced plastics are mixed with epoxy resin and preheated at 90°C for 15 minutes. The mixed material is transferred to an extrusion molding device, and each layer is molded into a separate mold. During molding, the temperature is maintained at 150°C and the pressure is set to 50 MPa.

[0078] Each molded layer is moved to a cooling device and cooled to 25°C for 5 to 10 minutes.

[0079] A first layer (110a), a second layer (110b), a third layer (110c), and a reinforcing layer (130) can be laminated in order (S100, S110, S120, S130). Each molded layer can be combined into a single multilayer structure through a heat bonding process using a binder (e.g., epoxy adhesive) between the layers.

[0080] Raw materials with a multi-layered structure can be prepared into suitable sizes using a press machine.

[0081] A mold manufactured according to the design of the battery cover to be molded can be installed in a press machine. The prepared multi-layered raw material is fed into the mold. The press machine is operated to close the mold, and high pressure is applied to the material to form it into a desired shape (S130). At this time, the material may be deformed according to the shape of the mold. Subsequently, when molding is completed, the mold is opened and the part is removed.

[0082] The technical features disclosed in each embodiment of the present invention are not limited to that embodiment only, and as long as they are not mutually incompatible, the technical features disclosed in each embodiment may be combined and applied to different embodiments.

[0083] Therefore, in each embodiment, the technical features are described primarily, but as long as the technical features are not mutually incompatible, they may be combined and applied together.

[0084] The present invention is not limited to the embodiments described above and the attached drawings, and various modifications and variations may be possible from the perspective of those skilled in the art to which the present invention belongs. Accordingly, the scope of the present invention should be defined not only by the claims of this specification but also by equivalents thereof.

Claims

1. Regarding automotive battery covers, A rectangular cover body having a flat upper surface and a lower surface partitioned by vertical and horizontal partitions to form a receiving space for a battery cell, with different lengths in the horizontal and vertical directions; It includes one or more reinforcing ribs protruding outward from one side of the cover body at a vulnerable part indicating a structural weakness of the cover body, and The above cover body is, A first layer representing a fire-prevention layer that prevents fire spread at high temperatures; A second layer representing a shock-absorbing layer that disperses external shocks; and Third layer representing durability or structural safety layer Automotive battery cover including additional 2. In Paragraph 1, The above rib body is, A protruding rib body of a certain shape; and The front upper surface of the above-mentioned rib body has a flat structure, and a curved portion extending downward from the front upper surface and gradually narrowing in width to approach one side of the battery cover. Automotive battery cover including additional 3. In Paragraph 1, The first layer is composed of an aluminum silicate-based ceramic composite, a heat-resistant resin, and brominated epoxy; the second layer is composed of glass fiber reinforced polypropylene, a polyurethane foam, and talc; the third layer is composed of carbon fiber reinforced plastic, glass fiber reinforced plastic, and epoxy resin; and the reinforcing layer is composed of an aluminum alloy, a magnesium alloy, and a surface treatment coating agent. Automotive battery cover.

4. In Paragraph 3, The thickness of the first layer is configured to be 0.5 mm to 1.5 mm, the thickness of the second layer is configured to be 2 mm to 5 mm, the thickness of the third layer is configured to be 1 mm to 3 mm, and the thickness of the fourth layer is configured to be 0.8 mm to 2 mm. Automotive battery cover.

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