Battery upper cover based on bionic scorpion backboard and battery pack

Abstract

The invention relates to the technical field of power batteries, in particular to a battery upper cover based on a bionic scorpion backboard and a battery pack. Comprising an outer reinforced protective layer, a middle heat insulation layer and an inner shock-resistant layer which are overlapped, a plurality of convex hull structures in dense array distribution are formed on the surface of the anti-impact layer, the surface of each convex hull structure is arc-shaped, the diameter of each convex hull structure is 1.0-1.5 times of the diameter of solid particles sprayed during thermal runaway of the battery, and the distance between every two adjacent convex hull structures is 0.8-1 time of the diameter of each convex hull structure. According to the battery upper cover, through the bionic convex hull array design, impact energy generated by thermal runaway of a battery cell is efficiently dispersed and absorbed, and the impact resistance is remarkably improved; meanwhile, a multi-layer composite structure is adopted, the outer layer enhances protection, the middle layer insulates heat, and the inner layer resists impact, so that high-temperature conduction during thermal runaway of the battery is effectively blocked, and heat diffusion is prevented.

Description

Technical Field

[0001] This application relates to the field of power battery technology, and in particular to a battery cover and battery pack based on a biomimetic scorpion backplate. Background Technology

[0002] Currently, battery covers for new energy vehicles primarily use metal or ordinary composite material structures, posing significant safety hazards. While metal covers offer some impact resistance, their high thermal conductivity means they cannot effectively block high temperatures during battery thermal runaway, leading to rapid heat dissipation and even meltdown. Furthermore, their weight negatively impacts overall vehicle energy efficiency. Ordinary composite material covers, though lightweight, lack sufficient impact resistance, easily cracking under puncture from sharp objects or severe impacts, failing to effectively protect the internal battery structure. In addition, existing cover structures are mostly planar or simple reinforcing rib designs, lacking efficient mechanisms for dispersing and absorbing impact energy, resulting in limited protective effects. Moreover, current technologies fail to balance high-temperature resistance and impact resistance, making it difficult to meet the increasingly stringent battery safety requirements of new energy vehicles and energy storage systems. An innovative structural design is urgently needed to overcome current technological bottlenecks. Summary of the Invention

[0003] This application provides a battery cover and battery pack based on a biomimetic scorpion backplate, which has both high temperature resistance and impact resistance, and can significantly improve the safety protection level of the battery system.

[0004] In the first aspect, this application provides a battery cover based on a biomimetic scorpion backplate, including an outer reinforcing protective layer, a middle heat insulation layer, and an inner impact-resistant layer. The surface of the impact-resistant layer forms several densely arrayed convex hull structures. The surface of each convex hull structure is arc-shaped. The diameter of each convex hull structure is 1.0 to 1.5 times the diameter of the solid particles ejected during battery thermal runaway. The spacing between two adjacent convex hull structures is 0.8 to 1 times the diameter of the convex hull structure.

[0005] In a preferred embodiment, the reinforcing protective layer is made of one or more of carbon fiber, glass fiber, and aramid fiber reinforced composite materials.

[0006] In a preferred embodiment, the insulation layer is made of one or more of silica aerogel felt and alumina microporous ceramic insulation board.

[0007] In a preferred embodiment, the thermal conductivity of the insulation layer is not higher than 0.03 W / m·K.

[0008] In a preferred embodiment, the material of the impact-resistant layer is polycarbonate or polyetheretherketone with added phosphorus and nitrogen flame retardants.

[0009] In a preferred embodiment, the convex hull structure is filled with SiO2 and / or Al2O3 nanoparticles as a support material.

[0010] In a preferred embodiment, the convex hull structure is generally hemispherical, ellipsoidal, or frustum-shaped.

[0011] In a preferred embodiment, the top of the convex hull structure is a flat or flat arc surface, and the bottom smoothly transitions to the surface of the impact-resistant layer.

[0012] In a preferred embodiment, the reinforcing protective layer, the heat insulation layer, and the impact-resistant layer are integrally molded by compression molding or by high-strength adhesive bonding.

[0013] Secondly, this application provides a battery pack, including the battery cover based on the biomimetic scorpion backplate.

[0014] This application has the following beneficial effects: The battery cover uses a biomimetic convex hull array design to efficiently disperse and absorb the impact energy generated by thermal runaway of the battery cell, significantly improving its impact resistance. At the same time, it adopts a multi-layer composite structure with an outer layer for enhanced protection, a middle layer for heat insulation, and an inner layer for impact resistance, effectively blocking the high-temperature conduction during battery thermal runaway and preventing heat diffusion.

[0015] This application significantly improves the safety protection level of the battery system, extends battery life, and reduces accident risks while maintaining a lightweight design, providing a reliable guarantee for the safe operation of new energy vehicles and energy storage equipment. Attached Figure Description To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 Microscopic structure diagram of the dorsal plate bulge of the Israeli golden scorpion; Figure 2 A first-view schematic diagram of a battery cover based on a biomimetic scorpion backplate provided for an embodiment of this application; Figure 3 A first-view schematic diagram of a battery cover based on a biomimetic scorpion backplate provided for an embodiment of this application; Figure 4 This is a cross-sectional view of the battery cover. Numbering on the map: 1-Outer cover plate; 2-Inner cover plate; 3-Convex structure; 4-Reinforced protective layer; 5-Insulation layer; 6-Impact-resistant layer; 7-Filling material. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and labeled in the accompanying drawings can generally be arranged and designed in various different configurations.

