Composite roof power battery rack of passenger car

Abstract

The utility model discloses a power battery rack for a composite roof of a passenger car. The power battery rack comprises a power battery rack body with a frame structure, the edge position of the power battery rack body is fixedly connected with a connecting support leg; the power battery rack body comprises an outer surface layer fiber fabric, an inner surface layer fiber fabric, sandwich foam arranged between the outer surface layer fiber fabric and the inner surface layer fiber fabric, and pultrusion groove-shaped beams with a set number; embedded connecting pieces are fixedly arranged at the two ends of the pultrusion groove-shaped beam and fixedly connected with the connecting supporting feet. Compared with the prior art, the composite roof power battery rack of the passenger car has the advantages that the power battery rack body which is of a frame structure and formed by curing fiber fabric through resin is adopted, the problems that a carbon steel welding framework is heavy in structure and large in deformation amount are solved, and the composite roof power battery rack is integrally formed, convenient to produce and high in size precision.

Description

Technical Field

[0001] This utility model relates to a composite material roof power battery rack for a bus, belonging to the technical field of power battery racks. Background Technology

[0002] Existing bus roof-mounted battery racks are all made of carbon steel welded grid frames, with the construction method involving the cutting and welding of carbon steel profiles. This method requires the positioning and welding of the profiles that make up the grid structure. However, due to the numerous welding joints and the fact that the battery rack is a planar grid structure, the welding stress is high, and the welding deformation is large. This requires heavy and sturdy tooling. Even after the workpiece is removed from the tooling, residual stress is still released, causing the product to twist to some extent. After being assembled on the roof, this has a negative impact on the roof structure. Furthermore, the metal battery rack is heavy, has low corrosion resistance, increases the vehicle's weight, thereby increasing energy consumption, increasing braking distance, and negatively impacting the overall vehicle safety. Utility Model Content

[0003] The purpose of this invention is to provide a composite material roof power battery rack for buses, which can solve the problems of bulky structure and large deformation of the roof power battery rack, and has excellent strength and vibration absorption performance.

[0004] To solve the above-mentioned technical problems, the purpose of this utility model is achieved as follows:

[0005] The present invention relates to a composite material roof power battery rack for a bus, comprising a power battery rack body with a frame structure; connecting legs are fixedly connected to the edge of the power battery rack body.

[0006] The power battery rack body includes an outer layer of fiber fabric and an inner layer of fiber fabric, as well as a sandwich foam between the outer layer of fiber fabric and the inner layer of fiber fabric and a set number of pultruded groove beams.

[0007] The two ends of the pultruded channel beam are fixedly provided with embedded connectors, which are fixedly connected to the connecting legs.

[0008] Based on the above scheme and as a preferred embodiment of the above scheme: the outer surface fiber fabric 10 and the inner surface fiber fabric 11 of the power battery frame body are fixed by a cured resin phase.

[0009] Based on the above scheme and as a preferred embodiment of the above scheme: the pultruded channel beam is a carbon fiber pultruded channel beam.

[0010] Based on the above scheme and as a preferred embodiment of the above scheme: the outer surface fiber fabric and the inner surface fiber fabric are carbon fiber fabric or glass fiber fabric.

[0011] Based on the above scheme and as a preferred embodiment of the above scheme: the power battery frame body and the connecting legs are fixedly connected by a set of fixing bolts.

[0012] Based on the above solution and as a preferred embodiment of the above solution: the connecting leg includes a bent support body, and a reinforcing connecting plate is provided on the support body.

[0013] Based on the above scheme and as a preferred embodiment of the above scheme: the pre-embedded connector includes a grooved part and a connecting plate, the grooved part is fixedly connected to the end of the pultruded grooved beam, and the connecting plate is fixedly connected to the connecting support leg.

[0014] The beneficial effects of this utility model are as follows: The composite material roof power battery rack for buses involved in this utility model uses a frame structure of power battery rack body formed by resin curing of fiber fabric. This solves the problems of heavy weight and large deformation of welded skeleton structures made of carbon steel. Furthermore, it is integrally molded, facilitating production and ensuring high dimensional accuracy. The integral molding process, with mold constraints, ensures high dimensional accuracy and solves the problems of large welding deformation and low product dimensional accuracy of metal roof battery racks. The integrated sandwich structure is lightweight, high-strength, corrosion-resistant, and has good vibration absorption, solving the problems of heavy weight, easy corrosion, and abnormal noise during vehicle vibration associated with metal roof power battery racks. The integrated composite material roof power battery rack uses a bolting process, ensuring reliable fixing, good sealing and vibration damping, quick replacement, and convenient maintenance. It is suitable for roofs of different lengths, widths, and appearances, with a wide range of applications. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the composite material roof power battery rack of a bus;

[0016] Figure 2 This is a top view of the composite material roof power battery rack of the bus;

[0017] Figure 3 yes Figure 2 Cross-sectional view along the AA direction;

[0018] Figure 4 yes Figure 3 A magnified view of a section at point I;

[0019] Figure 5 yes Figure 3 Enlarged view of a section at point II;

[0020] Figure 6 It is a connection structure diagram of the pultruded channel beam, the embedded connectors, and the connecting supports;

[0021] Figure 7 This is a structural diagram of the connecting legs;

[0022] Figure 8 This is a structural schematic diagram of the pre-embedded connector. Detailed Implementation

[0023] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0024] Combination Figures 1 to 8 This utility model relates to a composite material roof-mounted power battery rack for buses, comprising a power battery rack body 1 with a frame structure; connecting legs 2 are fixedly connected to the edge of the power battery rack body 1. The power battery rack body 1 has rounded rectangular holes pre-drilled according to design requirements and adapted to the power battery pack, and the power battery rack body 1 has holes at the edge of the rounded rectangular holes for fixed connection with the power battery pack. The connecting legs 2 are made of metal, facilitating the fixed connection of the composite material roof-mounted power battery rack to the bus.

