Aircraft battery shell and battery shell forming method

Abstract

The invention discloses an aircraft battery shell and a battery shell forming method, and belongs to the technical field of aerospace equipment engineering. The aircraft battery shell comprises a box-shaped main body, the interior of the box-shaped main body is provided with a battery accommodating cavity and an assembly window which are communicated, and the box wall of the box-shaped main body is formed by filling three-period extremely small curved surface units according to an array arrangement mode, so that continuous heat dissipation flow channels and heat dissipation curved surfaces are formed inside and outside the box wall of the box-shaped main body; and the box cover is detachably buckled on the assembly window in a matched manner. According to the aircraft battery shell and the battery shell forming method provided by the invention, the heat dissipation efficiency of unit volume can be improved.

Description

Technical Field

[0001] The present application belongs to the field of aerospace equipment engineering technology, and in particular relates to an aircraft battery housing and a battery housing forming method. Background Art

[0002] Aerospace equipment is typically equipped with a functional power supply to power various equipment components. Considering that these equipment often operate in extreme conditions such as high temperatures and extreme cold, and that equipment space is limited and load requirements are strict, high requirements are placed on the battery's heat dissipation capacity and overall weight.

[0003] In the prior art, power supplies are often equipped with fixed brackets and heat dissipation structures to protect the power supply while taking into account both the stability of the power supply fixation and the heat dissipation efficiency. However, this also increases the overall volume and weight of the power supply to a certain extent. Furthermore, due to limited installation space, the area of ​​the heat dissipation structure is limited, and the heat dissipation efficiency is also subject to certain restrictions. Summary of the Invention

[0004] This application provides an aircraft battery housing and a battery housing molding method, which aims to at least to some extent solve the technical problem of poor heat dissipation efficiency per unit volume of aerospace equipment that is usually equipped with a functional power supply. To this end,

[0005] In one aspect of an embodiment of the present application, an aircraft battery housing is provided, comprising:

[0006] A box-shaped body having a connected battery cavity and an assembly window, wherein the wall of the box-shaped body is filled with three-periodic minimal surface units arranged in an array, so as to form a continuous heat dissipation flow channel and heat dissipation curved surface inside and outside the wall of the box-shaped body;

[0007] The box cover is detachably matched and buckled on the assembly window.

[0008] In some embodiments, the box cover is filled with three-periodic minimal surface units arranged in an array to form continuous heat dissipation channels and heat dissipation surfaces inside and outside the box wall of the box cover.

[0009] In some embodiments, the heat dissipation channel of the box cover is connected to the heat dissipation channel of the box-shaped body.

[0010] In some embodiments, the box cover is provided with an electrode limiting slit for leading out the battery electrodes and limiting the electrode position.

[0011] In some embodiments, an insulating material layer is disposed on the surface of the electrical limiting slit.

[0012] In some embodiments, the unit cell side length a of the three-periodic minimal surface unit is in the range of 0.25d≤a≤0.5d, where d is the thickness of the box wall of the box-shaped body.

[0013] In some embodiments, the thickness da of the curved surface flow channel wall between the flow channels in the three-periodic minimal surface unit is in the range of 0.1a≤da≤0.3a, and da≥0.1mm.

[0014] In some embodiments, the relative density ρ of the three-periodic minimal surface unit relative to a solid block with the same length, width and height specifications is in the range of 20%≤ρ≤80%.

[0015] Another aspect of the present application provides a method for forming an aircraft battery housing, comprising:

[0016] Determine the internal size parameters of the shell according to the geometric characteristics of the battery, and perform model sub-component design and assembly design on the shell according to the selective laser melting process;

[0017] Filling the shell body with three-periodic minimal surface elements;

[0018] Setting the scanning speed, scanning spacing, scanning layer thickness, and scanning path of the selective laser melting forming scheme of the shell;

[0019] The housing is 3D printed and finely machined.

