Square Aluminum Battery Housing
Square aluminum battery housing is an external protection structure for electric vehicle battery modules. Made of high-strength aluminum alloy, it has excellent heat dissipation and impact resistance. Designed to meet the high performance, battery protection and environmental adaptability requirements of electric vehicles, it is an indispensable key component in the battery system of electric vehicles.
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Product Introduction
Managing internal pressure and thermal expansion in high-capacity energy storage requires robust enclosure integrity. Designed for electric vehicles and motive power, our Square Aluminum Battery Housing provides a rigid envelope for lithium iron battery configurations. Built from high-purity 3003 and 5052 aluminum sheets via deep drawing, CNC milling, and deburring, the Housing delivers ~160 W/m·K thermal conductivity, ≤0.15 mΩ grounding resistance, and electrolyte corrosion resistance. In addition to standard formats, we manufacture custom enclosures for electric bike, Lifepo4 motor car, and lead-acid replacement battery packs.
Product Advantages
| High strength and light weight | Square aluminum battery housings are known for their excellent strength and rigidity, while being lighter than steel housings, significantly reducing the weight of the entire vehicle, thereby increasing the range of electric vehicles. |
| Heat dissipation performance | The high thermal conductivity of aluminum alloys enables the battery housing to effectively dissipate heat and prevent the battery from overheating. This not only extends the battery life, but also improves the overall performance of electric vehicles. |
| Impact resistance | Our battery aluminum housings are specially designed and reinforced to withstand greater impact forces, provide effective battery protection, and ensure safety under various driving conditions. |
| Corrosion resistance | Through advanced surface treatment technology, aluminum battery housings have excellent corrosion resistance, can adapt to various climate and environmental conditions, and ensure long-term stable operation. |
| Processing technology | We use leading processing technologies, including CNC cutting, extrusion molding and precision milling, to ensure that the dimensions of each housing are accurate and meet high quality standards. This high-precision manufacturing process ensures product consistency and reliability. |
Quality Control & Testing Standards
100% Automated Vacuum Helium Testing
Every Polymer Lithium battery Case production unit passes through high-vacuum chambers to confirm helium mass spectrometer leak rates remain below 1x10^-9 Pa·m³/s, ensuring hermetic sealing for high-voltage energy storage systems.
Hexagon 3D CMM Geometric Verification
Automated coordinate measuring machines evaluate diagonal flatness, hole concentricity, and wall thickness against customer CAD models, maintaining critical dimensions within strict tolerances for Square Aluminum Battery Housing.
Hydrostatic Burst & Compression Testing
Structural sample lots undergo hydrostatic pressure testing to verify uniform expansion behavior and calibrated safety vent opening pressure under extreme internal loads for Customized Prismatic Battery Cell Casings.
Salt Spray & Electrolyte Immersion Resistance
Anodized and passivated surfaces pass 96-hour neutral salt spray evaluations (ASTM B117) and chemical immersion tests with no pitting or degradation, preventing Lithium Ion Battery Pack corrosion from aggressive lithium electrolyte salts.
Technical Frequently Asked Questions
Q: How do your anodizing and passivation treatments protect a Prismatic Cell Case against electrolyte attack?
A: We apply a controlled anodized barrier on external walls while utilizing chromate-free conductive passivation inside the cavity. This dual-surface treatment prevents chemical pitting from fluorine-containing lithium salts while preserving grounding conductivity with contact resistance below 0.15 mΩ.
Q: What tooling controls prevent corner thinning on a Deep Drawn Aluminum Battery Housing?
A: Our engineering team designs progressive drawing dies with polished tungsten carbide inserts and automated multi-point lubricant dosing. This controls material flow across deep drawing passes, maintaining overall wall thickness within ±0.015 mm without micro-fracturing.
Q: How does your fiber laser welding system prevent porosity when sealing battery covers?
A: We use high-speed continuous wave (CW) fiber lasers with dual-beam wobble heads and real-time vision tracking. Operating inside an argon shielding gas envelope ensures consistent penetration depth and zero spatter, maintaining joint tensile strength above 250 N.
Q: What documentation is provided during PPAP Level 3 submission for custom battery enclosures?
A: PPAP Level 3 packages include complete ballooned CMM inspection drawings, material mill test certificates, chemical composition analyses, process flow diagrams, PFMEA sheets, CPK capability reports (CPK ≥ 1.67), and 100% helium leak test logs.
Q: How does your air tightness leak detection process ensure zero defect shipment on an Aluminum shell for prismatic lithium ion battery?
A: Parts undergo a two-stage sealing inspection: preliminary differential pressure decay testing at 0.5 MPa, followed by automated vacuum helium mass spectrometry. Units exceeding 1×10⁻⁹ Pa·m³/s are automatically segregated by pneumatic rejection stations.
Contact Us
Submit your 2D/3D CAD files (STEP/DWG) or battery pack specifications to our engineering team for an immediate DFM evaluation and factory-direct quote within 24 hours.
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