GFRP battery tray and manufacturing method thereof

Abstract

The invention relates to the field of battery tray manufacturing and processing, in particular to a GFRP battery tray and a manufacturing method thereof. A bearing frame is arranged on the outer side of a side wall, the bearing frame and the side wall are bonded together through glue, a partition plate and a partition plate support are arranged between a cover plate and a bottom plate support, the partition plate is connected through the partition plate support, and the partition plate is connected with a bottom plate and the side wall; the side walls are connected through the joints, and the side walls, the joints, the bottom plate and the cover plate form a box body through adhesion; flame-retardant paint is integrally sprayed in a box body formed by the side walls, the connectors, the bottom plate and the cover plate, and plastic is integrally sprayed on the outer surface of the box body. A frame type structure is adopted, the comprehensive cost is greatly reduced by optimizing the frame structure form and the process scheme, and the weight of the product is reduced.

Description

Technical Field

[0001] The present invention relates to the field of manufacturing and processing of battery trays, and in particular to a GFRP battery tray and a manufacturing method thereof. Background Art

[0002] Electric vehicles play an important role in solving the energy crisis and environmental pollution. Their performance depends on batteries, and the lightweight and low cost of battery trays are key. Composite materials, due to their high strength and light weight, are ideal alternative materials that are expected to reduce tray weight and improve energy efficiency. However, the domestic manufacturing and application level in this field needs to be improved. Therefore, battery performance and vehicle lightweighting are crucial to the range of electric vehicles. Researching and realizing the lightweighting of battery trays is the key to improving range and promoting the development of new energy vehicles.

[0003] In CN106207029A "An Electric Vehicle Battery Tray and Manufacturing Method", the battery tray is divided into side panels, middle longitudinal beams, bulkheads, bottom plates, etc. The side panels and middle longitudinal beams are made of T300 carbon fiber cloth / YPH-42T epoxy resin prepreg; the bulkheads are made of GDUD400 fiber / ERPIQ epoxy resin prepreg; and the bottom plates are made of T300 carbon fiber cloth / YPH-42T epoxy resin prepreg. That is, each component uses different strength carbon fiber cloth or glass fiber ply, and then the corresponding epoxy resin prepreg is coated on it, layer by layer, and then formed by vacuum bag method, and then sent to the oven for curing. The side panels and the middle longitudinal beam are connected by glue rivets, and the connection surface is coated with glue. The bulkhead and the side panels are connected by core-pulling rivets, and the connection surface is coated with glue. Finally, the bottom plate and the above components are glued and connected by Araldite.

[0004] The weight of the pallet prepared in this way is greatly reduced, but this design has the following problems and disadvantages:

[0005] (1) High manufacturing cost: Side panels, center longitudinal beams, bulkheads, and floor panels all require molds and prepreg ply, and require oven curing during the curing process, resulting in high production costs;

[0006] (2) Poor product processability: The embedded parts inside the side panel are embedded in the process, which greatly weakens the bearing capacity of the side panel;

[0007] (3) Low production efficiency: The production process used in the manufacturing process of the battery tray parts requires long-term use of molds and manual layering. When faced with large-scale production tasks, production costs need to be continuously invested to ensure production progress;

[0008] (4) Low product safety: The side panels and center longitudinal beams are made of carbon fiber. In an aerobic environment, carbon fiber has poor antioxidant capacity, which may lead to a significant increase in the ablation rate. Summary of the invention

[0009] In view of the shortcomings of the prior art, the present invention provides a GFRP battery tray and a manufacturing method thereof. The present invention uses GFRP material and aluminum alloy as the main manufacturing materials, and mainly adopts adhesive connection for fixed connection, so that the present invention has the characteristics of low cost, high technical maturity, high reliability and safety, and high production efficiency.

