Ablation-resistant composite shield and method of manufacture

Abstract

The present application relates to a kind of ablation-resistant composite protective plate, including base layer, transition layer and composite material layer, the base layer, transition layer and composite material layer are sequentially laminated and are combined to form the ablation-resistant composite protective plate, the base layer is metal plate, the transition layer is PUR hot melt adhesive and glass fiber mixed layer, the composite material layer is phenolic resin-based pre-impregnated glass fiber layer.The ablation-resistant composite protective plate and preparation method designed in the present application, by the composite of phenolic resin-based pre-impregnated glass fiber layer, PUR hot melt adhesive and glass fiber mixed layer, metal panel layer, so that the ablation-resistant composite protective plate has good ablation resistance, load resistance, impact resistance, heat preservation, sound insulation and other excellent performance, and simple structure, low manufacturing cost.

Description

Technical Field

[0001] This invention relates to the field of composite protective plate technology, and in particular to an ablation-resistant composite protective plate and its preparation method. Background Technology

[0002] In existing technologies, the battery pack is a crucial component of new energy vehicles, and the protective plate within it is one of the protective measures for the battery pack. For new energy vehicles, the energy density (electric capacity per unit volume) of the battery pack is a key factor. For the same volume of battery pack, a higher energy density means it can store more electricity, and correspondingly, the driving range of the new energy vehicle is longer. To improve the energy density of the battery pack, components such as the outer casing and protective plate should be as small or thin as possible.

[0003] Current protective panels are generally made of a single material, such as sheets made solely of metal. These panels may suffer from issues like varying coefficients of thermal expansion, susceptibility to rust, and excessive weight, affecting their effectiveness and lifespan. To address these problems, existing technologies have introduced combinations of materials to create composite protective panels, such as metal-ceramic and metal-polyimide composites. However, these composite protective panels still have some drawbacks, such as complex structures, high processing difficulty, and high costs. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a composite protective plate with a simple structure, low manufacturing cost, and excellent protective performance, as well as a method for its preparation.

[0005] To achieve the above objectives, the ablation-resistant composite protective plate designed in this invention includes a base layer, a transition layer, and a composite material layer. The base layer, transition layer, and composite material layer are sequentially laminated to form the ablation-resistant composite protective plate. The base layer is a metal plate, the transition layer is a mixture of PUR hot melt adhesive and glass fiber, and the composite material layer is a phenolic resin-based preimpregnated glass fiber layer.

[0006] A further option is that the base layer is formed by stamping any one of cold-rolled steel, galvanized steel, and stainless steel, and the thickness of the base layer is 0.6-1mm.

[0007] A further option is that the base plate has bolt holes and rivet holes integrally formed on its surface. There are multiple bolt holes, which are respectively located at the four corners and the middle part of the base plate. There are also multiple rivet holes, which are spaced apart along the periphery of the base plate edge.

[0008] A further proposed solution is to set the distance between adjacent rivet holes at 100mm.

[0009] A method for preparing an ablation-resistant composite protective plate includes the following steps:

[0010] S1. A base layer is prepared by stamping using any one of cold-rolled steel sheet, galvanized steel sheet, and stainless steel sheet, and a fire-retardant coating is applied to the outer surface of the prepared base layer.

[0011] S2. Fiberglass mat is made by needle punching process, and the prepared fiberglass mat is pre-impregnated in phenolic resin-based prepreg solution to form phenolic resin-based prepreg fiberglass layer. At least one layer of phenolic resin-based prepreg fiberglass layer is hot-pressed to form a composite material layer.

[0012] S3. Use a spiral spraying method to evenly spray PUR hot melt adhesive onto the back of the base panel. At the same time, during the spraying process, cut glass fibers and evenly cover the PUR hot melt adhesive to prepare a transition layer.

[0013] S4. Place the prepared composite material layer on the back of the substrate panel, and use a composite shaping tool to bond the base layer and the composite material layer through a transition layer to form an ablation-resistant composite protective plate.

[0014] A further option is that, in step S1, the thickness of the base layer formed by stamping any one of cold-rolled sheet, galvanized sheet, and stainless steel sheet is 0.6-1mm, and the panel of the base layer has bolt holes and rivet holes integrally formed.

