Electromagnetic shielded battery tray with metal-coated fiber-stitched wall and corresponding manufacturing process

Abstract

A battery tray is provided, comprising a first component and a second component. The first component has a first set of walls, wherein the first set of walls has a first stitched fabric, and wherein the first stitched fabric has a first metal-coated fiber. The second component has a second set of walls, wherein the second set of walls has a second stitched fabric; the second stitched fabric has a second metal-coated fiber; and the second component is attached to the first component to form the battery tray, the battery tray being configured to hold a battery pack of a vehicle. The first metal-coated fiber and the second metal-coated fiber provide electromagnetic shielding around the battery pack.

Description

Technical Field

[0001] The information provided in this section is for the purpose of generally presenting the context of this disclosure. The work of the currently attributed inventors within the scope described in this section, and aspects of the description that may not conform to the prior art at the time of filing, are neither expressly nor impliedly acknowledged as prior art with respect to this disclosure.

[0002] This disclosure relates to a battery tray assembly for a battery pack used in an electric vehicle. Background Technology

[0003] Electric vehicles have a battery tray in which a battery pack is housed. The battery pack provides power to various vehicle systems, including propulsion, lighting, infotainment, air conditioning, braking, steering, autonomous control, and navigation systems. The propulsion system may have one or more motors for driving the vehicle's wheels.

[0004] The battery tray is typically implemented as a housing with metal walls. The high-voltage power supply circuitry for the battery pack is located within the housing and supplies power to the vehicle systems. Low-voltage control circuitry can be located on or outside the housing to monitor the battery pack's status and control the power supply to the vehicle systems. Summary of the Invention

[0005] A battery tray is provided, comprising a first component and a second component. The first component has a first set of walls, wherein the first set of walls has a first stitched fabric, and wherein the first stitched fabric has a first metal-coated fiber. The second component has a second set of walls, wherein the second set of walls has a second stitched fabric; the second stitched fabric has a second metal-coated fiber; and the second component is attached to the first component to form the battery tray, the battery tray being configured to hold a battery pack of a vehicle. The first and second metal-coated fibers provide electromagnetic shielding around the battery pack.

[0006] Among other features, the first sewn fabric has a first sewn fabric layer. The second sewn fabric has a second sewn fabric layer.

[0007] Among other features, each of the first stitched fabric layers has some of the first metal-coated fibers in the first metal-coated fibers. Each of the second stitched fabric layers has some of the second metal-coated fibers in the second metal-coated fibers.

[0008] Among other features, the first stitching fabric is realized as a first preform. The second stitching fabric is realized as a second preform.

[0009] Among other features, the first stitched fabric has a first hole, wherein some of the first metal-coated fibers extend through the first hole. The second stitched fabric has a second hole, wherein some of the second metal-coated fibers extend through the second hole.

[0010] Among other features, each of the first and second holes has a cross-sectional dimension greater than λ / 50 and less than λ / 20. The cross-sectional dimension is measured perpendicular to at least one of (i) the respective longitudinal length of the first and second holes or (ii) the respective paths of the first and second holes.

[0011] Among other features, each of the first and second metal-coated fibers includes a non-metallic fiber core and a metallic coating disposed on the non-metallic fiber core.

[0012] Among other features, the first metal-coated fiber and the second metal-coated fiber are connected to the reference ground.

[0013] Among other features, the first and second sewn fabrics together have: 25%-59% by volume reinforcing fibers; 40%-70% by volume polymeric resin matrix; and 1-5% by volume metal-coated fibers, the metal-coated fibers having first and second metal-coated fibers.

[0014] Among other features, the reinforcing fibers of the first and second stitched fabrics include at least one of glass fiber, carbon fiber, polyester fiber, or natural fiber.

[0015] Among other features, the first metal-coated fibers form at least one of a mesh array or a hole array, and / or the second metal-coated fibers form at least one of a mesh array or a hole array.

[0016] Among other features, the metal coating of the first metal-coated fiber and the second metal-coated fiber includes at least one of nickel or copper.

[0017] Among other features, the areal density of the first metal-coated fiber varies on the first sewn fabric, and / or the areal density of the second metal-coated fiber varies on the second sewn fabric.

[0018] Among other features, a power system is provided, the power system having a battery tray, a battery pack contained within the battery tray, and control circuitry. The control circuitry is connected to at least one of the battery tray or the battery pack, and monitors and controls the state of the battery pack.

[0019] Among other features, a pressurized resin transfer molding method for forming a battery tray for a vehicle is provided. The method includes: forming a stitched fabric having metal-coated fibers and an adhesive; cutting the stitched fabric to provide a sheet; stacking the sheet; covering a section of a first mold with the sheet; heating and pressing the stacked sheet to form a preform; applying resin to the preform and curing the resin; and demolding the preform to provide a section of the battery tray.

[0020] Among other features, at least one of the metal-coated fibers is sewn together using a customized fiber placement process.

[0021] Among other features, forming the stitched fabric includes stitching at least some of the metal-coated fibers in the metal-coated fibers through holes in the stitched fabric, wherein the holes extend through the stitched fabric.

[0022] Among other features, the application of resin includes: setting the preform in a second mold; positioning a section of the second mold in a partially open state; injecting resin into the second mold and the preform; and pressing the resin-injected preform.

[0023] Among other features, a compression molding method for forming a battery tray for a vehicle is provided. The method includes: forming a prepreg material having metal-coated fibers; preheating the prepreg material; pressing the heated prepreg material; cutting and stacking the pressed and heated prepreg material to form a stacked material layer; placing the stacked material layer in a heated press; and pressing the stacked material layer to form a segment of the battery tray.

[0024] Among other features, at least one metal-coated fiber is sewn together using a customized fiber placement process. Forming the prepreg involves sewing together at least some of the metal-coated fibers through holes in the prepreg. The holes extend through the prepreg. Pressing the heated prepreg involves double-band pressing the heated prepreg to reinforce the fibers of the heated prepreg.

