Components of a vehicle battery box

Abstract

The present invention provides a battery box component that can remove air trapped between a metal layer and a fiber-reinforced resin layer. [Solution] A component of a vehicle battery box, comprising a shaped fiber-reinforced resin layer containing reinforcing fibers and resin, and a shaped metal layer, bonded together via an adhesive layer, The thickness of the adhesive layer is 0.1 mm or more and 0.5 mm or less. A ventilation passage is provided between the metal layer and the fiber-reinforced resin layer. A component of a vehicle battery box.

Description

[Technical Field]

[0001] The present invention relates to a component of a vehicle battery box, comprising a fiber-reinforced resin layer containing reinforcing fibers and resin, and a metal layer, bonded together via an adhesive layer. [Background technology]

[0002] Various methods have been considered to remove trapped air when bonding sheets using adhesive. Patent Document 1 describes an invention relating to an air-vent adhesive sheet in which an adhesive layer is formed by applying an adhesive to one side of the sheet, and the adhesive surface has air vents. The air vents are grooves formed on the adhesive surface, and the air vents are irregularities formed on the adhesive surface.

[0003] Patent Document 2 describes an adhesive sheet comprising a base film and a pressure-sensitive adhesive layer, the adhesive layer having a surface pattern formed by transferring the uneven shape of a release paper, and having at least two interconnected passages. This adhesive sheet has the effect of releasing air trapped between the sheet and the object to which it is attached. The first-stage passages are arranged at a relatively low height and provide air release even after the adhesive sheet has adhered to the surface. The second-stage passages also release air after the first-stage passages have disappeared.

[0004] Patent Document 3 describes an impact-resistant resin used in battery cases for electric vehicles and electric hybrid trucks. This battery case has multiple electromagnetic wave shielding sheets arranged on the inside and bonded together via a conductive adhesive. The arrangement of the electromagnetic wave shielding sheets can be selected from a first arrangement in which adjacent sheets are electrically connected with a conductive material, and a second arrangement in which conductive sheets are overlapped. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2002-332463 [Patent Document 2] Special Publication No. 2007-520623 [Patent Document 3] Japanese Patent Publication No. 2012-186125 [Overview of the project] [Problems that the invention aims to solve]

[0006] However, the grooves described in Patent Document 1 have too many grooves to serve as air vents between the components of a vehicle battery box and the metal layer. Furthermore, since the metal layer for bonding to the battery box components is not in roll form, it is impossible to gradually bond it while removing air.

[0007] In Patent Document 2, the airflow passage disappears with a time delay. Therefore, it is necessary to provide an air discharge passage in a complex shape, making it difficult to apply to the components of a battery box with a defined three-dimensional shape.

[0008] Patent Document 3 uses a conductive adhesive to provide an electromagnetic shielding layer on the inside of the battery case, but it does not consider the air escaping between the battery and the electromagnetic shielding layer. Furthermore, although it is considered on the premise of attaching divided sheets, attaching divided sheets would complicate the process, such as processing the seams.

[0009] Therefore, the object of the present invention is to provide a battery box component that can remove air trapped between a metal layer and a fiber-reinforced resin layer when bonding the complexly shaped metal layer and the fiber-reinforced resin layer. [Means for solving the problem]

[0010] As a result of diligent research, the inventors of this invention discovered that the above problems can be solved by the means described below, and thus arrived at the present invention. 1. A component of a vehicle battery box, comprising a shaped fiber-reinforced resin layer containing reinforcing fibers and resin, and a shaped metal layer, bonded together via an adhesive layer, The thickness of the adhesive layer is 0.1 mm or more and 2.0 mm or less. A ventilation passage is provided between the metal layer and the fiber-reinforced resin layer. A component of a vehicle battery box. 2. The battery box component described in paragraph 1, wherein the width of the ventilation passage of the battery box is 1 mm or more and 20 mm or less, and the spacing between the ventilation passages is 0.5 m or less. 3. The relationship between the area S1 of the ventilation channel and the area S2 of the adhesive layer is, 0.01 <S1 / (S1+S2) < 0.3 A component of the battery box described in either 1 or 2 above, which is related to the battery box component described in either 1 or 2 above. 4. The battery box components have a height difference of 150 mm or more between the high and low sections, and ventilation passages are provided in both the high and low sections. A component of the battery box as described in any one of items 1 to 3 above. 5. A component of a battery box according to any one of 1 to 4 above, wherein the ventilation passage is formed in a grid pattern. 6. The battery box component according to any one of 1 to 5, wherein the battery box component has a top surface, an upright surface, and a flange, and at least the flange is provided with a ventilation passage. 7. The metal layer shields at least one of the electric field or the magnetic field. A component of the battery box as described in any one of items 1 to 6 above. 8. The battery box component described in any one of 1 to 7 above, wherein the battery box component is a component of a vehicle battery box, and is selected from one of a battery tray, a battery cover, or a battery under cover. 9. A method for manufacturing a component of the battery box according to any one of 1 to 8 above, wherein an adhesive is applied to a metal layer to provide an adhesive layer and a ventilation path, and then laminated on a fiber reinforced resin layer. 10. The method for manufacturing a component of the battery box according to 9 above, after bonding the shaped fiber reinforced resin layer and the shaped metal layer through an adhesive layer, a method for manufacturing a component of the battery box, which discharges air generated between the adhesive layer and the metal layer from the ventilation path.

