Vehicle

Abstract

The utility model discloses a vehicle which comprises a composite profile, and the composite profile comprises a reinforced profile and a woven pultrusion profile. The woven pultrusion profile is arranged on the periphery of the reinforced profile and is reinforced through the reinforced profile, the woven pultrusion profile comprises a first continuous fiber woven body and a first resin matrix, and the first resin matrix is connected with the first continuous fiber woven body. According to the woven pultrusion profile, the strength and rigidity of the woven pultrusion profile are higher than those of a common composite pultrusion profile, and a reinforcing profile is further arranged in the woven pultrusion profile, supports the woven pultrusion profile and plays a role in reinforcing the woven pultrusion profile, so that the strength and rigidity of the woven pultrusion profile are improved, and the service life of the woven pultrusion profile is prolonged. The strength and the rigidity of the composite section bar are high, so that the composite section bar is not easy to break when being collided, the service life of a vehicle is prolonged, and the personal safety of passengers is protected.

Description

Technical Field

[0001] This application relates to the field of transportation technology, and more particularly to a vehicle. Background Technology

[0002] From the perspective of market development, people have placed higher demands on vehicle safety performance. In particular, vehicles are in motion during operation and frequently experience vibrations. To improve vehicle lifespan and ensure the safety of passengers and drivers, the industry has set higher requirements for vehicle strength and rigidity. Utility Model Content

[0003] To solve the above-mentioned technical problems, this application provides a vehicle with high strength and high rigidity.

[0004] This application is achieved through the following technical solution.

[0005] This application provides a vehicle including a composite profile, which includes a reinforcing profile and a braided pultruded profile. The braided pultruded profile is disposed on the outer periphery of the reinforcing profile and is reinforced by the reinforcing profile. The braided pultruded profile includes a first continuous fiber braid and a first resin matrix, with the first resin matrix connected to the first continuous fiber braid.

[0006] This application embodiment includes a braided pultruded profile. The strength and stiffness of the braided pultruded profile are higher than those of ordinary composite pultruded profiles. Furthermore, this application embodiment also provides a reinforcing profile within the braided pultruded profile. The reinforcing profile supports the braided pultruded profile and strengthens it, thereby improving the strength and stiffness of the braided pultruded profile. This results in a composite profile with higher strength and stiffness, making it less prone to breakage upon impact, thus extending the vehicle's lifespan and protecting passenger safety.

[0007] In some embodiments, the first continuous fiber braided profile includes multiple continuous fiber braided layers arranged sequentially from the inside out. The continuous fiber braided layers are woven from multiple continuous fibers, and at least a portion of the multiple continuous fibers are spirally arranged around the reinforcing profile.

[0008] Multi-layer continuous fiber braiding improves the strength and stiffness of braided pultruded profiles. Furthermore, some continuous fibers are spirally arranged around the reinforcing profile, which can better bind the internal continuous fibers. The continuous fibers are continuous in the circumferential direction of the braided pultruded profile, making the continuous fiber braiding layer less prone to breakage along the circumferential direction of the braided pultruded profile, thereby further improving the strength of the braided pultruded profile.

[0009] In some embodiments, the reinforcing profile has multiple cavities, and reinforcing ribs are formed between adjacent cavities.

[0010] The reinforcing profile has multiple cavities, which reduce weight and contribute to vehicle lightweighting. Furthermore, the reinforcing profile also has reinforcing ribs, increasing its structural strength and thus improving the strength and stiffness of the braided pultruded profile. This further extends the vehicle's lifespan and protects passenger safety.

[0011] In some embodiments, at least a portion of the plurality of cavities are arranged along a first direction, which intersects the extension direction of the reinforcing profile.

[0012] The arrangement direction of a number of cavities (the first direction) intersects with the extension direction of the reinforcing profile, so that the cross-section of the reinforcing profile has multiple cavities and reinforcing ribs. That is, along the extension direction of the reinforcing profile, the cross-section at each part has reinforcing ribs, thus improving the strength and stiffness of the reinforcing profile.

[0013] In some embodiments, at least a portion of the plurality of cavities are arranged along a second direction, and the second direction, the first direction, and the extension direction of the reinforcing profile intersect each other.

[0014] In this way, multiple cavities are arranged along both the first and second directions, which helps to make the outer contour dimensions of the reinforcing profiles relatively close along the first and second directions. This facilitates the formation of composite profiles with an approximately square outer contour and allows for greater diversity in composite profile structures. Furthermore, the distribution of cavities in both directions creates reinforcing ribs extending in both directions, thereby improving both strength and stiffness in both directions.

[0015] In some embodiments, the cross-sections of the plurality of cavities have the same shape and size; or, at least two of the plurality of cavities have the same cross-section shape but different sizes; and / or, at least two of the plurality of cavities have different cross-section shapes, and the cross-sections are perpendicular to the extension direction of the reinforcing profile.

[0016] In this way, by setting cavities of various shapes and / or sizes, various reinforcing profiles with different cross-sections can be formed, which is beneficial for the diversification of composite profile structures. Furthermore, various reinforcing ribs can be formed, which helps to improve the strength and stiffness of the composite profile.

[0017] In some embodiments, the reinforcing profile includes a metal profile having a plurality of cavities.

[0018] Metals are highly malleable, making it easy to form profiles with various cavities; moreover, metals generally have high strength, which is beneficial for improving the strength of reinforced profiles.

[0019] In some embodiments, the metal profile includes at least one of aluminum extrusion profiles, magnesium alloy profiles, and steel profiles.

[0020] Because braided pultruded profiles have low elongation, the continuous fibers are easily broken. However, the reinforcing profiles within the braided pultruded profiles possess high rigidity, meaning they are less prone to deformation. Under the influence of these reinforcing profiles, the braided pultruded profiles are also less likely to deform under external forces, thus reducing the likelihood of the continuous fibers breaking and improving the rigidity and strength of the braided pultruded profiles. Furthermore, aluminum, magnesium alloys, and steel possess advantages such as high strength, lightweight, corrosion resistance, and high plasticity. Therefore, reinforcing profiles, including aluminum extrusion profiles, magnesium alloy profiles, or steel profiles, offer advantages such as high strength, light weight, strong corrosion resistance, and ease of molding.

[0021] In some embodiments, the reinforcing profile is a one-piece molded structure.

[0022] This design not only improves the manufacturing efficiency of reinforced profiles but also enhances their structural strength. This, in turn, improves both the manufacturing efficiency and structural strength of composite profiles.

[0023] In some embodiments, an adhesive layer is provided between the reinforcing profile and the braided pultruded profile.

[0024] The bonding between the reinforced profile and the braided pultruded profile makes the combination of the reinforced profile and the braided pultruded profile more reliable, further improving the strength and rigidity of the composite profile.

[0025] In some embodiments, the reinforcing profile is formed by connecting multiple braided pultruded composite tubes. Each braided pultruded composite tube includes a second continuous fiber braid and a second resin matrix. The second resin matrix is ​​connected to the second continuous fiber braid. The inner cavity of each braided pultruded composite tube forms a cavity in the reinforcing profile. The portion of two adjacent braided pultruded composite tubes located between the two adjacent cavities forms a reinforcing rib.

[0026] The reinforced profile is made of multiple braided pultruded composite tubes, giving it multiple cavities and reinforcing ribs, resulting in high structural strength and light weight. Therefore, it improves the strength and stiffness of the composite profile while maintaining its light weight.

[0027] In some embodiments, the cross-sectional shapes and dimensions of the outer surfaces of the plurality of braided pultruded composite tubes are all the same; or, the cross-sectional shapes of the outer surfaces of at least two of the plurality of braided pultruded composite tubes are the same but the dimensions are different; and / or, the cross-sectional shapes of the outer surfaces of at least two of the plurality of braided pultruded composite tubes are different, and the cross-sections are perpendicular to the extension direction of the braided pultruded composite tubes.

[0028] Thus, by using braided pultruded composite tubes of various shapes and / or sizes, reinforced profiles with different cross-sections can be formed, facilitating the diversification of composite profile structures. Furthermore, various reinforcing ribs can be formed, which helps to improve the strength and stiffness of the composite profiles.

[0029] In some embodiments, the wall thickness of the plurality of braided pultruded composite tubes is the same; or, at least two of the plurality of braided pultruded composite tubes have different wall thicknesses.

[0030] This design allows for the creation of reinforced profiles with various cross-sections, facilitating the diversification of composite profile structures. Furthermore, it enables the formation of various reinforcing ribs, thereby improving the strength and stiffness of the composite profiles.

[0031] In some embodiments, adjacent braided pultruded composite tubes are bonded together by an adhesive layer, and / or adjacent braided pultruded composite tubes are welded together.

[0032] In this way, multiple braided pultruded composite tubes are connected to form a whole, and the connection strength of the above connection method is high, which is conducive to improving the overall strength and rigidity of the reinforced profile.

