Anti-condensation stone-impact-resistant battery tray and preparation process thereof
By combining an anti-condensation layer and an anti-stone impact layer sprayed onto the battery tray substrate, the contradiction between anti-condensation and anti-stone impact is resolved, achieving lightweight and reliable comprehensive protection and extending the service life of the battery tray.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-26
- Publication Date
- 2026-03-27
AI Technical Summary
Existing battery trays cannot simultaneously meet the requirements of anti-condensation and stone impact resistance. Anti-condensation solutions often have low hardness, making it difficult to meet the requirements of bottom stone impact resistance, while stone impact resistance solutions increase weight and are prone to forming thermal bridges, affecting anti-condensation performance.
The design employs a combination of an anti-condensation layer and an anti-stone impact layer. The anti-condensation layer is composed of polyether polyol, catalyst, modified nano-silica, and foaming agent, while the anti-stone impact layer is composed of polyvinyl chloride, plasticizer, and modified hollow glass microspheres. The two layers are formed on the battery tray substrate through a spraying process.
It achieves significant improvements in anti-condensation and anti-stone impact performance while maintaining a lightweight design, extends the lifespan of the battery tray, reduces costs, and is suitable for mass production.
Smart Images
Figure CN121748674A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of new energy vehicle battery tray technology, specifically relating to an anti-condensation and anti-stone impact battery tray and its preparation process. Background Technology
[0002] With the global energy transition and increasingly stringent environmental requirements, new energy vehicles, especially pure electric vehicles, have experienced rapid development. As the "heart" of an electric vehicle, the performance, safety, and lifespan of the power battery pack directly determine the core competitiveness of the entire vehicle. The battery tray, as a key structural component of the battery pack, not only bears the important responsibility of supporting, fixing, and protecting the battery cell modules, but also must possess multiple functions such as lightweight design, sealing, thermal conductivity / insulation, and corrosion resistance.
[0003] However, among the many performance requirements of battery trays, anti-condensation and stone impact resistance are two crucial but contradictory technical challenges, and existing technical solutions often fail to address both: (1) Anti-condensation problem: The battery pack generates heat during operation. In environments with temperature changes or high humidity, the wall temperature of the internal cavity of the battery pack may be lower than the dew point temperature of the air, resulting in water vapor condensation. The generation of condensate can cause serious safety hazards, including causing internal short circuits in the battery, triggering leakage accidents, accelerating the corrosion of metal parts, and reducing high-voltage insulation performance. Currently, the mainstream anti-condensation solution is to design complex anti-condensation coatings on the battery tray or use composite materials with low thermal conductivity to isolate thermal bridges. However, these coatings or materials often have low hardness and insufficient toughness, making it difficult to meet the requirements for bottom stone impact resistance. (2) Stone impact resistance problem: During vehicle operation, especially at high speeds or in poor road conditions, the bottom of the battery tray will be subjected to severe impacts from foreign objects such as flying stones on the road. This requires the bottom material of the tray to have extremely high impact strength, puncture resistance, and wear resistance. Currently, the industry typically uses metal materials such as aluminum alloys and structural designs (such as thickening and adding reinforcing ribs) to address this issue. However, this significantly increases the weight of the pallet, contradicting the trend towards lightweighting in the automotive industry. Furthermore, metal materials are excellent conductors of heat, easily forming thermal bridges and creating a breeding ground for condensation. While there are solutions using engineering plastics or composite materials to reduce weight, the surface hardness and impact resistance of these materials are often insufficient to withstand harsh stone impact conditions, and research on their integrated design with anti-condensation functions is still in its early stages.
[0004] Therefore, there is an urgent need in this field for an innovative battery tray solution that can fundamentally and synergistically resolve the contradiction between anti-condensation and anti-stone impact, and achieve long-term, reliable comprehensive protection while ensuring lightweight design, so as to meet the increasingly stringent safety and performance requirements of electric vehicles. Summary of the Invention
[0005] The purpose of this invention is to provide an anti-condensation and anti-stone-impact battery tray and its manufacturing process, so as to solve the technical problems involved in the background art.
