Battery cell spacer and manufacturing device

Abstract

The invention relates to the technical field of energy storage batteries, in particular to a battery cell distance piece and a manufacturing device.The distance piece comprises a base plate, a foam layer and an inner side ceramic layer, the base plate is of a continuous bent plate structure, and a flow channel is formed in the base plate in the extending direction of the base plate; after the substrate is bent, a plurality of arc-shaped temperature control grooves which are arranged at intervals are formed in one side of the substrate, and a plurality of arc-surface limiting grooves which are arranged at intervals are formed in the other side of the substrate; the foam layer covers the surface of the side, provided with the cambered surface limiting groove, of the base plate. The flexible ceramic membrane comprises an inner side ceramic layer arranged between the foam layer and the substrate, and an outer side ceramic layer arranged on the side, away from the substrate, of the foam layer and used as outer layer protection. The invention provides a battery cell distance piece and a manufacturing device, and aims to solve the problems that an existing distance piece lacks active heat management capacity, the temperature of a battery cell cannot be effectively regulated and controlled under the working conditions of high-rate charging and discharging or an extreme environment, and the battery cell is likely to be overheated.

Description

Technical Field

[0001] This invention relates to the field of energy storage battery technology, and in particular to a cell spacer and manufacturing apparatus. Background Technology

[0002] Lithium-ion batteries have been widely used in new energy vehicles and energy storage systems due to their high energy density and long cycle life. In power battery modules composed of multiple rows of cylindrical cells, physical spacers are usually placed between adjacent rows of cells. These spacers are pre-bent into a wavy shape by a bending machine to match the outer contour of the cells. Their core function is to achieve electrical insulation, mechanical buffering, and positioning between the cells.

[0003] However, such spacing structures have limited functionality and cannot effectively regulate cell temperature to prevent heat accumulation under high-rate charging and discharging or high and low temperature environments. Furthermore, they are difficult to maintain structural integrity and functional stability under extreme thermal stress conditions, making it difficult to meet the stringent requirements for comprehensive safety performance of high-energy-density battery modules. Summary of the Invention

[0004] In view of this, the present invention proposes a cell spacer and manufacturing apparatus. By integrating flow channels and arc-shaped temperature control grooves in the substrate to achieve active thermal management, and setting a composite protective structure composed of foam layers and double-sided flexible ceramic layers in the limiting area, the cell temperature can be effectively controlled under high-rate charging and discharging or high and low temperature conditions, and the interface adhesion, electrical insulation and mechanical integrity can be maintained under long-term service or severe thermal stress conditions, thereby comprehensively improving the overall thermal safety performance of the battery module.

[0005] The technical solution of this invention is implemented as follows: On one hand, the present invention provides a cell spacer, comprising a substrate, a foam layer, and a flexible ceramic film, wherein, The substrate is a continuous bent plate structure with flow channels arranged inside along its extension direction; After the substrate is bent, multiple spaced arc-shaped temperature control grooves are formed on one side, and multiple spaced arc-shaped limiting grooves are formed on the other side. The foam layer covers the side surface of the substrate where the arc-shaped limiting groove is located; The flexible ceramic membrane includes an inner ceramic layer disposed between the foam layer and the substrate, and an outer ceramic layer disposed on the side of the foam layer away from the substrate as an outer protective layer.

[0006] Based on the above technical solutions, preferably, the central angle of the arc-shaped limiting groove is smaller than the central angle of the arc-shaped temperature control groove.

[0007] Based on the above technical solutions, preferably, it also includes a retainer fixed inside the flow channel, wherein, The shape of the cage is adapted to the inner cavity shape of the flow channel; The flow channel is divided into a heat exchange channel and a pressure relief channel that are not interconnected by the retainer.

[0008] Based on the above technical solution, preferably, the foam layer is provided with a plurality of first through holes extending along the thickness direction, and the substrate is provided with second through holes at positions corresponding to the first through holes, wherein... The first through hole is filled with inorganic aerogel material; The inner ceramic layer has a locally thinned area in the region where the first through hole and the second through hole are aligned; The outer ceramic layer has a third through hole in the area corresponding to the first through hole.

