Manufacturing process of a light-weight integrated liquid cooling channel composite battery tray

Abstract

The present application relates to the field of racks, modules or assemblies for multiple batteries or multiple battery units, and particularly relates to a manufacturing process of a lightweight integrated liquid cooling channel composite battery tray, comprising the following steps: preparing a profile and splicing the profile into a skeleton; preparing a bottom plate containing a liquid cooling channel; assembling the skeleton and the bottom plate, and laying a skin on the outer surfaces of the skeleton and the bottom plate; feeding the skeleton and the bottom plate with the laid skin into a hot pressing device for hot pressing, so that the skin, the skeleton and the bottom plate are combined into one body. The liquid cooling channel of the present application is directly integrated in the inside of the bottom plate, instead of using an independent liquid cooling plate, which significantly reduces the overall thickness of the bottom plate. The bottom plate and the skeleton are covered in the inside of the skin and integrally formed through the skin curing process, without the need for welding, bolts and rivets, thereby simplifying the manufacturing process and reducing the manufacturing cost.

Description

Technical Field

[0001] This invention relates to the field of racks, modules or components for multiple batteries or multiple battery cells, and more specifically to a manufacturing process for a lightweight integrated liquid-cooled flow channel composite material battery tray. Background Technology

[0002] Battery trays typically include a base plate for supporting battery modules and a frame surrounding the base plate. In the prior art, battery trays are mostly made of aluminum alloy extruded profiles that are welded or bolted together. In order to achieve thermal management functions, traditional battery trays usually adopt an independent liquid cooling plate design, that is, an additional metal plate with brazed flow channels is installed at the bottom of the battery tray, or the liquid cooling pipes are glued to the base plate with thermally conductive adhesive.

[0003] This traditional structure has significant drawbacks: the all-metal structure has a high density, which makes it difficult to meet the lightweight requirements of new energy vehicles; the independent liquid cooling system makes the overall structure of the battery tray complex, occupies a large space in the height direction, and there are assembly tolerances and contact gaps between the metal liquid cooling plate and the bottom plate of the battery tray, resulting in high contact thermal resistance and low heat exchange efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide a manufacturing process for a lightweight integrated liquid-cooled composite material battery tray, which aims to solve the problems of complex structure, large space occupation, and low heat exchange efficiency of traditional battery tray independent liquid cooling systems.

[0005] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution: A manufacturing process for a lightweight integrated liquid-cooled flow channel composite battery tray includes the following steps: Step A: Prepare the profiles and assemble them into a skeleton; Step B: Prepare a base plate containing liquid cooling channels; Step C: Assemble the frame and the base plate, and cover the outer surfaces of the frame and the base plate with skin; Step D: The skeleton covered with the skin and the base plate are fed into a molding equipment for hot pressing, so that the skin, the skeleton and the base plate are combined into one piece.

[0006] Furthermore, step B specifically includes the following sub-steps: Step B1: Processing the tubing into a metal tube with the preset shape of the liquid cooling channel; Step B2: Machining a flow channel groove that matches the metal tube on the upper surface of the base plate; Step B3: Apply thermally conductive structural adhesive into the flow channel groove, and press the formed metal tube into the flow channel groove.

[0007] Furthermore, step B specifically includes the following sub-steps: Step B1: Machining a channel groove of the preset shape of the liquid cooling channel on the upper surface of the base plate; In step C, the skin is laid directly above the top opening of the flow channel groove, and the top opening of the flow channel groove is closed by the skin, thereby forming the liquid cooling flow channel.

[0008] Furthermore, step B specifically includes the following sub-steps: Step B1: Fabricate a sacrificial core mold with water solubility or heat fusion properties, wherein the shape of the sacrificial core mold is the preset shape of the liquid cooling channel; Step B2: Place the sacrificial core mold into a foaming mold for in-situ foaming to form the base plate in which the sacrificial core mold is fitted; Step B3: The upper surface of the foamed base plate is flattened, and the foam layer covering the sacrificial core mold is ground away until the top surface of the sacrificial core mold is exposed; Following step D, step E is also included: injecting water or heating to dissolve or melt the sacrificial core mold and remove it.

[0009] Furthermore, in step C, the skin includes a substrate made of resin-based fiber-reinforced prepreg and an inner liner pre-attached to the bottom wall of the substrate, the inner liner being an adhesive film or resin-rich felt, the inner liner forming the inner surface of the top wall of the liquid cooling channel.