[0006] The objective of this invention can be achieved through the following technical solutions: The first aspect of the present invention provides an anti-condensation and anti-stone-impact battery tray, the anti-condensation and anti-stone-impact battery tray comprising a battery tray substrate, an anti-condensation layer and an anti-stone-impact layer; the thickness of the anti-condensation layer is 3-5 mm; the thickness of the anti-stone-impact layer is 0.8-1.5 mm; The anti-condensation layer comprises component A and component B; The mass ratio of component A to component B is 0.9–1.2:1; The A component comprises the following raw materials in parts by weight: 96-100 parts of polyether polyol, 3-5 parts of catalyst, 13-18 parts of modified nano silica, 3-5 parts of foaming agent and 1-2 parts of foaming stabilizer; Component B comprises the following raw materials in parts by weight: 100 parts of polyisocyanate.
[0007] Furthermore, the modified nano-silica is prepared through the following steps: S1. Rosin, N,N-diisopropylethylamine and O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid were added to N,N-dimethylformamide and stirred at room temperature for 1-1.5 h. Cysteine was then added and the reaction was continued for 22-26 h. After the reaction was completed, the mixture was washed, dried and separated by chromatographic column to obtain modified rosin acid. S2. Add dopamine, benzoyl peroxide, modified rosin and nano silica to anhydrous ethanol, ultrasonically disperse until uniform, stir for 3-3.5 h, after the reaction is complete, filter, wash and dry to obtain modified nano silica.
[0008] Furthermore, in S1, the ratio of rosin, N,N-diisopropylethylamine, O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid, N,N-dimethylformamide, and cysteine is 3–3.1 g: 2.5–2.6 g: 3.8–3.85 g: 100 mL: 2.25–2.28 g; in S2, the ratio of dopamine, benzoyl peroxide, modified rosin, nano-silica, and anhydrous ethanol is 0.32–0.34 g: 0.12–0.16 g: 0.24–0.25 g: 0.3–0.35 g: 100 mL.
[0009] In the above technical solution, hydrophobic nano-silica is prepared by coating mercapto-modified rosin onto the surface of nano-silica with dopamine, which effectively reduces the agglomeration of nano-silica and allows nano-silica to be better dispersed in polyurethane prepolymer, thereby effectively increasing the hydrophobicity and mechanical strength of polyurethane material.
[0010] Further, the polyether polyol is at least one of trimethylolpropane-propylene oxide polyether, pentaerythritol-propylene oxide polyether, and sorbitol-propylene oxide polyether; the catalyst is at least one of dibutyltin dilaurate, stannous octoate, stannous oleate, triethylenediamine, and cyclohexylmethyl tertiary amine; and the polyisocyanate is at least one of toluene diisocyanate and diphenylmethylene diisocyanate.
[0011] Furthermore, the foaming agent is water; the foaming stabilizer is at least one of dimethyl silicone oil, hydrogen-containing silicone oil, hydroxyl silicone oil, amino silicone oil, and polyether-modified silicone oil.
[0012] Furthermore, the anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 30-40 parts plasticizer, 8-15 parts modified hollow glass microspheres, 1-3 parts organotin stabilizer, and 1.5-2 parts tackifier; The modified hollow glass microspheres are prepared through the following steps: Hollow glass microspheres and stearic acid were added to anhydrous ethanol, and the mixture was heated to 75–80 °C and stirred for 1–2 hours. After the reaction was completed, the microspheres were filtered, washed, and dried to obtain modified hollow glass microspheres. The stearic acid modification of the hollow glass microspheres reduced their agglomeration in polyvinyl chloride (PVC), thereby reducing the chance of stress concentration in the matrix under stress. This effectively allowed the nanoparticles to exert their reinforcing and toughening effects, ultimately improving the mechanical properties of the composite material.
[0013] Furthermore, the ratio of hollow glass microspheres, stearic acid, and anhydrous ethanol is 1.2–1.5 g: 0.3–0.4 g: 50 mL; wherein the mass fraction of stearic acid is 4%–10%; and the particle size of the hollow glass microspheres is 50–100 nm.