Advantages of the Invention

[0011] In the component of the battery box, since a ventilation path is provided between the metal layer and the fiber reinforced resin layer, it is difficult for air to accumulate between the metal layer and the fiber reinforced resin layer.

Brief Description of the Drawings

[0012] [Figure 1] Exploded perspective view of the battery box 101. [Figure 2] Explanatory drawing of the battery under cover, which is an example of a component of the battery box. [Figure 3] Cross-sectional view showing an example of a component of a vehicle battery box in which a fiber reinforced resin layer and a shaped metal layer are bonded through an adhesive layer. [Figure 4] Schematic diagram showing an example of a ventilation path.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described, but the present invention is not limited thereto.

[0014] [Reinforcing Fiber] In this specification, the reinforcing fiber is preferably at least one selected from the group consisting of carbon fiber, aramid fiber, and glass fiber. More preferably, the reinforcing fiber is carbon fiber or glass fiber.

[0015] [Reinforcement fiber: carbon fiber] 1. Carbon Fibers in General When using carbon fibers, polyacrylonitrile (PAN) carbon fibers, petroleum / coal pitch carbon fibers, rayon carbon fibers, cellulose carbon fibers, lignin carbon fibers, and phenolic carbon fibers are generally known, but in the present invention, any of these carbon fibers can be suitably used. Among them, in the present invention, polyacrylonitrile (PAN) carbon fibers are preferred because they have excellent tensile strength. As a PAN carbon fiber, for example, Teijin Limited's carbon fiber "Tenax" (registered trademark) STS40-24KS (average fiber diameter 7 μm) can be used.

[0016] 2. Carbon fiber sizing agent The carbon fibers used in the present invention may have a sizing agent attached to their surface. When using carbon fibers with a sizing agent attached, the type of sizing agent can be appropriately selected according to the type of carbon fiber and the type of resin, and is not particularly limited.

[0017] 3. Carbon Fiber and Electrolytic Corrosion Countermeasures When using carbon fibers, an adhesive layer placed between the fiber-reinforced resin layer and the metal layer provides protection against galvanic corrosion.

[0018] [Reinforced fiber: glass fiber] The present invention will now describe the case where the reinforcing fiber used is glass fiber. 1. All types of glass fibers The glass fibers used in this invention may be any glass fibers that are generally referred to as glass fibers. The glass composition is not particularly limited to A glass, C glass, E glass, etc., and may contain components such as TiO2, SO3, P2O5, etc., depending on the circumstances. As a glass fiber, for example, Nitto Boseki's glass fiber E-glass RS240QR-483 (count: 2400g / 1000m) can be used.

[0019] 2. Glass fiber sizing agent The glass fibers used in the present invention may have a sizing agent attached to their surface. When using glass fibers with a sizing agent attached, the type of sizing agent can be appropriately selected according to the type of glass fiber and the type of resin, and is not particularly limited. Preferably, glass fibers that have been pre-treated with conventionally known coupling agents such as organosilane compounds, organotitanium compounds, organoborane compounds, and epoxy compounds can be used.

[0020] [Reinforcement fibers: Dispersed in the in-plane direction] The reinforcing fibers of the present invention are discontinuous fibers and are preferably dispersed in the in-plane direction of the fiber-reinforced resin layer. Furthermore, in order to disperse them in the in-plane direction in the fiber-reinforced resin layer, it is preferable to disperse the reinforcing fibers contained in the molding material in the in-plane direction.

[0021] In this invention, the molding material is a material for creating a fiber-reinforced resin layer, and it is preferable that the molding material is press-molded to become a fiber-reinforced resin layer. Therefore, although the molding material in this invention is in the shape of a flat plate, the fiber-reinforced resin layer is shaped and has a three-dimensional shape. Press molding is also called compression molding.

[0022] Dispersion of reinforcing fibers in the in-plane direction means that the fiber axes of the reinforcing fibers are oriented in the in-plane direction. Preferably, the angle that the fiber axes of the reinforcing fibers make with the in-plane direction is 45° or less.

[0023] 1. In-plane direction The in-plane direction refers to an undefined direction of parallel planes perpendicular to the thickness direction of the molding material or fiber-reinforced resin layer. The molding material is preferably a plate-shaped material.