[0020] In some embodiments, 3D printing the housing includes:

[0021] Dry the powder at a temperature of 80-90°C for 6-8 hours;

[0022] Preheat the printed substrate to 200°C and fill the build chamber with argon to maintain an oxygen content of ≤0.05%;

[0023] printing the shell layer by layer;

[0024] The shell is subjected to liquid sand blasting, with an abrasive particle size of 20 mesh to 180 mesh, a compressed air pressure of 0.3 MPa to 0.5 MPa, a nozzle diameter of 10 mm, and a sand blasting distance of ≥120 mm.

[0025] The embodiments of the present application have at least the following beneficial effects:

[0026] The aircraft battery shell and battery shell forming method provided in the embodiment of the present application include a box-shaped body and a box cover that can be matched and snapped together. A battery cavity is set in the box-shaped body, thereby forming a wrap-around fixed structure slightly larger than the battery volume, thereby obtaining a stable and reliable protective fixed structure with a smaller volume; at the same time, the box-shaped body is filled with three-period minimal surface units arranged in an array, thereby forming continuous heat dissipation channels and heat dissipation surfaces inside and outside the box wall of the box-shaped body. On the one hand, it communicates the inside and outside, accelerates air flow, and improves the heat dissipation effect. On the other hand, compared with conventional shell structures, the use of three-period minimal surface units can double the heat dissipation area, thereby greatly increasing the heat dissipation efficiency. It is worth noting that because the box-shaped body is filled with three-period minimal surface units arranged in an array, the shell forms a hollow structure, which greatly reduces the weight of the shell and can take into account the structural strength, meeting the high strength and low weight requirements of aerospace equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions in the embodiments of the present application, a brief introduction will be given below to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0028] Figure 1 A schematic structural diagram of a box-shaped main body of a housing in an embodiment of the present application is shown;

[0029] Figure 2 Shown Figure 1 Schematic diagram of the structure of the three-periodic minimal surface unit of the box-shaped body;

[0030] Figure 3 A schematic structural diagram of the box cover of the housing in an embodiment of the present application is shown.

[0031] Reference numerals:

[0032] 1-box-type body, 1a-three-periodic minimal surface unit, 11-box heat dissipation flow channel, 12-box heat dissipation surface, 13-assembly window;

[0033] 2-tank cover, 21-tank cover heat dissipation channel, 22-tank cover heat dissipation curved surface. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0035] In addition, this application may repeat reference numbers and / or reference letters in different examples. This repetition is for the purpose of simplicity and clarity and does not in itself indicate the relationship between the various embodiments and / or arrangements discussed. In addition, this application provides examples of various specific processes and materials, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0036] The present application is described below with reference to specific embodiments and with reference to the accompanying drawings:

[0037] Aerospace equipment is typically equipped with functional power supplies to power various equipment components. Considering that these power supplies often operate in extreme conditions, such as high temperatures and extreme cold, and that the equipment has limited space and strict load requirements, high requirements are placed on the heat dissipation capacity and overall weight of the battery. In aerospace equipment, the functional power supply's mounting bracket only secures the power supply, requiring an additional heat dissipation structure. However, this is limited by the installation space, resulting in a small heat dissipation area, a larger overall weight, and unsatisfactory heat dissipation efficiency per unit volume.

[0038] To this end, the embodiments of the present application provide an aircraft battery housing and a battery housing forming method, which aim to solve, to a certain extent, the technical problems of heavy weight of functional power supplies in aerospace equipment and unsatisfactory heat dissipation efficiency per unit volume; and achieve the technical effect of reducing the overall weight of the battery assembly and improving the heat dissipation efficiency per unit volume while taking into account the battery protection strength.

[0039] See also Figure 1 、 Figure 2 and Figure 3 In some embodiments, the aircraft battery housing includes a snap-fit ​​box-shaped body 1 and a box cover 2 .

[0040] The box-shaped body 1 has a battery cavity inside for restraining and protecting the battery. Its internal dimensions are slightly larger than the battery's, leaving only a certain amount of clearance for expansion. The box-shaped body 1 also has an assembly window 13 for inserting the battery into the cavity. The box-shaped body 1 can be shaped like a square, similar to the battery's outer shape, thereby reducing both overall volume and weight while maintaining sufficient protection for the battery.

