Aviation power battery anti-falling and anti-collision energy absorption structure and electric aircraft

Abstract

The invention relates to an aviation power battery anti-falling and anti-collision energy absorption structure and an electric aircraft, and the aviation power battery anti-falling and anti-collision energy absorption structure comprises a bottom shell, a honeycomb structure, a battery cabin bottom plate and a plurality of corrugated beams. An inner cavity and an opening communicated with the inner cavity are defined by the bottom shell, the corrugated beams are arranged in the inner cavity and connected to the bottom wall of the bottom shell, the corrugated beams are sequentially arranged at intervals, gap cavities are formed between the adjacent corrugated beams, the honeycomb structures are arranged in the gap cavities, and the battery compartment bottom plate is connected to the bottom shell in an attached mode and covers the opening. The battery compartment bottom plate is connected with the corrugated beam and the honeycomb structure, and the bottom shell, the corrugated beam and the battery compartment bottom plate are all made of carbon fiber reinforced composite materials. The anti-falling and anti-collision energy absorption structure of the aviation power battery mainly adopts the carbon fiber reinforced composite material, and the effects of light weight, high energy absorption efficiency and good impact resistance are achieved through the design of the corrugated beam and honeycomb structure combined structure.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of aviation structure safety protection, and particularly relates to an aviation power battery anti-drop and anti-collision energy absorption structure and an electric airplane. BACKGROUND

[0002] With the transformation of the global aviation industry towards green and low carbon, electric aircraft has become an important breakthrough in aviation technology innovation. Under this background, the power battery system as the core energy component of the electric airplane, its safety performance, especially the anti-drop performance, is directly related to the airworthiness certification and commercial application of the whole machine. The latest airworthiness regulations of the International Civil Aviation Organization (ICAO) have clearly required that the electric aircraft must ensure the integrity of the battery system under the extreme drop condition, which puts higher requirements on the aircraft structure design. The traditional aviation energy absorption structure is mainly based on metal material system. Although these structures perform well in conventional aviation components, they have obvious shortcomings in dealing with the unique high energy density battery protection requirements of electric airplanes. On the one hand, the inherent density of metal materials limits the energy absorption efficiency; on the other hand, these traditional structures lack targeted design for the dynamic impact response of battery modules, and often cannot effectively suppress the risk of battery shell rupture under extreme conditions.

[0003] The preferred material for modern aviation structure light weight is composite material, supplemented by aluminum alloy and titanium alloy material. Carbon fiber reinforced composite material, with its excellent mechanical properties, has been widely used from Boeing 787 to Airbus A350XWB. The substantial increase in the use of composite materials not only brings significant weight reduction effect, but also promotes the overall improvement of aircraft performance. However, when this light weight technology advantage is extended to the battery compartment protection field, the existing composite material energy absorption structure still faces many technical bottlenecks. The current mainstream single-layer corrugated beam structure has obvious upper limit in energy absorption efficiency, and its energy absorption mechanism is often difficult to meet the needs of high energy impact scenarios; the stability of traditional corrugated structure under dynamic load is insufficient, and it is easy to cause unexpected structural failure mode; in addition, the stress concentration problem of the connection interface between composite material and metal also seriously restricts the reliability of the overall structure. SUMMARY

[0004] To solve one of the above technical problems, the present application provides an aviation power battery anti-drop and anti-collision energy absorption structure.

[0005] The present application provides the following technical solutions: In a first aspect, the present application provides an aviation power battery anti-drop and anti-collision energy absorption structure, comprising: a bottom shell, the bottom shell enclosing an inner cavity and an open mouth communicating with the inner cavity; a plurality of corrugated beams arranged in the inner cavity and connected to the bottom wall of the bottom shell, each corrugated beam is arranged in sequence and spaced, and a gap cavity is formed between adjacent corrugated beams; a honeycomb structure arranged in the gap cavity; a battery compartment bottom plate connected to the bottom shell in a fit manner and covering the opening, the battery compartment bottom plate being connected to the corrugated beams and the honeycomb structure; wherein the bottom shell, the corrugated beams and the battery compartment bottom plate are all made of carbon fiber reinforced composite material.