[0010] Furthermore, between step B1 and step B2, the following steps are performed: a foaming inhibitor is pre-placed on the surface of the sacrificial core mold, so that during the in-situ foaming process, the foam closely attached to the sacrificial core mold is inhibited to form a high-density, dense, hardened layer.

[0011] Furthermore, in step B1, a boss is pre-designed at the top center of the sacrificial core mold, and a step is formed at the top edge of the sacrificial core mold to connect the boss; Between step B1 and step B2, the following steps are performed: covering the surface of the sacrificial core mold with a leak-proof layer, the leak-proof layer being a gel coat layer or a thermoplastic film layer; In step B3, after the top surface of the sacrificial core mold is exposed, the boss is ground away until the leak-proof layer covering the step is exposed, so that the leak-proof layer covering the step forms an inwardly turned-up edge shape. In step C, the skin is laid on top of the sacrificial core mold and pressed onto the inner flange of the leak-proof layer.

[0012] Furthermore, in step A, the profile is prepared using a continuous pultrusion resin-based glass fiber composite material process; Between steps B and C, a positioning groove is machined on the upper surface of the base plate, and the skeleton is fitted into the positioning groove.

[0013] Furthermore, in step B, a metal connector is installed at the end of the liquid cooling channel; In step D, the skin and the metal joint are integrated into one unit.

[0014] Furthermore, the metal joint includes a connecting section exposed on the outside of the liquid cooling channel and an anchoring section embedded inside the liquid cooling channel, the anchoring section being flat in shape and having a thrust flange. In step B, the anchoring section of the metal joint is embedded into the base plate; In step C, the skin is laid over the thrust flange.

[0015] The advantages of this invention compared to the prior art include: The liquid cooling channels are directly integrated into the interior of the base plate, rather than using a separate liquid cooling plate, which significantly reduces the overall thickness of the base plate. The base plate and frame are covered inside the skin and integrally formed through the skin curing process, eliminating the need for welding, bolts and rivets, simplifying the manufacturing process and reducing manufacturing costs. Attached Figure Description

[0016] To more clearly illustrate the embodiments of the present invention or the technical solutions in 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 merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0017] Figure 1 This is an assembly diagram of the skeleton according to the first embodiment of the present invention; Figure 2 This is a perspective view of the skeleton of the first embodiment of the present invention; Figure 3 This is an assembly diagram of the first embodiment of the present invention; Figure 4 This is a perspective view of the first embodiment of the present invention, in which the skin is transparent; Figure 5 This is a top view of the first embodiment of the present invention; Figure 6 for Figure 5 A cross-sectional view along the AA direction; Figure 7 This is a perspective view of the base plate of the second embodiment of the present invention, and an enlarged view of its partial structure; Figure 8This is a perspective view of the base plate of the third embodiment of the present invention, and an enlarged view of its partial structure; Figure 9 This is a perspective view of the base plate of the fourth embodiment of the present invention, and an enlarged view of its partial structure; The labels in the diagram represent the following: 1-Frame; 11-Profile; 2-Base plate; 21-Flow channel; 22-Leak-proof layer; 23-Inner flange; 24-Positioning groove; 3-Skin; 4-Metal tube; 5-Metal joint; 51-Connecting section; 52-Anchoring section; 53-Thrust flange; 6-Sacrificial core mold. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] (First embodiment) To address the problems of complex structure, large space occupation, and low heat exchange efficiency of traditional battery trays with independent liquid cooling systems, this invention proposes a lightweight integrated liquid cooling channel composite material battery tray. Its core technology lies in: 1. The frame 1 of the battery tray is made of multiple profiles 11 spliced ​​together by pultruded resin-based glass fiber composite material.

[0020] 2. The liquid cooling channel is formed directly inside the bottom plate 2 of the battery tray.

[0021] 3. The skin 3 covers the surface of the frame 1 and the base plate 2 (including the top wall, bottom wall and peripheral wall), and is tightly bonded to the frame 1 and the base plate 2 through a curing process to form an integral structure.

[0022] The advantages of the above design are: First, the skeleton 1, manufactured by pultrusion process, has fibers oriented along the direction of force, which gives the skeleton 1 high axial strength and specific modulus. While significantly reducing weight (more than 40% weight reduction compared to aluminum alloy), it ensures the rigidity requirements of the battery tray under impact conditions. In addition, the skeleton 1, made of composite materials, is naturally corrosion-resistant, insulating, and has a low coefficient of thermal expansion, which improves the overall safety of the battery pack.