[0014] Furthermore, the plasticizer is at least one selected from dioctyl sebacate, diallyl phthalate, and epoxidized soybean oil. The plasticizer can improve the processing performance and flexibility of PVC anti-stone chip coatings by weakening the intermolecular forces of PVC in the modified PVC paste resin and lowering the temperature required for its softening.
[0015] Furthermore, the tackifier is one of polyurethane, polyacrylic acid, polyamide, terpene resin, and polyethylene glycol diester. The tackifier enhances the cohesiveness and adhesion of the PVC anti-stone chip coating to the substrate, thereby ensuring that the PVC anti-stone chip coating adheres firmly to the substrate surface after application.
[0016] A second aspect of the present invention provides a manufacturing process for an anti-condensation and anti-stone-impact battery tray, comprising the following steps: Step 1: Degrease and clean the molded battery tray substrate to remove surface oil. Step 2: Load the anti-condensation coating into the spraying equipment. Mix the two components according to the ratio before use. Spray the anti-condensation coating evenly onto the treated battery tray substrate, control the spraying thickness, and perform preliminary curing until surface dry or semi-cured to form an anti-condensation layer. Step 3: Using the same spraying process, evenly spray the anti-stone chip coating onto the anti-condensation layer, control the spraying thickness, and continue to cure the double-layered battery tray. Allow it to cool naturally to room temperature to obtain the final product.
[0017] The beneficial effects of this invention are: This invention provides an anti-condensation and stone-impact resistant battery tray. The battery tray includes a battery tray substrate, an anti-condensation layer, and an anti-stone-impact layer. The anti-condensation coating and the anti-stone-impact coating are sprayed sequentially onto the surface of the battery tray substrate, forming two functionally distinct and highly interfacially bonded organic coatings on the surface of the battery tray substrate. The anti-condensation layer effectively eliminates the risk of internal condensation, and the anti-stone-impact layer has excellent stone-impact resistance. Together with the anti-condensation layer, they constitute a double protection for the battery tray, significantly extending the service life of the battery tray.
[0018] The anti-condensation layer in this invention is composed of component A and component B. Through the interaction of the components, the hydrophobicity of the coating surface is improved, and the contact angle with water is increased, thereby preventing the adsorption and deposition of condensation. The coating is also less prone to damage and exhibits excellent waterproof, anti-condensation, flame-retardant, and mechanical properties. The hydrophobically modified nano-silica has good interfacial compatibility with the polyurethane matrix, allowing it to be uniformly dispersed in the matrix, improving the coating's impact resistance and roughness. Simultaneously, it gives the coating superhydrophobicity, significantly enhancing its waterproof and anti-condensation performance. Furthermore, the anti-condensation layer also has good anti-icing properties. The micro-nano rough structure on the surface of the anti-condensation layer plays a key role in improving its anti-icing performance. This structure allows an air layer to form on the sample surface, significantly reducing the actual contact area between the material and water droplets, thereby delaying the freezing process of the droplets and achieving an anti-icing effect.
[0019] The impact-resistant coating provided by this invention uses polyvinyl chloride (PVC) as its main raw material, with the addition of plasticizers. Compared with the commonly used polyethylene, the coating material exhibits superior adhesion, toughness, and creep resistance. By introducing modified hollow glass microspheres, the stone-impact resistance and corrosion resistance of the PVC stone-impact coating are further optimized. Furthermore, due to the low-density characteristics of the hollow glass microspheres, the weight of the coating is effectively controlled, avoiding the use of heavy inorganic materials and achieving lightweighting, thus meeting the lightweight development requirements of electric vehicles.
[0020] The present invention provides a manufacturing process for an anti-condensation and anti-stone-impact battery tray. The manufacturing method is simple, and all processes are achieved by spraying, without the need for more complex processes such as baking paint. The process is concise, effectively reducing costs and improving work efficiency, making it suitable for mass production. Attached Figure Description
[0021] The invention will now be further described with reference to the accompanying drawings.