[0006] Optionally, the bottom shell comprises a skin and an energy-absorbing web, the energy-absorbing web being arranged at least at the edge of the skin, the energy-absorbing web extending along the thickness direction of the skin, and a side edge strip being arranged at the side edge of the energy-absorbing web away from the skin; the surface of the battery compartment bottom plate is covered with a film; in the state that the battery compartment bottom plate is connected to the bottom shell, the film is bonded to the side edge strip of the energy-absorbing web, the corrugated beams and the honeycomb structure.

[0007] Optionally, the energy-absorbing web comprises an edge energy-absorbing web and a middle energy-absorbing web; the edge energy-absorbing web is arranged at the edge of the skin, and the edge energy-absorbing web and the skin enclose the inner cavity; the middle energy-absorbing web is located in the inner cavity and connected to the skin, and the middle energy-absorbing web divides the inner cavity into a plurality of sub-inner cavities; each corrugated beam is arranged in a corresponding sub-inner cavity.

[0008] Optionally, the corrugated beam is in the shape of a periodic sine wave; in the arrangement direction of each corrugated beam, adjacent corrugated beams are arranged symmetrically.

[0009] Optionally, a rectangular edge strip is arranged at the side of the corrugated beam away from the skin; the rectangular edge strip is perpendicular to the corrugated beam; the rectangular edge strip is used to connect the battery compartment bottom plate in a fit manner.

[0010] Optionally, the bottom shell and the corrugated beam are made into an integral piece by a co-curing process.

[0011] Optionally, the honeycomb structure comprises a plurality of honeycomb structure layers; each honeycomb structure layer is arranged in sequence along the direction perpendicular to the bottom wall of the bottom shell.

[0012] Optionally, in the direction from the bottom wall to the battery compartment bottom plate, the density of each honeycomb structure layer gradually increases.

[0013] Optionally, the bottom shell and the corrugated beam comprise a plurality of carbon fiber layers, each carbon fiber layer is sequentially laid along the thickness direction; Among each carbon fiber layer, the fiber laying angles of at least some adjacent carbon fiber layers are different, and each fiber laying angle at least includes 0°, +45° and -45°.

[0014] In a second aspect, the embodiments of the present application provide an electric aircraft, comprising: a fuselage body; The aviation power battery anti-impact energy absorption structure is arranged at the bottom of the fuselage body.

[0015] By adopting the above technical solution, the present application has the following beneficial effects: The aviation power battery anti-impact energy absorption structure of the present application mainly adopts carbon fiber reinforced composite material, and realizes the effects of lightweight structure, high energy absorption efficiency and good impact resistance by the combination structure design of the corrugated beam and the honeycomb structure. BRIEF DESCRIPTION OF DRAWINGS

[0016] The accompanying drawings, which are part of this application, serve to further understand the present application, and the illustrative embodiments of the present application and their descriptions are used to explain the present application, but do not constitute an improper limitation on the present application.

[0017] Obviously, the drawings in the following description are only some embodiments, and other drawings can be obtained by those skilled in the art without creative labor on the basis of these drawings.

[0018] Figure 1 A perspective view of the aviation power battery anti-impact energy absorption structure provided by the embodiments of the present disclosure is shown; Figure 2 A schematic view of the internal structure of the aviation power battery anti-impact energy absorption structure provided by the embodiments of the present disclosure is shown; Figure 3 A schematic view of the local structure of the aviation power battery anti-impact energy absorption structure provided by the embodiments of the present disclosure is shown; Figure 4 A top view schematic view of the honeycomb structure in the aviation power battery anti-impact energy absorption structure provided by the embodiments of the present disclosure is shown.