[0024] 2. Random distribution in 2.2 dimensions It is preferable that the reinforcing fibers are randomly dispersed in a two-dimensional direction in the in-plane direction. In regions where the molding material is press-molded without flowing, the shape of the reinforcing fibers is largely maintained before and after molding. Therefore, it is also preferable that the reinforcing fibers contained in the non-flowing region of the fiber-reinforced resin layer formed from the molding material are similarly randomly dispersed in a two-dimensional direction in the in-plane direction.

[0025] Here, "randomly dispersed in two dimensions" means that the reinforcing fibers are oriented in a disordered manner within the in-plane direction of the molding material or fiber-reinforced resin layer, rather than in a specific direction such as one direction, and are arranged within the sheet surface without exhibiting a particular direction overall. A fiber-reinforced resin layer (or molding material) obtained using these two-dimensionally randomly dispersed discontinuous fibers is a substantially isotropic fiber-reinforced resin layer (or molding material) that does not have anisotropy within the plane.

[0026] The degree of two-dimensional random orientation is evaluated by determining the ratio of the tensile moduli in two mutually orthogonal directions. If the ratio (Eδ) obtained by dividing the larger of the measured tensile moduli in any direction of the fiber-reinforced resin layer (or molding material) and in a direction orthogonal thereto by the smaller value is 5 or less, more preferably 2 or less, and even more preferably 1.5 or less, then the reinforcing fibers can be evaluated as being dispersed randomly in two dimensions.

[0027] When the resin contained in a fiber-reinforced resin layer is a thermoplastic resin, and the fiber-reinforced resin layer is three-dimensionally shaped including curved surfaces, a good method for evaluating the two-dimensional random dispersion in the in-plane direction is to heat the fiber-reinforced resin layer above its softening temperature to return it to a flat plate shape, and then solidify it. After that, by cutting out a test piece and determining the tensile modulus, the random dispersion state in the two-dimensional direction can be confirmed.

[0028] [Reinforcement fiber: Fiber length] The reinforcing fibers are preferably discontinuous. When discontinuous fibers are used, the shapeability is improved compared to fiber-reinforced plastics using only continuous fibers, and it becomes easier to create complex fiber-reinforced resin layers.

[0029] Since the weight-average fiber length of the reinforcing fibers does not change before and after molding, the weight-average fiber length Lw of the reinforcing fibers contained in the molding material can be determined by examining the weight-average fiber length of the reinforcing fibers in the fiber-reinforced resin layer.

[0030] The weight-average fiber length Lw of the reinforcing fibers is preferably 1 mm or more, and more preferably 3 mm or more. More preferably the weight-average fiber length Lw of the reinforcing fibers is 3 mm or more and 100 mm or less, more preferably 3 mm or more and 80 mm or less, and even more preferably 5 mm or more and 60 mm or less. If the weight-average fiber length Lw of the reinforcing fibers is 100 mm or less, the fluidity of the molding material is less likely to decrease when the molding material is manufactured by press molding, making it easier to create the desired shape. Also, if the weight-average fiber length Lw is 1 mm or more, the mechanical strength of the resulting fiber-reinforced resin layer member is less likely to decrease, which is preferable.

[0031] The weight-average fiber length Lw and number-average fiber length Ln of the reinforcing fiber can be calculated using equations (1) and (2) described below. In addition, in fiber-reinforced resin layers produced by injection molding, the weight-average fiber length of the reinforcing fibers is approximately 0.1 to 0.3 mm. Therefore, when the weight-average fiber length of the reinforcing fibers is to be between 1 mm and 100 mm, it is preferable to create the fiber-reinforced resin layer by press molding.

[0032] In the present invention, discontinuous reinforcing fibers having different fiber lengths may be used in combination. In other words, the discontinuous reinforcing fibers used in the present invention may have a single peak in the weight-average fiber length distribution, or they may have multiple peaks.

[0033] [Reinforcement fibers: Number-average fiber length Ln and weight-average fiber length Lw] Generally, if the fiber length of each reinforcing fiber is Li, the number-average fiber length Ln and the weight-average fiber length Lw can be calculated using the following equations (1) and (2). The units for the number-average fiber length Ln and the weight-average fiber length Lw are mm.

[0034]

number

[0035] When the fiber length is constant, the number-average fiber length and the weight-average fiber length will be the same value. Reinforcement fibers can be extracted from the fiber-reinforced resin layer by, for example, heat treatment at 500°C for about 1 hour, followed by removal of the resin in the furnace.

[0036] The average fiber length can be determined, for example, by measuring the fiber length of 100 fibers randomly selected from the fiber-reinforced resin layer to the nearest 1 mm using a caliper or similar device, and then calculating it based on equation (1) or equation (2).