[0022] Figure 1 This is a schematic diagram of the structure of an anti-condensation and anti-stone-impact battery tray according to the present invention; In the diagram: 1. Battery tray substrate; 2. Anti-condensation layer; 3. Anti-stone impact layer. Detailed Implementation
[0023] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0024] Example
[0025] Example 1
[0026] This embodiment provides an anti-condensation and anti-stone-impact battery tray and its manufacturing process: A battery tray with anti-condensation and anti-stone impact properties, comprising a battery tray substrate, an anti-condensation layer (3 mm thick), and an anti-stone impact layer (0.8 mm thick). The anti-condensation layer comprises component A and component B; The mass ratio of component A to component B is 0.9:1; Component A comprises the following raw materials in parts by weight: 96 parts of trimethylolpropane-propylene oxide polyether, 3 parts of dibutyltin dilaurate, 13 parts of modified nano silica, 3 parts of water, and 1 part of dimethyl silicone oil. Component B comprises the following raw materials in parts by weight: 100 parts of toluene diisocyanate.
[0027] The modified nano-silica is prepared through the following steps: S1. 3g of rosin, 2.5g of N,N-diisopropylethylamine and 3.8g of O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid were added to 100mL of N,N-dimethylformamide and stirred at room temperature for 1h. Then 2.25g of cysteine was added and the reaction was continued for 4h. After the reaction was completed, the product was washed 5 times with saturated brine, dried and separated by chromatographic column to obtain modified rosin acid. S2. Add 0.32g dopamine, 0.12g benzoyl peroxide, 0.24g modified rosin and 0.3g nano silica to 100mL anhydrous ethanol, ultrasonically disperse until uniform, stir for 3h, and after the reaction is completed, filter, wash and dry to obtain modified nano silica.
[0028] The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 30 parts dioctyl sebacate, 8 parts modified hollow glass microspheres, 1 part organotin stabilizer, and 1.5 parts polyurethane; The modified hollow glass microspheres are prepared through the following steps: 1.2 g of hollow glass microspheres (60 nm in diameter) and 0.3 g of stearic acid (5% by mass) were added to 50 mL of anhydrous ethanol. The mixture was heated to 75 °C and stirred for 1 h. After the reaction was completed, the mixture was filtered, washed, and dried to obtain modified hollow glass microspheres.
[0029] A manufacturing process for an anti-condensation and anti-stone-impact battery tray includes the following steps: Step 1: Degrease and clean the molded battery tray substrate to remove surface oil. Step 2: Load the anti-condensation coating into the spraying equipment. Mix the two components according to the ratio before use. Spray the anti-condensation coating evenly onto the treated battery tray substrate, control the spraying thickness, and perform preliminary curing until surface dry or semi-cured to form an anti-condensation layer. Step 3: Using the same spraying process, evenly spray the anti-stone chip coating onto the anti-condensation layer, control the spraying thickness, and continue to cure the double-layered battery tray. Allow it to cool naturally to room temperature to obtain the final product.
[0030] Example 2
[0031] The only difference compared to Example 1 is: The modified nano-silica is prepared through the following steps: S1. 3.1 g of rosin, 2.6 g of N,N-diisopropylethylamine and 3.85 g of O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid were added to 100 mL of N,N-dimethylformamide and stirred at room temperature for 1.5 h. Then 2.28 g of cysteine was added and the reaction was continued for 24 h. After the reaction was completed, the product was washed 5 times with saturated brine, dried and separated by chromatographic column to obtain modified rosin acid. S2. Add 0.32g dopamine, 0.12g benzoyl peroxide, 0.24g modified rosin and 0.3g nano silica to 100mL anhydrous ethanol, ultrasonically disperse until uniform, stir for 3h, and after the reaction is completed, filter, wash and dry to obtain modified nano silica.
