JP2012084445A - Battery container for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight battery container for vehicle with toughness and strength.SOLUTION: The battery container for vehicle is molded using a synthetic resin material. The peripheral wall of the battery container has a double wall structure consisting of an outside wall and an inside wall. Furthermore, the outside wall and the inside wall constitute a two-layer structure of an inner layer and an outer composed of materials having different characteristics. The outer layer of the two-layer structure uses a material which brings predetermined toughness and strength in the battery container for vehicle, and the inner layer uses a synthetic resin material on which an electromagnetic wave shielding coating material not passing an electromagnetic wave can be applied. The electromagnetic wave shielding coating material is applied to the inside of the inner layer.

Description

  The present invention relates to a vehicle battery container that houses a drive storage battery to be mounted on a vehicle and is attached to the outside of the vehicle body.

  An electric vehicle or a so-called hybrid vehicle in which an electric motor is combined with an internal combustion engine is equipped with a drive storage battery, and uses electric power stored in the drive storage battery for driving power or the like. On the other hand, the drive storage battery is formed by stacking a plurality of single cells called cells, and may be considerably heavy as a whole. Further, when the drive storage battery is attached to the outside of the vehicle body, it is conceivable that a stone hits the vehicle during traveling or an excessive force is applied during an accident.

  Therefore, it is considered that the storage battery for driving is housed in a battery container having a predetermined strength and mounted on the vehicle via the battery container. In a freight vehicle such as a truck, a main frame extending in the front-rear direction is provided at the center of the vehicle body. In a hybrid vehicle of such a vehicle, a battery container containing a drive storage battery is attached to the side of the main frame. ing.

  On the other hand, in particular, vehicles are required to be lighter. For example, if the battery container is made of a general metal material, the vehicle weight increases significantly. Thus, it has been considered to form the battery container with a synthetic resin material.

JP-A-8-186390

  However, when the battery container is mounted on a vehicle and used, the battery container is required to have a toughness that does not easily break along with the rigidity and does not form a hole or the like in the peripheral wall portion. As a synthetic resin material having high rigidity, a fiber reinforced plastic is known, but in terms of toughness, the fiber reinforced plastic is not sufficient.

  In addition, the drive storage battery is precisely controlled, and may generate electromagnetic waves due to current / voltage fluctuations caused by charging and discharging. The battery container is required to have a function of blocking electromagnetic waves emitted from the housed drive storage battery so that the human body and peripheral devices are not affected by the electromagnetic waves.

  If the battery case is made of metal, the problem of electromagnetic waves does not occur because the metal reflects the electromagnetic waves. However, the synthetic resin material cannot normally block electromagnetic waves, and when the battery container is formed of the synthetic resin material, there is a problem that electromagnetic waves emitted from the drive storage battery pass through the battery container and are emitted to the surroundings.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a vehicle battery container that can be reduced in weight, has sufficient rigidity and toughness, and does not cause electromagnetic waves to be released to the outside.

In order to solve the above-mentioned problems, the present invention has a vehicle battery container configured as follows.
The battery container for vehicles is comprised from a container main body and the cover body attached to a container main body. The container main body is a container body having a capacity for storing a predetermined amount of the storage battery for driving and having an open upper surface. The lid is formed in accordance with the upper surface opening of the container main body, and seals the inside of the container main body when assembled to the opening of the container main body.

  Both the container body and the lid are formed of a double wall structure consisting of an outer wall and an inner wall. The outer wall and the inner wall are formed approximately parallel to each other at an appropriate distance. Furthermore, the outer wall and the inner wall are each formed in a two-layer structure in which members having different properties are stacked in the thickness direction.

  The outer layer of the two-layer structure is a synthetic resin material having impact resistance, such as high-density polyethylene. The inner layer is a synthetic resin material that has good adhesion to the outer layer and has the property that an electromagnetic wave shielding coating material can be applied to the surface. The electromagnetic wave shielding coating material is a coating material in which, for example, a fibrous metal piece or a carbon material is mixed in a paint, and has conductivity and a property of suppressing the passage of electromagnetic waves.

