High-impact-resistant thermoplastic composite bottom protective plate

Abstract

The invention discloses a high-impact-resistant thermoplastic composite material bottom protection plate which comprises a lower surface layer, a first high-impact-resistant layer, a sound insulation and heat preservation layer and an upper surface layer which are sequentially bonded through adhesive films from bottom to top, and the upper surface layer and the lower surface layer are both made of multiple layers of continuous fiber reinforced thermoplastic composite materials. And the first high-impact-resistant layer is made of an ultra-high molecular weight polyethylene material. Metal plates are not needed, the weather resistance of the metal plates does not need to be considered, machining is convenient, and continuous production can be achieved; compared with a bottom protection plate with a metal plate, the weight is reduced by 30-60%, the sound insulation and heat insulation performance is improved, and the gain effect is provided for battery heat preservation and automobile body noise reduction.

Description

Technical Field

[0001] The present invention belongs to the technical field of fiber-reinforced thermoplastic composite battery bottom guard plates, and in particular relates to a high-impact resistant thermoplastic composite bottom guard plate. Background Art

[0002] As the popularity of new energy vehicles continues to increase, consumers pay more and more attention to the protection of new energy vehicle batteries, and put forward higher requirements for the impact resistance, safety, durability and comfort of the bottom guard plate of the battery of new energy vehicles. The traditional protective plate for battery packs is made of fiberglass or stainless steel, but the preparation process of fiberglass is not environmentally friendly, and it cannot be recycled after molding. The specific gravity of traditional steel cannot meet the demand for lightweight. Continuous fiber reinforced thermoplastic composite material is a reinforced thermoplastic composite material in which the reinforcing fibers are arranged unidirectionally and their length is equal to the length of the resin sheet. Continuous fibers are the main bearers of loads, and the resin matrix transmits and disperses loads. Because the reinforcing fibers in the composite material are continuously reinforced in one direction, and the continuous fiber breakpoints are relatively few, the stress concentration effect can be effectively reduced. It has the characteristics of light weight, chemical corrosion resistance, fatigue resistance and flexible design. It has been applied to the manufacturing field of bottom guard plates for new energy vehicles. The structure of existing battery bottom guard plate products is generally a sandwich structure of continuous fiber reinforced thermoplastic composite plate + metal plate (composite frame) + continuous fiber reinforced thermoplastic composite plate. The above structure uses metal plates, has heavy overall weight, poor thermal insulation and sound insulation performance, poor corrosion resistance, and there is room for improvement. Summary of the invention

[0003] In view of this, an object of the present invention is to provide a high-impact resistant thermoplastic composite bottom guard plate to address the deficiencies in the prior art.

[0004] In order to achieve the above object, the present invention is achieved through the following technical solutions:

[0005] Provided is a high-impact resistant thermoplastic composite bottom guard plate, which includes, from bottom to top, a lower skin layer, a first high-impact resistant layer, a sound insulation layer and an upper skin layer which are sequentially bonded by adhesive films, the upper skin layer and the lower skin layer are both made of multi-layer continuous fiber reinforced thermoplastic composite materials, and the first high-impact resistant layer is made of ultra-high molecular weight polyethylene material.

[0006] As described in the high impact resistant thermoplastic composite bottom guard plate, wherein a second high impact resistant layer is further included between the sound insulation layer and the upper surface layer, and the second high impact resistant layer is made of ultra-high molecular weight polyethylene material.

[0007] As described in the high-impact resistant thermoplastic composite bottom guard plate, wherein the sound insulation layer is made of GMT.

[0008] As described in the high impact resistant thermoplastic composite bottom guard plate, wherein the first high impact resistant layer and the second high impact resistant layer are both made of continuous ultra-high molecular weight polyethylene fiber reinforced thermoplastic composite material, and are obtained by laminating ultra-high molecular weight polyethylene UD tapes through 0° / 90° or -45° / 45° multi-layer lamination, or are obtained by laminating ultra-high molecular weight polyethylene continuous fiber fabric prepreg impregnated with thermoplastic resin.

[0009] As described in the high-impact thermoplastic composite bottom guard plate, wherein the thickness of the first high-impact resistant layer and the second high-impact resistant layer is 0.05-2 mm, the weight content of continuous ultra-high molecular weight polyethylene fiber is 50-95%, the weight content of low-temperature thermoplastic resin is 5-50%, the tensile strength is 20-40 N / dtex, the tensile modulus is 500-1400 N / dtex, and the elongation at break is 3-4%.

[0010] As described in the high impact resistant thermoplastic composite bottom guard plate, wherein the GMT is a thermoplastic resin impregnated fiber felt composite material with a thickness of 0.5 to 20 mm and a density of 300 to 1500 kg / m 3 The fiber felt is one of surface felt, needle felt, and chopped strand felt. The thermoplastic resin is one of PE, PP, PA, PC, PMMA, PET, and ABS. The fiber weight content is 30-60%. The tensile strength is 100-250 MPa, and the bending strength is 50-250 MPa.