[0018] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0019] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0020] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. 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, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0021] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0022] 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 based on the specific circumstances.

[0023] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0024] The dense granular protrusions on the surface of the cephalothorax of the Israeli golden scorpion are a key structural specialization that enables it to adapt to the desert environment. Figure 1 This image shows the microstructure of the dorsal plate protrusions of the Israeli golden scorpion, demonstrating extremely high levels of enhanced physical defense, structural strength, and damage resistance. The dense, granular protrusions disperse impact force, preventing localized fractures. This is equivalent to forming a "matrix-like reinforced structure" on the dorsal plate surface. When subjected to predator struggles, predator bites, or impacts from rocks, the protrusions distribute concentrated impact force across a larger area of ​​the dorsal plate, preventing the chitinous exoskeleton from fracturing due to excessive localized pressure. Simultaneously, it reduces the transmission of impact damage to internal organs (heart, ganglia). Analogous to "honeycomb structures" or "rib-reinforced designs" in engineering, this design enhances overall compressive and impact resistance by increasing surface roughness and structural redundancy.

[0025] The sharp, raised edges (in some subspecies, the raised edges are micro-spiky) can resist puncture and friction damage, increasing the "anti-slip" and "puncture resistance" of the contact surface. When hunting, the Israeli golden scorpion can prevent the limbs of its prey (such as insects and small arthropods) from scratching its dorsal plate while struggling; and reduce the wear and tear on its dorsal plate from desert sand and gravel when crawling (in the desert environment, the sand and gravel are hard, and a smooth dorsal plate is easily scratched, leading to moisture loss).

[0026] Based on the advantages of the Israeli Golden Scorpion backplate, this embodiment proposes a battery cover based on a biomimetic scorpion backplate, with the specific structure as follows: Figures 2-4 As shown.

[0027] The battery cover is visually divided into an outer cover plate 1 and an inner cover plate 2. The outer cover plate 1 is flat and faces the external environment; the inner cover plate 2 faces the battery cell and has several densely arranged convex hull structures 3. The arrangement can be honeycomb or matrix.

[0028] The convex structure 3 is generally hemispherical, ellipsoidal, or frustum-shaped, with a flat or flat arc-shaped top and a smooth transition to the inner cover plate 2 at the bottom to achieve uniform force distribution. The diameter of the convex structure 3 is 1.0 to 1.5 times the diameter of the solid particles ejected during battery thermal runaway; the spacing between two adjacent convex structures 3 is slightly smaller than the diameter of the convex structure 3, typically 0.8 to 1 times the diameter of the convex structure 3, thus ensuring that the impact force can be borne collaboratively by multiple convex structures. This design significantly improves the impact resistance of the top cover, effectively disperses external impact forces, avoids cracking or deformation caused by localized stress concentration, and thus enhances the safety of the battery under extreme conditions such as collisions and drops.

[0029] Structurally, the battery cover includes an outer reinforcing protective layer 4, a middle heat insulation layer 5, and an inner impact-resistant layer 6, which are stacked together.

[0030] The battery adopts a three-layer composite structure of "outer-middle-inner", with each layer having a clearly defined function. The outer reinforcing protective layer 4 is made of one or more of carbon fiber, glass fiber and aramid fiber reinforced composite materials, which mainly bear external mechanical loads such as impact, puncture and extrusion, and protect the internal structure of the battery from physical damage.

[0031] The middle layer is the heat insulation layer 5, which uses silica aerogel felt or alumina microporous ceramic heat insulation board with a thermal conductivity of less than 0.03 W / m·K. It can effectively block the high temperature during battery thermal runaway and prevent heat from spreading to the outside of the top cover.

[0032] The inner layer is the impact-resistant layer 6, which is made of polycarbonate (PC) or polyether ether ketone (PEEK) with added phosphorus and nitrogen flame retardants, so that it still has good structural stability and flame retardancy in high temperature environment.

[0033] In addition, a lightweight supporting material 7 can be placed inside the convex hull structure 6. The filling material 7 can be selected from nanoparticles such as SiO2 and / or Al2O3 to improve the structural stiffness and resistance to deformation.

[0034] During processing, a compression molding process is used, with the reinforcing protective layer 4, heat insulation layer 5, and impact-resistant layer 6 being integrally molded or compositely bonded using a high-strength adhesive process. Specifically, firstly, the materials of the reinforcing protective layer 4, heat insulation layer 5, and impact-resistant layer 6 undergo surface treatment to improve interlayer bonding strength; then, a high-precision mold is designed based on a biomimetic convex hull structure; next, the laminated materials are placed in the mold and cured under high temperature and pressure, simultaneously forming the biomimetic convex hull structure; finally, the surface of the molded battery cover is treated, such as by spraying a high-temperature resistant coating or an anti-corrosion coating, to improve environmental adaptability.