[0010] The technical solution of the present invention is: an electric vehicle battery tray, comprising side enclosures, joints, a bottom plate, a cover plate, a partition, a partition support, and a load-bearing frame; a side enclosure is arranged between the bottom plate and the cover plate, and the side enclosure is fixed to the cover plate and the bottom plate by means of blind rivets and support plate nuts, and is characterized in that: a load-bearing frame is arranged on the outside of the side enclosure, the load-bearing frame and the side enclosure are bonded together with glue, a partition and a partition support are arranged between the cover plate and the bottom plate support, the partition is connected by the partition support, and the partition is respectively connected to the bottom plate and the side enclosure; the side enclosures are connected by joints, and the side enclosures, the joints, the bottom plate, and the cover plate are pasted to form a box body; the interior of the box body formed by the side enclosures, the joints, the bottom plate, and the cover plate is sprayed with flame-retardant paint as a whole, and the outer surface of the box body is sprayed with plastic as a whole; the side enclosures and the load-bearing frame are GFRP pultruded profiles, the joints are aluminum alloy shells, the partition supports are aluminum alloys, and the partitions are GFRP laminates; the bottom plate and the cover plate are foam sandwich structures.

[0011] According to the electric vehicle battery tray as described above, it is characterized in that: mounting holes for the electrical system interface seat and the thermal management system interface seat are opened on the side wall, the electrical system interface seat is pressed on the side wall through an O-ring and an R-type radial locking nut, the thermal management system interface seat is pressed on the side wall through an O-ring and an R-type radial locking nut, and the R-type radial locking nut is applied to the connection part with the side wall.

[0012] According to the electric vehicle battery tray as described above, the feature is that mounting holes for the safety valve interface seat are arranged opposite to each other on the bottom plate, the safety valve interface seat is glued into the mounting holes, and the safety valve is mounted on the safety valve interface seat.

[0013] According to the electric vehicle battery tray as described above, the feature is that the contact edges of the side panels, joints, partitions and bottom plates are reinforced with glass fiber twill cloth.

[0014] According to the electric vehicle battery tray as described above, the feature is that the bottom plate and the side panels are reinforced with glass fiber twill fabric on the edges in contact with the load-bearing frame.

[0015] According to the electric vehicle battery tray as described above, the feature is that the electrical system interface seat and the thermal management system interface seat are circular aluminum alloy shapes.

[0016] According to the electric vehicle battery tray as described above, it is characterized in that the safety valve interface seat is in a circular aluminum alloy shape.

[0017] According to the electric vehicle battery tray as described above, it is characterized in that the middle partition is an epoxy board.

[0018] According to the electric vehicle battery tray as described above, the feature is that the cross-sections of the side panels and the load-bearing frame are in the shape of a Japanese character.

[0019] According to the electric vehicle battery tray as described above, it is characterized by having flame retardant and heat insulating properties, and the bottom plate, cover plate and side panels are made of modified epoxy resin.

[0020] According to the electric vehicle battery tray as described above, it is characterized in that: the GFRP battery tray has battery shielding characteristics, a layer of carbon fiber fabric is laid in the inner cavity of the GFRP battery tray or a small amount of carbon fiber is mixed in the bottom plate, cover plate and side panel.

[0021] The present invention also discloses a method for manufacturing a GFRP battery tray, which is characterized by adopting the following steps:

[0022] Step (1) side panel: the raw material of the side panel is glass fiber / modified epoxy resin. Under the traction force of the pultrusion equipment, the glass fiber / modified epoxy resin is fully impregnated with glue in the dipping tank, and then reasonably guided by the pre-forming template, and finally enters the heated metal mold, and reacts and solidifies under the action of the high temperature of the metal mold to obtain a glass fiber reinforced plastic profile. After the curing is completed, the side panel blank is removed from the mold, and the support plate nut is fixed to the side panel with a core-pulling rivet;

[0023] Step (2) Joint: The raw material of the joint is aluminum alloy. Liquid aluminum alloy is filled into the cavity of a preheated die casting mold at 300 MPa, and the liquid aluminum alloy is solidified under pressure to form a casting;

[0024] Step (3) Load-bearing frame: The raw material of the load-bearing frame is glass fiber / modified epoxy resin, and the molding is the same as the side frame in step (1);