[0037] If short fibers that cannot be measured with calipers are present, the resin is removed, and the resulting reinforced fibers are placed in water containing a surfactant and thoroughly stirred using ultrasonic vibration. A random sample of the stirred dispersion is taken using a measuring spoon to obtain an evaluation sample, and the length of 3000 fibers is measured using a Luzex AP image analysis device manufactured by Nireco. Using the measured fiber lengths, the number-average fiber length Ln and the weight-average fiber length Lw can be determined in the same manner as in equations (1) and (2) described above.

[0038] [Reinforcement fibers: fiber volume ratio] There are no particular limitations on the fiber volume ratio Vf of the reinforcing fibers, but 20-70% is preferred, 25-60% is more preferred, and 30-55% is even more preferred. The fiber volume ratio (Vf, unit: volume%) refers to the ratio of the volume of reinforcing fibers to the total volume, which includes not only the reinforcing fibers and resin, but also other additives.

[0039] There are no limitations to the analysis of the volume ratio of reinforcing fibers, but it is recommended to measure it as follows. A sample is cut from the fiber-reinforced resin layer, and the resin is burned off in a furnace at 500°C for 1 hour. The mass of the reinforcing fibers, resin, and other additives is calculated by weighing the sample before and after treatment. Next, the volume ratio of reinforcing fibers to resin is calculated using the specific gravity of each component. Vf = 100 × volume of reinforcing fiber / (volume of reinforcing fiber + volume of resin + other additives)

[0040] [resin] The resin contained in the fiber-reinforced resin layer may be thermosetting or thermoplastic. 1.Thermoplastic resin When a thermoplastic resin is used, the type is not particularly limited, and one with the desired softening point or melting point can be appropriately selected and used. Typically, thermoplastic resins with a softening point in the range of 180°C to 350°C are used, but are not limited to this range.

[0041] Examples of thermoplastic resins include polyolefin resins, polystyrene resins, polyamide resins, polyester resins, polyacetal resins (polyoxymethylene resins), polycarbonate resins, (meth)acrylic resins, polyarylate resins, polyphenylene ether resins, polyimide resins, polyethernitrile resins, phenoxy resins, polyphenylene sulfide resins, polysulfone resins, polyketone resins, polyetherketone resins, thermoplastic urethane resins, fluoropolymer resins, and thermoplastic polybenzimidazole resins.

[0042] The thermoplastic resin used in the fiber-reinforced resin layer of the present invention may be of one type or two or more types. Examples of using two or more thermoplastic resins in combination include, but are not limited to, a combination of thermoplastic resins with different softening points or melting points, or a combination of thermoplastic resins with different average molecular weights. When using thermoplastic resins, it is more preferable to use polyolefin resins, and even more preferable to use polypropylene resins.

[0043] 2.Thermosetting resin The resin may be a thermosetting resin. When using a thermosetting resin, it is preferably an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, or a phenolic resin. One type of resin may be used alone, or two or more types may be used in combination.

[0044] Furthermore, when using a thermosetting resin as the resin of the present invention, a sheet molding compound containing reinforcing fibers (sometimes called SMC) may be used. Due to its high moldability, sheet molding compounds can be easily molded even into complex shapes. Sheet molding compounds have higher fluidity and formability compared to continuous fibers, making it easy to create ribs and bosses.

[0045] [Other agents] The resin used in the molding material may contain additives such as various fibrous or non-fibrous fillers of organic or inorganic fibers, flame retardants, UV inhibitors, stabilizers, mold release agents, pigments, softeners, plasticizers, and surfactants, to the extent that the objectives of the present invention are not impaired. When a thermosetting resin is used, it may also contain thickeners, curing agents, polymerization initiators, polymerization inhibitors, etc. As additives, one type may be used alone, or two or more types may be used in combination.

[0046] [Method for manufacturing fiber-reinforced resin layer: press molding] 1. Hot press molding and cold press molding In the present invention, a fiber-reinforced resin layer can be created by press molding (sometimes called compression molding) of a composite material containing reinforcing fibers and resin. Press molding methods such as hot press molding and cold press molding can be used. By press molding the composite material, various shapes can be imparted to the fiber-reinforced resin layer. The fiber-reinforced resin layer manufactured by press molding is preferably a single molded body.

[0047] 2. Cold press molding When using a composite material containing a thermoplastic resin as the resin, press molding using cold press is preferred. In the cold press molding method, for example, the composite material heated to a first predetermined temperature is placed into a mold set to a second predetermined temperature, and then pressurized and cooled.

[0048] Specifically, if the thermoplastic resin contained in the composite material is crystalline, the first predetermined temperature is above the melting point, and the second predetermined temperature is below the melting point. If the thermoplastic resin is amorphous, the first predetermined temperature is above the glass transition temperature, and the second predetermined temperature is below the glass transition temperature. In other words, the cold press method includes at least the following steps A-1) to A-2). Step A-1) A step in which the thermoplastic resin is heated to a temperature above its melting point and below its decomposition temperature if it is crystalline, or above its glass transition temperature and below its decomposition temperature if it is amorphous. Step A-2) The composite material heated in Step A-1) is placed in a mold that has been temperature-controlled to below the melting point if the thermoplastic resin is crystalline, or below the glass transition temperature if it is amorphous, and then pressurized. By performing these steps, the molding of the composite material can be completed (a fiber-reinforced resin layer, which is a press-molded body, can be manufactured).