[0023] Second, the liquid cooling flow channel is directly integrated inside the base plate 2, instead of using an independent liquid cooling plate, which significantly reduces the overall thickness of the base plate 2.

[0024] Third, the base plate 2, the framework 1 and the skin 3 are integrally formed through a co-curing process, without requiring processes such as welding, bolts and rivets. On the premise of satisfying the structural strength, the manufacturing process is simplified and the manufacturing cost is reduced.

[0025] Reference Figure 1 and Figure 2 , the manufacturing process of the framework 1 includes the following steps: adopting a continuous pultrusion process, drawing the alkali-free glass fiber yarn or mat impregnated with the resin mixture (such as epoxy resin or polyurethane resin) through a heating mold (the temperature is usually controlled at 120-180°C), and curing and forming it into a beam body with a preset cross section (such as a rectangle, a mesh shape or a square shape).

[0026] Reference Figure 3 and Figure 4 , the co-curing process includes the following steps: after the framework 1 and the base plate 2 (including the liquid cooling flow channel) are assembled into a whole, covering the top and bottom surfaces thereof with the skin 3 (resin-based fiber-reinforced prepreg), then placing the whole into a hot pressing mold, and co-curing and connecting the framework 1, the base plate 2 and the skin 3 through hot pressing, so as to form an integral body.

[0027] Reference Figure 5 and Figure 6 , in this embodiment, the base plate 2 is made of a foam material, the upper surface of the base plate 2 is provided with a flow channel groove 21 and a positioning groove 24 (for example, formed by milling), and the shape of the bottom of the framework 1 matches the positioning groove 24.

[0028] The liquid cooling flow channel is made of a metal tube 4, the metal tube 4 has a preset bent shape (such as a serpentine shape) and is entirely embedded in the flow channel groove 21 formed on the upper surface of the foam base plate 2; a thermally conductive structural adhesive is filled between the metal tube 4 and the flow channel groove 21, and the thermally conductive structural adhesive is used to fix the metal tube 4, while eliminating the air gap between the metal tube 4 and the flow channel groove 21 to enhance heat conduction.

[0029] Both ends of the metal tube 4 extend to the edge or the outer side of the base plate 2 and are processed into the shape of a circular metal joint 5, and the portion of the metal tube 4 located inside the base plate 2 is stamped into a flat shape.

[0030] The liquid cooling flow channel is manufactured through the following steps: Step 1, forming the metal tube 4: processing the tube material into a preset flow channel shape through a numerically controlled pipe bender, and performing pipe end forming treatment (such as flaring) and pipe body shaping treatment (such as pressing into a flat cross section).

[0031] Step 2, milling: Use a CNC machine tool to mill a flow channel groove 21 on the upper surface of the base plate 2 to match the path of the metal tube 4. The depth of the flow channel groove 21 is equal to or slightly greater than the thickness of the metal tube 4 to ensure that the metal tube 4 does not protrude from the surface of the base plate 2 after being embedded.

[0032] Step 3, Embedding and Filling: Apply thermally conductive structural adhesive to the milled flow channel 21, press the formed metal tube 4 into the flow channel 21, and scrape off any overflowing adhesive.

[0033] Step 4, Skin 3 covering and co-curing molding: Assemble the frame 1 and the base plate 2 with the embedded metal tube 4. The frame 1 is pre-positioned and fixed by fitting into the positioning groove 24. Then, skin 3 is laid on the outer surface of the frame 1 and the base plate 2. The frame 1, the base plate 2 and skin 3 are sent into the molding equipment for hot pressing and curing. Skin 3 forms a hard shell, pressing the frame 1, the base plate 2 and the metal tube 4 inside into a whole.

[0034] In addition, refer to Figure 7 , Figure 8 and Figure 9 The liquid cooling channel can be formed inside the base plate 2 of the battery tray using the processes described in the other three embodiments.

[0035] (Second Embodiment) refer to Figure 7 In this embodiment, the base plate 2 is made of foamed material, and the upper surface of the base plate 2 is provided with a flow channel groove 21 (e.g., milled). The flow channel groove 21 constitutes the bottom wall and side wall of the liquid cooling channel. The inner surface of the skin 3 covering the upper surface of the base plate 2 directly crosses and closes the top opening of the flow channel groove 21, thereby constituting the top wall of the liquid cooling channel.