[0025] Step (4) Bottom plate: The bottom plate is a foam sandwich structure, the material is glass fiber / modified epoxy resin prepreg, and is formed in one piece using VIP;

[0026] Step (5) Cover plate: The cover plate is a foam sandwich structure, made of glass fiber / modified epoxy resin prepreg, and is formed in the same manner as the base plate in step (4);

[0027] Step (6) The partition support is made of aluminum alloy and is formed by extrusion process;

[0028] Step (7) The electrical system interface seat, the thermal management system interface seat and the safety valve interface seat are all processed by turning and milling;

[0029] Step (10) partition, O-ring, R-type radial locking nut, safety valve: the partition material is epoxy plate, the O-ring material is nitrile rubber, the size of the R-type radial locking nut is M30, and the size of the safety valve installation hole is φ42mm;

[0030] Step (11) Assembly: assemble and glue the side panels and joints, and use a tool to position them; use a tool to position the partitions and partition supports, and glue them to the side panels; apply adhesive film to the assembly surfaces of the side panels and joints with the bottom plate, and glue and screw the bottom plate to the side panels and joints; if a small amount of carbon fiber is not mixed in the bottom plate, cover plate and side panels, lay a layer of carbon fiber fabric in the inner cavity of the GFRP battery tray; glue the partitions, partition supports and bottom plate; fix the load-bearing frame to the frame using a tool, and adopt a gluing process;

[0031] The electrical system interface seat, thermal management system interface seat, O-ring, and R-type radial locking nut are installed in the corresponding positions according to the assembly sequence, and sealant is applied to the threaded connection part; the safety valve mounting seat is glued to the mounting hole on the base plate, and the interior of the box body formed by the side panel, joint, base plate, and cover plate is sprayed with flame retardant paint as a whole, and the outer surface of the box body is sprayed with plastic as a whole.

[0032] Compared with the prior art, the positive effects of the present invention are: the present invention adopts a frame structure, and by optimizing the frame structure form and process scheme, the comprehensive cost is greatly reduced; the present invention mainly adopts GFRP and aluminum alloy tube materials, and reduces the weight of the battery tray to 80% of the weight of the traditional aluminum battery tray; the side enclosure of the present invention adopts pultruded pultruded profiles as the main component of the pultruded frame, and the pultrusion process can quickly produce high-strength side enclosures, while the aluminum alloy joints are made by high-pressure static injection process, and the high-pressure precision casting process can quickly produce high-precision joints; the battery tray of the present invention is sprayed with flame retardant paint and modified epoxy resin, which can effectively delay the time of battery tray explosion when the internal battery is on fire; the GFRP battery tray of the present invention is mixed with carbon fiber or a layer of carbon fiber fabric is laid on the GFRP battery tray, which can provide good electromagnetic shielding and ensure the stable operation of the electronic system in the GFRP battery tray. The raw materials of the present invention are mainly GFRP and aluminum alloy. Under the condition of relatively stable market, low-cost raw materials can be obtained in the production of battery trays. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0034] Figure 1 This is an exploded view of the overall structure of a battery tray according to an embodiment of the present invention;

[0035] Figure 2 It is a schematic diagram of the overall structure of a battery tray according to an embodiment of the present invention;

[0036] Figure 3 yes Figure 2 Cross-sectional view in the MM direction;

[0037] Figure 4 yes Figure 2 Sectional view along the NN direction;

[0038] Figure 5 yes Figure 2 Sectional view in the mid-PP direction;

[0039] Figure 6 yes Figure 2 A partial enlarged view of the middle I area;

[0040] Figure 7 yes Figure 3 A partial enlarged view of the middle II area;

[0041] Figure 8 yes Figure 3 A partial enlarged view of the middle III region;

[0042] Fig. 9 yes Figure 2 A partial enlarged view of the middle IV region;

[0043] Fig.10 It is a schematic diagram of the VIP process device;

[0044] Fig.11 It is a schematic diagram of the GFRP pultrusion device;

[0045] Fig.12 It is a schematic diagram of the aluminum high pressure casting process flow;

[0046] Fig.13 It is a schematic diagram of the metal extrusion process.