[0049] Each of the above steps must be performed in the order listed above, but other steps may be included between each step. Other steps include, for example, a forming step performed before step A-2), in which a different forming die than the one used in step A-2) is used to pre-form the shape of the cavity of the forming die. The shape of the composite material may be derived from the 3D shape of the press-formed product to be manufactured, using computer-aided reverse forming analysis.

[0050] 3. Hot press molding The hot press molding method involves, for example, placing a composite material into a mold, applying pressure while raising the temperature of the mold to a first predetermined temperature, and then cooling the mold to a second predetermined temperature. Specifically, if the thermoplastic resin constituting the composite material is crystalline, the first predetermined temperature is above the melting point, and the second predetermined temperature is below the melting point. If the thermoplastic resin contained in the composite material is amorphous, the first predetermined temperature is above the glass transition temperature, and the second predetermined temperature is below the glass transition temperature. Hot press molding preferably includes at least the following steps B-1) to B-4). B-1) The process of placing the composite material into the mold (second mold, lower mold). B-2) A process (first pressing process) in which the mold is heated and pressurized to a temperature above the melting point of the thermoplastic resin but below the thermal decomposition temperature if the thermoplastic resin is crystalline, or to a temperature above the glass transition temperature of the thermoplastic resin but below the thermal decomposition temperature if the thermoplastic resin is amorphous. B-3) A process (second pressing process) that involves one or more stages, in which the pressure in the final stage is increased to 1.2 times or more and 100 times or less the pressure in the first pressing process. B-4) A step of adjusting the mold temperature to be below the melting point if the thermoplastic resin is crystalline, or below the glass transition temperature if it is amorphous. By performing these steps, a single, integrally molded structure can be created.

[0051] 4. Common features of cold press molding and hot press molding methods Steps A-2) and B-3) are steps in which pressure is applied to the composite material to obtain a fiber-reinforced resin layer of a desired shape. There are no particular limitations on the molding pressure at this time, but it is preferable to keep it as low as possible within the range in which the desired fiber-reinforced resin layer shape can be obtained. Specifically, it is preferable to have a molding pressure of less than 30 MPa relative to the mold cavity projected area, more preferably 20 MPa or less, and even more preferably 10 MPa or less. A molding pressure of less than 30 MPa is preferable because it eliminates the need for capital investment and maintenance costs of a press machine. Also, naturally, various steps may be inserted between the above steps during compression molding, for example, vacuum compression molding, which is performed while compressing under vacuum, may be used.

[0052] [Material of the metal layer (metal sheet)] There are no particular limitations on the type of metal sheet that forms the metal layer. Examples include pure aluminum, aluminum alloys containing magnesium (Mg), copper (Cu), zinc (Zn), silicon (Si), manganese (Mn), etc., pure copper, copper alloys containing nickel (Ni), tin (Sn), zinc (Zn), aluminum (Al), lead (Pb), phosphorus (P), etc., pure magnesium, magnesium alloys containing aluminum (Al), zinc (Zn), manganese (Mn), zirconium (Zr), etc., and conductive carbon such as graphite foil. Aluminum, aluminum alloys, copper, and copper alloys are particularly preferred. In this specification, the metal layer is formed, and it is preferable to form the metal layer from a metal sheet.

[0053] [Battery box components] 1. Battery tray and battery cover The components of the battery box of the present invention are preferably for use in a vehicle, and more preferably, the components of the battery box are located in the lower part of the vehicle body. Figure 1 is an example of an exploded perspective view of a battery box 101. The battery box 101 comprises a battery cover 102, a battery 103, a temperature control system (cooling mechanism) 104, a battery tray 105, a reinforcing frame 106, and an energy absorption member 107. The components of the battery box of the present invention can be used as the battery cover 102 or the battery tray 105. The battery 103 is housed in the battery box 101, which comprises the battery tray 105 and the battery cover 102.

[0054] 2. Battery under cover 2.1 Overview The battery box components of the present invention may also serve as a battery under cover to protect the battery tray. A battery under cover is an understructure of an electric vehicle that covers the bottom surface of the battery tray. The battery under cover is designed to deform and absorb impact energy when struck by objects such as stones, gravel, or metal fragments from the road.