[0041] The walls of the box-shaped body 1 can be filled with three-periodic minimal surface units 1a arranged in an array, thereby forming continuous box-shaped heat dissipation channels 11 and box-shaped heat dissipation curved surfaces 12 inside and outside the box-shaped body 1. This significantly increases the heat dissipation area compared to conventional box walls, that is, obtaining a larger heat dissipation surface per unit volume, thereby increasing heat dissipation efficiency. At the same time, it can also reduce the weight per unit volume while maintaining structural strength, thus better meeting the requirements of aircraft equipment.

[0042] The box cover 2 is detachably fastened in the assembly window 13 to close the battery cavity in the box-shaped body 1 and restrict the removal of the battery.

[0043] In some embodiments, the box cover 2 may also be filled with the three-periodic minimal surface units 1a, thereby increasing the heat dissipation area, improving the heat dissipation efficiency to a certain extent, and reducing the overall weight of the housing.

[0044] More importantly, since the box cover 2 is filled with three-periodic minimal surface units 1a, it can naturally form a box cover heat dissipation channel 21 and a box cover heat dissipation curved surface 22, which can cooperate with the box body heat dissipation channel 11 and the box body heat dissipation curved surface 12 to dissipate heat, rather than forming a heat dissipation barrier by the box cover 2, thereby relatively improving the heat dissipation efficiency.

[0045] In some embodiments, the box cover 2 can be configured as a T-shaped structure, so that part of the cover body can be embedded in the assembly window 13, thereby improving the structural strength of the area where the assembly window 13 is located to a certain extent.

[0046] In some embodiments, the structural specifications can be designed so that the box body heat dissipation channel 11 and the box cover heat dissipation channel 21 are connected to each other, thereby promoting air flow and accelerating heat dissipation, rather than hindering each other to form a heat dissipation barrier, thereby improving the overall heat dissipation effect.

[0047] In some embodiments, the box cover 2 is further provided with a voltage limiting slit for allowing the battery electrodes to extend out, and can provide voltage limiting protection.

[0048] In some embodiments, in order to improve the insulation performance at the voltage limiting slit, an insulating material may be provided on the surface of the voltage limiting slit to form an insulating material layer.

[0049] In some embodiments, considering that the box wall of the shell is filled with the three-periodic minimal surface units 1a arranged in an array, in order to ensure the structural strength and molding accuracy of the repeating unit, the unit cell side length a of the three-periodic minimal surface unit 1a is limited to 0.25d≤a≤0.5d, where d is the box wall thickness of the box-type main body 1.

[0050] That is to say, the minimum unit cell side length a of the three-period minimal surface unit 1a is 1 / 4 to 1 / 2 of the box wall thickness of the box-type main body 1; in the direction of the box wall thickness on one side, a maximum of four three-period minimal surface units 1a are stacked, and a minimum of two three-period minimal surface units 1a are stacked.

[0051] In some embodiments, in order to further increase the heat dissipation efficiency and take into account the structural strength, the range of the thickness da of the curved channel wall between the heat dissipation channels in the three-period minimal curved surface unit 10a is limited to 0.1a≤da≤0.3a; thereby expanding the space of the heat dissipation channel to a certain extent and increasing the heat dissipation area per unit volume.

[0052] Generally speaking, in order to maintain processing accuracy, the thickness da of the curved flow channel wall is greater than 0.1 mm.

[0053] In some embodiments, considering that the three-periodic minimal surface unit 1a is the smallest constituent unit of the box wall, its structural strength determines the overall strength and reliability of the shell. The relative density ρ of the three-periodic minimal surface unit 1a relative to the solid block with the same length, width and height dimensions can be limited to 20%≤ρ≤80%, thereby taking into account the heat dissipation efficiency, structural strength and lightweight performance.

[0054] The present application also provides a method for forming the aircraft battery housing, comprising:

[0055] Determine the internal size parameters of the shell according to the geometric characteristics of the battery, and perform model sub-component design and assembly design on the shell according to the selective laser melting process;

[0056] Filling the shell body with three-periodic minimal surface elements;

[0057] Setting the scanning speed, scanning spacing, scanning layer thickness, and scanning path of the selective laser melting forming scheme of the shell;

[0058] The housing is 3D printed and finely machined.