  For example, a blow molding method is used as a method of molding the container body and the lid. The parison is formed of the above two types of resin materials. For example, a high density polyethylene resin is used for the outer layer and a polyamide resin is used for the inner layer.

  The parison is sandwiched between molds, air is sent into the parison during or after mold clamping, and a synthetic resin material is pressed against the mold to form a vehicle battery container (container body or lid). And when sending in air, an electromagnetic wave shielding coating material is inject | poured inside a parison, and an electromagnetic wave shielding coating material is made to adhere to the inner surface of a parison.

  Since the vehicle battery container has a double wall structure including an outer wall and an inner wall, the vehicle battery container has high rigidity and strength compared to the plate thickness of the outer wall and the inner wall alone. Therefore, it is possible to reliably hold the drive storage battery having a predetermined weight. Further, a fastening band or the like can be turned around the outer surface of the vehicle battery container so that it can be securely attached to the vehicle chassis frame or the like.

  Even if an accident occurs and the impact is received from the outside, the material forming the outer layer, for example, high-density polyethylene, has toughness, so it does not cause breakage or holes in the outer peripheral member of the vehicle battery container. . Therefore, it is possible to reliably prevent the conductive portion of the drive storage battery from being in contact with the outside of the vehicle battery container or the drive storage battery being exposed to the outside of the vehicle battery container.

  Since the vehicle battery container is made of synthetic resin, it can be reduced in weight, and the fuel efficiency and running performance of the vehicle equipped with the drive storage battery can be improved. Even when electromagnetic waves are emitted from the drive storage battery, the electromagnetic wave shielding coating material blocks the electromagnetic waves, and the electromagnetic waves are not diffused outside the vehicle battery container. Since the inner layer has adhesion to the electromagnetic wave shielding coating material, the electromagnetic wave shielding coating material is reliably applied to the inner surface of the vehicle battery container. Since the vehicle battery container can be formed by the blow molding method, the vehicle battery container having an accurate shape can be easily and inexpensively manufactured.

It is sectional drawing which shows a part of one Embodiment of the battery container for vehicles concerning this invention. It is a perspective view which shows the battery container for vehicles. It is a perspective view which shows the state which attached the battery container for vehicles to the vehicle. It is a top view which shows the frame structure of a vehicle. It is a perspective view which shows a vehicle. It is explanatory drawing which shows the blow molding method of a battery container. It is sectional drawing which shows a shaping die.

  An embodiment of a vehicle battery container according to the present invention will be described.

  FIG. 5 shows the vehicle 100. The vehicle 100 is a freight hybrid vehicle in which a vehicle battery container (hereinafter referred to as “battery container”) 10 according to the present invention is mounted on the side. The vehicle 100 includes a cabin 102 at the front, a cargo box 104 at the rear, a front wheel 12 a at the lower part of the cabin 102, and a rear wheel 12 b at the lower part of the cargo box 104. The vehicle 100 is provided with a main frame 106 extending through the front and rear of the vehicle, and the battery case 10 is attached to the side of the main frame 106.

  FIG. 4 shows a schematic configuration when the vehicle 100 is viewed from above. A main frame 106 is provided in the front-rear direction at the center in the width direction of the vehicle 100. The main frame 106 is configured by arranging a pair of left and right parallel frame members 107 having a U-shaped cross section. An engine 14, a clutch mechanism 16, an electric motor 20, and a transmission 18 are attached to the main frame 106 from the front. Further, the battery case 10 and the power control unit 26 are attached to the main frame 106 on the side.