[0009] Based on the above technical solutions, preferably, a metal mesh is embedded inside the first through hole.

[0010] Based on the above technical solutions, preferably, the retainer includes a flexible keel plate fixed inside the flow channel, wherein multiple support protrusions are distributed on both sides of the flexible keel plate, wherein... The support protrusion contacts the inner wall of the flow channel on the corresponding side, so that a gap is formed between the retainer and the inner wall of the flow channel to form the heat exchange channel and the pressure relief channel.

[0011] Based on the above technical solution, preferably, the supporting protrusion is connected to the flexible keel plate via fins, wherein... The fins extend along the bending axis of the substrate.

[0012] On the other hand, the present invention also provides a manufacturing apparatus for preparing the above-mentioned cell spacer, comprising a bending table and a rolling head, wherein, The bending table is fixed with a lower die and a support at the top. The lower mold is fixed with clamps on the front and rear sides for clamping the substrate, and has rails on the left and right sides. A cross slide is fixed on the top of the bracket. The rolling head is fixed to the output end of the cross slide, and a bearing is provided on its side. The bearing rolls along the track.

[0013] Based on the above technical solutions, preferably, the upper surface of the lower mold is provided with grooves that match the shape of the bottom surface of the substrate, and the side of the track is provided with a path groove that matches the contour of the bottom surface of the substrate. The bearing is in rolling engagement with the path groove; The front and rear ends of the path groove are funnel-shaped.

[0014] Based on the above technical solutions, preferably, the rolling head includes a rolling roller and two auxiliary rollers, wherein, The rolling roller is elastically and floatingly connected to the output end of the cross slide table via a spring telescopic rod. The rolling roller has swing arms hinged to both ends of its central shaft, and the bearing is sleeved on the central shaft of the rolling roller. Each of the swing arms is rotatably connected to an auxiliary wheel at its lower end, and the side of each swing arm is elastically connected to the side of the rolling wheel via a tension spring; The tension spring has a roller on its side, and the roller is rotatably mounted on the side of the rolling wheel, so that the tension spring is arranged in an L-shape.

[0015] The battery cell spacer and manufacturing apparatus of the present invention have the following advantages over the prior art: (1) By setting multiple spaced arc-shaped limiting grooves on one side of the substrate after bending, and covering them with a foam layer, and setting flexible ceramic layers on both sides of the foam layer, mechanical limiting, buffering energy absorption and high-temperature insulation of the battery cell are achieved, maintaining excellent electrical insulation and interface bonding stability. At the same time, the substrate integrates flow channels arranged along the extension direction, and an arc-shaped temperature control groove is provided on the other side to be in close contact with the surface of the battery cell, so that the cooling or heating medium in the flow channel can be efficiently heat-exchanged with the battery cell through the arc-shaped temperature control groove. Thus, this structure integrates passive protection function and active thermal management function into one, supports the regulation of battery cell temperature under high-rate charging and discharging or high and low temperature conditions, so as to reduce the risk of local overheating and ensure the functional continuity of the spacer in harsh service environments, thereby improving the pre-heat safety protection capability of the battery module.

[0016] (2) The flow channel is divided into a heat exchange channel and a pressure relief channel that are not connected by the retainer, and the first through hole and the second through hole filled with inorganic aerogel are opened on the foam layer and the substrate respectively. The inner ceramic layer has a local thinning area in the alignment area, and the outer ceramic layer has a third through hole in the corresponding area. This makes the spacer not only have efficient thermal management capabilities, but also further constructs an active safety response mechanism under extreme conditions: when the monomer experiences thermal runaway, the high temperature gas can be discharged in a controlled path, effectively suppressing the lateral spread of the flame, and realizing full-chain thermal safety protection from pre-prevention to post-incident suppression.

[0017] (3) By setting support protrusions and connecting flexible keel plates through fins extending along the bending axis, the support protrusions can adapt to the curvature changes during the bending process. When bending, the support protrusions can offset slightly along the flow channel extension direction to avoid damage or breakage caused by rigid interference and ensure the forming quality of the thermal management structure.

