Lithium battery industry topic: Key points of Aluminum cover plate for batteries structure in detail
Mar 12, 2026
Core positioning and classification of power battery structural components
Precision structural components of power batteries are the core components of lithium batteries, which broadly cover Aluminum cover plate for batteries, steel aluminum shells, positive and negative electrode soft connections, and more. Narrowly defined, they mainly refer to the battery cell shell and battery cover plate. Their performance directly determines the safety, sealing, and energy efficiency of lithium batteries, and they are key materials to ensure the stable operation of batteries.
According to the differences in battery packaging technology routes, power batteries are mainly divided into three forms: square, cylindrical, and soft pack. The corresponding supporting structural components are square structural components, cylindrical structural components, and aluminum-plastic film; Both cylindrical and square batteries belong to the hard shell packaging system, with similar structural composition, consisting of a shell and a Battery aluminum safety cover set. Soft pack batteries use a special aluminum-plastic film packaging form, which is significantly different from hard shell structural components.
Structural component raw material system and core production process
The selection of raw materials and production processes for power battery structural components directly affect the final performance and cost of the product. From the perspective of raw materials, square aluminum shell structural components are made of aluminum alloy as the core material, supplemented by auxiliary materials such as copper, steel, and engineering plastics, to meet the precision manufacturing needs of Aluminum cover plate for batteries; The aluminum-plastic film used in soft pack batteries is mainly made of aluminum foil, nylon, and polypropylene, and is combined with a special adhesive to achieve multi-layer structural bonding.
At the process level, the core of battery cover production relies on precision processes such as stamping, welding, and injection molding, while the shell is mainly produced through stamping and stretching processes. Aluminum plastic film is often made using precision coating and multi-layer bonding processes. In addition to basic manufacturing technology, extended technologies such as explosion-proof design of safety valves and high-precision welding have become the core direction for optimizing and upgrading the structure of Aluminum battery box covers. At the same time, the industry has widely introduced automation equipment and flexible production lines to meet the scale and consistency requirements of large-scale precision manufacturing.
Development status and packaging requirements of hard shell structural components
The safety and service life of power batteries highly depend on the level of packaging technology, and the technical difficulties of different packaging routes vary significantly. Packaging design not only needs to meet physical protection requirements such as impact resistance, vibration resistance, and anti extrusion puncture, but also needs to have core chemical properties such as fire resistance and flame retardancy, suitable for harsh use environments such as new energy vehicles and energy storage. This is also the core consideration of Copper and aluminum bimetal bipolar plate design. In the hard shell structural component system, the manufacturing process complexity of the battery cover plate is much higher than that of the shell, which is the technical core and value center of the entire hard shell structural component.
Core functions and component composition of Lithium battery top cap
The hard shell Power battery cover plate integrates multiple core functions to comprehensively ensure the safe operation and stable performance of the battery. The core functions are divided into four categories:
One is fixed sealing, achieved by laser welding the top cover and aluminum shell to wrap and fix the battery cells, and provide full sealing protection; The second is current conduction, which relies on the pole and adapter to achieve internal charge and discharge conduction of the battery cell, as well as series parallel circuit connection at the module level; The third is safety protection, which combines the dual mechanism of explosion-proof plate pressure relief and flipping plate fuse protection to avoid the risk of abnormal battery explosion; The fourth is to prevent electrical corrosion, by using positive electrode conductive PPS plastic to reduce the potential difference between the pole and the aluminum shell, reduce electrical corrosion losses, and extend the service life of the battery.
The core components of Prismatic lithium battery lid include explosion-proof plates, flip plates, and poles. The three types of components have clear division of labor and work together to form the core functional carrier of the cover plate.
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