[0019] In the drawings: 1, bottom shell; 11, skin; 12, energy absorption web; 121, edge energy absorption web; 122, middle energy absorption web; 123, side edge strip; 2, corrugated beam; 3, honeycomb structure; 31, first honeycomb structure layer; 32, second honeycomb structure layer; 33, third honeycomb structure layer; 4, power battery; 41, battery compartment bottom plate; 5, rectangular edge strip. DETAILED DESCRIPTION

[0020] In order to make the objects, technical solutions and advantages of the present application clearer, the following will be combined with the preferred embodiments of the present application and the accompanying drawings to make the technical solutions in the embodiments of the present application more fully described. In the drawings, identical or similar reference numerals represent identical or similar elements or elements with identical or similar functions throughout. The described embodiments are part of the embodiments of the present application, rather than all the embodiments. The embodiments described below by reference to the drawings are exemplary and are intended to explain the present application, and cannot be understood as a limitation of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work are within the scope of protection of the present application. The embodiments of the present application will be described in detail below with reference to the drawings.

[0021] In the description of the present embodiments, it should be understood that the terms "center", "longitudinal", "transverse", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present embodiments and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the scope of protection of the present embodiments.

[0022] As shown in Figures 1 to 4 The present application provides an aviation power battery anti-drop energy absorption structure, which comprises a bottom shell 1, a honeycomb structure 3, a battery cabin bottom plate 41 and a plurality of corrugated beams 2. The bottom shell 1 forms an inner cavity and an open mouth communicating with the inner cavity. The corrugated beams 2 are arranged in the inner cavity and connected to the bottom wall of the bottom shell 1. Each corrugated beam 2 is arranged in sequence and spaced apart. Adjacent corrugated beams 2 form a gap cavity. The honeycomb structure 3 is arranged in the gap cavity. The battery cabin bottom plate 41 is connected to the bottom shell 1 in a close manner and covers the open mouth. The battery cabin bottom plate 41 is connected to the corrugated beams 2 and the honeycomb structure 3. The bottom shell 1, the corrugated beams 2 and the battery cabin bottom plate 41 are all made of carbon fiber reinforced composite material.

[0023] The aviation power battery anti-drop energy absorption structure of the present application mainly adopts carbon fiber reinforced composite material, and realizes the effects of lightweight structure, high energy absorption efficiency and improved impact resistance through the combined structure design of the corrugated beams 2 and the honeycomb structure 3.

[0024] In the present application, the corrugated beam 2 can adopt a periodic sinusoidal wave design (preferably configured as five corrugations), and achieve hierarchical energy dissipation through symmetrical distribution and buckling deformation. The corrugated beam 2 structure has specific amplitude-thickness ratio and wavelength geometric parameters, and preferably, the beam height of the corrugated beam 2 is 136-157 mm, the wavelength ratio is 1.2, and the amplitude-thickness ratio is 20.8.

[0025] In some possible embodiments, the bottom shell 1 includes a skin 11 and an energy-absorbing web 12 arranged at least at the edge of the skin 11, the energy-absorbing web 12 extending along the thickness direction of the skin 11, and the energy-absorbing web 12 being provided with a side edge strip 123 at the side edge away from the skin 11. The battery compartment bottom plate 41 is covered with a film, and in the state that the battery compartment bottom plate 41 is connected to the bottom shell 1, the film is bonded to the side edge strip 123 of the energy-absorbing web 12, the corrugated beam 2 and the honeycomb structure 3.

[0026] In some possible embodiments, as shown in Figure 2 The energy-absorbing web 12 includes an edge energy-absorbing web 121 arranged at the edge of the skin 11, and an intermediate energy-absorbing web 122 located in the inner cavity and connected to the skin 11. The intermediate energy-absorbing web 122 divides the inner cavity into a plurality of sub-cavities. Each corrugated beam 2 is arranged in each sub-cavity. For example, one intermediate energy-absorbing web 122 can be arranged to divide the inner cavity into two sub-cavities, and a set of corrugated beams 2 and honeycomb structures 3 are arranged in each sub-cavity.

[0027] In some possible embodiments, the corrugated beam 2 is in a periodic sinusoidal wave shape, and adjacent corrugated beams 2 are symmetrically arranged along the arrangement direction of each corrugated beam 2.

