Lightweight new energy automobile power battery upper cover

Abstract

The utility model relates to the technical field of new energy automobile power batteries, in particular to a lightweight new energy automobile power battery upper cover. Comprising a panel and a side coaming fixedly connected to the edge of the panel, the side coaming is of an annular structure, the upper end of the side coaming is fixedly connected to the panel, the lower end of the side coaming is provided with a folded edge, and the panel is provided with a first downwards-concave area and a second downwards-concave area; a transition zone between the first concave area and the second concave area forms a convex rib for connecting the two ends of the panel, and the corner of the side coaming and the joint of the side coaming and the panel are provided with thickening and reinforcing areas; an anti-explosion valve mounting hole and an electrical connecting piece mounting hole are formed in the side surrounding plate. The battery upper cover is simple to manufacture, high in strength, light in weight, voltage-resistant, low in heat conductivity coefficient and good in flame retardant property.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicle power batteries, and specifically provides a lightweight new energy vehicle power battery upper cover. Background Art

[0002] New energy vehicle power batteries, consisting of a battery tray, battery cover, and energy storage cell pack, are the power source for new energy vehicles. They are key components used in pure electric vehicles, extended-range vehicles, and plug-in hybrid vehicles. New energy vehicles require continuous discharge from the power battery to provide energy and maintain vehicle stability. New energy vehicles are limited by battery life, making it a challenging task to reduce power consumption and electricity usage to extend range. To improve range, reducing vehicle weight is a relatively simple breakthrough, making lightweight power batteries while maintaining sufficient mechanical strength and sealing performance imperative. Existing new energy vehicle power battery cover structures are mostly die-cast aluminum alloys. This structure is prone to electrical and thermal conductivity, making it difficult to form in one piece, and its sealing performance is relatively poor. Aluminum alloys increase product weight and overall vehicle energy consumption. They also have low rigidity and poor product safety. Chinese patent application 2023114760841 discloses "A power battery cover, power battery and automobile", with the announcement number CN117525721A, which includes an upper cover, a seat bracket and multiple support frames. The multiple support frames are all arranged on the upper cover, and the seat bracket is fixed on the multiple support frames, and there is a gap between the lower surface of the seat bracket and the upper surface of the upper cover; the seat bracket is used to connect with the seat, and the multiple support frames can be fixed on the frame of the power battery housing. This design can provide support for the seat through the frame of the power battery housing, thereby preventing the upper cover and the battery cell from being compressed. However, this design also puts higher requirements on the strength of the power battery cover. Increasing the compressive strength by increasing the thickness of the power battery cover material not only increases production costs, but also goes against the goal of reducing the weight of the entire vehicle and increasing the cruising range. Utility Model Content

[0003] The purpose of the utility model is to provide a lightweight new energy vehicle power battery cover that is simple to manufacture, has high strength, is light, has good voltage resistance, low thermal conductivity, good flame retardancy and is durable.

[0004] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0005] The utility model describes a lightweight new energy vehicle power battery cover including a panel and a side panel fixedly connected to the edge of the panel. The side panel is an annular structure with an upper end fixedly connected to the panel and a folded edge at the lower end. A first concave area and a second concave area are provided on the panel. A transition zone between the first concave area and the second concave area forms a convex rib connecting the two ends of the panel. Thickened reinforcement areas are provided at the corners of the side panel and at the connection with the panel. An explosion-proof valve mounting hole and an electrical connector mounting hole are provided on the side panel.

[0006] Through this solution, the strength of the battery cover is enhanced while reducing the thickness of the main body of the battery cover. It is simple to manufacture, has high strength and is light in weight.

[0007] Preferably, the panel and side panels are integrally formed of a fiberglass composite material using a resin transfer molding process, and the fiberglass composite material is made of continuous fiber cloth with a surface density of 600g / ㎡, a plain weave, a glass fiber direction of 0 / 90°, and a single layer thickness of 0.5mm.

[0008] Through this solution, the battery cover has high voltage resistance, low thermal conductivity, good flame retardancy and is durable.

[0009] Preferably, the thickness of the thickened and reinforced area is increased by 30%-100%; the explosion-proof valve mounting hole and the electrical connector mounting hole are located on the same side wall of the side panel, and the side wall of the side panel with the explosion-proof valve mounting hole and the electrical connector mounting hole is increased in thickness by 100%-300% compared with other side walls.