[0047] Figure numerals: side panel 1, joint 2, base plate 3, cover plate 4, partition plate 5, partition plate support 6, load-bearing frame 7, electrical system interface seat 8, thermal management system interface seat 9, safety valve interface seat 10, O-ring 11, R-type radial locking nut 12, safety valve 13, blind rivet 110, support plate nut 120.

[0048] Name explanation: GFRP (Glass Fiber Reinforced Plastics) refers to glass fiber reinforced plastics. DETAILED DESCRIPTION

[0049] The following provides a specific implementation of a GPRP battery tray and a manufacturing method thereof of the present invention.

[0050] like Figures 1 to 8As shown, an electric vehicle battery tray of the present invention comprises a side enclosure 1, a joint 2, a bottom plate 3, a cover plate 4, a partition 5, a partition support 6, a bearing frame 7, an electrical system interface seat 8, a thermal management system interface seat 9, a safety valve interface seat 10, an O-ring 11, an R-type radial locking nut 12, and a safety valve 13; a side enclosure 1 is arranged between the bottom plate 3 and the cover plate 4, and the side enclosure is fixed to the cover plate 4 and the bottom plate 3 by means of a blind rivet 110 and a support plate nut 120, a bearing frame 7 is arranged outside the side enclosure, and the bearing frame 7 and the side enclosure 1 are bonded to each other with glue. Together, a partition 5 and a partition support 6 are arranged between the cover plate 4 and the bottom plate 3 bracket, the partition 5 is connected through the partition support 6, and the partition 5 is respectively connected to the bottom plate 3 and the side panel 1; the side panels 1 are connected through the joint 2, and the side panel 1, the joint 2, the bottom plate 3, and the cover plate 4 are pasted to form a box body; a layer of carbon fiber fabric is laid inside the formed box body, and the bottom plate 3, the cover plate 4 and the side panel 1 form an inner cavity, and the carbon fiber fabric is arranged in the inner cavity; the interior of the box body formed by the side panel 1, the joint 2, the bottom plate 3, and the cover plate 4 is sprayed with flame retardant paint as a whole, and the outer surface of the box body is sprayed with plastic as a whole.

[0051] like Figure 1 , Figure 4 and Figure 5 As shown, the side enclosure 1 of the present invention is provided with mounting holes for the electrical system interface seat 8 and the thermal management system interface seat 9, the electrical system interface seat 8 is pressed on the side enclosure 1 through an O-type sealing ring 11 and an R-type radial locking nut 12, the thermal management system interface seat 9 is pressed on the side enclosure 1 through an O-type sealing ring 11 and an R-type radial locking nut 12, and a sealant is applied to the connection between the locking nut 12 and the side enclosure 1. This ensures that the interior of the box is in a sealed state.

[0052] like Figure 1 , Figure 3 As shown, a mounting hole for the safety valve interface seat 10 is opened at a corresponding position on the bottom plate 3 of the present invention, the safety valve interface seat 10 is glued into the mounting hole, and the safety valve 13 is installed on the safety valve interface seat 10 .

[0053] Furthermore, in order to enhance the connection strength between the side panel 1, the joint 2, the partition 5 and the bottom plate 3, glass fiber twill fabric is pasted on the contact edges between the side panel 1, the joint 2, the partition 5 and the bottom plate 3 inside the battery tray for reinforcement.

[0054] Furthermore, in order to enhance the connection strength between the load-bearing frame 7 and the bottom plate 3 and the side enclosure 1 , glass fiber twill fabric is pasted on the contact edges between the bottom plate 3 and the side enclosure 1 and the load-bearing frame 7 for reinforcement.