[0033] In some embodiments, the second continuous fiber braided body includes multiple continuous fiber braided layers distributed radially along the braided pultruded composite tube. The continuous fiber braided layers are woven from multiple continuous fibers, and at least a portion of the multiple continuous fibers of the continuous fiber braided layers of the second continuous fiber braided body are spirally arranged around the central axis of the braided pultruded composite tube.

[0034] The multi-layer continuous fiber braiding improves the strength and stiffness of the braided pultruded composite pipe. Furthermore, some of the continuous fibers are arranged around the spiral direction, which can better bind the internal continuous fibers. The continuous fibers are continuous in the circumference of the braided pultruded composite pipe, making the continuous fiber braiding layer less prone to breakage in the circumference of the braided pultruded composite pipe, thereby further improving the strength of the reinforced profile.

[0035] In some embodiments, the material of the second resin matrix is ​​a thermosetting resin or a thermoplastic resin.

[0036] In some embodiments, the material of the second resin matrix is ​​a thermosetting resin, and adjacent braided pultruded composite tubes are bonded together; or, the material of the second resin matrix is ​​a thermoplastic resin, and adjacent braided pultruded composite tubes are welded together.

[0037] In some embodiments, continuous fibers include one or a combination of two of organic fibers and inorganic fibers.

[0038] Organic fibers possess high strength, good elasticity, and flexibility. Inorganic fibers possess high strength and modulus. The use of one or more combinations of organic and inorganic fibers with a resin matrix helps to improve the strength of a single-layer continuous fiber braid, thereby enhancing the strength of braided pultruded profiles and braided pultruded composite pipes.

[0039] In some embodiments, inorganic fibers include any one or any combination of glass fibers, carbon fibers, basalt fibers, aramid fibers, or boron fibers; and / or, organic fibers include any one or any combination of aromatic polyamide fibers and ultra-high molecular weight polyethylene fibers.

[0040] In some embodiments, the material of the first resin matrix is ​​a thermosetting resin or a thermoplastic resin.

[0041] In some embodiments, the thermosetting resin includes epoxy resin, polyurethane; and / or, the thermoplastic resin includes polypropylene resin and / or polyamide resin.

[0042] In some embodiments, the adhesive layer material is any one of polyethylene, polypropylene, polyvinyl chloride, polyvinyl alcohol, polyacrylate, acrylic acid-acrylate copolymer, butadiene-styrene copolymer, styrene-acrylic acid copolymer, styrene-acrylate copolymer, ethylene-vinyl acetate copolymer, acrylic acid-grafted polyethylene, maleic anhydride-grafted polyethylene, acrylic acid-grafted polypropylene, maleic anhydride-grafted polypropylene, polyvinylidene fluoride, carboxymethyl cellulose, polyimide, polyetherimide, polyethylene phthalate, ethylene-vinyl acetate copolymer bisphenol A type epoxy resin, ethylene-vinyl acetate copolymer bisphenol F type epoxy resin, glycerol ether type epoxy resin, glycerol ester type epoxy resin, silicone type resin, polyurethane, and styrene-isoprene-styrene copolymer.

[0043] In some embodiments, the reinforcing profile includes a metal profile having at least one cavity.

[0044] Metals are highly malleable, making it easy to form profiles with various cavities; moreover, metals generally have high strength, which is beneficial for improving the strength of reinforced profiles.

[0045] In some embodiments, the reinforcing profile includes at least one of aluminum extrusion profile, magnesium alloy profile, and steel profile.

[0046] The profiles made of the above materials have high plasticity, which makes it easy to form profiles with cavities; and the profiles made of the above materials have relatively high strength, which is beneficial to improve the strength of reinforced profiles.

[0047] In some embodiments, the braided pultruded profile is formed on the outer periphery of the reinforcing profile using the reinforcing profile as a core rod.

[0048] This allows the reinforcing profile to be supported inside the braided pultruded profile, improving the strength and stiffness of the braided pultruded profile, thereby improving the strength and stiffness of the composite profile.

[0049] In some embodiments, the outer peripheral surface of the reinforcing profile has no concave surface, and / or the corners of the outer peripheral surface of the reinforcing profile are all rounded.

[0050] The outer periphery of the reinforcing profile is designed without concave surfaces, which not only improves the accuracy of the shape after the braided pultruded profile is formed, but also enhances the bonding strength between the reinforcing profile and the braided pultruded profile. In addition, the corners of the outer periphery of the reinforcing profile are all rounded, which makes it less likely to cut the continuous fibers, thereby improving the strength and stiffness of the braided pultruded profile.

[0051] In some embodiments, the vehicle includes a battery device for providing electrical energy. The battery device includes a battery box and a plurality of battery cells housed within a housing space of the battery box. The battery box includes a base plate, a frame, and a cover. The cover and the base plate are respectively connected to opposite sides of the frame to form a housing space. The frame includes a plurality of side beams connected end to end around the base plate and at least one partition beam disposed within the space enclosed by the plurality of side beams. The side beams and / or the partition beam include composite profiles.

[0052] The side beams utilize composite profiles. Due to the low thermal conductivity of woven pultruded profiles, composite profiles including woven pultruded profiles possess high thermal insulation performance. Therefore, using composite profiles for the side beams prevents cold or heat energy entering the containment space from the cover or bottom side from being easily conducted outwards through the side beams, achieving a thermal insulation effect, reducing energy dissipation, improving energy utilization, and facilitating thermal management of the battery unit. Furthermore, the high strength and light weight of the composite profiles contribute to the high strength and lightweight design of the battery unit. The partition beams also utilize composite profiles; the high strength and light weight of the composite profiles further contribute to the strength and lightweight design of the battery unit.

[0053] In some embodiments, the vehicle includes a body, which includes an A-pillar, a B-pillar, and a C-pillar, and at least one of the A-pillar, B-pillar, and C-pillar includes a composite profile.

[0054] The A-pillar, B-pillar, and C-pillar are located on the sides of the vehicle body and are mainly used to withstand the impact force when subjected to a side impact. Therefore, at least one of the A-pillar, B-pillar, and C-pillar is made of composite material. Since composite material has high strength and light weight, the embodiments of this application are beneficial to reducing the degree of deformation and damage to the vehicle when subjected to a side impact, and are also beneficial to the weight reduction of the vehicle.

[0055] In some embodiments, the vehicle includes a body and a chassis, with the body located above the chassis and detachably connected to the chassis.

[0056] This design allows for the separation and decoupling of the body and chassis, enabling the body to be replaced as needed, shortening the development cycle and reducing costs. In other words, it also improves the integration of the chassis, making it compatible with a variety of vehicle models.

[0057] In some embodiments, the vehicle includes a body and a chassis, the body and chassis together enclosing a passenger compartment of the vehicle, and the vehicle also includes a battery device for providing electrical power, the battery compartment of the battery device forming the floor of the passenger compartment.

[0058] By integrating the battery pack into the passenger compartment floor, additional brackets and connectors can be reduced, which helps to reduce the overall vehicle weight and allows for more efficient use of the vehicle's interior space.

[0059] Utility Model Effect

[0060] This application provides a vehicle with high strength and high rigidity. Attached Figure Description

[0061] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiments below. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0062] Figure 1 An exploded perspective view of a vehicle according to one or more embodiments;

[0063] Figure 2 This is a schematic diagram of the structure of a vehicle according to one or more embodiments;

[0064] Figure 3 This is an exploded perspective view of a battery device according to one or more embodiments;

[0065] Figure 4 This is an exploded perspective view of a battery cell according to one or more embodiments;

[0066] Figure 5 A cross-sectional view of a first structure of a composite profile according to one or more embodiments;

[0067] Figure 6 This is a cross-sectional view of a second structure of a composite profile according to one or more embodiments;

[0068] Figure 7 This is a cross-sectional view of a third structure of a composite profile according to one or more embodiments;

[0069] Figure 8 This is a cross-sectional view of a fourth structure of a composite profile according to one or more embodiments;

[0070] Figure 9 This is a cross-sectional view of a fifth structure of a composite profile according to one or more embodiments;

[0071] Figure 10 This is a cross-sectional view of a sixth structure of a composite profile according to one or more embodiments;

[0072] Figure 11 This is a cross-sectional view of a seventh structure of a composite profile according to one or more embodiments;

[0073] Figure 12 A cross-sectional view of a braided pultruded composite tube according to one or more embodiments;

[0074] Figure 13 A cross-sectional view of a reinforced profile formed by connecting multiple braided pultruded composite tubes according to one or more embodiments;

[0075] Figure 14 According to one or more embodiments, including Figure 13 A cross-sectional view of the composite profile with reinforced profile shown;

[0076] Figure 15 This is a three-dimensional structural diagram of a portion of a battery device according to one or more embodiments;

[0077] Figure 16 This is an exploded view of a vehicle body according to one or more embodiments.