[0011] As described in the high-impact resistant thermoplastic composite bottom guard plate, wherein the upper skin layer and the lower skin layer are obtained by composite of continuous fiber reinforced thermoplastic resin UD tapes through 0° / 90° or -45° / 45° multi-layer lamination, or are obtained by composite of thermoplastic resin impregnated continuous fiber fabric prepregs, with a thickness of 0.2 to 5 mm, a glass fiber weight content of 40 to 80%, a resin weight content of 20 to 60%, and a tensile strength of 200 to 500 MPa. The thermoplastic resin is one of PE, PP, PA, PC, PMMA, PET, and ABS, and the continuous fiber is one of glass fiber, carbon fiber, aramid fiber, and basalt fiber.

[0012] As described in the high-impact thermoplastic composite bottom guard plate, wherein the adhesive film is one of maleic anhydride grafted PE, maleic anhydride grafted POE, maleic anhydride grafted EVA, and ethylene propylene copolymer, with a melting point of 85 to 110°C, a thickness of 0.05 to 0.3 mm, a tensile strength of 10 to 30 MPa, and an elongation at break of 50 to 200%.

[0013] The beneficial effects of the technical solution of the present invention are:

[0014] No metal plates are required, and there is no need to consider the weather resistance of metal plates. It is easy to process and can be produced continuously. Compared with the bottom guard plate with metal plates, the weight is reduced by 30 to 60%, and the sound insulation and heat insulation performance are improved, providing a gain effect for battery insulation and body noise reduction. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] To further illustrate the above-mentioned objectives, structural features and effects of the present invention, the present invention will be described in detail below with reference to the accompanying drawings.

[0016] Figure 1 This is a schematic diagram of a preferred embodiment of the present invention;

[0017] Figure 2 This is a schematic structural diagram of another preferred embodiment of the present invention;

[0018] In the figure: 1. Adhesive film; 2. Lower epidermal layer; 3. First high impact resistant layer; 4. Sound insulation layer; 5. Upper epidermal layer; 6. Second high impact resistant layer. DETAILED DESCRIPTION

[0019] The terms "invention", "present invention" and "the present invention" used in this specification are intended to refer broadly to all subject matter of this specification and any patent claims below. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of any patent claim below. In addition, this specification does not attempt to describe or limit the subject matter covered by any claim of any specific component, paragraph, statement or figure of this application. The subject matter should be understood with reference to the entire specification, all drawings and any claims below. The present invention may have other embodiments and be practiced or implemented in other ways. Moreover, it should be understood that the words and terms used herein are for illustrative purposes and should not be considered as limiting.

[0020] The details of the present invention will now be discussed with reference to the accompanying drawings which illustrate the present invention by way of example only. In the accompanying drawings, similar features or components may be marked with the same reference numerals.

[0021] The use of "including," "having," and "comprising" and variations thereof herein is meant to encompass the items listed thereafter and their equivalents and additional items. Although reference may be made to directions such as above, below, upward, downward, rearward, bottom, top, front, rear, etc., in describing the drawings, for convenience, reference is made relative to the drawings. These directions are not intended to literally accept or limit the present invention in any form. In addition, terms such as "first," "second," "third," etc., are used herein for illustrative purposes and are not intended to indicate or imply importance or significance.

[0022] See also Figure 1As shown, in a preferred embodiment, the high impact resistant thermoplastic composite bottom guard plate of the present invention includes, from bottom to top, a lower epidermis layer 2, a first high impact resistant layer 3, a sound insulation layer 4 and an upper epidermis layer 5 which are sequentially bonded by an adhesive film 1. The upper epidermis layer 5 and the lower epidermis layer 2 are both made of multi-layer continuous fiber reinforced thermoplastic composite materials (CFRTP), and the first high impact resistant layer 3 is made of ultra-high molecular weight polyethylene material (UHMWPE). The CFRTP layer provides a certain impact strength and ensures the surface rigidity of the bottom guard plate. The high tensile modulus of the UHMWPE layer provides the bottom guard plate with anti-impact and anti-puncture properties.

[0023] See also Figure 2 As shown, in another preferred embodiment, the present invention further includes a second high impact resistant layer 6 between the sound insulation layer 4 and the upper skin layer 2, and the second high impact resistant layer 6 is made of ultra-high molecular weight polyethylene material.

