Abstract: Lightweight technology can effectively improve the range and driving performance of new energy vehicles, and has been widely applied in the production and manufacturing of automobiles. Compared with traditional metal materials, fiber composite materials have advantages such as specific strength and stiffness, low thermal expansion coefficient, and good fatigue resistance, ushering in a new era of lightweight. This paper takes the battery pack (the core component of new energy vehicles) as the research object. Based on the high pressure resin transfer molding (HP-RTM) process, the upper cover of the battery pack is lightweight designed using carbon fiber composite materials and glass fiber composite materials. A lightweight mass production plan for the battery pack cover is completed through technical means such as structural optimization, process optimization, and connection method optimization. The test results of the battery package prototype show that the upper cover of the battery pack made of carbon fiber composite material and glass fiber composite material can effectively improve the strength, stiffness, and fatigue resistance of the battery pack structure, with a comprehensive weight reduction of over 50%. The lightweight design scheme of continuous fiber composite materials described in this article can also provide guidance for the design of other automotive components.

Key words: HP-RTM; Continuous fiber composite; Battery package upper cover

摘要： 轻量化技术可有效提高新能源汽车续航能力和驾驶性能，已被广泛应用于汽车的生产 制造中。连续纤维复合材料在比强度、比刚度、热膨胀系数与抗疲劳性能等方面比传统金属 更具有优势，开启了轻量化新时代。文章以新能源汽车核心部件电池包为研究对象，基于高 压树脂传递模塑成型（HP-RTM）工艺，根据碳纤维复合材料与玻璃纤维复合材料的材料特点， 对电池包上盖进行了轻量化设计。通过结构优化、工艺优化、连接方式优化等技术手段完成 了电池包上盖的轻量化量产方案。电池包样机测试结果表明，采用碳纤维复合材料和玻璃纤 维复合材料制作的电池包上盖可以有效提升电池包结构的强度、刚度以及耐疲劳性，综合减 重达 50%以上。文章所述的连续纤维复合材料轻量化设计方案也可为汽车其他零部件设计提 供指导。

关键词: HP-RTM；连续纤维；电池包上盖