[0025] Other areas of application of this disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0026] Option 1. A battery tray, the battery tray comprising:

[0027] A first component, the first component comprising a first set of walls, wherein the first set of walls comprises a first stitched fabric, and wherein the first stitched fabric has a first metal-coated fiber; and

[0028] The second component includes a second set of walls, wherein the second set of walls includes a second stitched fabric, wherein the second stitched fabric has second metal-coated fibers, and wherein the second component is attached to the first component to form the battery tray, the battery tray being configured to hold the vehicle's battery pack.

[0029] The first metal-coated fiber and the second metal-coated fiber provide electromagnetic shielding around the battery pack.

[0030] Option 2. The battery tray according to Option 1, wherein:

[0031] The first stitched fabric includes a first plurality of stitched fabric layers; and

[0032] The second stitched fabric includes a second plurality of stitched fabric layers.

[0033] Option 3. The battery tray according to Option 2, wherein:

[0034] Each of the first plurality of stitched fabric layers includes some of the first metal-coated fibers in the first metal-coated fibers; and

[0035] Each of the second plurality of stitched fabric layers includes some of the second metal-coated fibers in the second metal-coated fibers.

[0036] Option 4. The battery tray according to Option 1, wherein:

[0037] The first stitched fabric is realized as a first preform; and

[0038] The second stitched fabric is realized as a second preform.

[0039] Option 5. The battery tray according to Option 1, wherein:

[0040] The first stitched fabric includes a first hole, wherein a portion of the first metal-coated fibers extend through the first hole; and

[0041] The second stitched fabric includes a second hole, wherein some of the second metal-coated fibers extend through the second hole.

[0042] Option 6. The battery tray according to Option 5, wherein:

[0043] Each of the first and second holes has a cross-sectional dimension greater than λ / 50 and less than λ / 20; and

[0044] The cross-sectional dimension is measured perpendicular to at least one of (i) the respective longitudinal lengths of the first hole and the second hole or (ii) the respective paths of the first hole and the second hole.

[0045] Option 7. The battery tray according to Option 1, wherein each of the first metal-coated fiber and the second metal-coated fiber includes a non-metallic fiber core and a metal coating, the metal coating being disposed on the non-metallic fiber core.

[0046] Option 8. The battery tray according to Option 1, wherein the first metal-coated fiber and the second metal-coated fiber are connected to a reference ground.

[0047] Option 9. The battery tray according to Option 1, wherein the first stitching fabric and the second stitching fabric together comprise:

[0048] 25%-59% reinforcing fiber by volume;

[0049] 40%-70% by volume of polymeric resin matrix; and

[0050] The metal-coated fibers comprise 1-5% by volume, wherein the metal-coated fibers have a first metal-coated fiber and a second metal-coated fiber.

[0051] Option 10. The battery tray according to Option 1, wherein the reinforcing fibers of the first stitching fabric and the second stitching fabric include at least one of glass fiber, carbon fiber, polyester fiber or natural fiber.

[0052] Option 11. The battery tray according to Option 1, wherein,

[0053] At least one of the first metal-coated fibers forms at least one of a mesh array or a pore array; or

[0054] At least one of the second metal-coated fibers forms at least one of a mesh array or a pore array.

[0055] Option 12. The battery tray according to Option 1, wherein the metal coating of the first metal-coated fiber and the second metal-coated fiber comprises at least one of nickel or copper.

[0056] Option 13. The battery tray according to Option 1, wherein at least one of the areal densities of the first metal-coated fibers varies on the first stitched fabric, or at least one of the areal densities of the second metal-coated fibers varies on the second stitched fabric.

[0057] Option 14. A power supply system, the power supply system comprising:

[0058] The battery tray according to Scheme 1;

[0059] The battery pack contained within the battery tray; and

[0060] A control circuit is connected to at least one of the battery tray or the battery pack, and monitors and controls the state of the battery pack.

[0061] Option 15. A pressurized resin transfer molding method for forming a battery tray for a vehicle, the method comprising:

[0062] A stitched fabric is formed, the stitched fabric having metal-coated fibers and an adhesive;

[0063] Cut the stitched fabric to provide a sheet;

[0064] Stack the sheets;

[0065] The sheet is applied to a section of the first mold;

[0066] Stacked sheets are heated and pressed to form preforms;

[0067] Resin is applied to the preform and the resin is cured; and

[0068] The preform is demolded to provide a section of the battery tray.

[0069] Option 16. The method according to Option 15, wherein at least one of the metal-coated fibers is sewn together using a customized fiber placement process.

[0070] Option 17. The method according to Option 15, wherein forming the stitched fabric includes stitching at least some of the metal-coated fibers through holes in the stitched fabric, wherein the holes extend through the stitched fabric.

[0071] Option 18. The method according to Option 15, wherein the application of the resin comprises:

[0072] The preform is placed in the second mold;

[0073] Position the section of the second mold in a partially open state;

[0074] The resin is injected into the second mold and the preform; and

[0075] The resin-injected preform is pressed.

[0076] Option 19. A compression molding method for forming a battery tray for a vehicle, the method comprising:

[0077] A prepreg material is formed, wherein the prepreg material has metal-coated fibers;

[0078] Preheat the prepreg material;

[0079] The heated prepreg material is pressed;

[0080] Cut and stack the pressed and heated prepreg material to form stacked material layers;

[0081] The stacked material layers are placed in a heated press; and

[0082] The stacked material layers are pressed to form sections of the battery tray.

[0083] Option 20. The method according to Option 19, wherein:

[0084] At least some of the metal-coated fibers in the metal-coated fibers are sewn together using a customized fiber placement process;

[0085] Forming the prepreg material includes stitching at least some of the metal-coated fibers through holes in the prepreg material;

[0086] The hole extends through the prepreg material; and

[0087] The pressing of the heated prepreg material includes double-band pressing of the heated prepreg material to strengthen the fibers of the heated prepreg material. Attached Figure Description

[0088] This disclosure will be more fully understood through a detailed description and accompanying drawings, in which:

[0089] Figure 1 According to the functional block diagram of the vehicle power system disclosed herein, the vehicle power system has a battery tray.