[0036] Metal connectors 5 are provided at the inlet and outlet of the liquid cooling channel. The metal connectors 5 have a circular connecting section 51 (exposed outside the battery tray) and a flat anchoring section 52 (embedded in the battery tray). The anchoring section 52 is fixed to the port of the channel groove 21 by structural adhesive, and the skin 3 covers the connection between the connector and the channel to assist in sealing.

[0037] The liquid cooling channel is fabricated through the following steps: Step 1, Metal Joint 5 Formation: The pipe is formed by end forming (e.g., one end is flared and the other end is flattened) to form metal joint 5.

[0038] Step 2, milling: Use a CNC machine tool to mill a flow channel groove 21 with a preset pattern (such as a snake) on the upper surface of the base plate 2, and mill the mounting position of the metal connector 5 at the end of the flow channel groove 21.

[0039] Step 3, Install the connector: Apply thermally conductive structural adhesive to the milled flow channel groove 21, press the anchoring section 52 of the formed metal connector 5 into the flow channel groove 21, and scrape off any overflowing adhesive.

[0040] Step 4, Skin 3 covering and co-curing molding: Assemble the skeleton 1 and the base plate 2 with embedded metal joints 5. Then, lay the skin 3 on the outer surface of the skeleton 1 and the base plate 2. The skin 3 is laid directly above the top opening of the flow channel 21 (the skin 3 is preferably a high-viscosity prepreg to prevent collapse). Send the skeleton 1, the base plate 2 and the skin 3 into the molding equipment for hot pressing and curing. The skin 3 forms a hard shell, pressing the skeleton 1, the base plate 2 and the metal tube 4 inside into a whole. At the same time, the skin 3 is bonded to the base plate 2 and seals the top opening of the flow channel 21 to form a liquid cooling flow channel.

[0041] In a preferred embodiment, to further improve the smoothness and sealing of the top wall of the flow channel, the skin 3 used is a composite structure, comprising a substrate made of resin-based fiber-reinforced prepreg and an inner liner pre-attached to the bottom surface of the substrate (facing the flow channel 21). This inner liner can be a film or a resin-rich felt. During installation, the inner liner directly contacts the opening of the flow channel 21, forming the inner surface of the top wall of the liquid-cooled flow channel.

[0042] (Third embodiment) refer to Figure 8 The third embodiment differs from the second embodiment in that: The base plate 2 is made of foamed material. During the foaming process of the base plate 2, the upper surface directly forms a flow channel groove 21, which constitutes the bottom wall and side wall of the liquid cooling flow channel.

[0043] In addition, metal connectors 5 are provided at the inlet and outlet of the liquid cooling channel, and the inner surface of the skin 3 covering the upper surface of the base plate 2 directly crosses over and closes the top opening of the channel groove 21, thus forming the top wall of the liquid cooling channel.

[0044] The inner wall of the flow channel 21 is a dense hardened layer with a density significantly higher than that of the base plate 2, which strengthens the sidewall of the liquid cooling flow channel and prevents coolant from seeping into the foam pores.

[0045] The liquid cooling channel is fabricated through the following steps: Step 1, make sacrificial core mold 6: The shape of sacrificial core mold 6 corresponds to the shape of the liquid cooling channel, and sacrificial core mold 6 has water solubility or heat fusion properties.

[0046] Step 2, install metal connector 5: The pipe is formed by end forming (e.g., one end is flared and the other end is flattened) to form metal connector 5. Then the metal connector 5 is installed at the end of the sacrificial mandrel 6. In particular, the flattened end of the metal connector 5 is formed with a thrust flange 53.

[0047] Step 3, in-situ foaming and wrapping: A foaming inhibitor (one or more combinations of silicone defoamers, mineral oil defoamers, or polyether defoamers can be selected) is pre-placed on the outer surface of the sacrificial core mold 6; then the sacrificial core mold 6 with the metal connector 5 is placed into the mold for foaming. During the foaming process, the foaming inhibitor inhibits the foaming material, and a high-density, dense, hardened layer is formed by the foam closely adhering to the sacrificial core mold 6; after foaming is completed, a base plate 2 with the sacrificial core mold 6 and the metal connector 5 is formed.

[0048] Step 4, Surface milling and exposure of sacrificial core mold 6: Use milling equipment to flatten the upper surface of the foamed base plate 2, control the milling depth, grind away the foam layer covering the sacrificial core mold 6 until the top surface of the sacrificial core mold 6 is exposed, so that the upper surface of the base plate 2 and the top surface of the sacrificial core mold 6 form a continuous flat plane.