[0028] In the present application, the corrugated beam 2 can adopt a multi-corrugated structure, for example, the corrugated beam 2 is preferably configured as five corrugations. By symmetrically designing and periodically distributing each corrugated beam 2, it is ensured that the impact load is uniformly transmitted, and the symmetric periodic buckling deformation of the corrugated beam 2 and the web shear deformation are synergistically acted to ensure the predictability and controllability of the energy absorption process.

[0029] In the present application, the anti-drop and anti-collision energy-absorbing structure of the aviation power battery is arranged in the thickness direction from the outside to the inside of the electric aircraft, and sequentially arranged are the skin 11, the energy-absorbing web 12, the corrugated beam 2, the honeycomb structure 3 and the battery compartment bottom plate 41. In the process of falling and colliding, a hierarchical and progressive crushing failure mechanism can be realized, so that the energy absorption presents a stable “wrinkling-compaction” alternating development mode. The structures synergistically act to form an energy absorption path of “global dispersion-local concentration”, and realize the stepwise attenuation of the impact load.

[0030] In some possible embodiments, a rectangular rib 5 is arranged on the side of the corrugated beam 2 away from the skin 11, the rectangular rib 5 is perpendicular to the corrugated beam 2, and the rectangular rib 5 is used for adhesively connecting the battery compartment bottom plate 41.

[0031] The surface of the battery compartment bottom plate 41 is covered with a film, and in the state that the battery compartment bottom plate 41 is connected to the bottom shell 1, the rectangular rib 5 is adhesively fixed to the film.

[0032] A layer of film with a thickness of preferably more than 1 mm can be first laid on the battery compartment bottom plate 41 of the power battery 4, and then the film is glued to the rectangular rib 5 on the upper side of the corrugated beam 2, the upper side rib 123 of the energy-absorbing web 121, and the honeycomb structure, and the power battery compartment shell is inverted and cured downward. On the basis of meeting the connection strength, the weight increase problem caused by mechanical connection is avoided, and the integrity of the power battery compartment and the energy-absorbing layer structure below is met.

[0033] In some possible embodiments, the bottom shell 1 and the corrugated beam 2 are made into an integral part by a co-curing process. That is, the skin 11, the energy-absorbing web 12, and the corrugated beam 2 are integrally formed by a co-curing process, which solves the reliability problem of the traditional connection mode.

[0034] In some possible embodiments, the honeycomb structure 3 includes a plurality of honeycomb structure layers, and each of the honeycomb structure layers is arranged in sequence in a direction perpendicular to the bottom wall of the bottom shell 1.

[0035] The honeycomb structure 3 is adhesively bonded to the skin 11 at room temperature to fill the gaps between the corrugated beams 2. The honeycomb structure 3 can adopt a plurality of honeycomb structure layers, such as three or more honeycomb structure layers, and the stacked layers are not bonded.

[0036] In some possible embodiments, the density of each of the honeycomb structure layers gradually increases in the direction from the bottom wall (skin) to the battery compartment bottom plate 41.

[0037] The honeycomb structure layer can adopt a gradient honeycomb structure 3, and the density gradually decreases in the direction from the skin 11 to the battery compartment bottom plate 41. For example, as shown in Figure 4 The gradient honeycomb structure 3 includes a first honeycomb structure layer 31, a second honeycomb structure layer 32, and a third honeycomb structure layer 33, the first honeycomb structure layer 31 directly contacts the skin 11, the first honeycomb structure layer 31, the second honeycomb structure layer 32, and the third honeycomb structure layer 33 are arranged in sequence, and the density gradually decreases.

[0038] In the embodiments of the present application, based on the design of the corrugated symmetric configuration supplemented by the gradient honeycomb structure 3, the anisotropic properties of the composite material are fully utilized by optimizing the layering scheme, and the lightweight and high-strength functions of the structure are considered. The progressive crushing of the symmetrically configured corrugated beam 2 and the stable crushing of the gradient honeycomb are mutually coordinated to absorb energy, ensuring the gradient dissipation of the impact load and improving the energy absorption efficiency, thereby providing a reliable crash protection solution for the power battery compartment of the electric aircraft.