[0018] (4) By embedding a metal mesh in the first through hole, the local collapse of the foam layer under assembly preload, vibration, or thermal runaway high pressure is effectively suppressed, maintaining the geometric integrity of the first through hole. At the same time, the outer ceramic layer provides environmental protection under normal conditions, and guides high-temperature gas into the first through hole in an orderly manner through the third through hole during pressure relief. It also constrains the deformation of the foam with its own rigidity, preventing structural failure caused by ablation and ensuring reliable pressure relief. The two work together to ensure that the spacer maintains a stable thermal conduction interface and controllable internal pressure release capability throughout its entire life cycle, providing structural protection for the long-term reliable operation of thermal safety functions.

[0019] (5) Through the coordinated operation of the bending table, lower die, track and rolling head, the bearing on the side of the rolling head rolls along the track path groove to continuously bend the substrate according to the preset trajectory. At the same time, the auxiliary wheels on both sides of the rolling head are elastically pressed against the upper surface of the substrate by the L-shaped tension springs, dynamically offsetting the forming reaction, effectively suppressing substrate warping and displacement, ensuring that the flow channel does not collapse and the channel partition is not damaged, which is suitable for bending substrates with asymmetrical waveform structure. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a perspective view of a battery cell spacer according to the present invention; Figure 2 for Figure 1 A partial cross-sectional schematic diagram; Figure 3 for Figure 2 A schematic diagram of a partial structure; Figure 4 This is a schematic diagram showing the usage state of a cell spacer according to the present invention; Figure 5 This is a side view of a manufacturing apparatus according to the present invention; Figure 6 This is a side view of the track. Figure 7 This is a 3D view of the roller head; Figure 8 A three-dimensional view of the rolling head from another perspective; Figure 9 This is a front view of the roller head; Figure 10 This is a schematic diagram of the rolling process; In the diagram: 1. Substrate; 2. Foam layer; 3. Flexible ceramic membrane; 4. Cage; 5. Bending table; 6. Roller head; 21. Metal mesh; 31. Inner ceramic layer; 32. Outer ceramic layer; 41. Flexible keel plate; 42. Support protrusion; 43. Fin; 51. Lower mold; 52. Bracket; 53. Fixture; 54. Track; 55. Cross slide; 61. Bearing; 62. Roller wheel; 63. Auxiliary wheel; 64. Spring telescopic rod; 65. Swing arm; 66. Tension spring; 67. Roller; 101. Flow channel; 102. Arc-shaped temperature control groove; 103. Arc-shaped limiting groove; 104. Second through hole; 105. Slot; 201. First through hole; 1011, Heat exchange channel; 1012, Pressure relief channel; 3101, Local thinning zone; 3201, Third through hole; 5101, Groove; 5401, Path groove. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0023] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention based on the specific circumstances.

[0024] In the description of the embodiments of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0026] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0027] The following disclosure provides numerous different embodiments or examples for implementing various structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. Additionally, examples of various specific processes and materials are provided in this invention; however, those skilled in the art will recognize the applicability of other processes and / or the use of other materials.

[0028] like Figure 1-10 As shown, a cell spacer of the present invention includes a substrate 1, a foam layer 2 and a flexible ceramic film 3.

[0029] The substrate 1 is made of a thin metal sheet, such as aluminum alloy or stainless steel, and is formed into a plate-like structure with periodic undulations through a continuous bending process. It has internal flow channels 101 extending along the extension direction. After bending, multiple spaced arc-shaped temperature control grooves 102 are formed on one side of the substrate 1. The radius of curvature of these arc-shaped temperature control grooves 102 matches the outer diameter of a standard cylindrical battery cell, allowing the outer wall of the battery cell to fit tightly against the inner surface of the groove, thereby improving heat conduction efficiency. On the other side, multiple spaced arc-shaped limiting grooves 103 are formed. These arc-shaped limiting grooves 103 are naturally formed by continuous arc bending, with a smooth surface and no sharp edges. They are used to self-center and limit adjacent battery cells, preventing assembly misalignment or vibration loosening. The central angle of the arc-shaped limiting groove 103 is smaller than the central angle of the arc-shaped temperature control groove 102, making the limiting area smaller than the temperature control contact area, thus balancing positioning stability and maximizing the heat exchange area.