[0090] Figure 2 According to the functional block diagram of the vehicle disclosed herein, the vehicle has a power system having a power supply with a battery tray.

[0091] Figure 3 This is a perspective view of a battery tray according to the present disclosure, which has metal-coated fibers;

[0092] Figure 4 This is a perspective view of a stitched fabric according to the present disclosure, the stitched fabric having metal-coated fibers;

[0093] Figure 5 This is a perspective view of metal-coated fibers according to the present disclosure, which are used in a customized fiber placement process to form a stitched fabric;

[0094] Figure 6 It is a cross-sectional side view of a section of the stitched fabric according to the present disclosure, the section having metal-coated fibers that have been through-stitched.

[0095] Figure 7 This is a schematic diagram illustrating the reflection of electromagnetic waves on a fabric sewn with metal-coated fibers according to the present disclosure;

[0096] Figure 8 The image is a perspective view of a preform according to this disclosure, the preform having metal-clad fibers;

[0097] Figure 9 It is formed into having Figure 8 A perspective view of a section of the prefabricated battery tray;

[0098] Figure 10 The high-pressure resin transfer molding (HP-RTM) process according to this disclosure is shown;

[0099] Figure 11 Shown in Figure 10 A flowchart illustrating the operations performed during the HP-RTM process;

[0100] Figure 12 This illustrates a compression molding process according to the present disclosure; and

[0101] Figure 13 Shown in Figure 12 A process diagram showing the operations performed during the compression molding process.

[0102] In the accompanying drawings, reference numerals may be used repeatedly to identify similar and / or identical elements. Detailed Implementation

[0103] Metal battery trays can be used as electromagnetic shielding to prevent electromagnetic interference between, for example, electromagnetic fields generated by high-voltage circuitry located within the battery tray and other electronic circuitry located outside and / or nearby the battery tray. Electromagnetic interference (EMI) refers to electromagnetic emissions from equipment and / or systems that interfere with the normal operation of other equipment and / or systems. EMI can be broadly classified into radiated emissions and conducted emissions. Metal battery trays provide electromagnetic compatibility between the battery tray and other electronic circuitry outside the battery tray. Electromagnetic compatibility (EMC) refers to the ability of a system to operate satisfactorily in its intended electromagnetic environment (EME) without causing intolerable electromagnetic disturbances to other electronic equipment in that environment.

[0104] While metal battery trays can prevent EMI and provide EMC protection for high-voltage power circuits and other electronic components and systems, they can be heavy. To reduce weight, the wall thickness of the battery tray can be reduced and / or lightweight metals can be used. However, it is difficult to form highly complex three-dimensional (3D) battery trays with durable, thin walls, and such trays can be expensive due to the materials and manufacturing costs involved.

[0105] Creating safe and reliable battery packs requires a battery tray comprising a lower half (or bottom section) and an upper half (or cover) to operate satisfactorily in electromagnetic environments. The battery tray can be formed from a polymer matrix including glass and / or carbon fiber. While this type of battery tray can be lightweight, glass fiber and certain types of carbon fiber are EMI-permeable. To make this type of battery tray non-EMI-permeable, it is possible to wrap the battery tray in a thin metal foil (e.g., aluminum foil). Covering a complex 3D geometry, such as a battery tray, with a thin metal foil and / or film layer (called a mask) can be challenging. Therefore, metal foil-wrapped battery trays can be expensive, and such wrapping tends to be less durable.

[0106] As another example, and in order to manufacture glass / carbon fiber type battery trays that are not EMI-permeable, metal fillers can be injected into the resin to fill the spaces between the glass seams and / or carbon fiber seams. The metal fillers improve conductivity and prevent EMI interference. However, to provide a sufficient level of conductivity and thus prevent EMI interference, a certain level of metal fiber load is required. The load of the metal fillers can offset the lightweight advantages associated with individual glass and / or carbon fibers. Furthermore, the injection of the metal fillers requires secondary processing to ensure that the metal fillers are uniformly dispersed in the resin, which is challenging.

[0107] Furthermore, carbon fiber only filters out high electromagnetic frequencies (e.g., in the gigahertz (GHz) range) but not low electromagnetic frequencies (e.g., in the kilohertz (kHz) range). This depends on the continuity of the carbon fiber and how the fiber bundles are woven into the composite fabric material. Requirements for battery trays may necessitate EMI shielding for frequencies greater than 1 kHz. As an example, a battery tray might be required to filter out electromagnetic frequencies greater than 200 MHz and / or between 200 MHz and 10 GHz. When a thin conductive layer (or mask) is designed to filter out high-frequency electromagnetic frequencies, the thickness of the composite component affects the electromagnetic shielding effectiveness (EMSE). This can affect (i.e., increase) the amount of space required for the resulting battery tray to meet performance requirements. High-frequency EMI noise can cause crosstalk between the high-voltage power circuitry in the battery array (or battery pack) and the low-voltage control circuitry in the battery management system.

[0108] Examples described herein include high-strength composite battery trays that provide EMI and EMC shielding performance. The disclosed battery tray has walls comprising a fabric stitched together using metal-coated fibers. A continuous fiber preform is formed using a custom fiber placement process that includes stitching together the metal-coated fibers to provide shielding. The shielding is capable of reflecting electromagnetic waves and preventing EMI between electronic components within the battery tray and other electronic components outside the battery tray. Compared to other battery trays with walls formed from stitched fabric made of polymeric materials, this battery tray is lightweight and provides enhanced EMI shielding performance.