  The engine 14 is, for example, a diesel engine. The output shaft of the engine 14 is connected to the clutch mechanism 16. The clutch mechanism 16 is provided between the engine 14 and the electric motor 20 and intermittently rotates output from the engine 14. The transmission 18 includes a transmission mechanism inside, and an output shaft (not shown) is connected to the rear wheel 12 b via the propeller shaft 30 and the differential device 31.

  The electric motor 20 is connected via a power control unit 26 to a drive storage battery 36 (see FIG. 2) housed in the battery container 10. The power control unit 26 supplies electric power to the electric motor 20 in accordance with an instruction from a control device (not shown). The electric motor 20 operates separately from the engine 14 and applies a driving force to the transmission 18. Further, the electric motor 20 generates electric power with a driving force received from the rear wheel 12b during braking. The electric power generated by the electric motor 20 is sent to the battery container 10 and stored in the drive storage battery 36.

  As described above, the vehicle 100 is a so-called hybrid vehicle that can travel by using different powers of the power from the engine 14 that is an internal combustion engine and the power from the electric motor 20 individually or simultaneously. The engine 14 may be another power source instead of an engine of another internal combustion engine such as a gasoline engine or an internal combustion engine. The vehicle according to the present invention may be an electric vehicle that runs using only electric power as a drive source.

  Furthermore, the electric motor 20 may be installed at any position. For example, the electric motor 20 may be provided between the engine 14 and the clutch mechanism 16. Furthermore, the electric motor 20 may be connected to the front wheel 12 a so that the front wheel 12 a can be driven by the electric motor 20.

  As shown in FIG. 2, the battery container 10 includes a container body 32 and a lid 34, and a drive storage battery 36 and a cooling mechanism 38 are accommodated therein.

  The drive storage battery 36 is a high-power battery formed by superposing a plurality of battery cells as a unit to have a predetermined voltage. The cooling mechanism 38 is provided in the upper part of the drive storage battery 36, and includes a blower 40, a temperature measuring device (not shown), various ducts 42, and the like. Based on the measurement result of the temperature measuring device, the battery container The outside air introduced from an inflow port (not shown) formed in 10 is passed through and discharged from an exhaust port (not shown) to keep the drive storage battery 36 at a predetermined temperature.

  Next, the structure of the battery container 10 will be specifically described.

  As shown in FIG. 3, the battery container 10 has a substantially rectangular parallelepiped shape, and is entirely formed of a synthetic resin material. The container main body 32 includes a bottom plate 50 and a wall plate 52 raised around the bottom plate 50. The bottom plate 50 is generally rectangular, and a wall plate 52 is raised substantially vertically at each edge around the bottom plate 50 to form a side wall. The bottom plate 50 and the wall plate 52 are wall bodies around the container main body 32.

  An opening 58 for inspection and repair is formed on the right side of the wall plate 52 on the front surface (left side surface in the vehicle 100) of the container body 32. An attachment lid 66 is attached to the opening 58, and the opening 58 is normally closed by the attachment lid 66. Further, an inflow port and an exhaust port (both not shown) for adjusting the internal temperature are formed in the bottom plate 50 and the wall plate 52.

  In FIG. 1, the cross section of the upper edge of the wall board 52 is shown. As shown in FIG. 1, the wall plate 52 is formed with a double wall structure including an outer wall 54 and an inner wall 56. The outer wall 54 is located outside the container body 32, and the inner wall 56 is located inside the container body 32. Further, as shown in the figure, the wall plate 52 has an outer wall 54 bent at the left end of the figure, that is, outward of the container body 32 at the upper end, bent upward at the left end, and extended upward. Connected. The inner wall 56 extends rightward from the upper end of the outer wall 54 and is bent downward at the right end of the figure. Note that the outer wall 54 and the inner wall 56 do not have to be strictly separated when the flange is formed in this way.