[0032] Example 3
[0033] The only difference compared to Example 1 is: The modified nano-silica is prepared through the following steps: S1. 3g of rosin, 2.5g of N,N-diisopropylethylamine and 3.8g of O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid were added to 100mL of N,N-dimethylformamide and stirred at room temperature for 1h. Then 2.25g of cysteine was added and the reaction was continued for 4h. After the reaction was completed, the product was washed 5 times with saturated brine, dried and separated by chromatographic column to obtain modified rosin acid. S2. Add 0.34g dopamine, 0.16g benzoyl peroxide, 0.25g modified rosin and 0.35g nano silica to 100mL anhydrous ethanol, ultrasonically disperse until uniform, stir for 3h, and after the reaction is completed, filter, wash and dry to obtain modified nano silica.
[0034] Example 4
[0035] The only difference compared to Example 1 is: The modified hollow glass microspheres are prepared through the following steps: 1.5 g of hollow glass microspheres (60 nm in diameter) and 0.4 g of stearic acid (5% by mass) were added to 50 mL of anhydrous ethanol. The mixture was heated to 75 °C and stirred for 1 h. After the reaction was completed, the mixture was filtered, washed, and dried to obtain modified hollow glass microspheres.
[0036] Example 5
[0037] The only difference compared to Example 1 is: The mass ratio of component A to component B is 1.2:1.
[0038] Example 6
[0039] The only difference compared to Example 1 is: Component A comprises the following raw materials in parts by weight: 98 parts of trimethylolpropane-propylene oxide polyether, 4 parts of dibutyltin dilaurate, 16 parts of modified nano silica, 4 parts of water, and 1.5 parts of dimethyl silicone oil.
[0040] Example 7
[0041] The only difference compared to Example 1 is: Component A comprises the following raw materials in parts by weight: 100 parts of trimethylolpropane-propylene oxide polyether, 5 parts of dibutyltin dilaurate, 18 parts of modified nano silica, 5 parts of water, and 2 parts of dimethyl silicone oil.
[0042] Example 8
[0043] The only difference compared to Example 1 is: The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 35 parts dioctyl sebacate, 12 parts modified hollow glass microspheres, 2 parts organotin stabilizer, and 1.8 parts polyurethane.
[0044] Example 9
[0045] The only difference compared to Example 1 is: The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 40 parts dioctyl sebacate, 15 parts modified hollow glass microspheres, 3 parts organotin stabilizer, and 2 parts polyurethane.
[0046] Example 10
[0047] The only difference compared to Example 1 is: A battery tray with anti-condensation and anti-stone impact properties, comprising a battery tray substrate, an anti-condensation layer (3 mm thick) and an anti-stone impact layer (1.4 mm thick).
[0048] Example 11
[0049] The only difference compared to Example 1 is: A battery tray with anti-condensation and stone impact resistance, comprising a battery tray substrate, an anti-condensation layer (5 mm thick), and a stone impact resistance layer (1 mm thick).
[0050] Comparative Example
[0051] Comparative Example 1
[0052] This comparative example provides an anti-condensation and anti-stone-impact battery tray and its manufacturing process: A battery tray with anti-condensation and anti-stone impact properties, comprising a battery tray substrate, an anti-condensation layer (3 mm thick), and an anti-stone impact layer (0.8 mm thick). The anti-condensation layer comprises component A and component B; The mass ratio of component A to component B is 0.9:1; Component A comprises the following raw materials in parts by weight: 96 parts of trimethylolpropane-propylene oxide polyether, 3 parts of dibutyltin dilaurate, 3 parts of water, and 1 part of dimethyl silicone oil; Component B comprises the following raw materials in parts by weight: 100 parts of toluene diisocyanate.
[0053] The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 30 parts dioctyl sebacate, 1 part organotin stabilizer, 1.5 parts polyurethane; A manufacturing process for an anti-condensation and anti-stone-impact battery tray includes the following steps: Step 1: Degrease and clean the molded battery tray substrate to remove surface oil. Step 2: Load the anti-condensation coating into the spraying equipment. Mix the two components according to the ratio before use. Spray the anti-condensation coating evenly onto the treated battery tray substrate, control the spraying thickness, and perform preliminary curing until surface dry or semi-cured to form an anti-condensation layer. Step 3: Using the same spraying process, evenly spray the anti-stone chip coating onto the anti-condensation layer, control the spraying thickness, and continue to cure the double-layered battery tray. Allow it to cool naturally to room temperature to obtain the final product.