[0015] A further proposed solution is that, in step S2, the amount of fiberglass mat used is 50-100 grams per square meter; when the phenolic resin-based preimpregnated fiberglass layer is hot-pressed, the temperature of the thermoforming mold is 180-200℃, the pressure is 6-7 MPa, and the holding time is 35-45 seconds.

[0016] A further proposed solution is that, in step S3, the amount of PUR hot melt adhesive sprayed is 80-100 grams per square meter, and the glass fiber is laid at 200 grams per square meter.

[0017] A further proposed solution is that, in step S4, the pressure of the composite shaping tooling for pressing and shaping is 0.5-0.6 MPa, and the pressure holding time is 15±2 seconds.

[0018] The ablation-resistant composite protective plate and its preparation method designed in this invention have a simple structure, low manufacturing cost, and excellent ablation resistance, load resistance, impact resistance, heat insulation, and sound insulation performance. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of Example 1;

[0020] Figure 2 This is a schematic diagram of the substrate structure in Example 1;

[0021] Figure 3 This is a schematic diagram of the preparation process of the ablation-resistant composite protective plate in Example 1;

[0022] Figure 4 This is a schematic diagram of the preparation process of the phenolic resin-based prepreg glass fiber layer in Example 1;

[0023] Figure 5 This is a schematic diagram of the thermoforming mold in Example 1;

[0024] Figure 6 This is a schematic diagram of the positioning tool for preparing the transition layer in Example 1.

[0025] Among them: base layer 1, bolt hole 11, rivet hole 12, transition layer 2, composite material layer 3, thermoforming mold 4, lower template 41, upper template 42, punch 43, support frame 44, positioning fixture 5, X-axis guide rail 51, Y-axis guide rail 52, glue gun holder 53, nozzle 54, wire stripping and cutting machine 55. Detailed Implementation

[0026] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0027] Example 1.

[0028] like Figure 1-2 As shown, the ablation-resistant composite protective plate described in this embodiment includes a base layer 1, a transition layer 2, and a composite material layer 3. The base layer 1, the transition layer 2, and the composite material layer 3 are sequentially laminated to form the ablation-resistant composite protective plate. The base layer 1 is a metal plate, the transition layer 2 is a mixture of PUR hot melt adhesive and glass fiber, and the composite material layer 3 is a phenolic resin-based pre-impregnated glass fiber layer. Thus, by combining a phenolic resin-based pre-impregnated fiberglass layer, a PUR hot melt adhesive and fiberglass hybrid layer, and a metal panel layer, the ablation-resistant composite protective panel possesses excellent properties such as ablation resistance, load resistance, impact resistance, thermal insulation, and sound insulation. Specifically, the use of a PUR hot melt adhesive and fiberglass hybrid layer as the lamination transition layer 2 not only achieves bonding between the metal base panel 1 and the phenolic resin-based pre-impregnated fiberglass layer, but also further improves the strength and load-bearing and impact resistance of the protective panel. In this embodiment, Hans PU16 is preferred as the PUR hot melt adhesive. After spraying and lamination, this PUR hot melt adhesive is completely irreversible, further enhancing the bonding strength between the base layer 1 and the composite material layer 3, resulting in better flame retardant properties.

[0029] In some embodiments of the present invention, the base layer 1 is formed by stamping using any one of cold-rolled steel sheet, galvanized steel sheet, and stainless steel sheet, and the thickness of the base layer 1 is 0.6-1mm. In this embodiment, the base layer 1 is preferably made of stainless steel and is formed by stamping, which has high production efficiency and relatively low cost. Furthermore, the thickness of the base layer 1 is 0.6-1mm, which provides sufficient strength and stability without adding too much weight and volume, making the entire protective plate lighter.