[0109] Continuous metal-coated fibers possess high strength and high conductivity, and can be woven into fiber preforms to provide adequate EMSE. The disclosed preforms include pins made of metal and / or polymer materials, some of which have a metal coating in various geometries, the metal coating forming conductive paths. The preforms can include conductive fiber pins arranged in an orthogonal grid extending through holes sized to meet EMSE requirements.

[0110] Figure 1 A vehicle power system 100 is shown, which has a battery tray 102 supplying power to a load 104. The vehicle power system 100 may have a high-voltage power circuit 106, which is monitored and controlled by a low-voltage control circuit 108. The high-voltage power circuit 106 is contained within the battery tray 102 and has a battery pack 110. The low-voltage control circuit 108 has a battery control module 112 that monitors the operation and status of, for example, the batteries and / or groups of batteries in the battery pack 110, and controls the operation of the battery pack 110. The battery control module 112 is capable of determining and controlling which batteries in the battery pack 110 are supplying power to which loads in the load 104. An example of load 104 is shown in... Figure 2 As shown, it can have electronic components, devices, and systems, including a propulsion motor, an actuator motor, lighting, navigation equipment, infotainment equipment, etc. The load 104 can have both high-voltage and low-voltage loads. The vehicle control module 120 can communicate with the low-voltage control circuit 108 and control the operation of the load 104. The low-voltage control circuit 108 can be controlled by and / or implemented as part of the vehicle control module 120.

[0111] Figure 2 A vehicle 200 is shown with a power system 203, which has a power source 204 and a battery tray (in Figure 2 (Not shown in the image). An example of a battery tray is shown in... Figure 1 and Figure 3 As shown in the diagram. Power supply 204 includes a battery pack 205 and a low-voltage control circuit 207 (e.g., Figure 1 The low-voltage control circuit 108). The battery tray provides electromagnetic shielding between the battery pack 205 and other electronic devices, circuits, and systems of the vehicle, some of which are in... Figure 2 As shown in the diagram. This prevents electromagnetic waves generated within the battery tray from affecting devices outside the battery tray and / or prevents electromagnetic waves generated outside the battery tray from affecting high-voltage circuitry within the battery tray. The low-voltage control circuitry 207 can be located outside the battery tray so that the electromagnetic shielding provided by the battery tray does not affect wireless communication between the low-voltage control circuitry 207 and other devices, such as the vehicle control module 209.

[0112] The vehicle 200 may also have a vehicle control module 209, an infotainment module 206, and other control modules 208. The vehicle control module 209 can replace... Figure 1 The vehicle control module 120. The low-voltage control circuit 207 and modules 209, 206, and 208 are capable of communicating with each other via one or more buses 210, such as a Controller Area Network (CAN) bus and / or other suitable interfaces. The vehicle control module 209 is capable of controlling the operation of the vehicle system. The vehicle control module 209 may include a mode selection module 212, a parameter adjustment module 214, and other modules. The mode selection module 212 is capable of selecting the vehicle operating mode. The parameter adjustment module 214 is capable of adjusting the parameters of the vehicle 200.

[0113] Vehicle 200 may also include: memory 218; display 220; audio system 222; one or more transceivers 223 with sensors 226; and navigation system 227 with a global positioning system (GPS) receiver 228. Sensors 226 may include sensors, cameras, object detection sensors, temperature sensors, accelerometers, vehicle speed sensors, and / or other sensors. GPS receiver 228 may provide vehicle speed and / or vehicle direction (or heading) and / or global clock timing information.

[0114] The memory 218 can store sensor data 230 and / or vehicle parameters 232, battery pack parameters 234, and applications 236. Applications 236 can include applications executed by modules 209, 206, and 208. Although the memory 218 and vehicle control module 209 are shown as separate devices, they can be implemented as a single device.

[0115] The vehicle control module 209 is capable of controlling the operation of the engine 240, converter / generator 242, transmission 244, window / door system 250, lighting system 252, seat system 254, mirror system 256, braking system 258, electric motor 260, and / or steering system 262 based on parameters set by modules 209, 206, and 208. The vehicle control module 209 can set some of these parameters based on signals received from sensor 226. The vehicle control module 209 can receive power from power source 204, which can be used to supply power to the engine 240, converter / generator 242, transmission 244, window / door system 250, lighting system 252, seat system 254, mirror system 256, braking system 258, electric motor 260, and / or steering system 262, etc. Some of the vehicle control operations described herein may include: unlocking the doors of window / door system 250, activating fuel and spark in engine 240, starting electric motor 260, supplying power to any of systems 250, 252, 254, 256, 258, 262, and / or performing other operations further described herein.

[0116] The engine 240, converter / generator 242, transmission 244, window / door system 250, lighting system 252, seat system 254, mirror system 256, braking system 258, electric motor 260, and / or steering system 262 may have actuators controlled by the vehicle control module 209 to, for example, adjust fuel, spark, airflow, steering wheel angle, throttle position, pedal position, door locks, window positions, seat angle, etc. This control can be based on the outputs of sensors 226, navigation system 227, GPS receiver 228, and the aforementioned data and information stored in memory 218.

[0117] The vehicle control module 209 can determine various parameters, including vehicle speed, engine speed, engine torque, gear status, accelerometer position, brake pedal position, regenerative (charging) power, boost (discharging) power, automatic start / stop discharge power, and / or other information, such as the priority of the source terminals of power supply 204, power requirements, current requirements, and voltage requirements for each source terminal, etc. The vehicle control module 209 can share this information and vehicle operating mode with the low-voltage control circuit 207. The low-voltage control circuit 207 can determine other parameters, such as: charging power at each source terminal; discharging power at each source terminal; maximum and minimum voltage at the source terminals; maximum and minimum voltage at the power rails, batteries, blocks, packs, and / or groups; SOX values ​​of batteries, blocks, packs, and / or groups; temperatures of batteries, blocks, packs, and / or groups; current values ​​of batteries, blocks, packs, and / or groups; power values ​​of batteries, blocks, packs, and / or groups, etc. The low-voltage control circuit 207 can determine the battery connection configuration and corresponding switching state based on parameters determined by the vehicle control module 209 and / or the low-voltage control circuit 207. In one embodiment, the vehicle control module 209 and the low-voltage control circuit 207 are implemented as a single control module.