[0054] Comparative Example 2
[0055] The only difference compared to Example 1 is: Component A comprises the following raw materials in parts by weight: 96 parts of trimethylolpropane-propylene oxide polyether, 3 parts of dibutyltin dilaurate, 13 parts of nano silica, 3 parts of water, and 1 part of dimethyl silicone oil.
[0056] Comparative Example 3
[0057] The only difference compared to Example 1 is: The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 30 parts dioctyl sebacate, 8 parts hollow glass microspheres, 1 part organotin stabilizer, and 1.5 parts polyurethane.
[0058] Comparative Example 4
[0059] The only difference compared to Example 1 is: The mass ratio of component A to component B is 0.8:1.
[0060] Comparative Example 5
[0061] The only difference compared to Example 1 is: The mass ratio of component A to component B is 1.35:1.
[0062] Comparative Example 6
[0063] The only difference compared to Example 1 is: Component A comprises the following raw materials in parts by weight: 96 parts of trimethylolpropane-propylene oxide polyether, 3 parts of dibutyltin dilaurate, 10 parts of modified nano silica, 3 parts of water, and 1 part of dimethyl silicone oil.
[0064] Comparative Example 7
[0065] The only difference from Example 7 is that: Component A comprises the following raw materials in parts by weight: 100 parts of trimethylolpropane-propylene oxide polyether, 5 parts of dibutyltin dilaurate, 21 parts of modified nano silica, 5 parts of water, and 2 parts of dimethyl silicone oil.
[0066] Comparative Example 8
[0067] The only difference compared to Example 1 is: The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 30 parts dioctyl sebacate, 6 parts modified hollow glass microspheres, 1 part organotin stabilizer, and 1.5 parts polyurethane.
[0068] Comparative Example 9
[0069] The only difference compared to Example 9 is: The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 40 parts dioctyl sebacate, 19 parts modified hollow glass microspheres, 3 parts organotin stabilizer, and 2 parts polyurethane.
[0070] Comparative Example 10
[0071] The only difference compared to Example 1 is: A battery tray with anti-condensation and anti-stone impact properties, comprising a battery tray substrate, an anti-condensation layer (3 mm thick) and an anti-stone impact layer (0.6 mm thick).
[0072] Comparative Example 11
[0073] The only difference compared to Example 1 is: A battery tray with anti-condensation and anti-stone impact properties, comprising a battery tray substrate, an anti-condensation layer (2 mm thick) and an anti-stone impact layer (0.8 mm thick).
[0074] Comparative Example 12
[0075] The only difference compared to Example 1 is: A battery tray with anti-condensation and anti-stone impact properties, comprising a battery tray substrate, an anti-condensation layer (6.5 mm thick) and an anti-stone impact layer (2 mm thick).
[0076] Performance testing
[0077] The battery trays prepared in Examples 1-11 and Comparative Examples 1-12 were subjected to performance tests, wherein the battery tray substrate was made of aluminum alloy. The tests are as follows: (1) Damp heat cycle test: The damp heat cycle test was conducted according to standard GB / T 2423.34-2012: The battery tray was placed in the temperature and humidity test chamber to simulate the day and night temperature difference and humidity change of the vehicle. Extreme cycle was set, and the temperature was rapidly switched from 60℃ and 95%RH to -10℃ within 3 hours and maintained for a period of time. The cycle was repeated 50 times, and it was observed whether condensation droplets or water mist appeared.
[0078] (2) Water absorption test: The water absorption test shall be conducted in accordance with the standard GB / T 8810-2005.