[0030] In some embodiments of the present invention, such as Figure 2 As shown, bolt holes 11 and rivet holes 12 are integrally formed on the surface of the base layer 1. Multiple bolt holes 11 are located at the four corners and the center of the base layer 1. Multiple rivet holes 12 are also provided, spaced apart along the periphery of the base layer 1. This arrangement of bolt holes 11 and rivet holes 12 allows for convenient fixing of the ablation-resistant composite protective plate. The arrangement of the bolt holes 11 and rivet holes 12 enables the composite protective plate to more evenly distribute the load-bearing pressure and external impact force, thereby improving its compressive strength and vibration resistance. Furthermore, in this embodiment, the distance between adjacent rivet holes 12 is 100mm to increase the number of fixing points, thus improving the overall stability of the protective plate during use. Simultaneously, to prevent corrosion caused by external factors, such as corrosion from car battery reactions, the bolts and rivets used to fix the protective plate are made of the same material as the base layer 1, thereby improving the service life and structural stability of the protective plate.

[0031] This embodiment also provides a method for preparing an ablation-resistant composite protective plate, such as... Figure 3 As shown, it includes the following steps:

[0032] S1. The base layer 1 is prepared by stamping using any one of cold-rolled steel, galvanized steel and stainless steel, and a layer of fireproof coating is applied to the outer surface of the base layer 1.

[0033] S2. Fiberglass mat is fabricated using a needle-punching process, and the prepared fiberglass mat is pre-impregnated in a phenolic resin-based preimpregnating solution to form a phenolic resin-based pre-impregnated fiberglass layer. At least one layer of the phenolic resin-based pre-impregnated fiberglass layer is then hot-pressed to form the composite material layer 3. In this embodiment, using a needle-punching process to fabricate the fiberglass mat and pre-impregnating it in phenolic resin allows for more uniform impregnation of the fiberglass mat with phenolic resin, and the phenolic resin can better adhere to the fiberglass mat, thereby improving the quality and performance of the composite material layer 3. Specifically, as shown... Figure 4As shown, the prepared fiberglass mat is traction and wound up using tension rollers and a winding shaft. First, the fiberglass mat is preheated in a heat treatment furnace, then pre-impregnated in a pre-impregnation tank. Next, it is evenly extruded by extrusion rollers, then pre-cured in a curing tunnel. Finally, uneven excess material on both sides is removed by a cutter, and the mat is wound up for later use. During the pre-impregnation process, the heat treatment temperature is 200-300 degrees Celsius, and the pre-curing tunnel temperature is 80-100 degrees Celsius. Of course, the heat treatment temperature and the pre-curing tunnel temperature can be adjusted according to the actual density of the fiberglass mat. The pre-curing temperature should be kept below the thermoplastic curing temperature of the phenolic resin to ensure effective curing of the phenolic resin-based pre-impregnated fiberglass layer. During the hot pressing of the phenolic resin-based pre-impregnated fiberglass layer, as shown in the figure, an appropriate number of phenolic resin-based pre-impregnated fiberglass layers 6 are placed on the lower template 41 of the thermoforming mold 4, and the upper template 42 of the thermoforming mold 4 drives the punch 43 to press the phenolic resin-based pre-impregnated fiberglass layers 6 together, so that the phenolic resin-based pre-impregnated fiberglass layers 6 are effectively pressed together in the support frame 44 to obtain the composite material layer 3.

[0034] S3. Using a spiral spraying method, PUR hot melt adhesive is evenly sprayed onto the back of the base layer 1 panel. Simultaneously, during the spraying process, glass fibers are chopped and evenly coated onto the PUR hot melt adhesive to form a transition layer 2. In this embodiment, specifically, as follows... Figure 6 As shown, the base layer 1 is placed in the positioning fixture 5. The base layer 1 is moved in the X-axis direction by the X-axis guide rail 51, and the glue gun holder 53 is moved in the Y-axis direction by the Y-axis guide rail 52. The glue is sprayed evenly on the back of the base layer 1 panel by the spiral spraying method of the nozzle 54, thereby improving the quality and consistency of the transition layer 2. At the same time, the glass fiber is chopped and laid simultaneously by the wire stripping and cutting machine 55 to prepare the transition layer 2. The addition of glass fiber chopped can increase the strength and rigidity of the transition layer 2 and improve its ablation resistance.

[0035] S4. Place the prepared composite material layer 3 on the back of the substrate panel, and use a composite shaping tool to bond the base layer 1 and the composite material layer 3 together through the transition layer 2 to form an ablation-resistant composite protective plate. This yields the ablation-resistant composite protective plate of this embodiment.