[0118] Figure 3 A battery tray 300 with metal-coated fibers is shown. Figure 1 The battery tray 102 can be implemented as the battery tray 300 and / or other battery trays mentioned herein. Figures 4-7 An example of metal-coated fiber is shown. The battery tray 300 has walls 302 (e.g., top, bottom, and side walls), which can be formed from a stitched fabric with metal-coated fibers. The battery tray 300 can have a single upper section (or component) 304 and a single lower section (or component) 306, which are attached together to provide the battery tray 300. The upper section can be adhesively and / or attached to the lower section by fasteners. The fasteners can extend through, for example, laterally outward-extending flanges of sections 304 and 306 that face each other.

[0119] As an example, wall 302 can be formed from a composite fabric material comprising 25%-59% by volume fiber reinforcement (or reinforcing fibers), 40%-70% by volume a polymeric resin matrix, and 1-5% by volume metal-coated fibers realized as pre-formed stitches. The value "by volume" refers to the volume of the composite fabric material. As used herein, "prefab" can refer to a pre-cut stitched fabric that is subsequently formed to provide a segment of the battery tray. Examples of prefabs are shown in... Figure 8 As shown below, prefabricated pins can be formed using a custom fiber placement process. This will be referenced below. Figure 5 Further description.

[0120] The reinforcing fibers of the stitched fabric of the battery tray 300 can include glass fibers, carbon fibers, heat-resistant and high-strength synthetic fibers, natural fibers, and / or polyester fibers. The metal-coated fibers are continuous and form a grid array or array of holes covering the surface of the preform. The grid size and hole size are set based on the wavelength of the electromagnetic signal to reflect it. At least some of the metal-coated fibers extend through a composite fabric material that can be cut to provide the preform. The metal-coated fibers can be nickel-coated and / or copper-coated. In one embodiment, the metal-coated fibers include a coating formed of nickel and copper.

[0121] Metal-coated fibers can possess a wide range of areal weights (or densities), resistivity, thickness, shape patterns, and dimensions. The unit of measurement for areal weight is grams per square meter (g / m²). 2 The larger the area weight, the lower the surface resistivity. Surface resistivity can refer to the surface resistivity of carbon, nickel-coated carbon, or steel, copper, and nickel-coated carbon. The unit of measurement for surface resistivity can be ohms per square (ω / sq). The surface resistivity of copper and nickel-coated carbon is lower than that of nickel-coated carbon, which in turn is lower than that of carbon.

[0122] The areal density of the metal-coated fibers at different locations can be customized based on EMI requirements. For example, the areal density of different areas of the battery tray can be selected, and the stitched fabric walls and / or sections of the battery tray can be formed to have the selected areal density. This can provide more electromagnetic shielding in certain areas of the battery tray than in other areas.

[0123] Metal-clad fibers provide electromagnetic shielding that reflects incident electromagnetic waves both internally and externally. Arrow 310 refers to the incident electromagnetic wave, and arrow 312 refers to the reflected electromagnetic wave.

[0124] An example of the stitched fabric of the battery tray 300 is shown in Figure 4 As shown in the image. Figure 4 A stitched fabric 400 with metal-coated fibers is shown. The stitched fabric has multiple layers of fibers arranged in layers. Each layer can have one or more types of reinforcing fibers, one or more types of metal-coated fibers and / or fibers coated with one or more metal materials, and a resin matrix. Exemplary materials for the reinforcing fibers and metal fibers are as described above. The reinforcing fibers and metal-coated fibers (referred to as "fibers") can have different sizes, thicknesses, cross-sectional shapes, the same or different numbers of layers, etc. The stitched fabric 400 can have one or more types of metal-coated fibers and / or fibers coated with one or more metal materials (e.g., copper, nickel and / or combinations thereof).

[0125] As an example, in Figure 4 In this structure, the first fiber 402 can be a reinforcing fiber (e.g., carbon fiber), the second fiber (or metal-coated fiber) 404 can be a copper-coated fiber, and the third fiber (or metal-coated fiber) 406 can be a nickel-coated fiber. The first fiber 402 extends in the 0° and 90° directions. The second fiber 404 can form a woven pattern on the surface of the total stack. The woven pattern can cover a segment of the entire surface of the total stack (e.g., the top and / or bottom surfaces). The second fiber 404 can extend parallel and / or laterally relative to the first fiber 402 and the third fiber 406. A fourth fiber 410, which can have a metal-coated fiber, can extend laterally across and through the layer via corresponding holes (or apertures) in the layer. Figure 4 In the figure, the fourth fiber 410 is shown extending vertically through the sewn fabric 400, but it can extend in other directions depending on the orientation of the sewn fabric 400. The third fiber 406 and the fourth fiber 410 can form a mesh in the thickness direction of the total stack. The mesh can be on the outside of the total stack as shown. As shown, adjacent fourth fibers in the fourth fiber 410 can be wound around different fiber stacks (e.g., fibers 402 and 404) in opposite vertical directions.

[0126] Figure 5 Displayed is a metal-coated fiber 500, which can be placed in different patterns using a customized fiber placement process to form a sewn fabric, for example... Figure 4 The sewn fabric 400. A roving tube 502 and / or a sewing head can be used to hold, place, and sew fibers (e.g., reinforcing fibers or metal-coated fibers). A metal-coated fiber 500 extends through one end of the roving tube 502. The metal-coated fiber 500 includes a core 504 and an outer metal coating 506. The core 504 can comprise a non-metallic fibrous material. The metal coating 506 can comprise copper and / or nickel.