[0055] More specifically, the vehicle structure 205 comprises a battery tray and a battery under cover provided beneath the battery tray, wherein the battery under cover preferably comprises a fiber-reinforced resin layer and a metal layer. The battery under cover is preferably fastened to the battery tray at least in one place by a fastening rod. An example of a battery under cover is shown in Figure 2, 201. The fastening rod is 202 in Figure 2, and 203 in Figure 2 is an insertion hole for inserting the fastening rod. It is preferable to have an insertion base (204 in Figure 2) protruding from the battery tray toward the battery under cover, and the insertion hole is located inside the insertion base.

[0056] 3. A metal layer as an electromagnetic shielding layer that shields electric or magnetic fields. 3.1 Overview When the components of the battery box are a battery tray, battery cover, or battery under cover for an electric vehicle, the battery tray, battery cover, or battery under cover is provided with a metal layer as an electromagnetic wave shielding layer that shields electric or magnetic fields in order to shield electromagnetic waves generated from the battery 103. The metal layer of the present invention can shield electromagnetic waves radiated from the battery, preventing radiation and leakage to the outside, and ensure sufficient electromagnetic wave shielding performance for the battery tray, battery cover, or battery under cover, making it possible to suppress adverse effects on the vehicle's control system and the human body caused by electromagnetic waves, for example. In the case of a battery under cover, it is preferable to provide the metal layer as an electromagnetic wave shielding layer on the upper surface (on top of the fiber-reinforced resin layer).

[0057] 3.2 Shielding of electric or magnetic fields The metal layer preferably shields at least one of an electric field or a magnetic field. The metal layer preferably has a shielding capability of 10 decibels or more in at least a portion of the region between 0 MHz and 3000 MHz. A shielding capability of 20 decibels or more is more preferable, and 30 decibels or more is even more preferable. Here, the shielding capability can be expressed as 10 times (in decibels) the common logarithm of the ratio of the power of the electromagnetic wave before passing through the shielding layer to the power of the electromagnetic wave after passing through the shielding layer.

[0058] Regarding the preferred range for each shielding region, it is preferable that the shielding of electric or magnetic fields be 10 decibels or more in at least 50% of the region between 0 MHz and 3000 MHz. It is more preferable that the shielding of electric or magnetic fields be 20 decibels or more, and even more preferable that it be 30 decibels or more. "At least 50% of the region between 0 MHz and 3000 MHz" means that the shielding region may be continuous or discontinuous within the region between 0 MHz and 3000 MHz.

[0059] Regarding the preferred range for each shielding region, it is preferable that the shielding of the electric or magnetic field is 10 decibels or more in all regions from 0 MHz to 3000 MHz. It is more preferable that the shielding of the electric or magnetic field is 20 decibels or more, and even more preferable that it is 30 decibels or more.

[0060] The following describes more desirable shielding properties. The metal layer shields at least one of the electric field or magnetic field, and it is preferable that the shielding of the electric field or magnetic field is 10 decibels or more in at least a portion of the region between 0 MHz and 100 MHz. It is more preferable that the shielding of the electric field or magnetic field is 20 decibels or more, and even more preferable that it is 30 decibels or more.

[0061] The preferred range for each shielding region is that in at least 50% of the region between 0 MHz and 100 MHz, the shielding of the electric or magnetic field is preferably 10 decibels or more. More preferably, the shielding of the electric or magnetic field is 20 decibels or more, and even more preferably 30 decibels or more. "In at least 50% of the region between 0 MHz and 100 MHz" means that there may be continuous shielding regions in the region between 0 MHz and 100 MHz, or discontinuous shielding. It's okay to have a designated area.

[0062] Regarding the preferred range for each shielding region, it is preferable that the shielding of the electric or magnetic field is 10 decibels or more in all regions from 0 MHz to 100 MHz. It is more preferable that the shielding of the electric or magnetic field is 20 decibels or more, and even more preferable that it is 30 decibels or more.

[0063] 3.3 Metal layer: conforming to recesses Battery trays, battery covers, or battery undercovers are complex and have uneven surfaces. It is preferable to pre-shape a metal plate and use a metal layer that conforms to the surface of the battery tray, battery cover, or battery undercover.

[0064] [Metal layer: thickness] There are no particular limitations on the thickness of the metal layer, but it is preferably 10 μm to 300 μm, more preferably 15 μm to 250 μm, and even more preferably 20 μm to 230 μm. Also, when creating a metal layer with a hat-shaped cross-section using a metal sheet, the vertical surface becomes slightly thinner than the top surface because it is stretched by the mold when the metal sheet is shaped. The thickness of the metal layer can be measured using the average thickness of 10 points.