[0059] Specifically, determining the internal dimension parameters of the housing according to the geometric characteristics of the battery includes:

[0060] The hollow structure is designed according to the geometric characteristics and size parameters of the contents, with an inner cavity geometric matching degree of ≥95% and an internal size tolerance of ±1mm;

[0061] Determine and complete the shell thickness d and other dimensional parameters according to the technical indicators of the parts' load-bearing requirements;

[0062] Considering the formability of the selective laser melting process, the parts are split and assembled. The processing overhang surface angle of the designed split parts should be ≥45°.

[0063] Porous lightweight design of part models: The split-designed parts are imported into topology optimization software, and the shell body is filled with three-periodic minimal surface elements, which are then exported as STL files.

[0064] The unit cell side length a is limited to a range of 0.25d≤a≤0.5d, the surface thickness da is limited to a range of 0.1a≤da≤0.3a and da≥0.1mm, the relative density ρ is limited to a range of 20%≤ρ≤80%, and the crushing load is ≥1.5 times the rated load.

[0065] Modeling and slicing: The lightweight designed STL file is imported into Magic Materialia software for model repair and processing. The slice layer thickness, laser parameters and scanning strategy are set in the slicing software, where 10um≤h≤60um, the laser power during printing is 200-350W, the scanning spacing is 0.08-0.12mm, the scanning speed is 800-1200mm / s, and the inter-layer rotation angle is 67°. The slice file is exported to the selective laser melting equipment for manufacturing.

[0066] In some embodiments, 3D printing the housing includes:

[0067] Dry the powder at a temperature of 80-90°C for 6-8 hours;

[0068] Preheat the printed substrate to 200°C and fill the build chamber with argon to maintain an oxygen content of ≤0.05%;

[0069] The housing is printed layer by layer.

[0070] Selective Laser Melting: First, the powder is dried at 80°C-90°C for 6-8 hours. The substrate is preheated to 200°C and the build chamber is filled with argon to maintain an oxygen content of ≤0.05%. Printing is then performed layer by layer until the porous shell is obtained.

[0071] Parts post-processing: Liquid sandblasting is performed on the parts, with corundum sand as the abrasive, particle size 20-180 mesh, compressed air pressure 0.3-0.5MPa, nozzle diameter 10mm, and sandblasting distance ≥120mm. The parts are then finished to meet the final size requirements.

[0072] Insulation layer and assembly: Insulation coating is applied at the contact point between the shell and the battery electrode, and then the parts are assembled to obtain the final parts.

[0073] The present invention is described in detail below with reference to a specific product embodiment.

[0074] The battery size is 67mm*88mm*4mm. The shell size is determined according to the battery size characteristics. The shell thickness is 5mm. Considering the characteristics of the selective laser melting process, the shell is split into two parts for manufacturing.

[0075] The model was imported into topology optimization software for three-periodic minimal surface filling, with a unit cell side length of 2.5mm and a surface thickness of 1mm. The part model was then imported into Magic Materialia software for repair and other processing. The settings were: a powder layer thickness of 40μm, a laser power of 300W, a scan pitch of 0.1mm, a scan speed of 1000mm / s, an island scanning strategy, and an inter-layer rotation angle of 67°, to complete the layered slicing.

[0076] 15-53um GH4169 powder was selected and baked at 90℃ for 6 hours. 304 stainless steel was selected as the substrate, preheated to 200℃, and argon was introduced to reduce the oxygen content to less than 0.05%. After printing was completed, the parts were separated from the substrate using wire cutting.

[0077] Finishing is when the parts meet the final size requirements, sandblasting and assembly to obtain the final housing components.