[0030] Foam layer 2 covers the side surface of substrate 1 where the arc-shaped limiting groove 103 is located, providing buffering, energy absorption, and vibration suppression. It is made of open-cell elastic foam material, such as flame-retardant EPDM or polyurethane foam, which, while providing buffering, energy absorption, and assembly tolerance compensation, also forms a thermal insulation barrier and has a certain degree of air permeability to facilitate pressure equalization. Simultaneously, under the pre-tightening force of subsequent module assembly, foam layer 2 can undergo moderate compression, effectively absorbing vibration impact while ensuring that the first through-hole 201 inside maintains an effective flow cross-section.

[0031] The flexible ceramic membrane 3 includes an inner ceramic layer 31 disposed between the foam layer 2 and the substrate 1, and an outer ceramic layer 32 disposed on the side of the foam layer 2 away from the substrate 1 as an outer protective layer. The two ceramic layers are used to isolate the battery cell from the metal substrate 1 to prevent short circuit risks. The flexible ceramic membrane 3 is made of alumina fiber nonwoven fabric or an Al2O3-SiO2 composite coating prepared by the sol-gel method, which has excellent electrical insulation, high temperature resistance and flexibility, and can deform according to the shape of the substrate 1 without breaking during bending.

[0032] In the above structure, the foam layer 2 and the flexible ceramic membrane 3 work together to endow the spacer with buffering, energy absorption, heat insulation, flame retardancy, and cell insulation properties. Simultaneously, the flow channel 101 inside the substrate 1 provides a transport path for the cooling or heating medium, and the arc-shaped temperature control groove 102 on one side fits tightly against the outer wall of the cell, promoting heat conduction. Thus, this structure integrates passive protection and active thermal management functions, supporting the regulation of cell temperature under high-rate charging and discharging or high and low temperature conditions to reduce the risk of localized overheating and ensure the functional continuity of the spacer in harsh service environments, thereby improving the pre-emptive thermal safety protection capability of the battery module.

[0033] When an internal short circuit in a single battery cell triggers thermal runaway, it generates high-temperature, high-pressure ejecta (including high-temperature gas and electrolyte-containing plasma). Traditional spacers cannot effectively block or conduct this extreme energy impact, which can easily lead to the lateral spread of flames and heat within the module (thermal propagation), triggering a chain reaction and causing serious module-level safety failures.

[0034] To this end, the cell spacer of the present invention further integrates a directional pressure relief structure. Specifically, a retainer 4 is fixed inside the flow channel 101, and the two are adapted in shape. The retainer 4 divides the internal space of the flow channel 101 into a heat exchange channel 1011 and a pressure relief channel 1012 that are not interconnected.

[0035] The heat exchange channel 1011, located near the arc-shaped temperature control tank 102, is used to introduce coolant or heating medium for active thermal management. The pressure relief channel 1012, located on the side of the heat exchange channel 1011 away from the arc-shaped temperature control tank 102, is normally closed by a pressure relief valve and automatically opens only in case of thermal runaway overpressure. Both ends of the heat exchange channel 1011 are equipped with a medium inlet pipe connection port and an outlet pipe connection port for connecting to an external circulation system.

[0036] To construct a directional pressure relief path, the foam layer 2 has multiple first through holes 201 extending along the thickness direction, and the substrate 1 has second through holes 104 at positions corresponding to the first through holes 201. The first through holes 201 are filled with inorganic aerogel material and embedded with a metal mesh 21. Meanwhile, the inner ceramic layer 31 has a locally thinned region 3101 in the area where the first through holes 201 and the second through holes 104 are aligned, and the outer ceramic layer 32 has a third through hole 3201 in the area corresponding to the first through hole 201.

[0037] The inorganic aerogel is a SiO2-based composite aerogel containing 5–15 wt% pyrolytic organic reinforcing fibers, which undergoes endothermic decomposition at 400–600°C, generating additional pores. The metal mesh 21 is a three-dimensional porous mesh made of copper or nickel with a porosity of 75%–85%, serving as a structural framework to support the inorganic aerogel and prevent it from collapsing and failing under long-term compression or vibration. The locally thinned region 3101 is used to form stress concentration points, facilitating preferential fracture under thermal runaway high pressure.

