Protective battery container

Abstract

The invention belongs to the technical field of battery storage, and particularly relates to a protective battery container which comprises a shell, a cable gland is arranged at the position, corresponding to a cable penetrating hole, of the shell, a cabin used for containing a battery is arranged in the shell, the shell comprises a framework, a blasting diaphragm is arranged on the framework, and a pressure relief channel is arranged at the position, corresponding to the blasting diaphragm, of the framework. The outer surface of the framework is coated with a glass fiber reinforced plastic skin; the shell comprises a buffering and damping layer, an adsorption layer and an anti-corrosion coating, the buffering and damping layer and the adsorption layer cover the inner wall of the cabin, the buffering and damping layer is located between the adsorption layer and the glass fiber reinforced plastic skin, and the anti-corrosion coating covers the glass fiber reinforced plastic skin on the outer side of the shell. According to the protective battery container, the composite shell is formed by the glass fiber reinforced plastic skin and the framework, salt mist and chemical gas are isolated from the framework by utilizing the characteristics of insulation, corrosion resistance and formability of glass fiber reinforced plastic, a galvanic corrosion path is blocked, and meanwhile, the overall weight is reduced.

Description

Technical Field

[0001] This invention belongs to the field of battery storage technology, and in particular relates to a protective battery container. Background Technology

[0002] With the rapid development of new energy technologies, batteries, as core energy storage components, are widely used in electric vehicles, energy storage power stations, emergency power supplies, and other fields. However, battery systems face many challenges in actual operation, especially in outdoor or harsh environments, where they are susceptible to factors such as moisture, salt spray, high and low temperatures, and mechanical shock, affecting battery safety and even causing safety accidents. Existing battery storage containers mostly use metal box structures, which, while possessing a certain mechanical strength, have significant shortcomings in terms of sealing, corrosion resistance, shock resistance, and explosion protection. For example, traditional metal boxes are prone to corrosion at the joints and lack effective graded protection mechanisms, making it difficult to cope with the multiple risks in complex environments. Therefore, there is an urgent need for a battery storage container with multiple protection functions, including high sealing, corrosion resistance, impact resistance, shock resistance, and explosion protection, to improve the safety, stability, and lifespan of batteries during storage. Summary of the Invention

[0003] In view of this, the present invention aims to provide a protective battery container to solve the problem of poor safety when storing batteries.

[0004] To achieve the above objectives, the technical solution of the present invention is implemented as follows: A protective battery container includes an outer shell with glands on the shell corresponding to cable perforations. The outer shell contains a compartment for housing a battery. The outer shell includes a frame with a rupture diaphragm and a pressure relief channel corresponding to the rupture diaphragm. The outer surface of the frame is covered with a fiberglass skin. The outer shell includes a shock-absorbing layer, an absorbent layer, and an anti-corrosion coating. The shock-absorbing layer and the absorbent layer cover the inner wall of the compartment, with the shock-absorbing layer located between the absorbent layer and the fiberglass skin. The anti-corrosion coating covers the outer fiberglass skin of the outer shell.

[0005] Furthermore, the fiberglass skin has a weakened portion in the area corresponding to the rupture diaphragm, and the wall thickness of the fiberglass skin at the weakened portion is smaller than the wall thickness of the surrounding fiberglass skin, so that when the rupture diaphragm breaks, the fiberglass skin can form cracks or openings along the weakened portion.

[0006] Furthermore, the thickness of the fiberglass skin is 3-10mm.

[0007] Furthermore, the skeleton is made of corrosion-resistant material, which is stainless steel or hot-dip galvanized steel, and the surface of the stainless steel or hot-dip galvanized steel is coated with a first epoxy coating.

[0008] Furthermore, the skeleton is made of Q355ND low-temperature tough steel, and its surface is first coated with a zinc-chromium coating with a thickness of 70μm~90μm, and then sprayed with a first epoxy coating to form a sacrificial anode and shielding composite anti-corrosion structure.

[0009] Furthermore, the buffer and shock-absorbing layer has a thickness of 8 mm to 12 mm and a density of 40 kg / m³. 3 ~50kg / m 3 High-density polyurethane foam layer.

[0010] Furthermore, the adsorption layer is a non-woven fabric or sponge impregnated with activated carbon.

[0011] Furthermore, the anti-corrosion coating has a double-layer structure, with a bottom layer being a second epoxy coating with a dry film thickness of 60μm~80μm, and a top layer being a polyurethane coating with a dry film thickness of 40μm~60μm.

[0012] Furthermore, the outer casing includes a box body and a box cover, the box cover being detachably mounted on the box body, and a sealing structure being provided between the box cover and the box body.