[0127] A customized fiber placement process can be used to manufacture preforms that are shaped and sized to include metal-coated fibers with a low areal density. Exemplary preforms are shown in... Figure 8 As shown in the diagram, this prefabricated component provides electromagnetic shielding with high EMSE for the implementation of the battery tray. The stitched fabric disclosed herein, manufactured using a customized fiber placement process, includes metal-coated fiber stitches as a non-reinforcing component. The metal-coated fiber stitches can be configured in different patterns, such as chain, warp-knitted, mixed, and / or triangular patterns. The reinforcing fiber material can include glass fiber, carbon fiber, natural fibers, polyester fibers, nylon fibers, and / or combinations thereof.

[0128] Figure 6A segment 600 of stitched fabric is shown, having through-stitched metal-coated fibers 602. A stack of stitched fiber layers 604 is shown, having metal-coated fibers 602 extending laterally and passing through holes 606 in the stitched fiber layers 604. Although the metal-coated fibers 602 are shown in a pattern with a quasi-square wave cross-section, the metal-coated fibers can be in other patterns. Furthermore, although a gap G is shown between the metal-coated fibers 602 and the outermost layer in layer 604, there may not be a gap between the metal-coated fibers 602 and the outermost layer in layer 604. Each layer in layer 604 can have reinforcing fibers, metal-coated fibers, and / or resin. A resin layer can be disposed between each fiber layer in fiber layer 604. The fibers in each layer in layer 604 can be arranged in a grid-like pattern and / or other patterns. Although a certain number of layers 604 are shown, any number of layers can be included.

[0129] The lamination of the stitched fiber layer 604 can be part of the fiber fabric and prefabrication, such as Figure 8 As shown. The fiber fabric includes metal-coated fibers that can be covered into a 3D shape and molded to form a battery tray component. As described herein, the battery tray assembly can include an upper (or top) half and a lower (or bottom) half, which are placed together to form the battery tray. Although the battery tray primarily refers to two parts as described herein, a battery tray can include more than two parts. Furthermore, the parts (or components) of the battery tray may not be of the same size. As an example, in Figure 9 A portion is shown. The upper part can be referred to as a cover. The battery tray component can be formed using various methods, including the HP-RTM process (in... Figures 10-11 Shown and referenced Figures 10-11 Examples describing the HP-RTM process), compression molding process (in Figures 12-13 Shown and referenced Figures 12-13 (Describe an example of the compression molding process) and / or other suitable processes.

[0130] The holes extend through layer 604 and are equal in length to the thickness T of the common layer 604. An exemplary distance DA between holes and an exemplary distance PM between parallel members (e.g., parallel members 610, 612) are shown. A parallel member refers to a member extending parallel to layer 604 and on the opposite side of the common layer 604. The distance PM can be greater than or equal to the thickness T. In one embodiment, the distance PM is equal to λ / 50 and the distance DA is equal to λ / 20, although in… Figure 6 Mid-range PM is shown as longer than distance DA.

[0131] In one embodiment, the cross-section of the hole can be circular, elliptical, rectangular, or have other geometries. In one embodiment, the principal dimensions of the hole (e.g., length and width) are greater than λ / 50 but not greater than λ / 20. The cross-sectional dimensions are measured perpendicular to at least one of (i) the corresponding longitudinal length of the hole or (ii) the corresponding path of the hole. In one embodiment, metal-clad fibers extend through and fill the opening of the hole and have an external dimension similar to the internal dimensions of the hole. Figure 6 The diagram illustrates an exemplary length dimension and width dimensions L and W of an elliptical slot. The shielding effectiveness of a single hole with a slot opening length (L = longest dimension) can be represented by Equation 1, where, λ is the length of the slot in the hole, and λ is the wavelength of the electromagnetic signal (or electromagnetic field), such as the one to which the battery tray is exposed. The wavelength λ can be measured in meters.

[0132] (1)

[0133] For hole arrays, Equation 2 can be satisfied, where it applies to slots. Suitable for round holes And in middle, It refers to the number of holes.

[0134] (2)

[0135] A higher shielding effectiveness value indicates better shielding performance. (Regarding length...) To solve Equation 3 below, we need to determine the aperture size for a given attenuation, where the aperture size is applicable to the slot. Suitable for round holes And in middle, It refers to the number of holes.

[0136] (3)

[0137] Figure 7 A schematic diagram illustrating the reflection of electromagnetic waves on a fabric 700 stitched with metal-coated fibers is shown. Fabric 700 can be a preform as disclosed herein. The preform can include conductive fiber stitches arranged in an orthogonal grid (e.g., 702, 704) and extending through holes sized to meet EMSE requirements. The holes can be arranged in a grid-like pattern. Electromagnetic waves E are shown and reflected by the fabric as indicated by arrow 710. Figure 1 As shown, the metal coating on the metal-coated fiber disclosed herein is connected to the ground reference 130.

[0138] Figure 8A preform 800 comprising metal-coated fibers as described herein is shown. Preform 800 and other preforms mentioned herein can be formed using the methods described herein. The preforms can be cut into various patterns. Figure 8 An exemplary pattern is shown. This pattern is shaped to allow a preform to be overlaid on a mold and formed into a predetermined 3D part. As an example, Figure 8 The preforms in the mold can be covered to form such as Figure 9 The battery tray component 900 is shown.

[0139] The stitched fabrics and preforms disclosed herein, including those containing metal-coated fibers, can be used... Figures 10-13 The method was formed. Figure 10 This illustrates the high-pressure resin transfer molding (HP-RTM) process. Figure 11 The description is shown in Figure 10 A flowchart illustrating the operations performed during the HP-RTM process.

[0140] The HP-RTM process can begin at 1000. At 1002, a stabilized sewn fabric 1001 is formed and / or provided, comprising metal-coated fibers with an adhesive (e.g., resin). At 1004, a layer of woven sheets (or fabric sheets) 1005 is formed. As shown, the sewn fabric 1001, which may be in rolls, can be cut into sheets and stacked. Each sheet can have a... Figure 4 The fiber arrangement may be similar to or different from the one shown.

