A new type of light weight high strength power battery shell

Abstract

This utility model relates to a novel lightweight, high-strength power battery casing. The power battery casing includes a barrier film. A continuous fiberglass woven layer is thermoset bonded to both sides of the barrier film using thermosetting polyurethane. A fiber felt layer is thermoset bonded to the side of each continuous fiberglass woven layer away from the barrier film using thermosetting polyurethane. The thickness of the power battery casing after thermoforming is 0.8mm~1.8mm, and the density of the thermoformed power battery casing is 1.6g / cm³. 3 ~1.7g / cm 3 The beneficial effects are: The barrier film, continuous fiberglass braided layer, and fiber felt layer are bonded together using thermosetting polyurethane and molded to form the power battery casing. Utilizing the high strength and low density of polyurethane, the product density is significantly lower compared to other thermosetting composite materials, and the thickness of the power battery casing is reduced. The use of continuous fiberglass braided material enhances tensile and flexural strength. The barrier film prevents moisture flow, reducing the hygroscopicity of the power battery casing and improving its airtightness.

Description

Technical Field

[0001] This utility model relates to the field of power battery casing technology, and in particular to a novel lightweight and high-strength power battery casing. Background Technology

[0002] Lightweighting of the battery pack is key to improving the driving range of electric vehicles.

[0003] Traditional metal casings (steel or aluminum) are heavy, and their thermal management, insulation, and sealing functions require the assembly of multiple components, resulting in complex systems, high costs, and low efficiency.

[0004] To reduce the weight of battery packs, the application of composite materials has been proposed, and various continuous fiber reinforced thermosetting composite materials have been developed. Currently, there are application schemes that use epoxy resin or unsaturated polyester resin to manufacture the battery upper shell, but these have the following problems: high density (at least 1.8 g / cm³), large thickness (1.2~1.8 mm), easy to absorb moisture, and low strength of short, randomly distributed glass fibers. Utility Model Content

[0005] The purpose of this utility model is to overcome the above-mentioned problems existing in the prior art and to provide a new type of lightweight and high-strength power battery casing.

[0006] To achieve the above-mentioned technical objectives and effects, this utility model is implemented through the following technical solution:

[0007] A novel lightweight, high-strength power battery casing includes a barrier membrane. A continuous fiberglass woven layer is thermoset bonded to both sides of the barrier membrane using thermosetting polyurethane. A fiber felt layer is thermoset bonded to the side of each continuous fiberglass woven layer away from the barrier membrane using thermosetting polyurethane. The thickness of the power battery casing after thermoforming is 0.8mm~1.8mm, and the density is 1.6g / cm³. 3 ~1.7g / cm 3 .

[0008] The barrier film is one of polyurethane film, polyethylene film, polypropylene film, and polyvinyl chloride film.

[0009] The thickness of the barrier film before bonding with the continuous fiberglass braided layer is 0.03mm to 0.1mm, and the areal density of the barrier film before bonding with the continuous fiberglass braided layer is 40g / m² to 120g / m².

[0010] The continuous fiberglass woven layer is a continuous glass fiber cloth.

[0011] The thickness of the continuous fiberglass braided layer before bonding with the barrier film is 0.5mm to 1.5mm, and the areal density of the continuous fiberglass braided layer before bonding with the barrier film is 400g / m² to 750g / m².

[0012] The fiber felt layer is either polyethylene terephthalate fiber felt or glass fiber felt.

[0013] The thickness of the fiber felt layer before bonding with the continuous fiberglass braided layer is 0.5mm to 1.5mm, and the areal density of the fiber felt layer before bonding with the continuous fiberglass braided layer is 30g / m² to 120g / m².

[0014] The beneficial effects of this utility model are as follows: a barrier film, a continuous fiberglass braided layer, and a fiber felt layer are bonded together using thermosetting polyurethane and molded to form a power battery casing. The high strength and low density of polyurethane result in a significantly lower product density compared to other thermosetting composite materials, and also reduce the thickness of the power battery casing. The use of continuous fiberglass braided material for reinforcement enhances tensile and bending strength. The barrier film prevents water vapor flow, reducing the hygroscopicity of the power battery casing and improving its airtightness. Attached Figure Description

[0015] The accompanying drawings, which are included to provide a further understanding of the present invention and form part of this application, illustrate exemplary embodiments of the present invention and, together with the description thereof, serve to explain the present invention and do not constitute an undue limitation thereof. In the drawings:

[0016] Figure 1 This is a partial structural schematic diagram of the power battery casing in this utility model;

[0017] The labels in the diagram are as follows: 1. Barrier membrane; 2. Continuous fiberglass woven layer; 3. Fiber felt layer; 4. Power battery casing 100. Detailed Implementation

[0018] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0019] like Figure 1 As shown, a novel lightweight, high-strength power battery casing 100 includes a barrier membrane 1. The barrier membrane 1 serves to block gas flow within the power battery casing 100. The barrier membrane 1 is one of a polyurethane film, a polyethylene film, a polypropylene film, or a polyvinyl chloride film. The thickness of the barrier membrane 1 before bonding with the continuous fiberglass braided layer 2 is 0.03 mm to 0.1 mm, and the areal density of the barrier membrane 1 before bonding with the continuous fiberglass braided layer 2 is 40 g / m² to 120 g / m².