[0024] The sound insulation layer 4 is made of GMT, which is a thermoplastic resin impregnated fiber felt composite material with a thickness of 0.5-20 mm and a density of 300-1500 kg / m 3 The fiber felt is one of surface felt, needle felt, and chopped strand felt. The thermoplastic resin is one of PE, PP, PA, PC, PMMA, PET, and ABS, preferably PP resin. The fiber weight content is 30-60%, the tensile strength is 100-250 MPa, and the bending strength is 50-250 MPa. The GMT layer provides thickness stiffness for the bottom guard plate, while improving the sound insulation and heat insulation performance of the product. In addition, the fibers in the GMT layer also provide certain impact resistance for the product.

[0025] The first high impact resistant layer 3 and the second high impact resistant layer 6 are both made of continuous ultra-high molecular weight polyethylene fiber reinforced thermoplastic composite materials, which are ultra-high molecular weight polyethylene UD tapes laminated by 0° / 90° or -45° / 45° multi-layer lamination, or thermoplastic resin impregnated ultra-high molecular weight polyethylene continuous fiber fabric prepreg multi-layer composite.

[0026] The thickness of the first high impact resistant layer 3 and the second high impact resistant layer 6 is 0.05-2 mm, the weight content of continuous ultra-high molecular weight polyethylene fiber is 50-95%, the weight content of low-temperature thermoplastic resin is 5-50%, the tensile strength is 20-40 N / dtex, the tensile modulus is 500-1400 N / dtex, and the elongation at break is 3-4%.

[0027] Continuing to refer to the figure, the upper skin layer 5 and the lower skin layer 2 are continuous fiber reinforced thermoplastic resin UD tapes obtained by 0° / 90° or -45° / 45° multi-layer lamination, or thermoplastic resin impregnated continuous fiber fabric prepreg multi-layer composite, with a thickness of 0.2-5 mm, a glass fiber weight content of 40-80%, a resin weight content of 20-60%, a tensile strength of 200-500 MPa, the thermoplastic resin is one of PE, PP, PA, PC, PMMA, PET, ABS, preferably PP resin, and the continuous fiber is one of glass fiber, carbon fiber, aramid fiber, basalt fiber, preferably glass fiber.

[0028] The adhesive film 1 is one of maleic anhydride grafted PE, maleic anhydride grafted POE, maleic anhydride grafted EVA, and ethylene propylene copolymer, with a melting point of 85-110° C., a thickness of 0.05-0.3 mm, a tensile strength of 10-30 MPa, and an elongation at break of 50-200%.

[0029] More specifically, see Figure 1 As shown, the lower CFRTP skin thickness is 1mm, which is composed of four layers of 0.25mm continuous fiber reinforced PP prepreg tapes, and the prepreg tape laying method is 0° / 90° / 0° / 90°. The UHMWPE layer thickness is 0.2mm, which is composed of 4 layers of continuous ultra-high molecular weight polyethylene fiber prepreg tapes, and the layer structure is 0° / 90° / 0° / 90°. The unit area weight is 220g / ㎡, and the GMT layer density is 400kg / m 3 , thickness 3mm, upper CFRTP skin thickness 1mm, composited by four layers of 0.25mm continuous fiber reinforced PP prepreg tapes, the prepreg tape laying method is 90° / 0° / 90° / 0°, and the thickness of all polyolefin film layers is 0.1mm.

[0030] The production process includes the following steps:

[0031] S1: Press Figure 1 Continuous unwinding and laying of layers in structural order;

[0032] S2: Enters the continuous Teflon belt laminating machine, the laminating machine heating temperature is 135℃, the cooling temperature is 0~10℃, the line speed is 2m / min, and the laminating gap is 5.5mm;

[0033] S3: Semi-finished bottom guard plate cut online to required size;

[0034] S4: CNC processing the semi-finished bottom guard plate, and assembling it to obtain the final bottom guard plate finished product.

[0035] See also Figure 2As shown, the lower CFRTP skin thickness is 1mm, which is composed of 2 layers of continuous glass fiber fabric reinforced PP composite, the first high impact resistant layer 3 is 0.15mm thick, which is composed of 2 layers of continuous ultra-high molecular weight polyethylene fiber prepreg tape composite, the ply structure is 0° / 90°, the unit area weight is 160g / ㎡, and the GMT layer density is 1200kg / m 3 , thickness 2mm, the second high impact resistant layer 6 thickness 0.1mm, composed of 2 layers of continuous ultra-high molecular weight polyethylene fiber prepreg tapes, the ply structure is 0° / 90°, the area weight is 110g / ㎡, the upper CFRTP skin thickness is 0.5mm, composed of two layers of 0.25mm continuous fiber reinforced PP prepreg tapes, the prepreg tape ply method is 90° / 0°, and the thickness of all polyolefin film layers is 0.05mm.

