Knowledge analysis on the new energy vehicle aluminum power battery casing industry

The continuous driving ability of electric vehicles is highly dependent on the performance of the power battery as an energy storage device, in which the quality and safety of the battery are particularly critical. The power battery case is responsible for the core function of fixing and protecting the battery module or cell, and the sealing performance is an important indicator to measure the quality of the case design. If the housing is not tightly sealed, it may lead to water intrusion, internal gas leakage and other failures, directly affecting the safety of vehicle operation. In response to this problem, this article focuses on the sealing design of the aluminum power battery casing of electric vehicles, systematically analyzes its structural characteristics and sealing interface, and proposes corresponding technical solutions. Among various types of aluminum shell structures, Lithium-ion Battery Aluminum Shell is widely used due to its lightweight and process adaptability, but the complexity of its sealing design still requires focus.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Currently, the mainstream material solution for power battery pack shells in the industry is "extruded aluminum alloy shell + PP/glass fiber composite upper cover". This solution takes into account lightweight, cost control and performance requirements, and has broad market prospects. Among them, the aluminum alloy shell is mostly made of 6 series extruded profiles and is welded with friction stir welding, MIG welding and other processes. It not only has a low comprehensive application cost and can meet the strength and sealing requirements of the battery pack, but also can realize the integrated design of water-cooled battery circulation channels to further optimize the battery heat dissipation performance; the upper cover is made of PP/ Glass fiber + LFT-D molding process production can not only improve production efficiency, but also meet flame combustion and sealing performance requirements, and the mold cost is relatively low, which complements the advantages of aluminum alloy shells. It has been widely used in many new energy vehicles such as BYD Song and Tang, Weilai ES8, and BAIC EV series.

 

Lithium-ion Battery Aluminum Shell usually uses steel or aluminum alloy as the main load-bearing material. Steel plates have the characteristics of convenient processing, controllable costs, and excellent rigidity, while aluminum alloys are outstanding in lightweighting and have the advantages of a simple extrusion process, low tooling investment, and high integration of casting processes. Among the current mainstream solutions in the industry, Lithium Batteries Square Aluminum Casing mostly adopts a box structure, consisting of an upper cover, a lower tray, and a bottom guard plate, and generally integrates water-cooling plates to achieve thermal management functions. The tray structure is usually composed of a frame and a water-cooling plate. This modular design not only improves space utilization but also provides a clear technical path for subsequent identification and optimization of sealing interfaces.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In the structural design of the battery case, the cooperation between the upper cover and the lower tray is crucial. In order to reduce the complexity of the sealing structure, the upper cover usually adopts an integrated design. Whether it is made of steel plate or aluminum, it is necessary to ensure that it has stable "self-sealing" performance. As the lower tray is the main load-bearing structure, the current mainstream solutions mostly use aluminum alloy extruded profiles with the friction stir welding process. This frame structure not only significantly reduces fixed investment but also optimizes thermal management through integrated water-cooling plate design. In this link, the use of high-precision Lithium-ion Battery Aluminum Shell can effectively ensure the dimensional accuracy and connection strength of the frame splicing, and provide a strong and lightweight physical protection space for the battery module.

The sealing interface is a technical difficulty in the manufacturing of aluminum battery cases. The matching surfaces of the upper cover and lower tray need to meet "even" and "continuous" sealing requirements. Materials such as CIPG (foam-in-place sealing) are usually used for gluing, and the compression ratio and bolt spacing are strictly controlled. For the splicing of aluminum profile frames and the connection between the frame and the water-cooling plate, self-sealing linear connection technology, such as CMT cold metal transition welding or friction stir welding, is required. These processes can ensure that the Lithium Batteries Square Aluminum Casing maintains excellent sealing stability when it withstands vibrations and impacts during vehicle driving, avoiding coolant leakage or external foreign matter intrusion due to process defects, thereby ensuring the long-term safe operation of the battery system.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

As the cruising range requirements of new energy vehicles continue to increase, battery system energy density has become a key technical indicator. The path to improve energy density mainly includes improving the specific energy of single cells and achieving lightweight battery pack structures. Compared with the former's high technical threshold and long research and development cycle, structural lightweighting is easier to achieve quickly at the engineering level. Aluminum alloy has become an ideal material for the lightweight design of Lithium-ion Battery Aluminum Shell due to its comprehensive advantages such as low density, high specific strength, good thermal stability, excellent corrosion resistance and thermal conductivity, non-magnetic, easy molding, and high recycling value. The current mainstream technology route uses an aluminum extruded profile shell with a non-metallic upper cover. The shell is spliced ​​by friction stir welding and MIG welding. The comprehensive application cost is low and the performance meets the requirements. At the same time, the integrated design of the water-cooling circulating water channel can be realized. The Deep Drawn Aluminum Battery Housing process shows unique advantages in complex curved surface molding, while the Aluminum Stamping technology provides efficient and stable manufacturing guarantee for mass production.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If you are looking for a reliable New Energy Vehicle Aluminum Battery Case partner, please feel free to contact us. We will use our professional technology and high-quality services to help your products take the lead on the new energy track.