[0055] The side enclosure 1 and the load-bearing frame 7 of the present invention are GFRP pultruded profiles, and holes are drilled at the connection points of the side enclosure 1, and the support plate nut 120 is installed from the inside of the side enclosure 1. The joint 2 is an aluminum alloy shell, which adopts a high-pressure casting process, and a wire screw sleeve is installed after drilling a hole on the surface of the connection point. The partition support 6 is an aluminum alloy and is formed by an extrusion process. The partition 5 is a GFRP laminate. The bottom plate 3 and the cover plate 4 are foam sandwich structures, which are integrally formed or step-by-step formed by VIP (Vacuum Infusion Process), and the curing method is room temperature or oven curing. Its function is to enhance the rigidity of the entire battery tray and provide battery pack load. The electrical system interface seat 8, the thermal management system interface seat 9, and the safety valve interface seat 10 are all circular aluminum alloy shapes. The O-type sealing ring 11, the R-type radial locking nut 12, and the safety valve 13 are all standard parts.

[0056] The side panels 1 and the joints 2 of the present invention serve as the main load-bearing structures, and the partitions 5 and the partition support 6 function to separate the batteries. The interior of the battery tray is sprayed with flame-retardant paint to enhance the safety of the battery tray. The exterior of the battery tray is sprayed with plastic to make the battery tray more beautiful. The middle partition 5 is an epoxy board, which can provide an excellent insulation environment to ensure the normal operation of the battery.

[0057] The present invention adopts a frame structure, and greatly reduces the overall cost by optimizing the frame structure form and process scheme; GFRP and aluminum alloy tube materials are used to reduce the weight of the battery tray to 80% of the weight of the traditional aluminum battery tray; in the present invention, the side panel 1 adopts pultruded profiles as the main component of the pultruded frame, and the pultrusion process can quickly produce high-strength side panels 1; at the same time, the aluminum alloy joint 2 is made of a high-pressure static injection process, and the high-pressure precision casting process can quickly produce a high-precision joint 2.

[0058] Embodiment 1 of the present invention:

[0059] Combination Figure 1, an electric vehicle battery tray, including a side panel 1, a joint 2, a bottom plate 3, a cover plate 4, a partition 5, a partition support 6, a bearing frame 7, an electrical system interface seat 8, a thermal management system interface seat 9, a safety valve interface seat 10, an O-type sealing ring 11, an R-type radial locking nut 12, and a safety valve 13. The battery tray size (length × width × height) is: 1505mm × 1200mm × 250mm, the number of batteries is 6, and the battery size (length × width × height) is: 420mm × 234mm × 160mm. To ensure the gap, the battery compartment size (length × width × height) is not less than 430mm × 250mm × 180mm. According to the strength calculation results and the specifications of the battery height, the side panel 1 has a thickness of 1mm and a Japanese-shaped cross section. The bearing frame 7 has a thickness of 1mm and a Japanese-shaped cross section. The joint 2 has an overall thickness of 4mm and a local thickness of 2mm. The partition 5 has a thickness of 1mm. The partition support 6 has a thickness of 1.5mm. The bottom plate 3 is 2mm thick, with 50mm reinforcement ribs added locally (PVC foam filling, density: 50kg / m 3 ). Cover plate 4 is 2mm thick, with 20mm reinforcement ribs added locally (PVC foam filling, density: 50kg / m 3 ).

[0060] The present invention also discloses a method for manufacturing a GFRP battery tray, which is as follows:

[0061] Step (1) Side panel 1: The raw material of side panel 1 is E7 / flame retardant epoxy resin. After the E7 / flame retardant epoxy resin is fully impregnated with glue (flame retardant epoxy resin) in the dipping tank under the traction of the pultrusion equipment, it is reasonably guided by a series of pre-forming templates to obtain a preliminary shape, and finally enters the heated metal mold. The mold reacts and solidifies under the action of high temperature, thereby obtaining a continuous, smooth-surfaced, dimensionally stable, and extremely strong FRP profile. See the curing process for details. Fig.11 After the curing is completed, the side wall 1 blank is removed from the mold, the blank is polished and filed, and then a hole is drilled on the mold, and the support plate nut 120 is fixed to the side wall 1 with a blind rivet 110.