  As shown in the drawing, the outer wall 54 and the inner wall 56 are formed substantially in parallel with a predetermined gap. It should be noted that the outer wall 54 and the inner wall 56 are not always a fixed gap, and the interval may be changed as appropriate according to the position of the container body 32. Further, the outer wall 54 and the inner wall 56 are formed in the same manner in the bottom plate 50 continuously from the wall plate 52.

  Further, the outer wall 54 and the inner wall 56 have a two-layer structure including an outer layer 70 and an inner layer 72, respectively. The outer layer 70 and the inner layer 72 are not based on the inside and outside of the container body 32 but are determined based on whether they are on the outside air side, and the side of the outer wall 54 and the inner wall 56 that contacts the outside air is defined as the outside, and the opposite side is defined as the inside. .

  The outer layer 70 is formed from a synthetic resin material such as high-density polyethylene. The outer layer 70 is formed by selecting a material, a thickness, a shape, and the like so that the outer layer 70 alone has sufficient rigidity, strength, and toughness to form the container body 32 and, by extension, the battery container 10. The outer layer 70 may be set so as to be integrated with the inner layer 72 and have a predetermined strength.

  The inner layer 72 is made of a synthetic resin material such as a polyamide resin. Inside the inner layer 72, a conductive coating material 73 that is an electromagnetic wave shielding coating material is applied. The synthetic resin material forming the inner layer 72 such as polyamide resin has good adhesion to the synthetic resin material such as high-density polyethylene forming the outer layer 70 and has a property that the conductive coating material 73 can be applied to the surface. Yes.

  The conductive coating material 73 is, for example, a coating material in which fibrous metal, carbon particles, carbon fiber, or the like is mixed in a coating material to impart conductivity. The conductive coating material 73 may be another coating material as long as electromagnetic waves can be blocked.

  The conductive coating material 73 is applied to the inner layer 72 with a substantially uniform thickness. The conductive coating material 73 is applied so as to reflect or absorb electromagnetic waves so that the electromagnetic waves generated by the drive storage battery 36 in the battery container 10 are not released to the outside of the battery container 10. Note that the coating thickness of the conductive coating material 73 may be partially changed according to the state of generation of electromagnetic waves.

  The lid 34 is formed in conformity with the upper surface shape of the container main body 32, and when the lid 34 is attached to the open portion of the container main body 32, the container main body 32 is sealed. Similar to the container body 32, the lid body 34 has a double-wall structure composed of an outer wall 54 and an inner wall 56, and a two-layer structure composed of an outer layer 70 and an inner layer 72. Further, a conductive coating material 73 is applied to the inner surface. ing.

  The configuration of the outer layer 70 and the inner layer 72 of the lid 34 is the same as the configuration of the container body 32, and the conductive coating material 73 applied to the inner surface of the inner layer 72 is also the same configuration. Accordingly, the lid body 34 has predetermined strength, rigidity, and toughness, and has an electromagnetic wave shielding property that blocks electromagnetic waves generated by the drive storage battery 36. The lid 34 may be attached to the container main body 32 by a hinge or the like so as to be opened and closed separately from the container main body 32.

  At the fastening portion between the lid 34 and the container main body 32, each outer layer 70 is removed by cutting or the like, the inner layer 72 and the conductive coating material 73 are exposed, and a conductive gasket or sealing material is interposed therebetween. Conclude. As a result, the lid 34 and the container main body 32 are in a conductive state, and electromagnetic waves are prevented from being released from the battery container 10 from the fastening portion.

FIG. 3 shows a state in which the battery container 10 is attached to the vehicle 100.
As shown in the figure, the battery container 10 is attached to a frame member 107 on the left side of the main frame 106. An L-shaped stay 74 is attached to the frame member 107. A shelf plate 76 is attached to the projecting portion of the lower portion of the stay 74, and the battery container 10 is placed on the shelf plate 76. One end of a belt 78 is fixed to the front end of the stay 74. The belt 78 is, for example, a metal belt, is rotated along the front surface and the upper surface of the battery case 10, and the other end is detachably attached to a fixture 80 provided on the main frame 106.