[0035] The following example uses a power battery pack for a new energy vehicle. This battery pack has a rated voltage of 400V and a capacity of 100kWh. It uses 12 square lithium-ion battery modules arranged in series. The battery pack cover uses the biomimetic battery cover described in this embodiment. The specific process is as follows: Step 1: Bionic Convex Bulb Structure Design: First, the battery cover is designed using biomimetic principles. The convex bulb structure is designed to be approximately hemispherical, with a slightly flattened top and a smooth transition to the inner cover plate at the bottom, achieving uniform distribution of impact force. The convex bulb structure is evenly distributed in a matrix, with the diameter of the convex bulbs approximately 1.2 times the diameter of the solid particles ejected during battery thermal runaway, and the spacing between them 0.9 times the diameter of the convex bulbs. This allows the impact force to be shared collaboratively by multiple convex bulbs, significantly improving the impact resistance of the cover.

[0036] Step Two: Material Selection and Multi-Layer Composite Structure Design: High-strength carbon fiber composite material is used as a reinforcing protective layer to ensure the mechanical strength and rigidity of the top cover. Simultaneously, a high-temperature resistant coating is added to the carbon fiber composite material to improve its high-temperature resistance. Silica aerogel felt is used as a heat insulation layer to further reduce the impact of heat generated during battery operation on the top cover. Polycarbonate with added phosphorus and nitrogen flame retardants is used as an impact-resistant layer.

[0037] Step 3: Molding and Preparation: Hot pressing technology is used to ensure precise molding of the convex structure and tight bonding of materials. Temperature, pressure, and time parameters are controlled during the molding process to reduce internal stress and defects. Then, the battery cover undergoes post-processing, including surface polishing and coating, to improve its surface quality and corrosion resistance.

[0038] Step 4: Performance Verification and Optimization: Comprehensive performance tests were conducted on the molded battery cover, including impact resistance, high temperature resistance, and corrosion resistance tests. Based on the test results, the design was further optimized and adjusted to ensure the stability and reliability of the cover in real-vehicle applications.

[0039] The battery cover uses a biomimetic convex hull array design to efficiently disperse and absorb the impact energy generated by thermal runaway of the battery cell, significantly improving its impact resistance. At the same time, it adopts a multi-layer composite structure with an outer layer for enhanced protection, a middle layer for heat insulation, and an inner layer for impact resistance, effectively blocking the high-temperature conduction during battery thermal runaway and preventing heat diffusion.

[0040] This application significantly improves the safety protection level of the battery system, extends battery life, and reduces accident risks while maintaining a lightweight design, providing a reliable guarantee for the safe operation of new energy vehicles and energy storage equipment.

[0041] This embodiment also provides a battery pack using the aforementioned battery cover based on a biomimetic scorpion backplate, which has all the advantages of the aforementioned battery cover, and will not be repeated here.

[0042] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A battery cover based on a biomimetic scorpion backplate, characterized in that, It includes an outer reinforcing protective layer, a middle heat insulation layer, and an inner impact-resistant layer; The surface of the impact-resistant layer forms several densely arrayed convex hull structures. The surface of each convex hull structure is arc-shaped. The diameter of each convex hull structure is 1.0 to 1.5 times the diameter of the solid particles ejected during battery thermal runaway. The spacing between two adjacent convex hull structures is 0.8 to 1 times the diameter of the convex hull structure.

2. The battery cover based on a biomimetic scorpion backplate according to claim 1, characterized in that, The reinforcing protective layer is made of one or more of carbon fiber, glass fiber, and aramid fiber reinforced composite materials.

3. The battery cover based on a biomimetic scorpion backplate according to claim 1, characterized in that, The insulation layer is made of one or more of silica aerogel felt and alumina microporous ceramic insulation board.

4. The battery cover based on a biomimetic scorpion backplate according to claim 3, characterized in that, The thermal conductivity of the insulation layer is not higher than 0.03 W / m·K.

5. The battery cover based on a biomimetic scorpion backplate according to claim 1, characterized in that, The impact-resistant layer is made of polycarbonate or polyether ether ketone with added phosphorus and nitrogen flame retardants.

6. The battery cover based on a biomimetic scorpion backplate according to claim 1, characterized in that, The convex hull structure is filled with SiO2 and / or Al2O3 nanoparticles as a support material.

7. The battery cover based on a biomimetic scorpion backplate according to claim 1, characterized in that, The convex hull structure is generally hemispherical, ellipsoidal, or frustum-shaped.

8. The battery cover based on a biomimetic scorpion backplate according to claim 7, characterized in that, The top of the convex hull structure is a flat or flat arc surface, and the bottom smoothly transitions to the surface of the impact-resistant layer.

9. The battery cover based on a biomimetic scorpion backplate according to claim 1, characterized in that, The reinforced protective layer, the heat insulation layer, and the impact-resistant layer are integrally molded by compression molding or composite molding by high-strength adhesive bonding.

10. A battery pack, characterized in that, Includes the battery cover as described in any one of claims 1 to 9.

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