[0062] Step (2) Joint 2: The raw material of joint 2 is 6061 aluminum alloy, which is formed by high pressure die casting process. Fig.12 , the liquid 6061 aluminum alloy is filled into the preheated die casting mold cavity at a high speed under 300MPa, and the liquid 6061 aluminum alloy is solidified under pressure to form a casting. After the casting is cooled and formed, it is demolded and the parts are post-processed, including cutting off the gate, flash, etc., and necessary inspections and tests are carried out to ensure the quality of the parts.

[0063] Step (3) Carrying frame 7: The raw material of the carrying frame 7 is E7 / flame retardant epoxy resin, and the molding steps are the same as (1) side frame 1;

[0064] Step (4) Base plate 3: Base plate 3 is a foam sandwich structure, made of EWR500T3 glass fiber twill cloth / flame retardant epoxy resin prepreg, and is integrally formed using VIP (Vacuum Infusion Process); the curing process is shown in Fig.10 , apply a release agent (PMR) on the surface of the mold cavity, lay a layer of release cloth, and then start the layering operation. First, lay 5 layers of EWR500T3 fiberglass twill cloth, then put in reinforcement ribs (foam), and then lay 5 layers of EWR500T3 fiberglass twill cloth, followed by laying release cloth and guide net in sequence. Paste a sealing strip 50mm away from the outer contour of the product on the mold, and then paste a sealing bag to vacuum. After the vacuum degree stabilizes, open the throttle valve at the resin inlet end. After the resin infiltrates the entire product, close the throttle valve at the resin inlet pipe. After 30 minutes, close the throttle valve at the vacuum end, check the air tightness of the mold, and check whether the vacuum degree remains unchanged; if the vacuum degree remains unchanged, open the throttle valve to continue to vacuum, so that it is maintained at negative 98kPa, and turn off the vacuum pump after 24 hours. Finally, the product with the mold is placed in an oven at 80°C for curing for 8 hours. After the curing is completed, the base plate 3 blank is removed from the mold, the blank is polished and filed, and then a hole is drilled on the drill jig;

[0065] Step (5) Cover plate 4: Cover plate 4 is a foam sandwich structure, and the material is EWR500T3 glass fiber twill cloth / flame retardant epoxy resin prepreg. The molding steps are the same as those of (4) bottom plate 3;

[0066] Step (6) The partition support 6 is made of aluminum alloy and is formed by extrusion process. The material is 6061 aluminum alloy. The forming process is shown in FIG. Fig.13 , and then cut to the required length;

[0067] Step (7) Electrical system interface seat 8: The raw material of the electrical system interface seat 8 is 6061-T651, the main structure is cylindrical, and is made by turning and milling.

[0068] Step (8) Thermal management system interface seat 9: The raw materials and molding steps of the thermal management system interface seat 9 are the same as those of (7) electrical system interface seat 8

[0069] Step (9) Safety valve interface seat 10: The raw materials and molding steps of the thermal management system interface seat 9 are the same as those of the electrical system interface seat 8 (7).

[0070] Step (10) partition 5, O-ring 11, R-type radial locking nut 12, safety valve 13: the material of the partition 5 is 3240 epoxy plate (thickness 1.5mm), the material of the O-ring 11 is nitrile rubber (outer diameter φ30mm×wire diameter φ1.5mm), the size of the R-type radial locking nut 12 is M30, and the size of the installation hole of the safety valve 13 is φ42mm.