[0038] Under normal operating conditions, inorganic aerogel fills the first through-hole 201 as a heat insulation medium. It works in conjunction with the foam layer 2, the inner ceramic layer 31, and the outer ceramic layer 32 to form a heat insulation barrier and suppress heat conduction between adjacent cells.

[0039] When a battery cell experiences thermal runaway, high-temperature, high-pressure gas passes through the third through-hole 3201 and acts on the inorganic aerogel inside the first through-hole 201, causing the inorganic aerogel to undergo endothermic decomposition or structural loosening, consuming some of the thermal energy. Subsequently, the gas penetrates the inorganic aerogel, ruptures the locally thinned region 3101, enters the pressure relief channel 1012 through the second through-hole 104, and is finally released by the pressure relief valve on the pressure relief channel 1012. Through this pressure relief structure, ejected material is effectively guided, and the spread of flames to adjacent battery cells is suppressed, thereby reducing the risk of module-level fires and achieving full-chain thermal safety protection from prevention to suppression. During this process, the metal mesh 21 maintains the structural integrity of the first through-hole 201, preventing it from becoming blocked under high-pressure impact.

[0040] In the above structure, the inner ceramic layer 31 serves as a controllable pressure relief layer. Its core function is to initiate the explosion in a directional manner. Under thermal runaway pressure, the locally thinned region 3101 ruptures, thereby actively and orderly opening the pressure relief path and guiding the high-temperature and high-pressure gas to the pressure relief channel 1012.

[0041] The outer ceramic layer 32 serves as a protective barrier, effectively resisting the direct impact of high-temperature gas on the foam layer 2 during thermal runaway, reducing the risk of ablation or thermal degradation, thereby ensuring the geometric integrity and smooth flow of the first through hole 201, and ensuring the reliability of the directional pressure relief path.

[0042] Furthermore, in the above structure, the retainer 4 includes a flexible keel plate 41, multiple support protrusions 42, and fins 43 connecting the two. The flexible keel plate 41 and fins 43 are made of heat-insulating and highly malleable composite materials (such as ceramic fiber reinforced epoxy resin or aramid fiber reinforced polyimide), which can reduce the lateral heat conduction between the heat exchange channel 1011 and the pressure relief channel 1012, and can deform according to the shape of the substrate 1 without breaking during bending.

[0043] Specifically, a slot 105 is provided inside the flow channel 101 corresponding to the flexible keel plate 41. The slot 105 is arranged along the extension direction of the flow channel 101, and its cross-sectional shape matches the flexible keel plate 41 to ensure a tight fit after insertion. The flexible keel plate 41 is inserted into the slot 105 and bonded and fixed with a soft sealant. The soft sealant is made of a high-temperature resistant material with good ductility (such as silicone-modified epoxy resin or inorganic phosphate adhesive), which does not crack or detach during the subsequent rolling and bending process of the substrate 1, ensuring long-term airtight isolation between the heat exchange channel 1011 and the pressure relief channel 1012.

[0044] Supporting protrusions 42 are distributed on both sides of the flexible keel plate 41, and their number corresponds one-to-one with the periodic undulating structure of the flow channel 101. Each supporting protrusion 42 is hemispherical and has a built-in metal liner (such as a stainless steel or aluminum alloy sheet) to enhance the supporting effect. After the substrate 1 is subsequently rolled and bent, the supporting protrusions 42 abut against the inner wall of the flow channel 101, forming a stable line contact or narrow surface contact to provide effective support. The supporting protrusions 42 create a uniform gap between the flexible keel plate 41 and the inner wall of the flow channel 101, thereby forming the flow cross-sections of the heat exchange channel 1011 and the pressure relief channel 1012, respectively.

[0045] The fins 43 consist of multiple parallel, slender connecting ribs extending along the bending axis of the substrate 1, connecting each support protrusion 42 to the flexible keel plate 41. During bending, the fins 43 primarily bear bending deformation rather than tensile load, allowing for controllable elastic lateral tilting. This enables the support protrusions 42 to self-offset along the extension direction of the flow channel 101, dynamically adapting to local curvature changes and preventing damage to the inner wall of the flow channel 101 or breakage of the cage 4 due to rigid interference.