[0020] A continuous fiberglass woven layer 2 is thermosettingly bonded to both sides of the barrier film 1 using thermosetting polyurethane. The continuous fiberglass woven layer 2 is a continuous glass fiber cloth. The thickness of the continuous fiberglass woven layer 2 before bonding with the barrier film 1 is 0.5mm~1.5mm, and the areal density of the continuous fiberglass woven layer 2 before bonding with the barrier film 1 is 400g / m²~750g / m².

[0021] On the side of each continuous fiberglass braided layer 2 away from the barrier film 1, a fiber mat layer 3 is thermosettingly bonded with polyurethane. The fiber mat layer 3 is either polyethylene terephthalate fiber mat or glass fiber mat. The thickness of the fiber mat layer 3 before bonding with the continuous fiberglass braided layer 2 is 0.5mm to 1.5mm, and the areal density of the fiber mat layer 3 before bonding with the continuous fiberglass braided layer 2 is 30g / m² to 120g / m².

[0022] The thickness of the power battery casing after hot molding is 0.8mm~1.8mm, and the density of the power battery casing after hot molding is 1.6g / cm³. 3 ~1.7g / cm 3 .

[0023] The manufacturing method of the power battery casing 100: Thermosetting polyurethane is sprayed onto the surface of the continuous fiberglass braided layer 2, according to... Figure 1 The fiber felt layer 3, continuous glass fiber braided layer 2, barrier film 1, continuous glass fiber braided layer 2, and fiber felt layer 3 are stacked together in the order from bottom to top to form a power battery housing blank. Then, the power battery housing blank is hot-molded into a power battery housing using a press.

[0024] Because the molding process compresses the thickness of the continuous fiberglass braided layer 2 and the fiber felt layer 3, the thickness of the continuous fiberglass braided layer 2 after molding is smaller than the thickness of the continuous fiberglass braided layer 2 before bonding, and the thickness of the fiber felt layer 3 after molding is smaller than the thickness of the fiber felt layer 3 before bonding; while the thermosetting polyurethane penetrates into the continuous fiberglass braided layer 2 and the fiber felt layer 3, the thermosetting polyurethane does not occupy the thickness space of the power battery casing alone.

[0025] A preferred embodiment: A novel lightweight, high-strength power battery casing includes a polyethylene film. A continuous glass fiber cloth is bonded to both sides of the polyethylene film using thermosetting polyurethane. On the side of each continuous glass fiber cloth away from the polyethylene film, a layer of polyethylene terephthalate fiber mat is bonded to it using thermosetting polyurethane. The thickness of the power battery casing is 0.8 mm, and its density is 1.6 g / cm³. 3 .

[0026] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., 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, an electrical connection, or a connection that allows communication between them; 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, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.

Claims

1. A novel lightweight, high-strength power battery casing, characterized in that: The power battery casing includes a barrier film. A continuous fiberglass woven layer is thermoset bonded to both sides of the barrier film using thermosetting polyurethane. A fiber felt layer is thermoset bonded to the side of each continuous fiberglass woven layer away from the barrier film using thermosetting polyurethane. The thickness of the power battery casing after thermoforming is 0.8mm~1.8mm, and the density of the power battery casing after thermoforming is 1.6g / cm³. 3 ~1.7g / cm 3 .

2. The power battery casing according to claim 1, characterized in that: The barrier film is one of polyurethane film, polyethylene film, polypropylene film, and polyvinyl chloride film.

3. The power battery casing according to claim 1, characterized in that: The thickness of the barrier film before bonding with the continuous fiberglass braided layer is 0.03mm~0.1mm, and the areal density of the barrier film before bonding with the continuous fiberglass braided layer is 40g / m²~120g / m².

4. The power battery casing according to claim 1, characterized in that: The continuous fiberglass woven layer is a continuous glass fiber cloth.

5. The power battery casing according to claim 1, characterized in that: The thickness of the continuous fiberglass braided layer before bonding with the barrier film is 0.5mm to 1.5mm, and the areal density of the continuous fiberglass braided layer before bonding with the barrier film is 400g / m² to 750g / m².

6. The power battery casing according to claim 1, characterized in that: The fiber felt layer is one of polyethylene terephthalate fiber felt or glass fiber felt.

7. The power battery casing according to claim 1, characterized in that: The thickness of the fiber felt layer before bonding with the continuous fiberglass braided layer is 0.5mm to 1.5mm, and the areal density of the fiber felt layer before bonding with the continuous fiberglass braided layer is 30g / m² to 120g / m².

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