[0071] Step (11) Assembly: Assemble and glue the side panel 1 and the joint 2, and use a tool to position them; use a tool to position the partition 5 and the partition support 6, and glue them to the side panel 1; stick adhesive film on the assembly surface of the side panel 1 and the joint 2 and the bottom plate 3, and glue and screw the bottom plate 3 to the side panel 1 and the joint 2; glue the partition 5, the partition support 6 and the bottom plate 3, and use the glue brand: X4103; then, in order to enhance the connection strength between the side panel 1, the joint 2, the partition 5 and the bottom plate 3, the inside of the battery tray and the contact edge of the bottom plate 3 are reinforced with glass fiber twill cloth, the thickness of the reinforcement cloth is 0.6 mm, the width is 60 mm, and the reinforcement material is EW200 / AO420; the load-bearing frame 7 is fixed to the frame using a tool, and the gluing process is adopted, and the glue brand is: AO420; In order to strengthen the connection strength between the load-bearing frame 7 and the bottom plate 3 and the side panel 1, the bottom plate 3 and the side panel 1 and the load-bearing frame 7 are reinforced with glass fiber twill cloth, the thickness of the reinforcement cloth is 0.6mm, the width is 80mm, and the reinforcement material is EW200 / AO420; A layer of T300 carbon fiber twill cloth is hand-pasted in the inner cavity formed by the bottom plate 3, the cover plate 4 and the side panel 1, and impregnated with flame-retardant epoxy resin; The electrical system interface seat 8, the thermal management system interface seat 9, the O-type sealing ring 11, and the R-type radial locking nut 12 are installed in the corresponding positions according to the assembly sequence, and the sealant is applied to the threaded connection part. The sealant brand is: Nanda 704; The safety valve 13 mounting seat is glued to the mounting hole on the bottom plate 3, and the glue brand is: AO420. The use of bonding does not require the opening of mounting holes on the side panel, which greatly guarantees the mechanical strength of the side panel. At the same time, the construction efficiency of the glue bonding is higher than that of the screw fastening efficiency.

[0072] Spray painting: In order to enhance the safety of the battery tray, the inside of the battery tray (including the inner side of the cover plate 4) is sprayed with flame retardant paint, the flame retardant paint brand is: SWI600, and the spraying thickness is 0.15mm.

[0073] Plastic spraying: The battery tray is sprayed with plastic on the outside. The plastic powder grade is RAL 7016 and the spraying thickness is 0.08mm.

[0074] After the upper cover is installed with the battery pack, electrical equipment, thermal management equipment, etc., the installation form of the upper cover and the side panel 1 is the same as the installation form of the bottom plate 3 and the side panel 1 .

[0075] The above is only a preferred embodiment of the present invention. It should be pointed out that ordinary technicians in this technical field can make several improvements and modifications without departing from the concept of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. An electric vehicle battery tray, comprising a side panel, a joint, a bottom plate, a cover plate, a partition, a partition support, and a bearing frame; a side panel is arranged between the bottom plate and the cover plate, and the side panel is fixed to the cover plate and the bottom plate by blind rivets and support plate nuts, characterized in that: A load-bearing frame is arranged on the outer side of the side wall. The load-bearing frame and the side wall are adhesively bonded together with glue. A partition and a partition support are arranged between the cover plate and the bottom plate support. The partition is connected through the partition support and is respectively connected to the bottom plate and the side wall. The side walls are connected through joints. The side walls, joints, bottom plate, and cover plate are pasted to form a box body. The interior of the box body formed by the side walls, joints, bottom plate, and cover plate is integrally sprayed with flame-retardant paint, and the outer surface of the box body is integrally sprayed with plastic. The side wall and the load-bearing frame are GFRP pultruded profiles, the joint is an aluminum alloy shell, the partition support is aluminum alloy, and the partition is a GFRP laminate. The bottom plate and the cover plate are foam sandwich structures. A layer of carbon fiber fabric is arranged in the inner cavity formed by the bottom plate, the cover plate, and the side wall, or a small amount of carbon fiber is mixed in the bottom plate, the cover plate, and the side wall.

2. The electric vehicle battery tray according to claim 1, characterized in that: Installation holes for the electrical system interface seat and the thermal management system interface seat are opened on the side wall. The electrical system interface seat is pressed on the side wall through an O-ring and an R-type radial locking nut. The thermal management system interface seat is pressed on the side wall through an O-ring and an R-type radial locking nut. A sealant is applied to the connecting part of the R-type radial locking nut and the side wall.

3. An electric vehicle battery tray according to claim 1 or 2, characterized in that: Installation holes for the safety valve interface seat are arranged on the bottom plate at corresponding positions. The safety valve interface seat is adhesively bonded in the installation hole, and the safety valve is installed on the safety valve interface seat.