[0013] Furthermore, the sealing structure employs waterproof sealant or a sealing ring.

[0014] Compared with existing technologies, the protective battery container of the present invention has the following advantages: (1) The protective battery container of the present invention has a composite shell formed by fiberglass skin and frame. The insulation, corrosion resistance and formability of fiberglass are used to isolate salt spray and chemical gas from steel frame, block the galvanic corrosion path and reduce the overall weight. The skin is provided with a weakening part in the area corresponding to the burst diaphragm. When the chamber is pressurized instantaneously due to thermal runaway, the diaphragm breaks first and the weakening part cracks along the predetermined texture to form a vent. This ensures rapid pressure relief and avoids fragments from flying, maintains the integrity of the box and achieves safe pressure relief by "directional rupture".

[0015] (2) The protective battery container of the present invention uses a corrosion-resistant material for the frame and adds a first epoxy coating on the surface to form a dual anti-corrosion system of metal shielding and coating barrier, so that the frame can still maintain its load-bearing capacity in high humidity, salt spray or chemical atmosphere, and extend the service life of the container; the buffer and shock-absorbing layer is close to the inner wall of the container, which can absorb multi-directional vibrations generated by transportation, earthquake or equipment operation, reduce the transmission of vibration to the battery pack, and reduce the risk of cell solder joints and busbars loosening due to fatigue. The adsorption layer is located between the buffer and shock-absorbing layer and the battery pack, which can adsorb acidic or corrosive gases that may escape from the container on the spot, and avoid gas accumulation on the surface of electrical connectors and contact corrosion; the anti-corrosion coating covers the outside of the fiberglass skin and forms a gradient barrier with the internal anti-corrosion system, so that even if it is exposed to ultraviolet rays, rainwater or industrial atmosphere for a long time, it can maintain stable appearance and protective performance, and reduce the number of maintenance.

[0016] (3) The protective battery container of the present invention adopts a detachable sealing structure between the cover and the body, and is equipped with waterproof sealant or sealing ring. While maintaining IP66 dustproof and waterproof rating, it can be quickly opened and closed on site, which is convenient for battery installation, maintenance and replacement. The sealing structure is compressible and can maintain a continuous sealing surface after multiple disassembly and assembly, reducing the probability of water vapor intrusion due to sealing failure and improving the reliability of system operation. Attached Figure Description

[0017] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the structure of a protective battery container according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the layer structure of the outer shell of a protective battery container according to an embodiment of the present invention.

[0018] Explanation of reference numerals in the attached figures: 1. Outer shell; 2. Cabin; 3. Bursting diaphragm; 4. Weakening section; 5. Box body; 6. Box cover; 7. Frame; 8. First epoxy coating; 9. Fiberglass skin; 10. Buffer and shock absorption layer; 11. Adsorption layer; 12. Second epoxy coating; 13. Polyurethane coating. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0020] A type of protective battery container, such as Figure 1 and Figure 2 As shown, the device includes an outer shell 1, on which a gland is provided at the position corresponding to the cable penetration. Inside the outer shell 1, there is a compartment 2 for accommodating the battery. The outer shell 1 includes a frame 7, on which a rupture diaphragm 3 is provided. A pressure relief channel is provided on the frame 7 at the position corresponding to the rupture diaphragm 3. The outer surface of the frame 7 is covered with a fiberglass skin 9. The outer shell 1 includes a shock-absorbing layer 10, an adsorption layer 11, and an anti-corrosion coating. The shock-absorbing layer 10 and the adsorption layer 11 cover the inner wall of the compartment 2, and the shock-absorbing layer 10 is located between the adsorption layer 11 and the fiberglass skin 9. The anti-corrosion coating covers the fiberglass skin 9 on the outer side of the outer shell 1.

[0021] In practical applications, the outer casing 1 has cable perforations. Modular sealing glands with built-in double-layer fluororubber sealing rings are used at these perforations, and IP68 protection is achieved through tapered thread tightening. A single perforation can accommodate cables with diameters from 6 to 25 mm. The inner and outer sheaths of the frame 7 are made of 3-10 mm thick fiberglass sheet.