[0078] Explanation of reference numerals in the attached figures

[0079] 1000 Vehicle; 100 Battery Unit; 200 Controller; 300 Motor; 400 Chassis; 500 Body; 501 A-pillar; 502 B-pillar; 503 C-pillar; 504 Crossbeam; 506 Sill Beam; 507 Bumper; 508 Hood; 509 Door Panel; 510 Window Frame; 10 Battery Box; 101 Box Cover; 102 Box Body; 1021 Base Plate; 1022 Side Beam; 1023 Separator Beam; 1 Battery Cell; 11 Shell; 111 End Cap; 112 Shell; 12 Electrode Assembly; 120 Electrode Tab; 13 Electrode Terminal; 14 Pressure Relief Mechanism; 2 Composite Profile; 21 Reinforcing Profile; 210 Cavity; 211 Reinforcing Rib; 212 Braided Pultruded Composite Tube; 22 Braided Pultruded Profile. Detailed Implementation

[0080] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0081] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification and the foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0082] In the description of the embodiments of this application, technical terms such as "first," "second," and "third" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0083] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0084] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects are in an "or" relationship.

[0085] In the description of the embodiments of this application, the technical terms "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "circumferential", etc., 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 this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed, operated or used in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0086] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0087] In the description of the embodiments of this application, unless otherwise expressly specified and limited, the technical term "contact" should be interpreted broadly, and can be direct contact, contact through an intermediate medium layer, contact between two contacting parties with substantially no interaction force, or contact between two contacting parties with interaction force.

[0088] The following is a detailed description of this application.

[0089] From the perspective of market development, people have placed higher demands on vehicle safety performance. In particular, vehicles are in motion during operation and often experience vibrations. Therefore, higher requirements are placed on vehicle strength and rigidity to improve vehicle lifespan and ensure the safety of passengers inside the vehicle.

[0090] Currently, some vehicle beams are made of composite pultruded profiles formed by ordinary pultrusion. Composite pultruded profiles have low strength and stiffness, and are prone to breakage when subjected to collisions, affecting the lifespan of the vehicle and the personal safety of passengers.

[0091] The inventors of this application discovered through research that by replacing ordinary composite pultruded profiles with braided pultruded profiles formed by braiding pultrusion, and adding reinforcing profiles inside the braided pultruded profiles, the structural strength and stiffness of the beam can be improved, making it less prone to breakage when subjected to collision, thereby extending the vehicle's lifespan and protecting the personal safety of passengers.

[0092] Based on this design concept, the inventors of this application designed a vehicle including a composite profile, the composite profile including a reinforcing profile and a braided pultruded profile, the braided pultruded profile being disposed on the outer periphery of the reinforcing profile and reinforced by the reinforcing profile, the braided pultruded profile including a first continuous fiber braided body and a first resin matrix, the first resin matrix being connected to the first continuous fiber braided body.

[0093] This design uses braided pultruded profiles, which have higher strength and stiffness than ordinary composite pultruded profiles. Furthermore, this design also incorporates reinforcing profiles within the braided pultruded profiles to support and strengthen them, thereby increasing their strength and stiffness. This makes the composite profile less prone to breakage upon impact, thus extending vehicle life and protecting passenger safety.

[0094] The composite profiles provided in this application embodiment can be applied to any component in a vehicle that has a beam structure, such as, but not limited to, the A-pillar, B-pillar, and C-pillar of a vehicle, as well as the side beams and transverse and longitudinal beams of the battery pack in a vehicle.

[0095] The vehicles provided in this application embodiment can be gasoline-powered vehicles, natural gas-powered vehicles, or new energy vehicles. New energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended vehicles, etc. This application embodiment does not impose any special limitations on the above-mentioned vehicles.

[0096] In the following embodiments, for ease of explanation, the description is provided in conjunction with the accompanying drawings.

[0097] Figure 1 This is an exploded perspective view of a vehicle according to one or more embodiments.

[0098] Vehicle 1000 can be a gasoline-powered vehicle, a natural gas-powered vehicle, or a new energy vehicle. New energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended vehicles, etc. For example... Figure 1 As shown, the vehicle 1000 includes a chassis 400 and a body 500 disposed on the chassis 400. The body 500 and the chassis 400 together enclose the passenger compartment of the vehicle 1000.

[0099] In some embodiments of this application, the chassis 400 and the body 500 are detachably connected.

[0100] For example, chassis 400 can be a skateboard chassis, and body 500 is detachably connected to skateboard chassis by a plurality of bolts around body 500.

[0101] This configuration allows for the separation and decoupling of the body 500 and the chassis 400, enabling the body 500 to be replaced as needed, shortening the development cycle and reducing costs. In other words, it also increases the integration of the chassis 400, making it compatible with various vehicle models.

[0102] Figure 2 This is a structural schematic diagram of a vehicle according to one or more embodiments.

[0103] In some embodiments of this application, such as Figure 2As shown, a battery device 100 is installed inside the vehicle 1000. The battery device 100 can be located at the bottom, front, or rear of the vehicle 1000. The battery device 100 can be used to power the vehicle 1000; for example, it can serve as the operating power source for the vehicle 1000. The vehicle 1000 may also include a controller 200 and a motor 300 located on the chassis 400. The controller 200 controls the battery device 100 to supply power to the motor 300, for example, to meet the power needs of starting, navigating, and driving the vehicle 1000. The battery device 100 can not only serve as the operating power source for the vehicle 1000 but also as its drive power source, replacing or partially replacing fuel or natural gas to provide driving power for the vehicle 1000.

[0104] In some embodiments of this application, the vehicle 1000 includes a battery device 100, the battery box 10 of which forms the floor of the passenger compartment.

[0105] By integrating the battery unit 100 into the floor of the passenger compartment, additional brackets and connectors can be reduced, which helps to reduce the overall vehicle weight and makes more efficient use of the interior space of the vehicle 1000.

[0106] The battery apparatus mentioned in the embodiments of this application may include one or more battery cell assemblies for providing voltage and capacity. A battery cell assembly may include multiple battery cells connected in series, parallel, or mixed connections via a busbar.

[0107] In some embodiments, a battery cell assembly is typically formed by arranging multiple battery cells.

[0108] As an example, a battery cell assembly can be a battery module, which is formed by arranging and fixing multiple battery cells together to form an independent module. As another example, a battery module can be formed by bundling multiple battery cells together with cable ties.

[0109] In some embodiments, the battery device may be a battery pack, which includes a battery case and one or more individual battery cells housed within the battery case.

[0110] As an example, a battery cell assembly can be a battery module, which can be housed in a battery case by fixing the battery module in the battery case.

[0111] As an example, battery cell assemblies can also be housed in a battery box by directly fixing multiple battery cells to the battery box.

[0112] Figure 3 This is an exploded perspective view of a battery device 100 according to one or more embodiments.

[0113] like Figure 3 As shown, the battery device 100 includes a battery box 10 and at least one battery cell 1. The battery box 10 has a receiving space, and at least one battery cell 1 is received in the receiving space.

[0114] In some embodiments of this application, the battery box 10 includes a box body 102 and a box cover 101, with the box cover 101 covering the box body 102, thereby forming the receiving space between the box body 102 and the box cover 101.

[0115] The housing 102 can be a hollow structure with one open end, and the cover 101 can be a plate-like structure. The cover 101 closes onto the open side of the housing 102 so that the cover 101 and the housing 102 together define the receiving space. Alternatively, both the cover 101 and the housing 102 can be hollow structures with one open side, and the open side of the cover 101 closes onto the open side of the housing 102. Of course, the battery box 10 formed by the cover 101 and the housing 102 can be of various shapes, such as a cylinder, a cuboid, etc.

[0116] In the battery device 100, there can be multiple battery cells 1, which can be connected in series, parallel, or in a mixed manner. A mixed connection means that multiple battery cells 1 are connected in both series and parallel configurations. Multiple battery cells 1 can be directly connected in series, parallel, or in a mixed manner, and then the entire assembly of multiple battery cells 1 is placed in the receiving space formed by the housing 102 and the cover 101. Alternatively, the battery device 100 can also consist of multiple battery cells 1 first connected in series, parallel, or in a mixed manner to form a battery module, and then multiple battery modules connected in series, parallel, or in a mixed manner to form a whole, which is then housed in the receiving space formed by the housing 102 and the cover 101. The battery device 100 may also include other structures; for example, it may include a busbar component for realizing electrical connections between multiple battery cells 1.

[0117] In this embodiment of the application, the battery cell 1 can be a secondary battery, which refers to a battery cell that can be recharged to activate the active materials and continue to be used after the battery cell has been discharged.

[0118] The battery cell 1 can be a lithium-ion battery, sodium-ion battery, sodium-lithium-ion battery, lithium metal battery, sodium metal battery, lithium-sulfur battery, magnesium-ion battery, nickel-metal hydride battery, nickel-cadmium battery, lead-acid battery, etc., and the embodiments of this application are not limited to this.