[0036] A further embodiment is that, in step S1, the thickness of the base layer 1, formed by stamping any one of cold-rolled steel, galvanized steel, or stainless steel, is 0.6-1mm, and bolt holes 11 and rivet holes 12 are integrally formed on the panel of the base layer 1. This allows for convenient fixing of the ablation-resistant composite protective plate via the bolt holes 11 and rivet holes 12.

[0037] A further proposed solution is that, in step S2, the amount of fiberglass mat used is 50-100 grams per square meter; when the phenolic resin-based preimpregnated fiberglass layer is hot-pressed, the temperature of the thermoforming mold is 180-200℃, the pressure is 6-7 MPa, and the holding time is 35-45 seconds.

[0038] A further proposed solution is that, in step S3, the amount of PUR hot melt adhesive sprayed is 80-100 grams per square meter, and the glass fiber is laid at 200 grams per square meter.

[0039] A further proposed solution is that, in step S4, the pressure of the composite shaping tooling for pressing and shaping is 0.5-0.6 MPa, and the pressure holding time is 15±2 seconds.

[0040] The ablation-resistant composite protective plate and its preparation method provided in this embodiment have a simple structure, low manufacturing cost, and excellent ablation resistance, load resistance, impact resistance, heat insulation, and sound insulation performance.

[0041] In the description of this invention, it should be noted that the terms "vertical," "upper," "lower," "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0042] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0043] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An ablation-resistant composite protective plate, comprising a base layer (1), a transition layer (2), and a composite material layer (3), characterized in that, The base layer (1), transition layer (2) and composite material layer (3) are sequentially laminated to form the ablation-resistant composite protective plate. The base layer (1) is a metal plate, the transition layer (2) is a mixture of PUR hot melt adhesive and glass fiber, and the composite material layer (3) is a phenolic resin-based pre-impregnated glass fiber layer. The base layer (1) is formed by stamping any one of cold-rolled steel plate, galvanized steel plate and stainless steel plate, and the thickness of the base layer (1) is 0.6-1mm; The method for preparing the ablation-resistant composite protective plate includes the following steps: S1. A base layer (1) is prepared by stamping and forming any one of cold-rolled steel plate, galvanized steel plate and stainless steel plate, and a fireproof coating is applied to the outer surface of the prepared base layer (1); S2. Fiberglass mat is made by needle punching process, and the prepared fiberglass mat is put into phenolic resin-based prepreg liquid for prepreg to make phenolic resin-based prepreg fiberglass layer. At least one layer of phenolic resin-based prepreg fiberglass layer is taken and hot-pressed to form composite material layer (3). S3. Using a spiral spraying method, PUR hot melt adhesive is evenly sprayed onto the back of the base layer (1) panel. At the same time, glass fiber is cut short and evenly covered on the PUR hot melt adhesive liquid to prepare a transition layer (2). S4. Place the prepared composite material layer (3) on the back of the substrate panel, and use the composite shaping tool to bond the base layer (1) and the composite material layer (3) through the transition layer (2) to form an ablation-resistant composite protective plate. The base layer (1) has bolt holes (11) and rivet holes (12) integrally formed on its surface. There are multiple bolt holes (11), which are located at the four corners and the middle part of the base layer (1). There are multiple rivet holes (12), which are arranged at intervals along the periphery of the edge of the base layer (1). The distance between adjacent rivet holes (12) is 100mm; In step S1, the thickness of the base layer (1) formed by stamping any one of cold-rolled sheet, galvanized sheet and stainless steel sheet is 0.6-1mm, and the panel of the base layer (1) is integrally formed with bolt holes (11) and rivet holes (12). In step S2, the amount of fiberglass mat used is 50-100 grams per square meter; when the phenolic resin-based preimpregnated fiberglass layer is hot-pressed, the temperature of the thermoforming mold is 180-200℃, the pressure is 6-7MPa, and the holding time is 35-45 seconds. In step S3, the amount of PUR hot melt adhesive sprayed is 80-100 grams per square meter, and the fiberglass is laid at 200 grams per square meter. In step S4, the pressure of the composite shaping tool for pressing and shaping is 0.5-0.6MPa, and the pressure holding time is 15±2S.

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