[0022] The corrosion resistance of the battery container shell 1 directly determines its environmental adaptability and service life. Through laboratory comparative testing of three mainstream materials, a differentiated selection scheme was formed. 316 stainless steel, with its alloy composition containing 2-3% molybdenum, achieved 5000 hours of no red rust in the ASTM B117 salt spray test. Its austenitic crystal structure endows the material with excellent ductility, and its yield strength is stably maintained above 205 MPa, making it suitable for withstanding high salt spray concentrations (≥5000 mg / m³) in coastal areas. 3 Long-term corrosion. Hot-dip galvanized steel sheets form an 80μm zinc layer through a hot-dip galvanizing process, achieving 2000 hours of white rust inhibition through a sacrificial anode protection mechanism. Its yield strength of 345MPa makes it outstanding in mechanical load-bearing scenarios. Fiberglass reinforced plastic (FRP), on the other hand, exhibits material advantages in extreme environments. Its composite structure of glass fiber and resin matrix allows it to withstand over 10,000 hours of salt spray, achieves a flexural strength of 180MPa, and has a density only 1 / 4 that of steel. However, its impact toughness is lower than that of metallic materials.

[0023] In this embodiment, covering the surface of the skeleton 7 with fiberglass skin 9 is a mature composite approach that organically combines the high strength of steel with the excellent properties of glass fiber reinforced plastic. The benefits it brings are multi-dimensional and synergistic.

[0024] First, fiberglass itself has outstanding electrical insulation properties, which can completely isolate the metal frame 7 from the battery module inside the battery container, cut off the microcouple corrosion path caused by potential difference, and also avoid accidental leakage from harming the module and maintenance personnel; at the same time, its density is much lower than that of steel, and after being formed into a thin-walled shell 1, it can significantly reduce the overall weight while maintaining or even increasing the bending stiffness, making transportation, hoisting and on-site layout lighter and safer.

[0025] Secondly, the dense surface of fiberglass has low porosity and exhibits good stability against environmental corrosion such as salt spray, acid and alkali, and ultraviolet rays. It can isolate external corrosive media from the metal load-bearing structure, which is equivalent to adding a sacrificial and repairable "permanent anti-corrosion coat" to the steel plate, thus extending the maintenance cycle of the entire cabin.

[0026] Furthermore, by employing processes such as vacuum infusion, hand lay-up, or precast panel bonding, complex geometric features such as reinforcing ribs, anti-slip textures, and cable sealing platforms can be formed in one step at room temperature, reducing subsequent machining and welding, lowering the risk of thermal deformation, and improving dimensional accuracy and production efficiency. The sandwich structure formed after the fiber and resin are cured also has excellent internal damping, which can absorb and attenuate the vibration energy generated during equipment operation or transportation, reduce peak resonance, and is also beneficial for protecting the cell solder joints and internal connectors.

[0027] Finally, a strong interface bond is formed between the frame 7 and the fiberglass through sandblasting, primer, and structural adhesive or vacuum introduction. The adhesive layer serves as a continuous seal and stress transition layer, preventing moisture penetration along the interface and inhibiting crack propagation under impact by utilizing the bridging effect of the fibers, thus preventing fragments from scattering. In particular, when the battery in compartment 2 continuously releases gas due to thermal runaway, causing excessive pressure inside the outer shell 1 and compartment 2, the rupture diaphragm 3 breaks and drives the fiberglass to crack, opening the pressure relief channel. Even then, the fiberglass is not easily shattered and splashed, achieving pressure relief of the battery container while minimizing secondary damage to external equipment, thus reducing the probability of the battery container exploding.

[0028] Therefore, covering the frame 7 of the protective battery container with fiberglass skin 9 not only achieves multiple goals such as lightweighting, corrosion resistance, electrical insulation, vibration reduction and rapid prototyping, but also provides a safer, more economical and longer-lasting solution for the entire battery system. It is a preferred structural form that combines functionality and manufacturability.

[0029] In a preferred embodiment of this example, the skeleton 7 is made of a corrosion-resistant material, which is stainless steel or hot-dip galvanized steel, and the surface of the stainless steel or hot-dip galvanized steel is coated with a first epoxy coating 8.

[0030] It should be noted that the material selection follows the principle of "scenario adaptation": for example, coastal wind power energy storage projects prioritize the use of 316 stainless steel, which, combined with regular passivation treatment, can achieve 15 years of maintenance-free operation; inland industrial scenarios adopt an economical solution of hot-dip galvanized steel sheet + first epoxy coating 8; while extreme corrosive environments such as deep-sea exploration and chemical plants adopt fiberglass integral molding process, and further improve weather resistance through resin matrix modification (e.g., adding 2% nano silica).