[0046] Because the substrate 1 forms an asymmetrical waveform structure after continuous bending (the central angle of the arc-shaped limiting groove 103 is smaller than that of the arc-shaped temperature control groove 102), the curvature difference between its two sides is significant. During the forming process, this structure is prone to warping, shifting, or channel collapse due to uneven stress. Traditional roll forming equipment struggles to simultaneously constrain the upper and lower surface contours and maintain the stability of the internal channel cross-section. Therefore, in the fabrication of the aforementioned cell spacer, a specialized manufacturing device is required to perform high-precision roll forming of the substrate 1.

[0047] To address this, the present invention provides a manufacturing apparatus specifically for bending and forming a substrate 1. The apparatus includes a bending table 5 and a rolling head 6. A lower die 51 and a support 52 are fixed to the top of the bending table 5. Clamps 53 are provided on the front and rear sides of the lower die 51 for clamping the substrate 1, and tracks 54 are fixed on the left and right sides. A cross slide 55 is mounted on the top of the support 52, and the rolling head 6 is fixed to the output end of the cross slide 55, with a bearing 61 rotatably mounted on its side. The upper surface of the lower die 51 has a groove 5101 that matches the shape of the bottom surface of the substrate 1. A path groove 5401 matching the contour of the bottom surface of the substrate 1 is opened on the inner side of the track 54, and the front and rear ends of the path groove 5401 are flared to facilitate the smooth entry of the bearing 61.

[0048] During bending, the bearing 61 is embedded in the path groove 5401 and rolls along it, thereby guiding the rolling head 6 to move along a preset trajectory. At the same time, the rolling head 6 works in conjunction with the lower die 51 and the fixture 53 to ensure that the position of the frame 4 remains stable and the cross-section of the flow channel 101 remains unchanged during continuous bending.

[0049] The rolling head 6 includes a rolling roller 62 and two auxiliary rollers 63. The rolling roller 62 is elastically and floatingly connected to the cross slide table 55 via a spring telescopic rod 64. A swing arm 65 is hinged to both ends of the central shaft of the rolling head 6, and a bearing 61 is sleeved on the central shaft. Each swing arm 65 is rotatably connected to an auxiliary roller 63 at its lower end, and its side is elastically connected to the side of the rolling roller 62 via a tension spring 66. A roller 67 is abutted against the middle of the tension spring 66, and the roller 67 is rotatably mounted on the side of the rolling roller 62, making the tension spring 66 L-shaped, thereby providing a stable preload and ensuring that the auxiliary roller 63 always presses against the upper surface of the substrate 1, effectively suppressing warping or displacement during the bending process and protecting the laminated foam layer 2 and flexible ceramic film 3 from shearing and peeling.

[0050] In this structure, the roller 67 is rotatable and rotates accordingly when the tension spring 66 extends or retracts, effectively reducing frictional resistance, preventing jamming, and ensuring dynamic stability of the preload.

[0051] Furthermore, after the two swing arms 65 are assembled with their respective tension springs 66, rollers 67, and auxiliary wheels 63, they form two sets of independent elastic abutment mechanisms. These two sets of mechanisms are centrally symmetrically arranged with the rolling roller 62 as the center, with a reasonable layout and no interference between their movements. In the non-rolling state, under the tension of the tension spring 66, the two auxiliary wheels 63 abut against each other below the rolling roller 62. At this time, the two swing arms 65 are arranged in a V-shape from a side view. When the rolling head 6 descends, the two auxiliary wheels 63 descend to the top surface of the plate to be bent, which will force the two swing arms 65 to open, achieving adaptive clamping.

[0052] In the aforementioned manufacturing apparatus, the support 52 is a rectangular frame structure, serving as the supporting base for the cross slide 55. The lower mold 51 is located on the inner lower side of this frame structure and is fixed to the bending table 5 by bolts. The clamp 53 is a bolt-type clamping structure; when the plate is placed on the bending table 5, rotating the bolt downwards to tighten the top surface of the plate, thereby locking the plate.