[0119] As an example, the battery cell 1 can be a cylindrical battery cell, a prismatic battery cell, a pouch battery cell, or a battery cell of other shapes. Prismatic battery cells include prismatic battery cells, blade-shaped battery cells, and multi-prismatic batteries, such as hexagonal prismatic batteries. This application does not have any particular limitations.

[0120] Figure 4 This is an exploded perspective view of a battery cell 1 according to one or more embodiments.

[0121] Battery cell 1 refers to the smallest unit that makes up a battery. Please refer to... Figure 4 The battery cell 1 includes a housing 11, an electrode assembly 12, and other functional components. The housing 11 includes an end cap 111 and a shell 112. The shell 112 has an accommodating space and an opening. The electrode assembly 12 is disposed in the accommodating space. The end cap 111 closes the opening of the shell 112.

[0122] End cap 111 refers to a component that covers the opening of housing 112 to isolate the internal environment of battery cell 1 from the external environment. Not limited to this, the shape of end cap 111 can be adapted to the shape of housing 112 to fit it. Optionally, end cap 111 can be made of a material with a certain hardness and strength (such as aluminum alloy), so that end cap 111 is not easily deformed under pressure or impact, giving battery cell 1 higher structural strength and improved safety performance. Electrode terminals 13 are electrically connected to electrode assembly 12 for outputting or inputting electrical energy from battery cell 1.

[0123] In some embodiments of this application, the end cap 111 may also be provided with a pressure relief mechanism 14 for releasing internal pressure when the internal pressure or temperature of the battery cell 1 reaches a threshold. The end cap 111 can be made of various materials, such as copper, iron, aluminum, stainless steel, aluminum alloy, plastic, etc., and this application does not impose any special limitations on this. In some embodiments of this application, an insulating component may also be provided on the inner side of the end cap 111. The insulating component can be used to isolate the electrical connection components within the housing 112 from the end cap 111 to reduce the risk of short circuits. For example, the insulating component may be made of plastic, rubber, etc.

[0124] The housing 112 is a component used to cooperate with the end cap 111 to form the internal environment of the battery cell 1. This internal environment can accommodate the electrode assembly 12, electrolyte, and other components. The housing 112 and the end cap 111 can be independent components. An opening can be provided on the housing 112, and the end cap 111 can be used to close the opening to form the internal environment of the battery cell 1. Alternatively, the end cap 111 and the housing 112 can be integrated. Specifically, the end cap 111 and the housing 112 can form a common connecting surface before other components are inserted into the housing. When it is necessary to encapsulate the interior of the housing 112, the end cap 111 closes the housing 112. The housing 112 can have various shapes and sizes, such as cuboid, cylindrical, or hexagonal prism. Specifically, the shape of the housing 112 can be determined according to the specific shape and size of the electrode assembly 12. The material of the housing 112 can be various, such as copper, iron, aluminum, stainless steel, aluminum alloy, or plastic. This application embodiment does not impose any special limitations on this.

[0125] Electrode assembly 12 is the component in the battery cell 1 where the electrochemical reaction occurs. The housing 112 may contain one or more electrode assemblies 12. The electrode assembly 12 is mainly formed by winding or stacking positive and negative electrode sheets, and typically a separator is provided between the positive and negative electrode sheets. The portions of the positive and negative electrode sheets containing active material constitute the main body of the electrode assembly, while the portions of the positive and negative electrode sheets without active material each constitute a tab 120. The positive and negative tabs may be located together at one end of the main body or separately at both ends of the main body. During the charging and discharging process of the battery, the positive and negative active materials react with the electrolyte, and the tabs 120 connect to the electrode terminals 13 to form a current loop.

[0126] Below, refer to Figures 5 to 16 Some embodiments of this application will be described in detail.

[0127] In some embodiments of this application, for ease of explanation, a first direction and a second direction are defined. The first direction, the second direction, and the extension direction of the composite profile 2 are intersecting directions, where intersecting includes perpendicular intersecting. The embodiments of this application are not limited to the case where these three directions intersect perpendicularly. For ease of explanation, as... Figures 5 to 7 , Figures 9 to 11 and Figure 14 As shown by the arrows in the diagram, the direction of arrow X is the first direction, and the direction of arrow Y is the second direction.

[0128] Figure 5 A cross-sectional view of a first structure of a composite profile according to one or more embodiments; Figure 6 This is a cross-sectional view of a second structure of a composite profile according to one or more embodiments; Figure 7 Cross-sectional view of the third structure of a composite profile according to one or more embodiments; Figure 8 Cross-sectional view of the fourth structure of a composite profile according to one or more embodiments; Figure 9 Cross-sectional view of the fifth structure of a composite profile according to one or more embodiments; Figure 10 Cross-sectional view of the sixth structure of a composite profile according to one or more embodiments; Figure 11 Cross-sectional view of the seventh structure of a composite profile according to one or more embodiments; Figure 12 Cross-sectional view of a braided pultruded composite tube according to one or more embodiments; Figure 13 Cross-sectional view of a tube group formed by connecting multiple braided pultruded composite tubes according to one or more embodiments; Figure 14 According to one or more embodiments, it includes Figure 13 Cross-sectional view of a composite profile including the reinforcing profile shown;

[0129] Figure 15 Schematic three-dimensional structure diagram of a partial structure of a battery device according to one or more embodiments; Figure 16 Exploded view of a vehicle body according to one or more embodiments.

[0130] An embodiment of the present application provides a vehicle 1000, as Figures 5 to 14 shown, the vehicle 1000 includes a composite profile 2, the composite profile 2 includes a reinforcing profile 21 and a braided pultruded profile 22, the braided pultruded profile 22 is disposed on the outer periphery of the reinforcing profile 21 and is strengthened by the reinforcing profile 21, the braided pultruded profile 22 includes a first continuous fiber braided body and a first resin matrix, and the first resin matrix connects the first continuous fiber braided body.

[0131] The composite profile 2 can be any component in the vehicle 1000 that can use a beam structure. The composite profile 2 can be at least part of the side beam or cross-longitudinal beam of the battery box 10 of the battery device 100 in the vehicle 1000, or can also be at least part of the A pillar 501, B pillar 502 or C pillar 503 of the vehicle body of the vehicle 1000. Of course, the composite profile 2 can also be other components of the vehicle 1000, which will not be listed one by one here.

[0132] The reinforcing profile 21 is a profile disposed in the hollow cavity of the braided pultruded profile 22. The reinforcing profile 21 has a certain strength and stiffness. The cross-section of the reinforcing profile 21 can be, but is not limited to, a Japanese character shape, a mesh shape, a field shape or other shapes, and the specific shape is not limited here. The material of the reinforcing profile 21 can be, but is not limited to, metal, plastic, continuous fiber composite material, and the specific material is not limited here.

[0133] Braided pultruded profile 22 is a high-performance composite profile manufactured using the braided pultrusion process, combining braiding and pultrusion techniques. Braided pultruded profile 22 is made by braiding continuous fibers (such as glass fiber, carbon fiber, aramid fiber, etc.) into a preform with a specific structure, then impregnating it with a resin matrix. Under the action of a traction device, the resin is cured and molded through a heated mold, ultimately resulting in a profile with a specific cross-sectional shape and properties. The preform formed by continuous fiber braiding becomes the first continuous fiber braided profile of braided pultruded profile 22, and the impregnated resin matrix becomes the first resin matrix of braided pultruded profile 22 after molding. Due to the use of continuous fiber reinforcement, braided pultruded profile 22 has high strength and stiffness, and can withstand large loads. Furthermore, due to the low density of continuous fibers and resin, braided pultruded profile 22 has a low density and is lightweight. In addition, the poor thermal conductivity of continuous fibers and resin results in a low thermal conductivity coefficient for braided pultruded profile 22.

[0134] "The braided pultruded profile 22 is reinforced by the reinforcing profile 21," and the reinforcement includes increasing the strength and stiffness of the braided pultruded profile 22. Since the reinforcing profile 21 is located inside the braided pultruded profile 22, it supports the braided pultruded profile 22 and plays the role of reinforcing the braided pultruded profile 22, thereby increasing the strength and stiffness of the braided pultruded profile 22.

[0135] This application embodiment includes a braided pultruded profile 22. The strength and stiffness of the braided pultruded profile 22 are higher than those of ordinary composite pultruded profiles. Furthermore, this application embodiment also provides a reinforcing profile 21 within the braided pultruded profile 22. The reinforcing profile 21 supports the braided pultruded profile 22 and strengthens it, thereby improving the strength and stiffness of the braided pultruded profile 22. As a result, the composite profile 2 has higher strength and stiffness, and therefore, the composite profile 2 is less likely to break when subjected to a collision, thereby extending the life of the vehicle 1000 and protecting the personal safety of passengers.

[0136] In the embodiments of this application, "multiple" means two or more.