[0141] At 1006, a preform 1007, indicated by box 1009, is formed during the prefabrication process. At 1006A, a stack of sheets 1005 is placed in a press 1011 having a prefabrication (or first) mold comprising an upper section 1013 and a lower section 1015. The stack of sheets 1005 covers the lower section 1015. At 1006B, the stack of sheets 1005 is pressed together and heated. At 1008, the preform 1007 is removed from the press, cooled (or brought to room temperature), and thus stabilized.

[0142] At 1010, resin filling is performed, indicated by box 1017. At 1010A, preform 1007 is placed in a second press with an HP-RPM die comprising an upper section 1019 and a lower section 1021. At 1010B, the upper section 1019 is moved relative to the lower section 1021 to a partially open state for resin injection via injection channel 1023. At 1010C, the resin-injected preform is pressed using a tonnage press, indicated by arrow 1025.

[0143] At 1012, the resin-injected preform 1027 is cured, as indicated by arrow 1029. This can include baking the preform 1027 at a predetermined temperature for a predetermined time period and / or allowing the resin to cool and cure. At 1014, the resulting part (or portion), such as a battery tray part, is removed from the HP-RPM mold, as indicated by arrow 1033. The process can end at 1016.

[0144] Figure 12 The compression molding process is shown. Figure 13 The illustration shows the use of thermosetting or thermoplastic prepreg systems in Figure 12 This is a process diagram illustrating the operations performed during the compression molding process. The method can begin at 1200. At 1202, a prepreg material 1203 is formed, which includes metal-coated fibers, indicated by arrow 1205. Prepreg material 1203 can include, for example... Figure 4 The stitched fabric shown or a similar fabric.

[0145] At 1204, the prepreg material 1203 is heated in an oven, indicated by the heating plane 1207. At 1206, the heated prepreg material is pressed. In one embodiment, the prepreg material is pressed with two belts (i.e., pressed between two belts), indicated by arrow 1209 and rolling belt 1211.

[0146] Then, at 1208, the heated and pressed prepreg material is cut to provide a stacked material layer 1213. At 1210, the stacked material layer 1215 is hot-pressed to form a battery tray component, indicated by arrow 1217. The stacked material layer 1215 is pressed in a hot press 1219 having a die including an upper section 1221 and a lower section 1223. The process can end at 1212.

[0147] The foregoing description is illustrative in nature and is not intended to limit the scope of this disclosure, its application, or use. The broad teachings of this disclosure can be implemented in many forms. Therefore, while this disclosure has specific examples, its true scope should not be so limited, as other modifications will become apparent from a study of the accompanying drawings, specification, and the following claims. It should be understood that one or more steps within the method may be performed in different orders (or simultaneously) without altering the principles of this disclosure. Furthermore, while each embodiment has been described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented in and / or combined with features of any other embodiment, even if such combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the arrangement of one or more embodiments with respect to each other remains within the scope of this disclosure.

[0148] Spatial and functional relationships between components (e.g., between modules, between circuit elements, between semiconductor layers, etc.) are described using various terms, including “connected,” “joined,” “linked,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “set.” Unless explicitly described as “direct,” when the relationship between the first and second components is described in the foregoing disclosure, the relationship can be a direct relationship in which no other intermediate components exist between the first and second components, or it can be an indirect relationship (spatially or functionally) in which one or more intermediate components exist between the first and second components. As used herein, at least one of the phrases A, B, and C should be interpreted as representing logic (A or B or C) using non-exclusive logic OR, and should not be interpreted as representing “at least one A, at least one B, at least one C.”

[0149] In a diagram, as indicated by the arrows, the direction of the arrows typically shows the flow of information of interest to the diagram, such as data or instructions. For example, when components A and B exchange various types of information, but the information transmitted from component A to component B is relevant to the diagram, the arrow might point from component A to component B. This unidirectional arrow does not mean that no other information is transmitted from component B to component A. Furthermore, for information sent from component A to component B, component B may send a request for or confirmation of receipt of that information to component A.

[0150] In this application, the terms "module" or "controller" are used in accordance with the following definitions and may be replaced by the term "circuit". The term "module" may refer to, belong to, or include: application-specific integrated circuits (ASICs); digital, analog, or mixed-signal analog / digital discrete circuits; digital, analog, or mixed-signal analog / digital integrated circuits; combinational logic circuits; field-programmable gate arrays (FPGAs); processor circuitry (shared, dedicated, or grouped) that executes code; memory circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the described functionality; or combinations of some or all of the above, such as in a system-on-a-chip.

[0151] A module may include one or more interface circuits. In some examples, the interface circuit may include a wired or wireless interface connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module disclosed herein may be distributed across multiple modules connected via the interface circuit. For example, multiple modules may allow for load balancing. In another example, a server (also known as a remote or cloud) module may perform certain functions on behalf of a client module.

[0152] The term "code" as used above can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuit" includes a single processor circuit that executes some or all of the code from multiple modules. The term "group processor circuit" includes a processor circuit that, in conjunction with additional processor circuitry, executes some or all of the code from one or more modules. References to multiple processor circuits include multiple processor circuits on a discrete die, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or combinations thereof. The term "shared memory circuit" includes a single memory circuit that stores some or all of the code from multiple modules. The term "group memory circuit" includes a memory circuit that, in conjunction with additional memory, stores some or all of the code from one or more modules.

[0153] The term memory circuit is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not include transient electrical or electromagnetic signals propagating through a medium such as on a carrier wave; therefore, the term computer-readable medium can be considered tangible and non-transient. Non-limiting examples of non-transient tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0154] The apparatus and methods described in this application can be implemented, in part or in whole, by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions contained in a computer program. The function blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the daily work of a skilled technician or programmer.