[0039] The gradient honeycomb and the corrugated beam 2 form a complementary mechanism, and the progressive energy dissipation is realized by the step-by-step compression of the honeycomb structure 3, thereby reducing the impact load peak and further enhancing the energy absorption efficiency.

[0040] Optionally, the bottom shell 1 and the corrugated beam 2 each include a plurality of carbon fiber layers, and each carbon fiber layer is sequentially laid in the thickness direction. Among each carbon fiber layer, the fiber laying angles of at least some adjacent carbon fiber layers are different, and each fiber laying angle at least includes 0°, +45° and -45°.

[0041] The plurality of carbon fiber layers can be optimized by 0° / ±45° alternating layering to improve the bending stiffness and in-plane shear performance of the carbon fiber reinforced composite structure, and can exhibit stable progressive crushing characteristics under dynamic impact.

[0042] For example, each carbon fiber layer of the corrugated beam 2 can be designed by symmetric layering, and the specific laying method can be [±45 / 02 / ±45 / 02 / ±45 / 02 / ±45 / 902] s The laying structure enables a staged progressive crushing failure mechanism during the crash process, and the energy absorption presents a stable “wrinkling-compaction” alternating development mode. For another example, The laying angle of the reinforcing fibers of the bottom shell 1 can be designed as [±45 / 02 / 902 / ±45] 2s , which is conducive to effectively dispersing the concentrated impact load to the entire battery compartment bottom plate 41 area.

[0043] The corrugated beam 2, the energy-absorbing web 12 and the fuselage skin 11 can be integrally formed by a co-curing process. A plurality of symmetrically configured corrugated beams 2, energy-absorbing webs 12 and skins 11 can be integrally formed by a co-curing process, thereby eliminating the weak links generated by the traditional connection method. The corrugated beam 2 and the energy-absorbing web 12 are uniformly arranged and perpendicular to the skin 11, and are optimized in the bottom transition area to ensure that the structure is deformed and gradually damaged to achieve high energy absorption efficiency.

[0044] The application mainly aims at the power battery module of the lower part of the typical frame section of the new energy electric aircraft fuselage for anti-falling and energy-absorbing structure design. A lightweight, high-energy-absorbing anti-falling and energy-absorbing structure is provided under low-speed impact (8 m / s falling speed) to effectively absorb and disperse the falling impact energy and protect the power battery 4 monomer from damage. The structure is mainly made of fiber reinforced composite material (FRP), and through the design of symmetrical corrugated beam 2 supplemented by gradient honeycomb structure 3, the synergistic effect of energy-absorbing web plate 12 and battery cabin bottom plate 41, multi-level energy absorption is realized.

[0045] The application embodiment also provides an electric aircraft, which comprises a fuselage body and the above-mentioned aviation power battery anti-falling and energy-absorbing structure, and the aviation power battery anti-falling and energy-absorbing structure is arranged at the bottom of the fuselage body. That is, the aviation power battery anti-falling and energy-absorbing structure can be arranged in the space between the fairing and the battery cabin of the electric aircraft, and the skin 11 of the bottom shell 1 of the aviation power battery anti-falling and energy-absorbing structure is part of the exposed skin of the bottom of the fuselage body.

[0046] The power battery 4 of the electric aircraft is the core protection unit of the energy system of the electric aircraft, and the anti-falling safety and structural lightweight requirements are extremely strict. The energy-absorbing structure is designed in the limited energy-absorbing layer space to maximize the energy absorption of falling. The traditional energy-absorbing structure design often cannot consider the energy-absorbing efficiency and weight reduction, that is, the specific energy-absorbing efficiency problem. In the application embodiment, a composite material symmetrical configuration corrugated beam anti-falling and energy-absorbing structure is provided to construct the corrugated beam and the protection assembly by the fiber reinforced composite material, so as to realize the unification of high-efficiency energy absorption and lightweight design.