[0053] Furthermore, both tracks 54 are rectangular plate structures, symmetrically arranged on the left and right sides of the lower mold 51, and each track 54 has a path groove 5401 at its opposite ends. The bottom surface of the flared area of ​​the path groove 5401 extends horizontally outward by a certain distance to form a positioning surface. When the cross slide 55 drives the rolling head 6 to descend, the bearing 61 of the rolling head 6 contacts the positioning surface, indicating that it has descended to the correct position. After reaching the correct position, the cross slide 55 drives the rolling head 6 to move back and forth, causing the bearings 61 on the left and right sides of the rolling head 6 to slide into the corresponding path grooves 5401.

[0054] In addition, the cross slide 55 is an electric slide module with two degrees of freedom, used to drive the rolling head 6 to translate or lift. In practical applications, the cross slide 55 can also adopt a combination structure of linear motor + cylinder or hydraulic cylinder, wherein the rolling head 6 is fixed to the output end of the cylinder or hydraulic cylinder, the driving cylinder or hydraulic cylinder is fixed vertically to the output end of the linear motor, and the linear motor is fixed horizontally to the bracket 52. The linear motor is used to drive the rolling head 6 to translate, and the driving cylinder or hydraulic cylinder is used to drive the rolling head 6 to lift.

[0055] In the aforementioned manufacturing apparatus, the spring telescopic rod 64 is a combination structure of telescopic rod and spring, used to compensate for the height change when the rolling roller 62 floats and to prevent collision with the cross slide table 55.

[0056] Furthermore, the rolling roller 62 is a combination mechanism of wheel frame + wheel body + central shaft. The central shaft is fixed on the wheel frame, and the wheel body is rotatably mounted on the shaft. The two ends of the central shaft extend outward to form a coaxial long shaft structure. The bearing 61 is assembled at the end of the shaft and is coaxial with the rolling roller 62, ensuring that the rolling trajectory is completely synchronized with the path groove 5401, resulting in high forming accuracy and good surface consistency.

[0057] Furthermore, the surface of the rolling roller 62 is coated with a polyurethane or silicone elastic layer with a Shore hardness of 60–80A, which can transmit sufficient forming force while avoiding scratching the surface of the substrate 1.

[0058] When using the above-mentioned manufacturing apparatus, firstly, the substrate 1 is placed on top of the lower mold 51, and one end of the substrate 1 is pressed and fixed on the lower mold 51 by the clamp 53, while the other end remains free, so as to allow it to stretch smoothly during the bending process and avoid the material from wrinkling or cracking due to excessive constraint.

[0059] Then, the rolling head 6 is driven to descend vertically by the cross slide 55 until the rolling roller 62 and the auxiliary rollers 63 on both sides are in contact with the upper surface of the substrate 1. At this time, the bearing 61 on the side of the rolling head 6 falls into the entrance of the path groove 5401 on the track 54 and contacts the bottom positioning plane of the front end of the path groove 5401, completing the initial alignment.

[0060] Finally, the rolling head 6 is driven by the cross slide 55 to move at a constant speed along the extension direction of the substrate 1. During this process, the bearing 61 is guided from the flared end into the path groove 5401 and rolls along its contour, guiding the rolling head 6 to move along a preset trajectory. At the same time, the grooves 5101 on the upper surface of the lower die 51 cooperate with the rolling roller 62 to apply continuous and uniform plastic deformation force to the substrate 1, gradually shaping it into a bent structure with periodic undulations.

[0061] Furthermore, the aforementioned manufacturing apparatus can also be used for integrated bending of a multilayer composite substrate 1 pre-composite with foam layer 2 and flexible ceramic film 3. In this mode, the curvature profiles of the path groove 5401 and the uneven groove 5101 are adaptively adjusted according to the total thickness after composite and the material stacking characteristics. Specifically, the trough depth of the uneven groove 5101 is slightly greater than the theoretical forming depth of the bare substrate 1 to compensate for the compression deformation of the foam layer 2.

