Detailed explanations of industry knowledge of battery aluminum shell solutions

In the field of energy storage, battery aluminum shells, as key packaging components, directly affect the safety, stability, and service life of batteries. The following introduces relevant professional knowledge.

 

 

6061 and 6063 aluminum alloys are commonly used to manufacture Aluminum Battery Cases. 6061 contains magnesium and silicon alloy elements, with a tensile strength of 200-300MPa, yield strength of about 100-200MPa, a low thermal expansion coefficient, and can withstand external force impact to maintain the stability of the battery structure. 6063 has excellent extrusion performance and is suitable for the manufacture of complex-shaped aluminum shells. After anodizing, it forms a 10-20μm oxide film with strong corrosion resistance. There is no obvious rust in the salt spray test for 500-800 hours.

 

 

 

(I) Structural design
Common structures are square and cylindrical. Square aluminum shells have high space utilization and are mostly used in power batteries and energy storage batteries. They are convenient for stacking and arranging battery cells and improving the energy density of battery packs. Cylindrical aluminum shells are often used for small batteries, such as 18650 batteries. They are often sealed by crimping or welding, with a sealing width of 1-2mm to prevent electrolyte leakage.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(II) Heat dissipation design
Battery charging and discharging will generate heat. Aluminum Battery Box can improve heat dissipation efficiency by adding heat dissipation fins and using heat-conducting aluminum alloy materials. High-performance aluminum shells have heat dissipation grooves on the surface, which reduces thermal resistance by 20%-30%. Thermal conductive silicone grease is filled between the aluminum shell and the battery cell to enhance heat transfer.

 

(I) Extrusion molding
The aluminum alloy billet is heated to 450-550℃ and pressed through an extruder to form it through a die. This process is suitable for mass production of Lithium-ion Battery Packs with regular shapes and can produce 5-10 pieces per minute.

(II) Stretching molding
Suitable for Aluminum Laminate Pouch for Li-ion Batteries with complex shapes and large depths. The stretching speed is controlled at 5-15mm/s, and the stretching ratio is 1.5-3 to prevent the aluminum shell from cracking and wrinkling and ensure quality.

(III) Welding process
Laser welding and resistance welding are commonly used. Laser welding has concentrated energy and fast speed, which can reach 5-10m/min. The weld is narrow 0 by .2-0.5mm, which reduces the heat-affected zone. Resistance welding is used for parts with high welding strength requirements.

 

 

 

(I) Sealing inspection
Use a helium mass spectrometer leak detector to fill helium for detection, with a detection accuracy of 1×10⁻⁹Pa・m³/s to ensure that the LiFePO Battery Pack is leak-free.

(II) Mechanical property inspection
Use a universal material testing machine to test tensile strength, yield strength, and elongation. For example, the tensile strength of the power battery aluminum shell is not less than 200MPa, and the elongation is not less than 10%.

(III) Dimensional accuracy inspection
Use a three-coordinate measuring instrument to measure with an accuracy of ±0.01mm to ensure that the size of the Powerwall Lithium battery Pack is consistent with the design.

 

In the field of electric vehicles, EV Battery Pouch Cell Aluminum Cases are encapsulated in power battery packs. Their lightweight, mechanical properties and corrosion resistance ensure the safe operation of batteries. In the field of energy storage, aluminum shells are used to encapsulate energy storage batteries to ensure long-term stable operation of the system. In the field of consumer electronics, aluminum shells are used to encapsulate small lithium batteries to meet the needs of thin, beautiful, and protective batteries.

The battery aluminum shell solution covers multiple links, and each link is strictly controlled to meet the requirements of battery performance and safety in different fields and promote the development of battery technology.