[0137] In some embodiments of this application, the first continuous fiber braided body includes multiple layers of continuous fiber braided layers arranged sequentially from the inside out. The continuous fiber braided layers are woven from multiple continuous fibers, and at least a portion of the multiple continuous fibers are spirally arranged around the reinforcing profile 21.

[0138] The multi-layer continuous fiber braiding improves the strength and stiffness of the braided pultruded profile 22. Furthermore, some of the continuous fibers are spirally arranged around the reinforcing profile 21, which can better bind the internal continuous fibers. The continuous fibers are continuous in the circumferential direction of the braided pultruded profile 22, making the continuous fiber braiding layer less likely to break along the circumferential direction of the braided pultruded profile 22, thereby further improving the strength of the braided pultruded profile 22.

[0139] In some embodiments of this application, such as Figures 5 to 7 As shown, the reinforcing profile 21 has multiple cavities 210, and reinforcing ribs 211 are formed between adjacent cavities 210.

[0140] The reinforcing profile 21 has multiple cavities 210, which reduce weight and contribute to the lightweight design of the vehicle 1000. Furthermore, the reinforcing profile 21 also has reinforcing ribs 211, which improves the structural strength of the reinforcing profile 21, thereby increasing the strength and stiffness of the braided pultruded profile 22. This further enhances the strength and stiffness of the braided pultruded profile 22, thus extending the lifespan of the vehicle 1000 and protecting passenger safety.

[0141] In some embodiments of this application, such as Figures 5 to 7 As shown, at least a portion of the plurality of cavities 210 are arranged along a first direction X, which intersects the extension direction of the reinforcing profile 21.

[0142] For example, such as Figure 5 , Figure 6 , Figure 10 , Figure 11 and Figure 15 As shown, all cavities 210 of the reinforcing profile 21 are arranged along the first direction X.

[0143] For example, such as Figure 7 and Figure 9 As shown, all the cavities 210 of the reinforcing profile 21 are arranged in a matrix along the first direction X and the second direction Y, and the second direction Y, the first direction X and the extension direction of the reinforcing profile 21 intersect each other.

[0144] The extension direction of the reinforcing profile 21 is the length direction of the reinforcing profile 21. The arrangement direction (first direction X) of a number of cavities 210 intersects the extension direction of the reinforcing profile 21, so that the cross section of the reinforcing profile 21 has multiple cavities 210, and the cross section has reinforcing ribs 211. That is, along the extension direction of the reinforcing profile 21, the cross section at each part has reinforcing ribs 211. Therefore, the strength and stiffness of the reinforcing profile 21 are improved.

[0145] In some embodiments of this application, such as Figure 7 and Figure 9As shown, at least a portion of the plurality of cavities 210 are arranged along the second direction Y, and the second direction Y, the first direction X, and the extending direction of the reinforcing profile 21 intersect pairwise.

[0146] Exemplarily, as Figure 7 and Figure 9 shown, all the cavities 210 of the reinforcing profile 21 are arranged in a matrix along the first direction X and the second direction Y.

[0147] Thus, the plurality of cavities 210 are arranged in two directions, namely the first direction X and the second direction Y, which is conducive to making the outer contour dimensions of the reinforcing profile 21 along the first direction X and the second direction Y relatively close, conducive to forming the composite profile 2 with an outer contour of the cross-section approximately square, and conducive to the diversification of the structure of the composite profile 2. Moreover, the cavities 210 are distributed in two directions, forming reinforcing rib strips 211 extending in two directions, so that the strength and stiffness in both directions are improved.

[0148] In some embodiments of the present application, as Figures 5 to 15 shown, the shapes and sizes of the cross-sections of the plurality of cavities 210 are the same; or, at least two of the plurality of cavities 210 have the same cross-sectional shape but different sizes; and / or, at least two of the plurality of cavities 210 have different cross-sectional shapes, and the cross-sections are perpendicular to the extending direction of the reinforcing profile 21.

[0149] The shape and size of the cross-section of the cavity 210 refer to the shape and size of the figure formed after the inner surface of the cavity 210 is剖切 by a plane perpendicular to the extending direction of the reinforcing profile 21. For example, Figure 5 the cross-sections of the three cavities 210 in

[0150] Exemplarily, as Figure 5 shown, the reinforcing profile 21 has three cavities 210 arranged along the first direction X and has two reinforcing rib strips 211 both perpendicular to the first direction X, and the shapes and sizes of the cross-sections of the three cavities 210 are the same, and the shapes and sizes of the cross-sections of the two reinforcing rib strips 211 are the same. Thus, the cross-section of the reinforcing profile 21 is in the shape of a Chinese character "mu".

[0151] Exemplarily, as Figure 6 shown, the reinforcing profile 21 has three cavities 210 arranged along the first direction X and has two reinforcing rib strips 211 both perpendicular to the first direction X, and the shapes and sizes of the cross-sections of the three cavities 210 are different. Along the first direction X, the sizes of the three cavities 210 in the second direction Y increase in sequence, and the sizes of the two reinforcing rib strips 211 in the second direction Y are also different. The outer contour of the cross-section of the reinforcing profile 21 is similar to a triangle.

[0152] Exemplarily, as Figure 10 As shown, the reinforcing profile 21 has two cavities 210 arranged along the first direction X and has a reinforcing rib 211 perpendicular to the first direction X, and the shapes and sizes of the cross-sections of the two cavities 210 are the same. Thus, the cross-section of the reinforcing profile 21 is in the shape of a Chinese character 'Ri' (日).

[0153] Exemplarily, as Figure 11 shown, the reinforcing profile 21 has two cavities 210 arranged along the first direction X and has a reinforcing rib 211 perpendicular to the first direction X, and the shapes and sizes of the cross-sections of the two cavities 210 are different. The cross-section of the reinforcing profile 21 is in the shape of a Chinese character 'Ri' (日).

[0154] Exemplarily, as Figure 7 and Figure 9 shown, the reinforcing profile 21 has four cavities 210, which are distributed in a two-row and two-column matrix, and the reinforcing profile 21 has four reinforcing ribs 211 connected to form a cross-shaped structure, and the shapes and sizes of the cross-sections of the four cavities 210 are the same, and the shapes and sizes of the four reinforcing ribs 211 are the same. Thus, the cross-section of the reinforcing profile 21 is in the shape of a Chinese character 'Tian' (田).

[0155] Thus, by setting cavities 210 with various shapes and / or various sizes, reinforcing profiles 21 with various different cross-sections can be formed, which is beneficial to the diversification of the structure of the composite profile 2. And, reinforcing ribs 211 with various structures can be formed, which is beneficial to improving the strength and stiffness of the composite profile 2.

[0156] In some embodiments of the present application, the reinforcing profile 21 includes a metal profile, and the metal profile is formed with a plurality of cavities 210.

[0157] Metal has strong plasticity, which is convenient for forming profiles with various cavities 210; and, the strength of metal is generally relatively high, which is beneficial to improving the strength of the reinforcing profile 21.

[0158] In some embodiments of the present application, the metal profile includes at least one of an aluminum extrusion profile, a magnesium alloy profile, and a steel profile.

[0159] Exemplarily, the reinforcing profile 21 is an aluminum extrusion profile. Aluminum material is convenient for forming profiles with reinforcing ribs 211 and cavities 210 during the pultrusion process, and the manufacturing process is simple and the forming rate is high.

[0160] Exemplarily, the reinforcing profile 21 is a magnesium alloy profile.

[0161] Exemplarily, the reinforcing profile 21 is a steel profile.

[0162] Because the woven pultruded profile 22 has a low elongation rate, the continuous fibers are easily broken. However, the reinforcing profile 21 within the woven pultruded profile 22, due to its high rigidity, is less prone to deformation. Under the influence of the reinforcing profile 21, the woven pultruded profile 22 is also less likely to deform under external forces, thus reducing the probability of the continuous fibers in the woven pultruded profile 22 breaking and improving its rigidity and strength. Furthermore, aluminum, magnesium alloys, and steel also possess advantages such as high strength, lightweight, corrosion resistance, and high plasticity. Therefore, the reinforcing profile 21, including aluminum extruded profiles, magnesium alloy profiles, or steel profiles, has advantages such as high strength, light weight, strong corrosion resistance, and ease of molding.

[0163] In some embodiments of this application, such as Figures 5 to 8 As shown, the reinforcing profile 21 is an integrally formed structure.

[0164] This design not only improves the manufacturing efficiency of the reinforcing profile 21, but also enhances its structural strength. This, in turn, improves both the manufacturing efficiency and structural strength of the composite profile 2.

[0165] In some embodiments of this application, an adhesive layer is provided between the reinforcing profile 21 and the braided pultruded profile 22.

[0166] For example, the adhesive layer material includes hot melt adhesive.

[0167] By providing an adhesive layer between the reinforcing profile 21 and the braided pultruded profile 22, the reinforcing profile 21 and the braided pultruded profile 22 are bonded to each other, making the bond between the reinforcing profile 21 and the braided pultruded profile 22 more secure, and further improving the strength and rigidity of the composite profile 2.