[0065] [Metal layer: Through hole] The metal layer may have through-holes. By providing through-holes, air trapped between the metal layer and the fiber-reinforced resin can be more easily removed. The number of through-holes depends on the size of the through-holes. If the through-holes are small and the number is small, the shielding performance of the electric field or magnetic field is excellent. If the through-holes are large and the number is large, the shielding performance of the electric field or magnetic field decreases, but the width of the ventilation path design becomes narrow. Let the area of the through-hole be S (m2) and the number of through-holes be n per m 2 When it is -6 2×10 -5 <S×n<2×10 -7 m 2 is preferable. More specifically, when the through-hole is a circular hole with a diameter of 1 mm (area S = 2.5π×10 2 m -6 2 2 ), the number of through-holes is preferably about 3 per m, and when the through-hole is a circular hole with a diameter of 5 mm (area S = 6.25π×10 -6 ), the number of through-holes is preferably about 1 per m.

[0066] [Adhesive layer and ventilation path] 1. Adhesive layer FIG. 3 is a schematic cross-sectional view showing a component 301 of a battery box according to an embodiment of the present invention. As shown in FIG. 3, the component 301 of the battery box includes a fiber-reinforced resin layer 302, a metal layer 304, and an adhesive layer 303. 1.1 Type of adhesive layer There is no particular limitation on the type of adhesive contained in the adhesive layer, and examples thereof include epoxy resin-based adhesives, acrylic resin-based adhesives, polyurethane-based adhesives, cyanoacrylate-based adhesives, and metal lock adhesives.

[0067] Also, when it becomes a battery box, it is preferable that the adhesive layer on the inner side of the battery box is an aqueous adhesive. This is because the risk is less likely to increase even when a fire breaks out from the internal battery. On the other hand, when the adhesive layer is on the outside of the battery box, either an aqueous adhesive or a solvent-based adhesive may be used.

[0068] 1.2 Thickness of adhesive layer In the components of the battery box of the present invention, the thickness of the adhesive layer is 0.1 mm or more and 2.0 mm or less. Preferably, it is 0.15 mm or more and 1.5 mm or less, more preferably 0.2 mm or more and 1.0 mm or less, and even more preferably 0.2 mm or more and 0.6 mm or less. If the adhesive layer thickness is 0.1 mm or more, the adhesive strength is stable, and if it is 0.5 mm or less, the weight of the battery box components will not increase. Conversely, if it is 0.1 mm or more, the adhesive strength is more easily guaranteed. The adhesive strength is preferably 10 N / 20 mm or more and 30 N / 20 mm or less in a 180-degree peel test.

[0069] 2. Ventilation channels 2.1 The problem of air pockets When bonding a fiber-reinforced resin layer and a metal layer with an adhesive, if the adhesive is applied to the entire surface of the fiber-reinforced resin layer before bonding, air pockets may form between the fiber-reinforced resin layer and the metal layer after some time has passed. Although there are various theories as to the cause of the air pockets, these researchers hypothesize that gas is being generated from the fiber-reinforced resin layer and the adhesive layer. It is also possible that when the adhesive layer is applied, air is trapped and bonded together between the fiber-reinforced resin layer and the metal layer.

[0070] 2.2. Width of the ventilation channel In the present invention, the width of the ventilation passage is preferably 1 mm or more and 20 mm or less, and the spacing between ventilation passages is preferably 0.5 m or less. The width of the ventilation passage is the width of one ventilation passage depicted as 403 in Figure 4, and if it is 1 mm or more, it is easy for air to pass through. If it is 20 mm or less, it is preferable as it does not reduce the adhesive strength. A preferred width for the ventilation passage is 1 mm or more and 10 mm or less, and a more preferred width for the ventilation passage is 2 mm or more and 7 mm or less.

[0071] If the spacing between the ventilation channels is 0.5 m or less, the air generated between the adhesive layer and the metal layer can be effectively removed at any point. A preferred spacing between ventilation channels is 0.4 m or less, and a more preferred spacing is 0.3 m or less.

[0072] 2.3 Area of ​​the ventilation channel The area S1 of the ventilation path and the area S2 of the adhesive layer preferably satisfy 0.01 < S1 / (S1 + S2) < 0.3, more preferably 0.05 < S1 / (S1 + S2) < 0.25, and even more preferably 0.05 < S1 / (S1 + S2) < 0.2. If 0.01 < S1 / (S1 + S2), the air generated between the adhesive layer and the metal layer can be efficiently discharged. If S1 / (S1 + S2) < 0.3, the area S2 of the adhesive layer is sufficiently larger than the area S1 of the ventilation path, and the adhesive force is likely to be stable.

[0073] Also, the sum (S1 + S2) of the area S1 of the ventilation path and the area S2 of the adhesive layer preferably satisfies (S1 + S2)×0.9 ≦ S3 with respect to the contact surface S3 formed by the shaped fiber reinforced resin layer and the shaped metal layer, more preferably (S1 + S2)×0.95 ≦ S3, and most preferably (S1 + S2) = S3.