[0010] Through this solution, the thickness of the local pressure-bearing part is increased to avoid a significant increase in weight.

[0011] Preferably, a label positioning line is provided on the first concave area or the second concave area, and the label positioning line is a strip-shaped body protruding from the upper surface of the first concave area or the second concave area.

[0012] This solution can meet the battery packaging requirements, save the development of label pasting tooling, reduce the time for label pasting, improve work efficiency and save costs.

[0013] Preferably, the middle section of the convex rib is a folded line section with a bend.

[0014] Through this solution, the coverage area of the ribs can be increased, and the strength of the panel can be further improved.

[0015] Compared with the prior art, the beneficial effects of the present invention are: the battery cover is simple to manufacture, has high strength, is lightweight, has good voltage resistance, low thermal conductivity, and good flame retardancy. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The figure shows the three-dimensional structure of the outer surface of the battery cover according to one embodiment of the present invention.

[0017] Figure 2 for Figure 1 The embodiment shows a schematic diagram of the three-dimensional structure of the inner surface of the battery cover. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0019] like Figure 1 、 Figure 2 As shown, the utility model describes a lightweight new energy vehicle power battery cover, including a panel and a side panel fixedly connected to the edge of the panel. The side panel is an annular structure with an upper end fixedly connected to the panel and a folded edge 5 at the lower end. A plurality of bolt holes are evenly distributed on the folded edge 5 for installing bolts and connecting to the battery housing to form an enclosed space.

[0020] The panel and side panels are integrally molded using a resin transfer molding process using a fiberglass composite material comprising a thermosetting matrix resin and continuous fibers. The continuous fibers used in the fiberglass composite material are continuous fiber cloth with a surface density of 600g / m2, a plain weave pattern, a 0 / 90° glass fiber orientation, and a single-layer thickness of 0.5mm. The thermosetting matrix resin is epoxy resin, a high-molecular-weight polymer with excellent bonding strength and chemical resistance, with a content of 35%-50%. The continuous fibers, primarily glass fibers, serve as reinforcements, enhancing the product's performance. These continuous fibers, comprising 50%-65% glass fibers, have a density of 1.8±0.2g / cm³. They are high-strength, aging-resistant, and low-thermal-conductivity RTM materials with a flame retardancy rating of UL94 V0 or higher. They offer advantages such as simple structure, easy molding, good voltage resistance, long durability, low weight, and excellent flame retardancy.

[0021] The processing process of the battery cover is as follows:

[0022] Cutting process: Battery cover products use high-voltage RTM continuous fiber material. First, the fiber cloth is cut into the shape of the unfolded diagram. Generally, the fiber cloth utilization rate is considered as much as possible during cutting, and layout cutting is required to improve the utilization rate of raw materials. When cutting, a 10mm margin is reserved for the main body.

[0023] Preforming process: The cut fiber cloth is placed in the preforming mold for preforming. After the preform is completed, the reinforcement area is reinforced. To ensure the effectiveness of the reinforcement, it is necessary to consider that the cutting cuts should not be in the same vertical position. After the laying is completed, it is fixed with a stapler to form a complete preform.

[0024] Molding process: Place the preform into the mold for injection molding. The heating temperature is about 105℃, the holding cycle is 180s, and the holding pressure is 2000T. After the mold is opened, take out the battery cover product and put it into the cold zone tooling for cooling. After cooling and shaping, take it out and use a trimming knife or file to grind the burrs.

[0025] Laser cutting: A three-dimensional five-axis laser cutting system is used to cut the mounting holes and special opening contours of the battery cover products. The product is inverted on the laser cutting tooling, and the special opening contour of the side is cut first, and then the sealing surface mounting hole is cut. Generally, the laser cutting head is about 0.5mm away from the product, and the laser cutting loss is 0.2mm. The laser cutting loss is reserved during cutting.

[0026] Airtightness test: Batteries have extremely high requirements for waterproofness and are required to undergo a full airtightness test before leaving the factory. Generally, tooling is used to press the batteries according to the installation hole position of the sealing surface, and then vacuum treatment is performed, pressure is maintained, and testing is performed to observe the leakage. The technical requirements of different products also vary to a certain extent.