[0049] Step 5, Skin 3 covering and co-curing molding: Assemble the skeleton 1 and the base plate 2 with the sacrificial core mold 6 embedded. Then, lay the skin 3 on the outer surface of the skeleton 1 and the base plate 2. The skin 3 is laid directly on top of the sacrificial core mold 6. Send the skeleton 1, the base plate 2 and the skin 3 into the molding equipment for hot pressing and curing. The skin 3 forms a hard shell, pressing the skeleton 1, the base plate 2 and the sacrificial core mold 6 inside into a whole.

[0050] Step 6, Liquid Cooling Channel Forming: After co-curing, water is injected or heated through the metal connector 5 to dissolve or melt the internal sacrificial core mold 6 and discharge it, forming a dense liquid cooling channel with an inner wall.

[0051] (Fourth embodiment) refer to Figure 9 The fourth embodiment differs from the third embodiment in that: The bottom and side walls of the flow channel 21 are covered with a continuous leak-proof layer 22 (such as a glass fiber gel coat layer or a thermoplastic film layer). The leak-proof layer 22 is integral with the base plate 2 and extends to the surface of the anchoring section 52 of the metal joint 5.

[0052] The leak-proof layer 22 forms an inwardly folded flange 23 extending horizontally towards the center of the liquid cooling channel at the top edge of the liquid cooling channel. The skin 3 covers the liquid cooling channel and presses against the inwardly folded flange 23, so that the skin 3 and the leak-proof layer 22 achieve a surface-to-surface overlapping seal.

[0053] The liquid cooling channel is fabricated through the following steps: Step 1, make sacrificial core mold 6: The shape of sacrificial core mold 6 corresponds to the shape of liquid cooling channel. Sacrificial core mold 6 is water-soluble or heat-meltable. In particular, an upward protruding boss is pre-designed at the middle position of the top of sacrificial core mold 6, and a step connecting the boss is formed at the edge of the top of sacrificial core mold 6.

[0054] Step 2, install metal connector 5: The pipe is formed by end forming (e.g., one end is flared and the other end is flattened) to form metal connector 5, and then the metal connector 5 is installed at the end of the sacrificial mandrel 6.

[0055] Step 3, Cover with leak-proof layer 22: Apply / cover the leak-proof layer 22 on the surface of the sacrificial core mold 6 and the surface of the anchoring section 52 of the metal joint 5. The leak-proof layer 22 not only covers the bottom and sides of the sacrificial core mold 6, but also extends to cover the side wall of the top boss of the core mold and the top edge of the boss.

[0056] Step 4, in-situ foaming: The sacrificial core mold 6 covered with the leak-proof layer 22 and the metal connector 5 are placed into the mold for foaming to form a base plate 2 with the sacrificial core mold 6 and the metal connector 5 fitted together.

[0057] Step 5, Surface milling and exposure of sacrificial core mold 6: The upper surface of the base plate 2 is milled and flattened, and the milling depth is set. After exposing the top surface of the sacrificial core mold 6, the boss of the sacrificial core mold 6 is ground away until the anti-leakage layer 22 on the step of the sacrificial core mold 6 is exposed, so that the anti-leakage layer 22 covering the bottom wall, side wall and step of the sacrificial core mold 6 forms an inwardly folded flange 23, and at the same time the top surface of the main body of the sacrificial core mold 6 is exposed.

[0058] Step 6, Skin 3 covering and co-curing molding: Assemble the skeleton 1 and the base plate 2 with the sacrificial core mold 6 embedded. Then, lay the skin 3 on the outer surface of the skeleton 1 and the base plate 2. The skin 3 is laid directly on top of the sacrificial core mold 6 and pressed on the newly formed inner flange 23 to form a reliable overlap seal. Send the skeleton 1, the base plate 2 and the skin 3 into the molding equipment for hot pressing and curing. The skin 3 forms a hard shell, pressing the skeleton 1, the base plate 2 and the sacrificial core mold 6 inside into a whole.

[0059] Step 7, Liquid Cooling Channel Forming: After co-curing, water is injected or heated through the metal connector 5 to dissolve or melt the internal sacrificial core mold 6 and discharge it, forming a liquid cooling channel with a leak-proof layer 22.

[0060] The above embodiments are merely exemplary embodiments of the present invention and are not intended to limit the present invention. The scope of protection of the present invention is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within its spirit and scope of protection, and such modifications or equivalent substitutions should also be considered as falling within the scope of protection of the embodiments of the present invention.