[0079] (3) Stone impact resistance test: According to standard SAE J400, a gravel impact tester is used to impact the bottom, sides and joints of the battery tray with gravel of size 4-10mm, angular shape and weight, with an impact volume of 1L, at a speed of 100km / h and an angle of 45° and 90°. After impact, check whether there are cracks, perforations, coating peeling or obvious dents on the surface.
[0080] (4) Hardness test: The hardness of the bottom of the battery tray was tested according to the standard ASTM D2240.
[0081] (5) Adhesion test: The battery tray base was tested using the cross-cut test (1mm×1mm).
[0082] The test results are shown in Table 1: Table 1
[0083] As shown in Table 1, the battery trays prepared in Examples 1-11 exhibit better anti-condensation and stone impact resistance than those prepared in Comparative Examples 1-12. Therefore, the anti-condensation and stone impact resistant battery tray prepared by this invention not only possesses excellent stone impact resistance but also, together with the anti-condensation layer, provides dual protection for the battery tray, significantly extending its service life.
[0084] Combining Comparative Examples 1-3 and Example 1, it can be seen that in Comparative Example 1, no modified silica was added to the anti-condensation coating material, and no modified hollow glass microspheres were added to the impact-resistant layer material; in Comparative Example 2, only the anti-condensation coating material lacked modified silica, and in Comparative Example 3, only the impact-resistant layer material lacked modified hollow glass microspheres. Furthermore, considering the data in Table 1, it can be seen that the anti-condensation and stone-impact resistance of the battery tray prepared in Comparative Example 1 were significantly lower than those in Example 1; the stone-impact resistance of Comparative Example 2 was higher than that of Comparative Example 1 but lower than that of Comparative Example 3; and the anti-condensation resistance of Comparative Example 3 was higher than that of Comparative Example 1 but lower than that of Comparative Example 2. Therefore, the addition of modified nano-silica greatly improves the hydrophobic properties of the polyurethane material, thereby improving the waterproof and anti-condensation performance of the coating. The addition of modified hollow glass microspheres to the impact-resistant layer further optimizes the stone-impact resistance and corrosion resistance of the polyvinyl chloride anti-stone-impact coating.
[0085] As can be seen from Comparative Examples 4-7 and Example 1, different proportions of raw materials result in different anti-condensation effects of the anti-condensation layer.
[0086] As can be seen from Comparative Examples 8-9 and Example 1, different proportions of raw materials result in different stone impact resistance effects of the impact-resistant layer.
[0087] As can be seen from Comparative Examples 10-12 and Example 1, the thickness of the impact-resistant layer in Comparative Example 10 is lower than the thickness specified in this invention; the thickness of the anti-condensation layer in Comparative Example 11 is lower than the thickness specified in this invention; and the thicknesses of both the anti-condensation and impact-resistant layers in Comparative Example 12 are much greater than the thickness specified in this invention. The anti-condensation layer material has low stiffness, and an excessively thick anti-condensation material layer will affect the stiffness and strength of the impact-resistant layer, thus having an adverse effect under compression or vibration conditions. Therefore, it is evident that different thicknesses also affect the effectiveness of anti-condensation and stone impact resistance.
[0088] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0089] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A battery tray with anti-condensation and anti-stone-impact properties, characterized in that, The anti-condensation and anti-stone-impact battery tray includes a battery tray substrate, an anti-condensation layer, and an anti-stone-impact layer; the thickness of the anti-condensation layer is 3-5 mm; the thickness of the anti-stone-impact layer is 0.8-1.5 mm. The anti-condensation layer comprises component A and component B; The mass ratio of component A to component B is 0.9–1.2:1; The A component comprises the following raw materials in parts by weight: 96-100 parts of polyether polyol, 3-5 parts of catalyst, 13-18 parts of modified nano silica, 3-5 parts of foaming agent and 1-2 parts of foaming stabilizer; Component B comprises the following raw materials in parts by weight: 100 parts of polyisocyanate.