[0031] In a preferred embodiment of this example, the fiberglass skin 9 has a weakening portion 4 in the area corresponding to the rupture diaphragm 3. The wall thickness of the fiberglass skin 9 at the weakening portion 4 is less than the wall thickness of the surrounding fiberglass skin 9, so that when the rupture diaphragm 3 ruptures, the fiberglass skin 9 can form cracks or openings along the weakening portion 4. For example, the weakening portion 4 is strip-shaped or annular, with a wall thickness of 3mm, while the wall thickness of the remaining positions of the fiberglass skin 9 is 5mm. As long as the wall thickness of the weakening portion 4 is less than the wall thickness of the surrounding fiberglass skin 9, when the battery in the chamber 2 continuously releases gas due to thermal runaway, the fiberglass skin 9 at the weakening portion 4 can quickly generate cracks or openings under gas pressure or the impact of the rupture diaphragm 3, thereby achieving rapid gas release.

[0032] In a preferred embodiment of this example, the skeleton 7 is made of Q355ND low-temperature tough steel, and its surface is first coated with a zinc-chromium coating with a thickness of 70μm~90μm, and then sprayed with a first epoxy coating 8 to form a sacrificial anode and shielding composite anti-corrosion structure.

[0033] Specifically, the skeleton 7 is made of Q355ND low-temperature toughness steel, which is shot-blasted to Sa2.5 grade and then coated with an 80μm zinc-chromium coating (zinc content ≥95%), forming a dual protection of sacrificial anode and passivation film, achieving a neutral salt spray test life of 1500 hours. The welding joints of skeleton 7 adopt a "fish scale" welding process, with a weld leg height ≥6mm and undergoing 100% penetrant testing to ensure that the joint shear strength reaches 345MPa under seismic conditions. The skin of skeleton 7 is made of 3mm thick fiberglass sheet, and the resin content is controlled at 45-50% through vacuum induction molding process, achieving a flexural modulus of elasticity of 25GPa, which improves the structural strength compared to traditional hand lay-up molding.

[0034] In the ISTA 3A transport vibration test, the peak acceleration at the resonance point under 30Hz sinusoidal vibration was only 42g, and the maximum deformation of frame 7 was 0.8mm. Under the simulated horizontal acceleration of 0.4g from an 8-magnitude earthquake, the stress value in the stress concentration area of ​​the cabin structure was 210MPa, far below the yield strength of Q355ND steel. In the static load test, the deflection value was 1.2mm when a uniform pressure of 500kg was applied to the top, meeting the long-term load-bearing requirements of ISO 1219-1 standard. Through structural optimization design, the overall weight was reduced compared to the all-steel solution, reducing transportation costs, while meeting the thermal expansion and contraction compensation requirements in the temperature range of -40℃ to 60℃.

[0035] In a preferred embodiment of this example, the buffer and shock-absorbing layer 10 has a thickness of 8 mm to 12 mm and a density of 40 kg / m³. 3 ~50kg / m 3 High-density polyurethane foam layer.

[0036] Specifically, the cabin is equipped with a 10mm thick high-density polyurethane cushioning layer (density 45kg / m³). 3 By absorbing vibration energy through an elastic matrix with a Shore hardness of 60±5, the vibration acceleration attenuation in the 10-2000Hz frequency band can reach more than 40dB, which is beneficial to improving the shock resistance and buffer protection performance of this battery container for the battery.

[0037] In a preferred embodiment of this example, the adsorption layer 11 is a non-woven fabric or sponge impregnated with activated carbon. Specifically, the adsorption layer 11 can be arranged in key locations within the chamber 2, such as near the battery. By using non-woven fabric or sponge impregnated with activated carbon, it has a good adsorption effect on corrosive gases such as hydrogen sulfide and sulfur dioxide, effectively neutralizing any trace amounts of leaked gas that may be generated in the chamber 2. This reduces the probability of corrosion of the battery and the inner wall of the chamber 2, and helps to improve the service life of the battery and its container.

[0038] In a preferred embodiment of this example, the anti-corrosion coating has a double-layer structure, with the bottom layer being a second epoxy coating 12 with a dry film thickness of 60μm~80μm, and the top layer being a polyurethane coating 13 with a dry film thickness of 40μm~60μm.

[0039] Specifically, the construction process employs electrostatic spraying technology, which atomizes the coating material into 5-10μm particles. These particles are then uniformly adsorbed onto the workpiece surface under a 100,000-volt high-voltage electric field, with the dry film thickness of the anti-corrosion coating precisely controlled within the range of 80-120μm. For critical areas such as edges and corners, a "coating thickening zone" is formed by pre-applying a primer (dry film thickness 30μm).

[0040] In this embodiment, the coating system acts as a secondary barrier for material protection, enhancing corrosion resistance through the synergistic effect of chemical barrier and electrochemical protection. The polyurethane coating 13 achieves a grade 0 standard in the cross-cut adhesion test, forming a molecular-level bond between the coating and the substrate. It maintains its gloss after 3000 hours of QUV aging testing, making it particularly suitable for outdoor environments with strong ultraviolet radiation. Its elastomeric structure absorbs stress generated by the thermal expansion and contraction of the substrate, effectively preventing cracking. The second epoxy coating 12 exhibits excellent chemical inertness.