[0078] The embodiments of the present application have at least the following beneficial effects:

[0079] The aircraft battery shell and battery shell forming method provided in the embodiment of the present application include a box-shaped body and a box cover that can be matched and snapped together. A battery cavity is set in the box-shaped body, thereby forming a wrap-around fixed structure slightly larger than the battery volume, thereby obtaining a stable and reliable protective fixed structure with a smaller volume; at the same time, the box-shaped body is filled with three-period minimal surface units arranged in an array, thereby forming continuous heat dissipation channels and heat dissipation surfaces inside and outside the box wall of the box-shaped body. On the one hand, it communicates the inside and outside, accelerates air flow, and improves the heat dissipation effect. On the other hand, compared with conventional shell structures, the use of three-period minimal surface units can double the heat dissipation area, thereby greatly increasing the heat dissipation efficiency. It is worth noting that because the box-shaped body is filled with three-period minimal surface units arranged in an array, the shell forms a hollow structure, which greatly reduces the weight of the shell and can take into account the structural strength, meeting the high strength and low weight requirements of aerospace equipment.

[0080] In this application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Moreover, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0081] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise" and "counterclockwise" indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0082] It should be noted that all directional indications in the embodiments of the present application are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0083] In this application, unless otherwise specified or limited, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can mean fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. For those skilled in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0084] In addition, the terms "first," "second," and so on, used in this application are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0085] In the description of this specification, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification.

[0086] In addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the fact that ordinary technicians in this field can implement them. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0087] Although the embodiments of the present application have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions, and variations may be made to the embodiments without departing from the principles and intent of the present application, and that the scope of the present application is defined by the claims and their equivalents.

Claims

1. An aircraft battery housing, characterized in that: include: A box-shaped body having a connected battery cavity and an assembly window, wherein the wall of the box-shaped body is filled with three-periodic minimal surface units arranged in an array, so as to form a continuous heat dissipation flow channel and heat dissipation curved surface inside and outside the wall of the box-shaped body; The box cover is detachably matched and buckled on the assembly window.

2. The aircraft battery housing according to claim 1, wherein: The box cover is filled with three-periodic minimal surface units arranged in an array, so as to form continuous heat dissipation channels and heat dissipation curved surfaces inside and outside the box wall of the box cover.

3. The aircraft battery housing according to claim 2, wherein: The heat dissipation channel of the box cover is communicated with the heat dissipation channel of the box-shaped body.

4. The aircraft battery housing according to claim 2, wherein: The box cover is provided with an electrode limiting slit for leading out the battery electrodes and limiting the electrode positions.

5. The aircraft battery housing according to claim 4, wherein: An insulating material layer is provided on the surface of the electrical limiting slit.

6. The aircraft battery housing according to any one of claims 1 to 5, wherein: The unit cell side length a of the three-periodic minimal surface unit is in the range of 0.25d≤a≤0.5d, wherein d is the thickness of the box wall of the box-shaped body.

7. The aircraft battery housing according to claim 6, wherein: The thickness da of the curved surface flow channel wall between the flow channels in the three-periodic minimal surface unit is in the range of 0.1a≤da≤0.3a, and da≥0.1mm.

8. The aircraft battery housing according to claim 7, wherein: The relative density ρ of the three-periodic minimal surface unit relative to a solid block with the same length, width and height specifications is in the range of 20%≤ρ≤80%.

9. A method for forming an aircraft battery housing, characterized in that: include: Determine the internal size parameters of the shell according to the geometric characteristics of the battery, and perform model sub-component design and assembly design on the shell according to the selective laser melting process; Filling the shell body with three-periodic minimal surface elements; Setting the scanning speed, scanning spacing, scanning layer thickness, and scanning path of the selective laser melting forming scheme of the shell; The housing is 3D printed and finely machined.

10. The method for forming an aircraft battery housing according to claim 9, wherein: The 3D printed housing includes: Dry the powder at a temperature of 80-90°C for 6-8 hours; Preheat the printed substrate to 200°C and fill the build chamber with argon to maintain an oxygen content of ≤0.05%; printing the shell layer by layer; The shell is subjected to liquid sand blasting, with an abrasive particle size of 20 mesh to 180 mesh, a compressed air pressure of 0.3 MPa to 0.5 MPa, a nozzle diameter of 10 mm, and a sand blasting distance of ≥120 mm.

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