4. An electric vehicle battery tray according to claim 1 or 2, characterized in that: The contact edges of the side wall, joint, partition, and bottom plate are reinforced with glass fiber twill cloth.

5. An electric vehicle battery tray according to claim 1 or 2, characterized in that: The contact edges of the bottom plate and the side wall with the load-bearing frame are reinforced with glass fiber twill cloth.

6. The electric vehicle battery tray according to claim 2, characterized in that: The electrical system interface seat and the thermal management system interface seat are in the shape of a circular aluminum alloy.

7. The electric vehicle battery tray according to claim 3, characterized in that: The safety valve interface seat is in the shape of a circular aluminum alloy.

8. An electric vehicle battery tray according to claim 1 or 2, characterized in that: The middle partition is an epoxy board.

9. An electric vehicle battery tray according to claim 1 or 2, characterized in that: The thickness of the side wall is 1 mm, and the cross-section is in the shape of a Chinese character 'Ri'. The thickness of the load-bearing frame is 1 mm, and the cross-section is in the shape of a Chinese character 'Ri'. The overall thickness of the joint is 4 mm, and the local thickness is 2 mm. The thickness of the partition is 1 mm, and the thickness of the partition support is 1.5 mm. The thickness of the bottom plate is 2 mm, and the thickness of the cover plate is 2 mm.

10. A method for manufacturing a GFRP battery tray, characterized in that: The manufacturing is carried out in the following steps: Step (1) Side wall: The raw material of the side wall is glass fiber / modified epoxy resin. Under the traction of the pultrusion equipment, the glass fiber / modified epoxy resin is fully impregnated with the sizing agent in the sizing tank, reasonably guided by the preforming template, and finally enters the heated metal mold. Under the action of the high temperature of the metal mold, it reacts and cures to obtain a fiberglass profile. After the curing is completed, the side wall blank is removed from the mold, and the pallet nut is fixed on the side wall with a blind rivet. Step (2) Joint: The raw material of the joint is aluminum alloy. The liquid aluminum alloy is filled into the preheated die cavity of the die casting mold under 300 MPa, and the liquid aluminum alloy solidifies under pressure to form a casting. Step (3) Load-bearing frame: The raw material of the load-bearing frame is glass fiber / modified epoxy resin, and the forming is the same as that of the side wall in step (1). Step (4) Bottom plate: The bottom plate is a foam sandwich structure, and the material is glass fiber / modified epoxy resin prepreg, which is formed by VIP one-piece molding. Step (5) Cover plate: The cover plate is a foam sandwich structure, and the material is glass fiber / modified epoxy resin prepreg, and the forming is the same as that of the bottom plate in step (4). Step (6) The partition support is aluminum alloy and is formed by an extrusion process. Step (7) The electrical system interface seat, the thermal management system interface seat and the safety valve interface seat are all processed by turning and milling; Step (10) partition, O-ring, R-type radial locking nut, safety valve: the partition material is epoxy plate, the O-ring material is nitrile rubber, the size of the R-type radial locking nut is M30, and the size of the safety valve installation hole is φ42mm; Step (11) assembly: assembling and gluing the side panels and joints, and positioning them with a tool; positioning the partitions and partition support with a tool, and gluing them with the side panels; pasting adhesive films on the assembly surfaces of the side panels and joints with the bottom plate, and gluing and screwing the bottom plate with the side panels and joints; If there is no small amount of carbon fiber mixed in the bottom plate, cover plate and side panels, a layer of carbon fiber fabric is laid in the inner cavity of the GFRP battery tray; the partition, partition support and bottom plate are glued together; the load-bearing frame and the frame are fixed with tooling and glued; The electrical system interface seat, thermal management system interface seat, O-ring, and R-type radial locking nut are installed in the corresponding positions according to the assembly sequence, and sealant is applied to the threaded connection part; the safety valve mounting seat is glued to the mounting hole on the base plate, and the interior of the box body formed by the side panel, joint, base plate, and cover plate is sprayed with flame retardant paint as a whole, and the outer surface of the box body is sprayed with plastic as a whole.

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