[0027] In addition, the panel is provided with a first recessed area 1 and a second recessed area 2. The transition zone between the first recessed area 1 and the second recessed area 2 forms a rib 3 connecting the two ends of the panel. The middle section of the rib 3 is a curved line segment. Thickened and reinforced areas 4 are provided at the corners of the side panels and at their junctions with the panel. The side panels are provided with explosion-proof valve mounting holes 6 and electrical connector mounting holes 7. The explosion-proof valve mounting holes 6 are used to install the explosion-proof valve that controls the internal pressure of the battery. Separating the explosion-proof valve mounting holes not only reduces interference during product assembly but also allows for timely operation in the event of a danger, reducing the risk of safety accidents. The electrical connector mounting holes 7 are used to install electrical connectors or connectors.

[0028] The thickness of the reinforced area 4 is increased by 30% to 100%, enhancing the strength of the three-sided intersection. The explosion-proof valve mounting hole 6 and the electrical connector mounting hole 7 are located on the same side panel. The side panel with the explosion-proof valve mounting hole 6 and the electrical connector mounting hole 7 is 100% to 300% thicker than the other side panels, improving the strength of the side surface. Specifically, for a battery cover with dimensions of 1800*600*150mm, a surface area of 1.96㎡, and a body thickness of 1.0mm, the reinforced area 4 is 1.5mm thick, and the side surface with the explosion-proof valve mounting hole 6 and the electrical connector mounting hole 7 is 2.5mm thick. Furthermore, the thickness of the folded edge 5 can be increased to 3.0mm as needed. This results in a total weight of 4.3kg, an insulation resistance greater than 500MΩ, and a dielectric constant ≤5, meeting the requirements of light weight, high strength, and excellent insulation performance.

[0029] As a further improvement to the present invention, a label positioning line 8 is provided on the first concave area 1 or the second concave area 2. The label positioning line 8 is a strip-shaped body protruding from the upper surface of the first concave area 1 or the second concave area 2. The label positioning line 8 is an integrated structure molded during the pre-molding process, with a height of 0.1mm and a width of 0.1mm, which is flush with the thickness of the label. Later, when the battery is packaged at the factory, a labeling machine or manual labor will affix a label to the battery cover based on the marking of the label positioning line 8. This meets the requirements of the entire battery packaging, saves the development of label affixing tooling, and also saves the time of label affixing, greatly improving work efficiency and saving costs.

[0030] The contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0031] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A lightweight new energy vehicle power battery cover, comprising a panel and a side panel fixedly connected to the edge of the panel, wherein the side panel is an annular structure with an upper end fixedly connected to the panel and a folded edge (5) at the lower end, characterized in that: The panel is provided with a first concave area (1) and a second concave area (2); a transition zone between the first concave area (1) and the second concave area (2) forms a convex rib (3) connecting the two ends of the panel; the corners of the side panel and the connection between the side panel and the panel are provided with a thickened reinforcement area (4); and the side panel is provided with an explosion-proof valve installation hole (6) and an electrical connector installation hole (7).

2. The lightweight new energy vehicle power battery cover according to claim 1, characterized in that: The panel and side panels are integrally formed of a fiberglass composite material using a resin transfer molding process. The fiberglass composite material is made of continuous fiber cloth with a surface density of 600g / m2, a plain weave, a glass fiber direction of 0 / 90°, and a single layer thickness of 0.5mm.

3. A lightweight new energy vehicle power battery cover according to claim 1 or 2, characterized in that: The thickness of the thickened and reinforced area (4) is increased by 30% to 100%; the explosion-proof valve mounting hole (6) and the electrical connector mounting hole (7) are located on the same side wall of the side panel, and the side wall of the side panel with the explosion-proof valve mounting hole (6) and the electrical connector mounting hole (7) is increased in thickness by 100% to 300% compared with other side walls.

4. A lightweight new energy vehicle power battery cover according to claim 1 or 2, characterized in that: A label positioning line (8) is provided on the first concave area (1) or the second concave area (2), and the label positioning line (8) is a strip-shaped body protruding from the upper surface of the first concave area (1) or the second concave area (2).

5. A lightweight new energy vehicle power battery cover according to claim 1 or 2, characterized in that: The middle section of the convex rib (3) is a broken line section with a bend.

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