[0041] In a preferred embodiment of this invention, the outer casing 1 includes a housing 5 and a lid 6. The lid 6 is detachably mounted on the housing 5, and a sealing structure is provided between the lid 6 and the housing 5. The sealing structure uses waterproof sealant or a sealing ring. For example, one end of the lid 6 can be rotatably mounted on the housing 5 via a pivot, and the other end can be detachably connected to the housing 5 via a snap lock, screws, or other means, while the sealing structure uses a sealing ring.

[0042] Optionally, ethylene propylene diene monomer (EPDM) rubber can be used as the core sealing material at the joint between the lid 6 and the body 5. This material maintains over 90% elasticity within a temperature range of -40℃ to 120℃ and exhibits no cracking resistance at 1000ppm·h ozone aging. For example, a "double-seal + lip protection" structure can be designed: the inner pre-compression sealing structure has a hollow D-shaped cross-section, with the compression controlled at 28%±2% during assembly to form an initial sealing barrier; the outer side uses modified silicone sealant for secondary sealing, with the sealant layer thickness uniformly controlled at 3mm, forming a slightly elastic waterproof membrane after curing. It should be noted that the sealing process implements strict dynamic monitoring of compression, for example, a laser displacement sensor can be used to provide real-time feedback on the deformation of the sealing structure, ensuring that the sealing pressure in key areas is maintained within the optimal range, thus improving the waterproof lifespan compared to traditional single-seal structures.

[0043] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A protective battery container, characterized in that: The device includes an outer shell (1), on which a gland is provided at the position corresponding to the cable hole. Inside the outer shell (1) is a compartment (2) for accommodating the battery. The outer shell (1) includes a frame (7), on which a bursting diaphragm (3) is provided. On the frame (7) at the position corresponding to the bursting diaphragm (3), a pressure relief channel is provided. The outer surface of the frame (7) is covered with a fiberglass skin (9). The outer shell (1) includes a shock-absorbing layer (10), an adsorption layer (11), and an anti-corrosion coating. The shock-absorbing layer (10) and the adsorption layer (11) cover the inner wall of the compartment (2), and the shock-absorbing layer (10) is located between the adsorption layer (11) and the fiberglass skin (9). The anti-corrosion coating covers the fiberglass skin (9) on the outer side of the outer shell (1).

2. The protective battery container according to claim 1, characterized in that: The fiberglass skin (9) has a weakening part (4) in the area corresponding to the rupture diaphragm (3). The wall thickness of the fiberglass skin (9) at the weakening part (4) is smaller than the wall thickness of the surrounding fiberglass skin (9), so that when the rupture diaphragm (3) breaks, the fiberglass skin (9) can form cracks or openings along the weakening part (4).

3. A protective battery container according to claim 1, characterized in that: The thickness of the fiberglass skin (9) is 3-10mm.

4. A protective battery container according to claim 1, characterized in that: The skeleton (7) is made of corrosion-resistant material, which is stainless steel or hot-dip galvanized steel, and the surface of the stainless steel or hot-dip galvanized steel is coated with a first epoxy coating (8).

5. A protective battery container according to claim 4, characterized in that: The skeleton (7) is made of Q355ND low-temperature tough steel. Its surface is first coated with a zinc-chromium coating with a thickness of 70μm~90μm, and then sprayed with a first epoxy coating (8) to form a sacrificial anode and shielding composite anti-corrosion structure.

6. A protective battery container according to claim 1, characterized in that: The buffer and shock-absorbing layer (10) has a thickness of 8 mm to 12 mm and a density of 40 kg / m³. 3 ~50kg / m 3 High-density polyurethane foam layer.

7. A protective battery container according to claim 1, characterized in that: The adsorption layer (11) is a non-woven fabric or sponge impregnated with activated carbon.

8. A protective battery container according to claim 1, characterized in that: The anti-corrosion coating has a double-layer structure. The bottom layer is a second epoxy coating (12) with a dry film thickness of 60μm~80μm, and the top layer is a polyurethane coating (13) with a dry film thickness of 40μm~60μm.

9. A protective battery container according to claim 1, characterized in that: The outer casing (1) includes a box body (5) and a box cover (6). The box cover (6) is detachably mounted on the box body (5), and a sealing structure is provided between the box cover (6) and the box body (5).

10. A protective battery container according to claim 1, characterized in that: The sealing structure uses waterproof sealant or sealing rings.

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