  Next, a method for manufacturing the battery container 10 will be described with reference to FIGS.

  FIG. 6 shows a mold apparatus 130 for blow molding. The mold apparatus 130 includes a male mold 132 and a female mold 134. Either one or both of the male mold 132 and the female mold 134 are movably provided and can be opened and closed.

  A movable mold part 136 is attached to the female mold 134 via a hinge 138 so as to be rotatable. In FIG. 6, the movable mold part 136 is provided only at two locations of the female mold 134, but in reality, it is provided on each of the four surfaces of the female mold 134, and for the convenience of the drawing, in the front and back direction of the paper surface. The provided movable mold part 136 is omitted.

  Each movable mold part 136 is provided with a drive mechanism 140 composed of a piston cylinder mechanism. The drive mechanism 140 is operated by hydraulic pressure or the like, and rotates the movable mold part 136 around the hinge 138.

  A parison dispensing mechanism 146 is provided on the upper part of the mold apparatus 130. The parison pouring mechanism 146 pours a predetermined synthetic resin material into a cylindrical shape and closes the lower end to form the parison 148. Furthermore, the parison extraction mechanism 146 includes a plurality of outlets (not shown), and different resin materials can be extracted in layers from each outlet.

  The parison dispensing mechanism 146 includes an air inlet 150 and a coating material inlet 152. The air inlet 150 injects compressed air from a pneumatic feeder (not shown) into the interior of the parison 148. The coating material injection port 152 is connected to a coating material dispensing device (not shown) and injects the coating material into the parison 148.

  Next, a specific method for forming the battery container 10 will be described. First, a resin material is poured out from the parison dispensing mechanism 146 to form a parison 148. The parison 148 has a two-layer structure of different resin materials inside and outside.

  Next, the male mold 132 and the female mold 134 are clamped. At that time, the driving mechanism 140 is contracted, and the movable mold part 136 is opened outward. The drive mechanism 140 is operated in accordance with the clamping of the male mold 132 and the female mold 134, and the four movable mold parts 136 are rotated and closed. When the movable mold part 136 rotates, the parison 148 is pressed from four directions and is clamped as shown in FIG.

  Further, air is injected into the inside of the parison 148 from the air injection port 150 during and after the mold clamping, so that a hollow double wall structure including the outer wall 54 and the inner wall 56 is formed. When air is injected, the conductive coating material 73 is poured out from the coating material injection port 152, and the conductive coating material 73 is injected into the inside of the parison 148. The injected conductive coating material 73 is applied to the entire inner layer 72 of the hollow portion so as to have a substantially uniform thickness. As a result, the container body 32 is formed by the mold apparatus 130. In FIG. 7, as in FIG. 6, two movable mold parts 136 in the front and back direction with respect to the paper surface are omitted.

  Furthermore, since the parison 148 has a two-layer structure made of different resin materials inside and outside, the outer wall 54 and the inner wall 56 are each formed in a two-layer structure. The outer layer 70 of the parison 148 is formed of a synthetic resin material having a predetermined strength and toughness such as high-density polyethylene, and the inner layer 72 is formed of a resin material capable of applying an electromagnetic wave shielding coating material such as polyamide resin on the surface. The A conductive coating material 73 is applied to the inner surface of the inner layer 72. Thereby, the outer wall 54 and the inner wall 56 of the bottom plate 50 and the wall plate 52 are each formed in a three-layer structure.

  Further, the lid body 34 has an inner and outer two layers as in the case of the container body 32 and has a double wall structure, and is molded by the same blow molding method as described above. Similarly to the container body 32, the lid body 34 also includes an outer wall 54 and an inner wall 56, each of which is formed of an outer layer 70 made of high-density polyethylene and an inner layer 72 to which an electromagnetic wave shielding coating material can be applied. A conductive coating material 73 is coated on the surface. Therefore, the lid 34 also has predetermined strength, rigidity, and toughness, and when assembled to the container body 32, the entire battery container 10 is formed with predetermined strength, rigidity, and the like.