[0036] During production, the following steps are included:

[0037] S1: Press Figure 2 Continuous unwinding and laying of layers in structural order;

[0038] S2: Enter the continuous Teflon belt laminating machine, the laminating machine heating temperature is 135℃, cooling temperature: 0~10℃, line speed is 3m / min, and the laminating gap is 4mm;

[0039] S3: Semi-finished bottom guard plate cut online to required size;

[0040] S4: CNC processing the semi-finished bottom guard plate, and assembling it to obtain the final bottom guard plate finished product.

[0041] In other embodiments, the adhesive film can replace the low-temperature thermoplastic resin in the UHMWPE layer and be directly used as the low-temperature resin when making UHMWPE unidirectional tape or prepreg, which can reduce the use of the adhesive film layer when the finished product is composited and simplify the finished product composite process.

[0042] The present invention does not require metal plates, does not need to consider the weather resistance of metal plates, is easy to process, and can be produced continuously. Compared with the bottom guard plate with metal plates, the weight is reduced by 30-60%, and the sound insulation and heat insulation performance are improved, providing a gain effect for battery insulation and vehicle body noise reduction.

[0043] The above are only preferred embodiments of the present invention, and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should be aware that all solutions obtained by equivalent substitutions and obvious changes made using the description and illustrations of the present invention should be included in the protection scope of the present invention.

Claims

1. A high impact resistant thermoplastic composite bottom guard plate, characterized in that: From bottom to top, it includes a lower epidermis layer, a first high impact resistant layer, a sound insulation layer and an upper epidermis layer which are sequentially bonded by adhesive films. The upper epidermis layer and the lower epidermis layer are both made of multi-layer continuous fiber reinforced thermoplastic composite materials, and the first high impact resistant layer is made of ultra-high molecular weight polyethylene material.

2. The high impact resistant thermoplastic composite bottom guard plate according to claim 1, characterized in that: A second high impact resistant layer is also included between the sound insulation layer and the upper skin layer, and the second high impact resistant layer is made of ultra-high molecular weight polyethylene material.

3. The high impact resistant thermoplastic composite bottom guard plate according to claim 1 or 2, characterized in that: The sound insulation layer is made of GMT.

4. The high impact resistant thermoplastic composite bottom guard plate according to claim 2, characterized in that: The first high impact resistant layer and the second high impact resistant layer are both made of continuous ultra-high molecular weight polyethylene fiber reinforced thermoplastic composite materials, and are obtained by laminating ultra-high molecular weight polyethylene UD tapes through 0° / 90° or -45° / 45° multi-layer laminations, or are obtained by laminating ultra-high molecular weight polyethylene continuous fiber fabric prepregs impregnated with thermoplastic resins.

5. The high impact resistant thermoplastic composite bottom guard plate according to claim 4, characterized in that: The thickness of the first high impact resistant layer and the second high impact resistant layer is 0.05 to 2 mm, the weight content of continuous ultra-high molecular weight polyethylene fiber is 50 to 95%, the weight content of low-temperature thermoplastic resin is 5 to 50%, the tensile strength is 20 to 40 N / dtex, the tensile modulus is 500 to 1400 N / dtex, and the elongation at break is 3 to 4%.

6. The high impact resistant thermoplastic composite bottom guard plate according to claim 3, characterized in that: The GMT is a thermoplastic resin impregnated fiber felt composite material with a thickness of 0.5 to 20 mm and a density of 300 to 1500 kg / m 3 The fiber felt is one of surface felt, needle felt, and chopped strand felt. The thermoplastic resin is one of PE, PP, PA, PC, PMMA, PET, and ABS. The fiber weight content is 30-60%. The tensile strength is 100-250 MPa, and the bending strength is 50-250 MPa.

7. The high impact resistant thermoplastic composite bottom guard plate according to claim 1, characterized in that: The upper skin layer and the lower skin layer are obtained by composite of continuous fiber reinforced thermoplastic resin UD tape through 0° / 90° or -45° / 45° multi-layer plying, or by composite of thermoplastic resin impregnated continuous fiber fabric prepreg, with a thickness of 0.2 to 5 mm, a glass fiber weight content of 40 to 80%, a resin weight content of 20 to 60%, and a tensile strength of 200 to 500 MPa. The thermoplastic resin is one of PE, PP, PA, PC, PMMA, PET, and ABS, and the continuous fiber is one of glass fiber, carbon fiber, aramid fiber, and basalt fiber.

8. The high impact resistant thermoplastic composite bottom guard plate according to claim 1, characterized in that: The adhesive film is one of maleic anhydride grafted PE, maleic anhydride grafted POE, maleic anhydride grafted EVA, and ethylene propylene copolymer, with a melting point of 85-110° C., a thickness of 0.05-0.3 mm, a tensile strength of 10-30 MPa, and an elongation at break of 50-200%.

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