[0074] 2.4 Shape of the ventilation path, etc. FIG. 4 is a schematic cross-sectional view showing a component 401 of a battery box according to an embodiment of the present invention. 402 in FIG. 4 is a fiber reinforced resin layer, and a ventilation path 403 and an adhesive layer 404 are depicted in FIG. 4 thereon. The metal layer is laminated on top of the fiber reinforced resin layer 402 (upward in the Z direction in FIG. 4), but is omitted. The ventilation path preferably penetrates in the vehicle width direction and is more preferably in a lattice shape. When there are uneven shapes in the components of the battery box, it is preferable to provide the ventilation path along the unevenness.

[0075] [Shape of components of the battery box] 1. The components of the battery box preferably have a top surface, an upright surface, and a flange. Specifically, it is preferable to have at least one planar surface having at least one thickness (plate thickness), and the cross-sectional shape may be T-shaped, L-shaped, U-shaped, hat-shaped (sometimes called a hat shape), or a three-dimensional shape including these, and may also have an uneven shape (e.g., ribs, bosses). The structure manufactured according to the present invention preferably has a shape that includes a portion with a hat-shaped cross-section. Furthermore, it is preferable that a ventilation passage is provided in at least the flange. By providing a ventilation passage in the flange, air can suitably escape to the outside of the battery box components. 2. The components of a battery box may have high and low points with a height difference of 150 mm or more. In this case, it is advisable to provide ventilation passages in both the high and low points. However, since there are vertical surfaces and corners between the high and low points, it is difficult for air to pass through even if a ventilation passage is provided there. Therefore, it is advisable to provide separate ventilation passages for the high and low points and extend the ventilation passages in the vehicle width direction or in the direction of vehicle travel.

[0076] [Manufacturing method for battery box components] A good method for manufacturing the components of a battery box is to apply adhesive to a metal layer to create an adhesive layer and ventilation channels, and then laminate it onto a fiber-reinforced resin layer. Furthermore, after bonding the formed fiber-reinforced resin layer and the formed metal layer via the adhesive layer, it is preferable to remove the air generated between the adhesive layer and the metal layer through the ventilation channel. In other words, it is preferable to move the air generated between the adhesive layer and the metal layer and remove it through the ventilation channel before the adhesive layer has completely solidified and hardened. If the adhesive layer has completely solidified and hardened, it becomes difficult to remove the air generated between the adhesive layer and the metal layer. There are no particular restrictions on the method of removing air from the ventilation channel; it can be done by hand or by using a jig. Alternatively, a method of sucking out the air can also be used. [Explanation of symbols]

[0077] 101: Battery Box 102: Battery cover 103: Battery 104: Temperature control system (cooling mechanism) 105: Battery tray 106: Reinforcement frame 201: Battery under cover 202: Fastening rod 203: Insertion hole 204: Insertion tray; 301, 401: Battery box components 205: Vehicle structure comprising a battery tray and a battery under cover located beneath the battery tray. 302, 402: Fiber-reinforced resin layer 303, 404: Adhesive layer 304: Metal layer 403: Ventilation channel

Claims

1. A component of a vehicle battery box, comprising a shaped fiber-reinforced resin layer containing reinforcing fibers and resin, and a shaped metal layer, bonded together via an adhesive layer, The thickness of the adhesive layer is 0.1 mm or more and 2.0 mm or less. A ventilation passage is provided between the metal layer and the fiber-reinforced resin layer. A component of a vehicle battery box.

2. The battery box component according to claim 1, wherein the width of the ventilation passage in the battery box is 1 mm or more and 20 mm or less, and the spacing between the ventilation passages is 0.5 m or less.

3. The relationship between the area S1 of the ventilation channel and the area S2 of the adhesive layer is, 0.01 <S1 / (S1+S2) <0.3 A component of a battery box according to either claim 1 or 2, relating to the above.

4. The battery box components have a height difference of 150 mm or more between the high and low sections, and ventilation passages are provided in both the high and low sections. A component of a battery box according to any one of claims 1 to 3.

5. The ventilation passage is formed in a grid pattern, a component of the battery box according to any one of claims 1 to 4.

6. The component of the battery box according to any one of claims 1 to 5, wherein the component of the battery box has a top surface, an upright surface, and a flange, and at least the flange is provided with a ventilation passage.

7. The metal layer shields at least one of an electric field or a magnetic field. A component of a battery box according to any one of claims 1 to 6.

8. The battery box component according to any one of claims 1 to 7, wherein the battery box component is a component of a vehicle battery box, and is selected from one of a battery tray, a battery cover, or a battery under cover.

9. A method for manufacturing a component of a battery box according to any one of claims 1 to 8, comprising applying an adhesive to a metal layer to provide an adhesive layer and a ventilation passage, and then laminating it onto a fiber-reinforced resin layer.

10. A method for manufacturing components of a battery box according to claim 9, After bonding the formed fiber-reinforced resin layer and the formed metal layer via an adhesive layer, A method for manufacturing battery box components, which involves removing air trapped between the adhesive layer and the metal layer through a ventilation channel.

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