  By forming the battery case 10 in this manner, the outer peripheral member of the battery case 10 has sufficient rigidity due to the double wall structure, and the high-density polyethylene forming the outer layer 70 provides sufficient toughness, so that the vehicle Even if the battery case 10 receives an impact due to a collision or a stepping stone, the wall plate 52 is not cracked or an opening is not formed. Therefore, the conductive portion of the drive storage battery 36 is not accessible from the outside of the battery container 10, and the drive storage battery 36 is not exposed to the outside from the battery container 10.

  Further, since the conductive coating material 73 is coated on the inner surface of the inner layer 72, the electromagnetic wave generated from the drive storage battery 36 is reflected or absorbed by the conductive coating material 73, and its passage is blocked. Therefore, electromagnetic waves are not emitted from the battery case 10 to the outside, and people and peripheral devices are not affected by the electromagnetic waves in the vicinity of the battery case 10.

  Furthermore, since the battery container 10 is molded from a synthetic resin material, an increase in the weight of the battery container 10 can be suppressed, and deterioration of the running performance and fuel consumption of the vehicle 100 can be prevented. Since the battery case 10 has moderate rigidity, strength, and toughness, it can be securely fixed to the main frame 106 of the vehicle 100 by fastening with the belt 78.

  The outer layer 70 and the inner layer 72 need not be limited to high-density polyethylene resin and polyimide resin, and may be other materials as long as they have a property that satisfies the requirements of the present invention. The vehicle according to the present invention is not limited to the vehicle 100 in the above example.

  The present invention can be used for an electric vehicle, a hybrid vehicle, or the like equipped with a drive storage battery.

  DESCRIPTION OF SYMBOLS 10 ... Vehicle battery container 14 ... Engine 20 ... Electric motor 32 ... Container main body 34 ... Cover body 36 ... Drive storage battery 50 ... Bottom plate 52 ... Wall plate 54 ... Outer wall 56 ... Inner wall 70 ... Outer layer 72 ... Inner layer 73 ... Conductive coating material DESCRIPTION OF SYMBOLS 100 ... Vehicle 106 ... Main frame 130 ... Mold apparatus 132 ... Male mold 134 ... Female mold 136 ... Movable mold part 146 ... Parison pouring mechanism 148 ... Parison 150 ... Air inlet 152 ... Coating material inlet

Claims (5)

In the vehicle battery container that houses the drive storage battery to be mounted on the vehicle and is attached to the outside of the vehicle body,
The vehicle battery container has a double wall structure in which a surrounding wall body is composed of an outer wall and an inner wall provided at a predetermined distance from the outer wall,
The outer wall and the inner wall have a two-layer structure composed of an outer layer and an inner layer in which members having different properties are laminated in the thickness direction of the outer wall and the inner wall,
Any one of the outer layer and the inner layer is made of a synthetic resin material that provides the vehicle battery container with a predetermined strength and toughness only in the one layer,
The other layers of the outer layer and the inner layer are made of a synthetic resin material having a property that an electromagnetic wave blocking member that adheres to the one layer and suppresses the passage of electromagnetic waves can be applied to the surface of the other layer. ,
The vehicle battery container, wherein the electromagnetic wave shielding coating material is coated on the surface of the other layer.   The vehicle battery container according to claim 1, wherein the member forming the one layer is high-density polyethylene.   The vehicle battery container according to claim 1 or 2, wherein the member forming the other layer is a polyamide resin.   The said battery container for vehicles was shape | molded by the blow molding method, The battery container for vehicles of any one of Claims 1-3 characterized by the above-mentioned.   5. The vehicle battery container according to claim 4, wherein the electromagnetic wave shielding coating material is injected and coated in a parison.

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