Heterogeneous Fiber-Reinforced Composite for EV Battery Adhesion
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Solution Overview
Problem
Polypropylene resin reinforced with continuous glass fibers lacks sufficient adhesion with aluminum in conventional sheet molding compounds, particularly for undercover parts of electric vehicle batteries, which requires both excellent flame resistance and adhesion performance.
Innovation Solution
A fiber-reinforced composite material is created with distinct properties on its upper and lower surfaces, comprising first and second fiber-reinforced sheets with different thermoplastic resins and reinforcing fibers, where the second fiber-reinforced sheet is laminated between the first and third sheets, allowing for bonding without a separate adhesive, and manufactured using a pultrusion method and slitting process to achieve a plain weave structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polypropylene resin is used as the base material for fiber-reinforced composite, then the composite achieves good flame resistance, but the adhesion performance with aluminum cooling plate is insufficient
Solution Approach 1:
The patent applies local quality by creating a heterogeneous composite structure where different resin systems are used in different regions: polypropylene resin (good flame resistance) in the first and third sheets, and polyamide resin (good adhesion) in the second sheet that contacts the aluminum cooling plate. This allows each region to optimize for its specific function - flame resistance on the outer surfaces and adhesion at the aluminum interface.
Solution Approach 2:
The patent uses composite materials by combining multiple fiber-resin systems in a laminated structure. The composite comprises three sheets with different compositions: glass fiber-reinforced polypropylene (outer sheets) and carbon fiber-reinforced polyamide (inner sheet). This multi-material composite approach allows simultaneous achievement of flame resistance from polypropylene and adhesion from polyamide.
2Ease of manufacture
If conventional sheet molding compound (SMC) is used, then the manufacturing process is simple, but the adhesion performance with aluminum cannot be improved beyond conventional levels
Solution Approach 1:
The patent segments the composite into three distinct fiber-reinforced sheets that are laminated together. Each sheet can be manufactured separately using conventional pultrusion processes, then bonded together. This segmentation allows optimization of each layer's properties while maintaining manufacturability through established processes.
Solution Approach 2:
The second sheet made of polyamide resin acts as an intermediary layer between the polypropylene outer sheets and the aluminum cooling plate. This intermediary layer provides the adhesion function that polypropylene cannot achieve alone, while the overall structure remains manufacturable using standard composite processes.
3Device complexity
If a single homogeneous resin system is used throughout the composite, then the manufacturing process is simplified, but the composite cannot achieve both excellent flame resistance and adhesion performance simultaneously
Solution Approach 1:
The patent implements local quality by assigning different resin systems to different locations within the composite structure. The polypropylene resin is placed in regions requiring flame resistance (outer sheets), while polyamide resin is placed in the region requiring adhesion (inner sheet contacting aluminum). This spatial differentiation of material properties resolves the contradiction between simplicity and performance reliability.
Solution Approach 2:
The patent employs composite materials by creating a multi-phase fiber-resin system where glass fiber-reinforced polypropylene and carbon fiber-reinforced polyamide are combined in a laminated structure. This composite approach enables the material to exhibit multiple functions simultaneously - flame resistance from polypropylene and adhesion from polyamide - without requiring a single homogeneous material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting composite material exhibits excellent mechanical properties, flame resistance, and adhesion, with enhanced adhesive strength to aluminum, effectively addressing the limitations of conventional SMCs and ensuring safety and performance in electric vehicle battery applications.
Implementation Method 1
The first fiber-reinforced sheet, the second fiber-reinforced sheet, and the third fiber-reinforced sheet may be bonded by melting and pressing the first thermoplastic resin and the second thermoplastic resin.
Data Source
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AI summary
The present invention provides a fiber-reinforced composite material including a first fiber-reinforced sheet (110) in which first prepregs (11) including reinforcing fibers arranged in one direction and a first thermoplastic resin are woven to cross each other, a second fiber-reinforced sheet (120) in which the first prepreg (11), and a second prepreg (12) including reinforcing fibers arranged in one direction and a second thermoplastic resin are woven to cross each other, and a third fiber-reinforced sheet (130) in which the second prepregs (12) are woven to cross each other, wherein the second fiber-reinforced sheet is disposed between the first fiber-reinforced sheet (110) and the third fiber-reinforced sheet (130).