Claims

1. A manufacturing process for a lightweight integrated liquid-cooled flow channel composite material battery tray, Its features are, Includes the following steps: Step A: Prepare profile (11) and assemble the profile (11) into a skeleton (1); Step B: Prepare a base plate containing liquid cooling channels (2); Step C: Assemble the skeleton (1) and the base plate (2), and cover the surfaces of the skeleton (1) and the base plate (2) with skin (3). Step D: The skeleton (1) covered with the skin (3) and the base plate (2) are fed into the molding equipment for hot pressing, so that the skin (3), the skeleton (1) and the base plate (2) are combined into one.

2. The manufacturing process according to claim 1, characterized in that, Step B specifically includes the following sub-steps: Step B1: Process the tubing into a metal tube (4) with the preset shape of the liquid cooling channel. Step B2: A flow channel groove (21) matching the metal tube (4) is machined on the upper surface of the base plate (2). Step B3: Apply thermally conductive structural adhesive to the flow channel groove (21) and press the formed metal tube (4) into the flow channel groove (21).

3. The manufacturing process according to claim 1, characterized in that, Step B specifically includes the following sub-steps: Step B1: A flow channel groove (21) of the preset shape of the liquid cooling flow channel is machined on the upper surface of the base plate (2). In step C, the skin (3) is laid directly above the top opening of the flow channel (21) to close the top opening of the flow channel (21), thereby forming the liquid cooling flow channel.

4. The manufacturing process according to claim 1, characterized in that, Step B specifically includes the following sub-steps: Step B1: Fabricate a sacrificial core mold (6) with water solubility or heat fusion properties, wherein the shape of the sacrificial core mold (6) is the preset shape of the liquid cooling channel; Step B2: Place the sacrificial core mold (6) into the foaming mold for in-situ foaming to form the base plate (2) fitted with the sacrificial core mold (6). Step B3: Flatten the upper surface of the foamed base plate (2) and grind away the foam layer covering the sacrificial core mold (6) until the top surface of the sacrificial core mold (6) is exposed; After step D, step E is also included: injecting water or heating to dissolve or melt the sacrificial core mold (6) and discharge it.

5. The manufacturing process according to claim 3 or 4, characterized in that, In step C, the skin (3) includes a substrate made of resin-based fiber-reinforced prepreg and an inner liner pre-attached to the bottom wall of the substrate, the inner liner being a film or resin-rich felt, the inner liner forming the inner surface of the top wall of the liquid cooling channel.

6. The manufacturing process according to claim 4, characterized in that, Between step B1 and step B2, the following steps are performed: a foaming inhibitor is pre-placed on the surface of the sacrificial core mold (6) so that during the in-situ foaming process, the foam closely attached to the sacrificial core mold (6) is inhibited to form a high-density, dense, hardened layer.

7. The manufacturing process according to claim 4, characterized in that, In step B1, a boss is pre-designed at the top center of the sacrificial core mold (6), and a step is formed at the top edge of the sacrificial core mold (6) to connect the boss; Between step B1 and step B2, the following steps are performed: covering the surface of the sacrificial core mold (6) with a leak-proof layer (22), the leak-proof layer (22) being a gel coat layer or a thermoplastic film layer; In step B3, after the top surface of the sacrificial core mold (6) is exposed, the boss is ground away until the leak-proof layer (22) covering the step is exposed, so that the leak-proof layer (22) covering the step forms an inwardly folded edge (23). In step C, the skin (3) is laid on top of the sacrificial core mold (6) and pressed onto the inner flange (23) of the leak-proof layer (22).

8. The manufacturing process according to claim 1, characterized in that, In step A, the profile (11) is prepared using a continuous pultrusion resin-based glass fiber composite material process; Between steps B and C, a positioning groove (24) is machined on the upper surface of the base plate (2), and the skeleton (1) is fitted into the positioning groove (24).

9. The manufacturing process according to claim 3 or 4, characterized in that, In step B, a metal connector (5) is installed at the end of the liquid cooling channel. In step D, the skin (3) and the metal connector (5) are integrated into one unit.

10. The manufacturing process according to claim 9, characterized in that, The metal joint (5) includes a connecting section (51) exposed outside the liquid cooling channel and an anchoring section (52) embedded inside the liquid cooling channel. The anchoring section (52) is flat and has a thrust flange (53). In step B, the anchoring section (52) of the metal joint (5) is embedded into the base plate (2); In step C, the skin (3) is laid and covered on the thrust flange (53).

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