[0168] In some embodiments of this application, such as Figures 9 to 14 As shown, the reinforcing profile 21 is formed by connecting multiple braided pultruded composite tubes 212. Each braided pultruded composite tube 212 includes a second continuous fiber braid and a second resin matrix. The second resin matrix is ​​connected to the second continuous fiber braid. The inner cavity of each braided pultruded composite tube 212 forms a cavity 210 of the reinforcing profile 21. The portion of two adjacent braided pultruded composite tubes 212 located between two adjacent cavities 210 forms a reinforcing rib 211.

[0169] The braided pultruded composite tube 212 is a tube with an internal cavity formed by the braiding pultrusion process. Multiple braided pultruded composite tubes 212 are connected to each other to form a reinforcing profile 21. The internal cavity of each braided pultruded composite tube 212 forms the cavity 210 of the reinforcing profile 21. The portion of the tube body of two adjacent braided pultruded composite tubes 212 located between the cavities 210 of the two braided pultruded composite tubes 212 forms a reinforcing rib 211.

[0170] For example, multiple braided pultruded composite tubes 212 are connected by welding or bonding.

[0171] The reinforcing profile 21 is made of multiple braided pultruded composite tubes 212, giving it multiple cavities 210 and multiple reinforcing ribs 211, resulting in high structural strength and light weight. Therefore, it is beneficial to improve the strength and stiffness of the composite profile 2, and the composite profile 2 is lightweight.

[0172] In some embodiments of this application, such as Figures 9 to 14 As shown, the cross-sectional shapes and dimensions of the outer surfaces of the plurality of braided pultruded composite tubes 212 are all the same; or, the cross-sectional shapes of the outer surfaces of at least two of the plurality of braided pultruded composite tubes 212 are the same but the dimensions are different; and / or, the cross-sectional shapes of the outer surfaces of at least two of the plurality of braided pultruded composite tubes 212 are different, and the cross-sections are perpendicular to the extension direction of the braided pultruded composite tubes 212.

[0173] For example, such as Figure 9 and Figure 10 As shown, the shape and size of the cross-section of the outer surface of the braided pultruded composite tube 212 are the same, and the shape and size of the cross-section of the inner surface of the braided pultruded composite tube 212 (which is also the cross-section of the cavity 210) are the same.

[0174] For example, such as Figure 11 As shown, the shape and size of the cross-section of the outer surface of the braided pultruded composite tube 212 are different, and the shape and size of the cross-section of the inner surface of the braided pultruded composite tube 212 (which is also the cross-section of the cavity 210) are also different.

[0175] Thus, by setting braided pultruded composite tubes 212 of various shapes and / or sizes, various reinforcing profiles 21 with different cross-sections can be formed, which is beneficial to the diversification of the composite profile 2 structure. Furthermore, various reinforcing ribs 211 can be formed, which is beneficial to improving the strength and stiffness of the composite profile 2.

[0176] In some embodiments of this application, such as Figures 9 to 14 As shown, the wall thickness of the multiple braided pultruded composite tubes 212 is the same; or, at least two of the multiple braided pultruded composite tubes 212 have different wall thicknesses.

[0177] This configuration allows for the formation of various reinforcing profiles 21 with different cross-sections, facilitating the diversification of the composite profile 2 structure. Furthermore, it enables the formation of reinforcing ribs 211 with diverse structures, thereby improving the strength and stiffness of the composite profile 2.

[0178] In some embodiments of this application, adjacent braided pultruded composite tubes 212 are bonded together by an adhesive layer, and / or adjacent braided pultruded composite tubes 212 are welded together.

[0179] Welding includes, but is not limited to, hot air welding, infrared welding, hot plate welding, ultrasonic welding, and vibration friction welding.

[0180] In this way, the connection between multiple braided pultruded composite tubes 212 is realized, forming a whole. Moreover, the connection method described above has high connection strength, which is beneficial to improving the overall strength and rigidity of the reinforced profile 21.

[0181] In some embodiments of this application, the second continuous fiber braided body includes multiple continuous fiber braided layers distributed radially along the braided pultruded composite tube 212. The continuous fiber braided layers are woven from multiple continuous fibers, and at least a portion of the multiple continuous fibers of the continuous fiber braided layer of the second continuous fiber braided body are spirally arranged around the central axis of the braided pultruded composite tube 212.

[0182] The multi-layer continuous fiber braiding improves the strength and rigidity of the braided pultruded composite tube 212. Furthermore, some of the continuous fibers are arranged around the spiral direction, which can better bind the internal continuous fibers. The continuous fibers are continuous in the circumferential direction of the braided pultruded composite tube 212, making the continuous fiber braiding layer less prone to breakage in the circumferential direction of the braided pultruded composite tube 212, thereby further improving the strength of the reinforced profile 21.

[0183] In some embodiments of this application, the material of the second resin matrix is ​​a thermosetting resin or a thermoplastic resin.

[0184] This allows for a wide range of material options, which helps reduce costs.

[0185] In some embodiments of this application, the material of the second resin matrix is ​​a thermosetting resin, and adjacent braided pultruded composite tubes 212 are bonded together.

[0186] In some embodiments of this application, the material of the second resin matrix is ​​thermoplastic resin, and adjacent braided pultruded composite tubes 212 are welded together.

[0187] In some embodiments of this application, the continuous fiber includes one or a combination of two of organic fibers and inorganic fibers.

[0188] Organic fibers possess high strength, good elasticity, and flexibility. Inorganic fibers possess high strength and modulus. The use of one or more combinations of organic and inorganic fibers with a resin matrix helps to improve the strength of a single-layer continuous fiber braid layer, thereby increasing the strength of the braided pultruded profile 22 and the braided pultruded composite tube 212.

[0189] In some embodiments of this application, inorganic fibers include any one or any combination of glass fibers, carbon fibers, basalt fibers, aramid fibers, or boron fibers; and / or, organic fibers include any one or any combination of aromatic polyamide fibers and ultra-high molecular weight polyethylene fibers.

[0190] In some embodiments of this application, the material of the first resin matrix is ​​a thermosetting resin or a thermoplastic resin.

[0191] This allows for a wide range of material options, which helps reduce costs.

[0192] In some embodiments of this application, the thermosetting resin includes epoxy resin, polyurethane; and / or, the thermoplastic resin includes polypropylene resin and / or polyamide resin.

[0193] In some embodiments of this application, the adhesive layer material is any one of polyethylene, polypropylene, polyvinyl chloride, polyvinyl alcohol, polyacrylate, acrylic acid-acrylate copolymer, butadiene-styrene copolymer, styrene-acrylic acid copolymer, styrene-acrylate copolymer, ethylene-vinyl acetate copolymer, acrylic acid-grafted polyethylene, maleic anhydride-grafted polyethylene, acrylic acid-grafted polypropylene, maleic anhydride-grafted polypropylene, polyvinylidene fluoride, carboxymethyl cellulose, polyimide, polyetherimide, polyethylene phthalate, ethylene-vinyl acetate copolymer bisphenol A type epoxy resin, ethylene-vinyl acetate copolymer bisphenol F type epoxy resin, glycerol ether type epoxy resin, glycerol ester type epoxy resin, silicone type resin, polyurethane, and styrene-isoprene-styrene copolymer.

[0194] In some embodiments of this application, the reinforcing profile 21 includes a metal profile having at least one cavity 210.

[0195] For example, such as Figure 8 As shown, the metal profile forms a cavity 210, and the metal profile is made of extruded aluminum. With only one cavity 210, the aluminum extruded profile has no internal reinforcing ribs. However, due to the high strength of the aluminum extruded profile, this structure can still meet the strength and stiffness requirements.

[0196] Metals are highly malleable, making it easy to form profiles with various cavities 210; and metals generally have high strength, which helps to improve the strength of the reinforced profile 21.

[0197] In some embodiments of this application, the reinforcing profile 21 includes at least one of aluminum extrusion profile, magnesium alloy profile, and steel profile.

[0198] The profiles made of the above-mentioned materials have high plasticity, which makes it easy to form profiles with cavities 210; and the profiles made of the above-mentioned materials have relatively high strength, which is beneficial to improving the strength of the reinforcing profile 21.

[0199] In some embodiments of this application, the braided pultruded profile 22 is braided and pultruded onto the outer periphery of the reinforcing profile 21 using the reinforcing profile 21 as a core rod.

[0200] It should be noted that in the existing braided pultrusion process, the mandrel is fixed, and the workpiece moves relative to the mandrel along the axial direction of the mandrel. In the embodiment of this application, the reinforcing profile 21, which serves as the mandrel, moves synchronously with the braided pultruded profile 22. After it is removed, another reinforcing profile 21 needs to be placed, and a pultruded profile is braided and pultruded outward from the newly placed reinforcing profile 21 to ensure that the braided pultrusion operation can be carried out continuously.