2. The anti-condensation and anti-stone-impact battery tray according to claim 1, characterized in that, The modified nano-silica is prepared through the following steps: S1. Rosin, N,N-diisopropylethylamine and O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid were added to N,N-dimethylformamide and stirred at room temperature for 1-1.5 h. Cysteine was then added and the reaction was continued for 22-26 h. After the reaction was completed, the mixture was washed, dried and separated by chromatographic column to obtain modified rosin acid. S2. Add dopamine, benzoyl peroxide, modified rosin and nano silica to anhydrous ethanol, ultrasonically disperse until uniform, stir for 3-3.5 h, after the reaction is completed, filter, wash and dry to obtain modified nano silica.
3. The anti-condensation and anti-stone-impact battery tray according to claim 2, characterized in that, In S1, the ratio of rosin, N,N-diisopropylethylamine, O-benzotriazole-N,N,N',N'-tetramethylurea tetrafluoroboric acid, N,N-dimethylformamide, and cysteine is 3–3.1 g: 2.5–2.6 g: 3.8–3.85 g: 100 mL: 2.25–2.28 g; in S2, the ratio of dopamine, benzoyl peroxide, modified rosin, nano-silica, and anhydrous ethanol is 0.32–0.34 g: 0.12–0.16 g: 0.24–0.25 g: 0.3–0.35 g: 100 mL.
4. The anti-condensation and anti-stone-impact battery tray according to claim 1, characterized in that, The polyether polyol is at least one of trimethylolpropane-propylene oxide polyether, pentaerythritol-propylene oxide polyether, and sorbitol-propylene oxide polyether; the catalyst is at least one of dibutyltin dilaurate, stannous octoate, stannous oleate, triethylenediamine, and cyclohexylmethyl tertiary amine; and the polyisocyanate is at least one of toluene diisocyanate and diphenylmethylene diisocyanate.
5. The anti-condensation and anti-stone-impact battery tray according to claim 1, characterized in that, The foaming agent is water; the foaming stabilizer is at least one of dimethyl silicone oil, hydrogen-containing silicone oil, hydroxyl silicone oil, amino silicone oil, and polyether-modified silicone oil.
6. The anti-condensation and anti-stone-impact battery tray according to claim 1, characterized in that, The anti-stone impact layer comprises the following raw materials in parts by weight: 100 parts polyvinyl chloride, 30-40 parts plasticizer, 8-15 parts modified hollow glass microspheres, 1-3 parts organotin stabilizer, and 1.5-2 parts tackifier; The modified hollow glass microspheres are prepared through the following steps: Hollow glass microspheres and stearic acid were added to anhydrous ethanol, heated to 75-80℃ and stirred for 1-2 hours. After the reaction was completed, the microspheres were filtered, washed and dried to obtain modified hollow glass microspheres.
7. A battery tray for preventing condensation and stone impact according to claim 6, characterized in that, The ratio of hollow glass microspheres, stearic acid, and anhydrous ethanol is 1.2–1.5 g: 0.3–0.4 g: 50 mL; the mass fraction of stearic acid is 4%–10%; and the particle size of the hollow glass microspheres is 50–100 nm.
8. A battery tray for preventing condensation and stone impact according to claim 6, characterized in that, The plasticizer is at least one of dioctyl sebacate, diallyl phthalate, and epoxidized soybean oil.
9. A battery tray for preventing condensation and stone impact according to claim 6, characterized in that, The tackifier is one of polyurethane, polyacrylic acid, polyamide, terpene resin, and polyethylene glycol diester.
10. The manufacturing process of an anti-condensation and anti-stone-impact battery tray according to claim 1, characterized in that, Includes the following steps: Step 1: Degrease and clean the molded battery tray substrate to remove surface oil. Step 2: Load the anti-condensation coating into the spraying equipment. Mix the two components according to the ratio before use. Spray the anti-condensation coating evenly onto the treated battery tray substrate, control the spraying thickness, and perform preliminary curing until surface dry or semi-cured to form an anti-condensation layer. Step 3: Using the same spraying process, evenly spray the anti-stone chip coating onto the anti-condensation layer, control the spraying thickness, and continue to cure the double-layered battery tray. Allow it to cool naturally to room temperature to obtain the final product.