[0025] Furthermore, the power battery rack body 1 and the connecting leg 2 are fixedly connected by a set of fixing bolts 3, or other suitable connection methods may also be used.

[0026] The power battery frame body 1 includes an outer layer fiber fabric 10 and an inner layer fiber fabric 11, as well as a sandwich foam 12 disposed between the outer layer fiber fabric 10 and the inner layer fiber fabric 11 and a set number of pultruded groove beams 13; the outer layer fiber fabric 10 and the inner layer fiber fabric 11 in the power battery frame body 1 are fixed by a cured resin phase.

[0027] Furthermore, in this embodiment, the number of pultruded channel beams 13 is five. Of course, the number of pultruded channel beams 13 can also be selected according to the length of the power battery rack. Pre-embedded connectors 4 are fixedly provided at both ends of the pultruded channel beams 13, and the pre-embedded connectors 4 are fixedly connected to the connecting legs 2. The pre-embedded connectors 4 can be made of metal, such as stainless steel.

[0028] Furthermore, the pultruded channel beam 13 is a carbon fiber pultruded channel beam. The pultruded channel beam 13 made of carbon fiber has the advantage of being lighter than a channel beam made of metal. In this embodiment, the five pultruded channel beams 13 are arranged in parallel, and the two sides of the power battery frame body 1 parallel to the pultruded channel beams 13 are curved. Furthermore, a sandwich foam 12 perpendicular to the pultruded channel beams 13 is also provided on the power battery frame body 1. The outer layer fiber fabric 10 and the inner layer fiber fabric 11, which are connected by resin curing, form a protrusion at the location of the sandwich foam 12. That is, a recessed portion is present on one surface of the inner layer fiber fabric 11, while one side of the outer layer fiber fabric 11 is planar. A rounded rectangular hole is present at the bottom of the recessed portion.

[0029] Furthermore, the outer surface fiber fabric 10 and the inner surface fiber fabric 11 are carbon fiber fabrics or glass fiber fabrics. In this embodiment, carbon fiber fabric is selected.

[0030] Furthermore, the connecting leg 2 includes a bent support body 21, and a reinforcing connecting plate 22 is provided on the support body 21. Specifically, the support body 21 has three bent metal plates, and a reinforcing connecting plate 22 is provided between two adjacent metal plates to increase the strength of the connecting leg.

[0031] Furthermore, the pre-embedded connector 4 includes a channel-shaped portion 41 and a connecting plate 42. The channel-shaped portion 41 is fixedly connected to the end of the pultruded channel beam 13, and the connecting plate 42 is fixedly connected to the connecting support leg 2. Connecting holes are provided on the two side walls of the channel-shaped portion 41 for connecting to the side walls of the pultruded channel beam 13. Similarly, holes are provided on the bottom plate of the channel-shaped portion 41 for connecting to the bottom plate of the pultruded channel beam 13.

[0032] The manufacturing process of a composite material roof power battery rack for a bus involved in this embodiment is as follows:

[0033] The outer dimensions of the power battery rack are determined based on the combination of the power battery pack, and the mold for the battery rack is designed and manufactured. Then, the power battery rack is manufactured on the mold. Specifically, the outer layer of fiber fabric 10 is laid first, and the pultruded channel beam 13 and the prefabricated sandwich foam 12 are placed in the designated position close to the outer layer of fiber fabric 10. Then, the inner layer of fiber fabric 13 is laid, the mold is closed, vacuum is drawn, resin is poured in, and the resin is heated to cure. The mold is then removed, the shape is modified, and the prefabricated connecting legs 2 are fixedly connected to the power battery rack in the designated position. After inspection and approval, the battery rack is put into storage.

[0034] The preferred embodiments of this utility model have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of this utility model without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of this utility model through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A passenger car composite roof power battery rack, characterized in that, Including the power battery frame body (1) of frame structure, the edge position of power battery frame body (1) is fixedly connected with connecting leg (2); The power battery frame body (1) includes outer layer fiber fabric (10) and inner layer fiber fabric (11), and the sandwich foam (12) and the set number of pultruded channel beams (13) are arranged between outer layer fiber fabric (10) and inner layer fiber fabric (11); The both ends of pultruded channel beam (13) are fixedly provided with pre-buried connecting piece (4), and pre-buried connecting piece (4) is fixedly connected with connecting leg (2); The connecting leg (2) includes the bent leg body (21), and the reinforcing connecting plate (22) is arranged on the leg body (21), and the pre-buried connecting piece (4) includes the channel portion (41) and the connecting plate (42), the channel portion (41) is fixedly connected with the end of pultruded channel beam (13), and the connecting plate (42) is fixedly connected with connecting leg (2).

2. A composite material roof-top power pack for a passenger vehicle as claimed in claim 1, wherein, The outer layer fiber fabric (10) and the inner layer fiber fabric (11) in the power battery frame body (1) are fixed by cured resin.

3. A composite material roof-top power pack for a passenger vehicle as claimed in claim 1, wherein, The pultruded channel beam (13) is carbon fiber pultruded channel beam.

4. A composite material roof-top power pack for a passenger vehicle as claimed in claim 1, wherein, The outer layer fiber fabric (10) and the inner layer fiber fabric (11) are carbon fiber fabric or glass fiber fabric.

5. A composite material bus roof battery rack according to claim 1, wherein, The power battery frame body (1) and connecting leg (2) are fixedly connected by fixed bolt group (3).

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