[0062] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A cell spacer, characterized in that: It includes a substrate (1), a foam layer (2), and a flexible ceramic film (3), wherein, The substrate (1) is a continuous bent plate structure, and has flow channels (101) arranged in its extension direction inside. After the substrate (1) is bent, a plurality of spaced arc-shaped temperature control grooves (102) are formed on one side and a plurality of spaced arc-shaped limiting grooves (103) are formed on the other side. The foam layer (2) covers one side surface of the substrate (1) where the arc-shaped limiting groove (103) is provided; The flexible ceramic film (3) includes an inner ceramic layer (31) disposed between the foam layer (2) and the substrate (1), and an outer ceramic layer (32) disposed on the side of the foam layer (2) away from the substrate (1) as an outer protective layer.

2. The cell spacer as described in claim 1, characterized in that: The central angle of the arc-shaped limiting groove (103) is smaller than the central angle of the arc-shaped temperature control groove (102).

3. A cell spacer as described in claim 1, characterized in that: It also includes a retainer (4) fixed inside the flow channel (101), wherein, The shape of the retainer (4) is adapted to the inner cavity shape of the flow channel (101); The flow channel (101) is divided into a heat exchange channel (1011) and a pressure relief channel (1012) that are not connected to each other by the retainer (4).

4. A cell spacer as described in claim 3, characterized in that: The foam layer (2) is provided with a plurality of first through holes (201) extending along the thickness direction, and the substrate (1) is provided with second through holes (104) at positions corresponding to the first through holes (201), wherein, The first through hole (201) is filled with inorganic aerogel material; The inner ceramic layer (31) has a local thinning area (3101) in the area where the first through hole (201) and the second through hole (104) are aligned. The outer ceramic layer (32) has a third through hole (3201) in the region corresponding to the first through hole (201).

5. A cell spacer as described in claim 4, characterized in that: A metal mesh (21) is embedded inside the first through hole (201).

6. A cell spacer as described in claim 3, characterized in that: The retainer (4) includes a flexible keel plate (41) fixed inside the flow channel (101), and the flexible keel plate (41) has multiple support protrusions (42) distributed on both sides, wherein, The support protrusion (42) contacts the inner wall of the flow channel (101) on the corresponding side, so that a gap is formed between the retainer (4) and the inner wall of the flow channel (101) to form the heat exchange channel (1011) and the pressure relief channel (1012).

7. A cell spacer as described in claim 6, characterized in that: The support protrusion (42) is connected to the flexible keel plate (41) via fins (43), wherein, The fins (43) extend along the bending axis of the substrate (1).

8. A manufacturing apparatus for preparing a cell spacer as described in any one of claims 1-7, characterized in that, Includes a bending table (5) and a rolling head (6), wherein, The bending table (5) is fixed with a lower die (51) and a bracket (52) at the top. The lower mold (51) has clamps (53) fixed on the front and rear sides for clamping the substrate (1), and rails (54) fixed on the left and right sides. The bracket (52) has a cross slide (55) fixed on the top. The rolling head (6) is fixed to the output end of the cross slide (55), and a bearing (61) is provided on its side. The bearing (61) rolls along the track (54).

9. The manufacturing apparatus as claimed in claim 8, characterized in that: The upper surface of the lower mold (51) is provided with a groove (5101) that matches the shape of the bottom surface of the substrate (1), and the side of the track (54) is provided with a path groove (5401) that matches the contour of the bottom surface of the substrate (1). The bearing (61) is in rolling engagement with the path groove (5401); The front and rear ends of the path groove (5401) are flared.

10. The manufacturing apparatus as claimed in claim 8, characterized in that: The rolling head (6) includes a rolling roller (62) and two auxiliary rollers (63), wherein, The rolling roller (62) is elastically and floatingly connected to the output end of the cross slide (55) via a spring telescopic rod (64); The roller (62) has swing arms (65) hinged at both ends of its central shaft, and the bearing (61) is sleeved on the central shaft of the roller (62). Each of the swing arms (65) is rotatably connected to an auxiliary wheel (63) at its lower end, and the side of each swing arm (65) is elastically connected to the side of the rolling wheel (62) via a tension spring (66); The tension spring (66) abuts against a roller (67) on its side. The roller (67) is rotatably disposed on the side of the rolling wheel (62), so that the tension spring (66) is arranged in an L-shape.

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