[0201] In the braided pultrusion process, the reinforcing profile 21 is used as a mandrel, and braiding and pultrusion are performed on the outer periphery of the reinforcing profile 21. Afterwards, the portion that has solidified into a braided pultruded profile 22, along with the reinforcing profile 21, is removed from the production equipment to form a composite profile 2. In this way, the reinforcing profile 21 is supported within the braided pultruded profile 22, improving the strength and stiffness of the braided pultruded profile 22, thereby increasing the strength and stiffness of the composite profile 2.

[0202] In some embodiments of this application, the outer peripheral surface of the reinforcing profile 21 has no concave surface, and / or the corners of the outer peripheral surface of the reinforcing profile 21 are all rounded.

[0203] During the woven pultrusion process, continuous fibers need to be wound around the outer periphery of the reinforcing profile 21. If a concave surface is provided on the outer periphery of the reinforcing profile 21, the concave surface cannot contact the continuous fibers wound around the reinforcing profile 21, causing the direction of the continuous fibers to fail to meet the predetermined requirements. This results in the shape of the formed woven pultruded profile 22 not conforming to the standard. Furthermore, the continuous fibers wound around the reinforcing profile 21 not adhering to the concave surface also leads to an unreliable bond between the reinforcing profile 21 and the woven pultruded profile 22. Therefore, in this embodiment, the outer periphery of the reinforcing profile 21 is designed without a concave surface. This not only improves the accuracy of the shape of the woven pultruded profile 22 after molding but also enhances the reliability of the bond between the reinforcing profile 21 and the woven pultruded profile 22. In addition, the corners of the outer periphery of the reinforcing profile 21 are all rounded. Rounded corners are less likely to cut the continuous fibers, thereby improving the strength and rigidity of the woven pultruded profile 22.

[0204] In some embodiments of this application, such as Figure 2As shown, the vehicle 1000 includes a battery device 100 for providing electrical energy. The battery device 100 includes a battery box 10 and multiple battery cells 1 housed within a receiving space of the battery box 10. The battery box 10 includes a base plate 1021, a frame, and a box cover 101. The box cover 101 and the base plate 1021 are respectively connected to opposite sides of the frame to form the receiving space. Figure 15 As shown, the frame includes multiple side beams 1022 connected end to end around the base plate 1021 and at least one partition beam 1023 disposed in the space enclosed by the multiple side beams 1022. The side beams 1022 and / or partition beams 1023 include composite profiles 2.

[0205] It is understood that the box body 102 includes a bottom plate 1021, side beams 1022 and partition beams 1023.

[0206] For example, the side beam 1022 adopts composite profile 2. Because the woven pultruded profile 22 has a low thermal conductivity, the composite profile 2, including the woven pultruded profile 22, has high thermal insulation performance. Therefore, by adopting composite profile 2 for the side beam 1022, cold or hot energy entering the containment space from the side of the cover 101 or the bottom plate 1021 is less likely to be conducted outward through the side beam 1022, achieving a heat insulation effect, reducing energy dissipation, improving energy utilization, and facilitating the thermal management of the battery device 100. Furthermore, the composite profile 2 has high strength and light weight, which is beneficial for the high strength and lightweight design of the battery device 100.

[0207] For example, the partition beam 1023 is made of composite profile 2, which has high strength and light weight, thus improving the strength and weight reduction of the battery device 100.

[0208] In some embodiments of this application, such as Figure 16 As shown, vehicle 1000 includes body 500, which typically includes load-bearing structure and appearance structure. The load-bearing structure typically includes A-pillar 501, B-pillar 502, C-pillar 503, sill beam 506, crossbeam 504, bumper 507, etc. The appearance structure typically includes hood 508, door panel 509, window frame 510, etc.

[0209] In some embodiments of this application, such as Figure 16 As shown, the vehicle 1000 includes a body 500, which includes an A-pillar 501, a B-pillar 502, and a C-pillar 503. At least one of the A-pillar 501, B-pillar 502, and C-pillar 503 includes a composite profile 2.

[0210] The A-pillar 501, B-pillar 502, and C-pillar 503 are located on the sides of the vehicle body 500 and are mainly used to withstand the impact force when subjected to a side impact. Therefore, at least one of the A-pillar 501, B-pillar 502, and C-pillar 503 is made of composite profile 2. Since the composite profile 2 has high strength and light weight, the embodiments of this application are beneficial to reducing the degree of deformation and damage to the vehicle 1000 when subjected to a side impact, and are also beneficial to the lightweighting of the vehicle 1000.

[0211] The following describes specific examples of some embodiments of this application with reference to the accompanying drawings.

[0212] As a specific example, a composite profile (composite profile 2) with a reinforced inner core is provided, including an aluminum extrusion profile (reinforcing profile 21) and a braided pultruded composite profile (braided pultruded profile 22) disposed on the outer periphery of the aluminum extrusion profile. The aluminum extrusion profile has a multi-cavity structure with internal reinforcing ribs (reinforcing ribs 211). This embodiment utilizes the characteristic that aluminum material can form internal reinforcing ribs during the pultrusion process to form an aluminum extrusion profile with reinforcing ribs and multiple cavities (cavities 210). The aluminum extrusion profile is then used as a core rod to form a braided pultruded composite profile on the outer periphery of the aluminum extrusion profile using a braided pultrusion process. The setting of reinforcing ribs improves the strength and stiffness of the aluminum extrusion profile and enhances the ability of the braided pultruded composite profile to resist deformation under external forces. At the same time, the aluminum extrusion profile is wrapped by fiber-reinforced resin composite material, which reduces thermal conductivity and is beneficial to the thermal insulation performance of the battery pack (battery device 100) lower housing (housing 102). The material of the braided pultruded composite profile is a continuous fiber reinforced composite. Continuous fiber reinforced composites have high strength but low elongation at break, while aluminum extruded profiles have high elongation at break but low strength. Therefore, combining the two compensates for their respective shortcomings. Specifically, the high strength of the continuous fiber reinforced composite compensates for the low strength of the aluminum core, increasing the overall bending strength of the profile. The high elongation at break of the aluminum core compensates for the low elongation at break of the continuous fiber reinforced composite (the material of braided pultruded profile 22), improving the problem of brittle fracture under bending. The aluminum core withstands long-term loads, overcoming the creep characteristics of resin-based composites (continuous fiber reinforced composites). The high elongation of the aluminum and the high strength of the continuous fiber reinforced composite complement each other, improving the overall mechanical properties of the profile, especially its bending resistance.

[0213] In manufacturing the aforementioned braided pultruded composite profile, aluminum material is first extruded to produce an aluminum extruded profile with a multi-cavity structure. After the multi-cavity aluminum extruded profile is prepared, it is used as the mandrel for the braided pultruded composite profile, and braiding pultrusion is performed on the mandrel. During the braiding pultrusion process, hot melt adhesive is applied to the contact surface to improve the bonding between the aluminum and the composite material. This method results in a composite profile with reinforcing ribs in its cross-section, forming a multi-cavity structure, which significantly improves its resistance to external deformation and solves the problem of low stiffness and easy deformation of ordinary pultruded tubes. At the same time, since the aluminum extruded profile is wrapped by continuous fiber-reinforced composite material, the thermal conductivity of the entire composite profile is reduced, which can improve the thermal insulation performance when applied to the frame (structure composed of side beams 1022 and partition beams 1023) of a battery pack (battery device 100).

[0214] As another specific example, a composite profile with a reinforced inner core (composite profile 2) is provided, comprising a tube assembly (reinforced profile 21) formed by connecting multiple braided pultruded tubes (braided pultruded composite tubes 212) and a braided pultruded composite material profile (braided pultruded profile 22) disposed on the outer periphery of the tube assembly. The portion of the tube body of two adjacent braided pultruded tubes located between the inner cavities of the two braided pultruded tubes forms a reinforcing rib (reinforcing rib strip 211). In this embodiment, resin is used as the matrix and continuous fibers are used as the reinforcing material. A secondary braided pultrusion method is employed to form reinforcing ribs within the profile cavity, thus forming a multi-cavity structure to enhance the composite profile's resistance to deformation under external forces. Simultaneously, the inner and outer fiber layers employ an online braiding process, with the fibers continuous in the circumferential direction, which better binds the internal axial fibers. The braided pultruded tube obtained from the first braided pultrusion, after welding or bonding, serves as the supporting structure for the internal cavity of the second braided pultrusion, thereby forming a multi-cavity cross-section and improving the structural strength of the composite profile. Both braided pultruded tubes and braided pultruded composite profiles adopt a braiding process in which inner and outer fiber layers are interwoven. When subjected to external force, the inner and outer fiber layers are stressed as a whole, and it is not easy for the fiber layers to separate.