[0047] The above is only a preferred specific embodiment of the application, but the protection scope of the application is not limited thereto. Any person skilled in the art can make equivalent replacement or change according to the technical scheme and the inventive concept of the application within the technical range disclosed by the application, which is also covered by the protection scope of the application.

Claims

1. A crash-resistant energy-absorbing structure for aircraft power batteries, characterized in that, include: A bottom shell, which encloses an inner cavity and an opening communicating with the inner cavity; Multiple corrugated beams are disposed in the inner cavity and connected to the bottom wall of the bottom shell. The corrugated beams are arranged sequentially at intervals, and gap cavities are formed between adjacent corrugated beams. A honeycomb structure, wherein the honeycomb structure is disposed within the gap cavity; A battery compartment bottom plate is attached to the bottom shell and covers the opening. The battery compartment bottom plate is connected to the corrugated beam and the honeycomb structure. The bottom shell, corrugated beam, and battery compartment bottom plate are all made of carbon fiber reinforced composite material.

2. The impact-resistant energy-absorbing structure for aviation power batteries according to claim 1, characterized in that, The bottom shell includes a skin and an energy-absorbing web. The energy-absorbing web is at least disposed at the edge of the skin and extends along the thickness direction of the skin. A side edge strip is provided on the side edge of the energy-absorbing web opposite to the skin. The bottom plate of the battery compartment is covered with an adhesive film. With the battery compartment bottom plate connected to the bottom shell, the adhesive film is bonded to the side edge strips of the energy-absorbing web, the corrugated beam, and the honeycomb structure.

3. The impact-resistant energy-absorbing structure for aviation power batteries according to claim 2, characterized in that, The energy-absorbing web includes an edge energy-absorbing web and a middle energy-absorbing web; The edge energy-absorbing web is disposed on the edge of the skin, and the edge energy-absorbing web and the skin enclose the cavity to form the inner cavity; The central energy-absorbing web is located within the inner cavity and connected to the skin, and the central energy-absorbing web divides the inner cavity into several sub-cavities; Each of the corrugated beams is disposed within each of the sub-cavities.

4. The impact-resistant energy-absorbing structure for aviation power batteries according to claim 1, characterized in that, The corrugated beam has a periodic sine wave shape; Adjacent corrugated beams are arranged symmetrically along the arrangement direction of each corrugated beam.

5. The impact-resistant energy-absorbing structure for aviation power batteries according to claim 1, characterized in that, A rectangular flange is provided on the side of the corrugated beam opposite to the skin; The rectangular flange is perpendicular to the corrugated beam; The rectangular edge strip is used to fit and connect the bottom plate of the battery compartment.

6. The anti-crash energy absorption structure for aviation power batteries according to claim 1, characterized in that, The bottom shell and the corrugated beam are manufactured as a single piece using a co-curing process.

7. The impact-resistant energy-absorbing structure for aviation power batteries according to claim 1, characterized in that, The honeycomb structure includes multiple honeycomb structure layers; Each of the honeycomb structure layers is arranged sequentially along a direction perpendicular to the bottom wall of the bottom shell.

8. The impact-resistant energy-absorbing structure for aviation power batteries according to claim 1, characterized in that, The density of each of the honeycomb structure layers increases progressively in the direction from the bottom wall to the bottom plate of the battery compartment.

9. The impact-resistant energy-absorbing structure for aviation power batteries according to any one of claims 1-8, characterized in that, The bottom shell and the corrugated beam comprise multiple carbon fiber layers, each carbon fiber layer being laid sequentially along the thickness direction; In each carbon fiber layer, at least some adjacent carbon fiber layers have different fiber layup angles, and each fiber layup angle includes at least 0°, +45° and -45°.

10. An electric aircraft, characterized in that, include: Main body of the fuselage; The aviation power battery anti-collision energy absorption structure as described in any one of claims 1-9 is disposed at the bottom of the fuselage body.

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