Structure Design And Process Analysis Of Square Aluminum Shell Battery Cover

 

The square aluminum-shell battery cover has a unique and modern design, which is more compact and easy to stack compared to traditional round batteries. The square design makes better use of space, improves the efficiency of battery assembly, and ADAPTS to the needs of different models and sizes of batteries.

 

The aluminum shell has multiple advantages as a material for the battery case. First of all, aluminum has good thermal conductivity, can effectively dissipate the heat generated by the battery, improve the heat dissipation effect of the battery, thus extending the service life of the battery. Secondly, aluminum alloy has high strength and corrosion resistance, which can resist the impact and vibration of external factors on the battery and enhance the durability of the battery.

The square aluminum shell battery cover is designed with a tight sealing structure, which can prevent solution leakage or gas leakage inside the battery, as well as the entry of external substances. This excellent sealing performance can improve the safety, stability and reliability of the battery.

 

Appearance design

 

The appearance design of the square aluminum shell battery case is unique and modern, and has obvious advantages compared with the traditional round battery. The square design is more compact, making better use of space and improving battery assembly efficiency. In different application scenarios, square batteries can be more easily stacked to adapt to the needs of different models and sizes. For example, the square battery case design in the Ningde era has a more reasonable square cell composition, and the coordination of the case, aluminum shell and coil core makes the overall structure of the battery more stable.

 

Material selection

 

The thermal conductivity of aluminum can effectively dissipate the heat generated by the battery, improve the heat dissipation effect of the battery, and thus extend the service life of the battery. At the same time, the strength of aluminum alloy is high, which can resist the impact and vibration of external factors on the battery, and enhance the durability of the battery.

 

Sealing performance

 

The square aluminum shell battery case adopts a tight sealing structure, which is crucial for the safety, stability and reliability of the battery. The sealed structure can prevent the leakage of solution and gas inside the battery, as well as the entry of external substances.

 

 

In the manufacturing and assembly process of the square aluminum shell lithium battery, the laser welding process is crucial, and the development of the top laser welding equipment and process can be divided into three eras.

 

In the 1.0 era (2015-2017), domestic new energy vehicles began to break out driven by policy, and the power battery industry expanded, but the enterprise technology precipitation and talent reserve were relatively small, and the related manufacturing process and equipment technology were in their infancy. At this stage, the production efficiency requirements of the square battery laser sealing equipment are usually 6-10PPM, and the equipment scheme is mostly the use of 1kw fiber laser through the ordinary laser welding head, driven by the servo platform motor or linear motor to move the welding head and welding, and the welding speed is 50-100mm /s. Because the welding speed is relatively low, the weld heat cycle time is long, the molten pool has enough time to flow and solidified, the protective gas can cover the molten pool better, and it is easy to obtain the weld with smooth, full and good consistency. However, the 1.0 era of equipment also has limitations, the motor drive ability is difficult to meet the needs of speed, simply improve the welding speed and laser power will lead to the welding process instability, yield decline, weld surface is easy to rough, consistency reduction.

 

Entering the 2.0 era (2017-2018), with the explosive growth of China's automotive power battery installed capacity, the industry's requirements for battery performance and quality are becoming more stringent. In order to meet the single-line production capacity requirements, the top laser welding equipment needs to increase the production capacity to 15-20PPM, and the laser welding speed can reach 150-200mm /s. Each equipment manufacturer upgrades the linear motor platform to make its motion mechanism meet the motion performance requirements of 200mm/s uniform welding on a rectangular trajectory. However, high-speed welding is faced with many problems, and it is difficult to meet the speed requirements by using common fiber laser and single point light source output by welding head. When the welding forming effect is controlled by adjusting the spot size and laser power, smaller spot will lead to smaller weld width, smaller keyhole and unstable shape. If the spot is larger, the welding power will be significantly increased, and the spatter and hole burst rate will be increased.

 

 

Since 2010, Xiamen Apollo Stamping Welding Technology Co., LTD has specialized in Metal Stamping and Welding solutions for New Energy, like Fuse Copper Contact Cap, Battery Aluminum Case and Safety Cover, EV Film Capacitor Copper BusBar, Laminated Copper BusBar, Insulated Copper Busbar, Flexible Busbar, and other electrical products Metal Stamping and Welding Assembly. Our teams are the experts from their respective fields, we can not only provide customers with products of qualified quality and competitive price, but also offer technical solutions to reduce costs but increase efficiency.