[0215] When manufacturing the above-mentioned composite profiles, an initial braiding pultrusion process is first performed to produce a product like... Figure 12 The image shows a braided pultruded tube with a specific cross-sectional shape; after multiple braided pultruded tubes are prepared, several braided pultruded tubes are combined together by welding or bonding to form a... Figure 13 The tube assembly shown; after the braided pultruded tubes are connected into a tube assembly, the tube assembly is used as the mandrel for braided pultrusion, and secondary braided pultrusion is performed on the outside of the tube assembly to form a tube assembly as shown. Figure 14 The composite profile shown above. The above structure gives the final composite profile a reinforcing rib structure in its cross-section, forming a multi-cavity structure, which significantly improves its ability to resist external deformation and solves the problem of low stiffness and easy deformation of ordinary pultruded pipes.

[0216] In order to enable continuous production, during the secondary braiding pultrusion process, the aforementioned tube assemblies of a certain length, which serve as mandrels, need to be fed into the pultrusion production line one after another to ensure that the secondary braiding operation can be carried out continuously.

[0217] The above embodiments are merely illustrative of the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and all should be covered within the scope of the specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way.

Claims

1. A vehicle, characterized in that, Includes composite profiles, said composite profiles comprising: Reinforced profiles; A braided pultruded profile is disposed on the outer periphery of the reinforcing profile and reinforced by the reinforcing profile. The braided pultruded profile includes a first continuous fiber braid and a first resin matrix, wherein the first resin matrix is ​​connected to the first continuous fiber braid.

2. The vehicle according to claim 1, characterized in that, The first continuous fiber woven profile includes multiple layers of continuous fiber woven layers arranged sequentially from the inside out. Each continuous fiber woven layer is formed by weaving multiple continuous fibers, and at least a portion of the multiple continuous fibers are spirally arranged around the reinforcing profile.

3. The vehicle according to claim 1 or 2, characterized in that, The reinforcing profile has multiple cavities, and reinforcing ribs are formed between adjacent cavities.

4. The vehicle according to claim 3, characterized in that, At least a portion of the plurality of cavities are arranged along a first direction, which intersects the extension direction of the reinforcing profile.

5. The vehicle according to claim 4, characterized in that, At least a portion of the plurality of cavities are arranged along a second direction, wherein the second direction, the first direction, and the extension direction of the reinforcing profile intersect each other.

6. The vehicle according to any one of claims 3 to 5, characterized in that, The cross-sectional shapes and dimensions of the multiple cavities are all identical; or At least two of the plurality of cavities have the same cross-sectional shape but different dimensions; and / or At least two of the plurality of cavities have different cross-sectional shapes. The cross section is perpendicular to the extension direction of the reinforcing profile.

7. The vehicle according to any one of claims 3 to 6, characterized in that, The reinforcing profile includes a metal profile, and the metal profile has a plurality of cavities.

8. The vehicle according to claim 7, characterized in that, The metal profiles include at least one of aluminum extrusion profiles, magnesium alloy profiles, and steel profiles.

9. The vehicle according to any one of claims 3 to 8, characterized in that, The reinforcing profile is a one-piece molded structure.

10. The vehicle according to any one of claims 3 to 9, characterized in that, An adhesive layer is provided between the reinforcing profile and the braided pultruded profile.

11. The vehicle according to any one of claims 3 to 6, characterized in that, The reinforcing profile is composed of multiple braided pultruded composite tubes connected together. Each braided pultruded composite tube includes a second continuous fiber braid and a second resin matrix, with the second resin matrix connected to the second continuous fiber braid. The inner cavity of each braided pultruded composite tube forms the cavity of the reinforcing profile, and the portion of two adjacent braided pultruded composite tubes located between the two adjacent cavities forms the reinforcing rib.

12. The vehicle according to claim 11, characterized in that, The cross-sectional shape and dimensions of the outer surfaces of the plurality of braided pultruded composite tubes are all identical; or At least two of the plurality of braided pultruded composite tubes have the same cross-sectional shape on their outer surfaces but different dimensions; and / or At least two of the plurality of braided pultruded composite tubes have different cross-sectional shapes on their outer surfaces. The cross-section is perpendicular to the extension direction of the braided pultruded composite tube.

13. The vehicle according to claim 11 or 12, characterized in that, The wall thickness of multiple braided pultruded composite tubes is the same; or At least two of the plurality of braided pultruded composite tubes have different wall thicknesses.

14. The vehicle according to any one of claims 11 to 13, characterized in that, Adjacent braided pultruded composite tubes are bonded together by an adhesive layer, and / or adjacent braided pultruded composite tubes are welded together.

15. The vehicle according to any one of claims 11 to 14, characterized in that, The second continuous fiber braided body includes multiple continuous fiber braided layers distributed radially along the braided pultruded composite tube. The continuous fiber braided layers are woven from multiple continuous fibers, and at least a portion of the multiple continuous fibers of the continuous fiber braided layers of the second continuous fiber braided body are spirally arranged around the central axis of the braided pultruded composite tube.

16. The vehicle according to any one of claims 11 to 15, characterized in that, The material of the second resin matrix is ​​a thermosetting resin or a thermoplastic resin.

17. The vehicle according to any one of claims 11 to 16, characterized in that, The second resin matrix is ​​made of thermosetting resin, and adjacent braided pultruded composite tubes are bonded together; or The second resin matrix is ​​made of thermoplastic resin, and the adjacent braided pultruded composite tubes are welded together.

18. The vehicle according to claim 2 or 15, characterized in that, The continuous fiber includes one or a combination of two of organic and inorganic fibers.

19. The vehicle according to claim 18, characterized in that, The inorganic fibers include any one or any combination of glass fibers, carbon fibers, basalt fibers, aramid fibers, or boron fibers; and / or, the organic fibers include any one or any combination of aromatic polyamide fibers and ultra-high molecular weight polyethylene fibers.

20. The vehicle according to any one of claims 1 to 19, characterized in that, The material of the first resin matrix is ​​a thermosetting resin or a thermoplastic resin.

21. The vehicle according to claim 16 or 20, characterized in that, The thermosetting resin includes epoxy resin, polyurethane; and / or The thermoplastic resin includes polypropylene resin and / or polyamide resin.

22. The vehicle according to claim 10 or 14, characterized in that, The adhesive layer is made of any one of the following materials: polyethylene, polypropylene, polyvinyl chloride, polyvinyl alcohol, polyacrylate, acrylic acid-acrylate copolymer, butadiene-styrene copolymer, styrene-acrylic acid copolymer, styrene-acrylate copolymer, ethylene-vinyl acetate copolymer, acrylic acid-grafted polyethylene, maleic anhydride-grafted polyethylene, acrylic acid-grafted polypropylene, maleic anhydride-grafted polypropylene, polyvinylidene fluoride, carboxymethyl cellulose, polyimide, polyetherimide, polyethylene phthalate, ethylene-vinyl acetate copolymer bisphenol A type epoxy resin, ethylene-vinyl acetate copolymer bisphenol F type epoxy resin, glycerol ether type epoxy resin, glycerol ester type epoxy resin, silicone type resin, polyurethane, and styrene-isoprene-styrene copolymer.

23. The vehicle according to claim 1, characterized in that, The reinforcing profile includes a metal profile, and the metal profile has at least one cavity.

24. The vehicle according to claim 23, characterized in that, The reinforcing profile includes at least one of aluminum extrusion profile, magnesium alloy profile, and steel profile.

25. The vehicle according to any one of claims 1 to 24, characterized in that, The braided pultruded profile is formed by braiding and pultruding the reinforcing profile as a core rod on the outer periphery of the reinforcing profile.

26. The vehicle according to any one of claims 1 to 24, characterized in that, The outer peripheral surface of the reinforcing profile has no concave surface, and / or the corners of the outer peripheral surface of the reinforcing profile are all rounded.

27. The vehicle according to any one of claims 1 to 26, characterized in that, The vehicle includes a battery device for providing electrical power, the battery device including a battery box and multiple battery cells housed within a storage space of the battery box. The battery box includes a base plate, a frame, and a cover. The cover and the base plate are respectively connected to opposite sides of the frame to form the accommodating space. The frame includes multiple side beams connected end to end around the base plate and at least one partition beam disposed within the space enclosed by the multiple side beams, wherein the side beams and / or the partition beams include the composite profile.

28. The vehicle according to any one of claims 7 to 10, 23, and 24, characterized in that, The vehicle includes a body, which includes an A-pillar, a B-pillar, and a C-pillar, and at least one of the A-pillar, the B-pillar, and the C-pillar includes the composite profile.

29. The vehicle according to any one of claims 1 to 28, characterized in that, The vehicle includes a body and a chassis, with the body located on top of the chassis and detachably connected to the chassis.

30. The vehicle according to any one of claims 1 to 28, characterized in that, The vehicle includes a body and a chassis, which together enclose the passenger compartment of the vehicle. The vehicle also includes a battery device for providing electrical power, and the battery box of the battery device forms the floor of the passenger compartment.

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