[0155] A computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. A computer program may also include or depend on stored data. A computer program may include a basic input / output system (BIOS) for interacting with the hardware of a special-purpose computer, device drivers for interacting with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0156] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated from source code by a compiler; (iv) source code executed by an interpreter; (v) source code compiled and executed by a just-in-time (JIT) compiler; and so on. As an example only, source code may be written using the syntax of languages ​​including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, JavaScript®, HTML5 (Hypertext Markup Language Version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

Claims

1. A battery tray, the battery tray comprising: A first component, the first component comprising a first set of walls, wherein the first set of walls comprises a first stitched fabric, and wherein the first stitched fabric comprises a first plurality of stitched fabric layers and a first metal-coated fiber; and The second component includes a second set of walls, wherein the second set of walls includes a second stitched fabric, wherein the second stitched fabric includes a second plurality of stitched fabric layers and a second metal-coated fiber, wherein the second component is attached to the first component to form the battery tray, the battery tray being configured to hold the vehicle's battery pack, and The first metal-coated fiber and the second metal-coated fiber provide electromagnetic shielding around the battery pack. The first stitched fabric includes a first hole, wherein a portion of the first metal-coated fibers extend laterally and through the first hole; and The second stitched fabric includes a second hole, wherein some of the second metal-coated fibers extend laterally and through the second hole.

2. The battery tray according to claim 1, wherein: The first stitched fabric is formed by a pressure resin transfer molding method; and The second stitched fabric is formed by a pressure resin transfer molding method.

3. The battery tray according to claim 1, wherein: Each of the first plurality of stitched fabric layers includes some of the first metal-coated fibers in the first metal-coated fibers; and Each of the second plurality of stitched fabric layers includes some of the second metal-coated fibers in the second metal-coated fibers.

4. The battery tray according to claim 1, wherein: The first stitched fabric is realized as a first preform; and The second stitched fabric is realized as a second preform.

5. The battery tray according to claim 1, wherein: The first stitched fabric further includes reinforcing fibers; and The second stitched fabric also includes reinforcing fibers.

6. The battery tray according to claim 1, wherein: Each of the first and second holes has a cross-sectional dimension greater than λ / 50 and less than λ / 20; and The cross-sectional dimension is measured perpendicular to at least one of (i) the respective longitudinal lengths of the first hole and the second hole or (ii) the respective paths of the first hole and the second hole.

7. The battery tray according to claim 1, wherein, Each of the first and second metal-coated fibers includes a non-metallic fiber core and a metal coating, wherein the metal coating is disposed on the non-metallic fiber core.

8. The battery tray according to claim 1, wherein, The first metal-coated fiber and the second metal-coated fiber are connected to the reference ground.

9. The battery tray according to claim 1, wherein, The first and second sewn fabrics together comprise: 25%-59% reinforcing fiber by volume; 40%-70% by volume of polymeric resin matrix; and 1-5% by volume of metal-coated fibers, wherein the metal-coated fibers have a first metal-coated fiber and a second metal-coated fiber.

10. The battery tray according to claim 9, wherein, The reinforcing fibers of the first and second stitched fabrics include at least one of glass fiber, carbon fiber, polyester fiber, or natural fiber.

11. The battery tray according to claim 1, wherein, At least one of the first metal-coated fibers forms at least one of a mesh array or a pore array; or At least one of the second metal-coated fibers forms at least one of a mesh array or a pore array.

12. The battery tray according to claim 1, wherein, The metal coatings of the first metal-coated fiber and the second metal-coated fiber include at least one of nickel or copper.

13. The battery tray according to claim 1, wherein, At least one of the areal densities of the first metal-coated fibers varies on the first stitched fabric, or at least one of the areal densities of the second metal-coated fibers varies on the second stitched fabric.

14. A power supply system, the power supply system comprising: The battery tray according to claim 1; The battery pack contained within the battery tray; and A control circuit is connected to at least one of the battery tray or the battery pack, and monitors and controls the state of the battery pack.

15. A method for forming a battery tray for a vehicle using pressure resin transfer molding, the method comprising: A stitched fabric is formed, the stitched fabric having metal-coated fibers and an adhesive; Cut the stitched fabric to provide a sheet; Stack the sheets; The sheet is applied to a section of the first mold; Stacked sheets are heated and pressed to form preforms; The resin is applied to the preform and the resin is cured. and Demolding the preform to provide the section of the battery tray. The stitched fabric includes multiple stitched fabric layers and metal-coated fibers, the stitched fabric including holes, wherein some of the metal-coated fibers extend laterally and through the holes.

16. The method according to claim 15, wherein, At least one of the metal-coated fibers is sewn together using a customized fiber placement process.

17. The method according to claim 15, wherein, Forming the stitched fabric includes stitching at least some of the metal-coated fibers through holes in the stitched fabric, wherein the holes extend through the stitched fabric.

18. The method according to claim 15, wherein, The application of the resin includes: The preform is placed in the second mold; Position the section of the second mold in a partially open state; The resin is injected into the second mold and the preform; and The resin-injected preform is pressed.

19. A compression molding method for forming a battery tray for a vehicle, the method comprising: A prepreg material is formed, wherein the prepreg material has metal-coated fibers; Preheat the prepreg material; The heated prepreg material is pressed; Cut and stack the pressed and heated prepreg material to form stacked material layers; The stacked material layers are placed in a heated pressing machine; and The stacked material layers are pressed to form sections of the battery tray. The material layer comprises multiple stitched fabric layers and metal-coated fibers, and the material layer includes pores, wherein some of the metal-coated fibers extend laterally and through the pores.

20. The method of claim 19, wherein: At least some of the metal-coated fibers in the metal-coated fibers are sewn together using a customized fiber placement process; Forming the prepreg material includes stitching at least some of the metal-coated fibers through holes in the prepreg material; The hole extends through the prepreg material; and The pressing of the heated prepreg material includes double-belt pressing of the heated prepreg material to strengthen the fibers of the heated prepreg material.

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