Aluminum Battery Shell
Products Description
An aluminum battery shell is a metal structural component specifically designed for encapsulating prismatic lithium-ion batteries. Its primary function is to provide stable mechanical support, protection, and a sealed space for the battery cells.
Compared to traditional steel shell solutions, aluminum alloy battery shells offer superior lightweighting, heat dissipation, and manufacturing flexibility, making them widely used in power batteries for new energy vehicles and energy storage battery systems.
The product typically consists of the following parts:
Battery aluminum shell body
Top cover assembly mating structure
Terminal mounting area
Sealed welding area
Safety and explosion-proof structure area
Module fixing and mounting structure
Customized development with different sizes, wall thicknesses, and structural forms is possible according to customer design requirements.
Production Process: Transformation from Aluminum Coil to Boundary Container
| Blanking and Pre-forming | After precision uncoiling and leveling, the aluminum alloy coil is fed into a progressive die or transfer die by a servo feeding system for blanking and pre-forming. This stage determines the accuracy of the Aluminum LTO Prismatic Battery Cell For EV's planar contour and the material allocation for subsequent deep drawing. |
| Multi-step Deep Drawing and Shaping | A multi-station mechanical press completes the progressive deformation from a flat-bottomed shallow cup to a deep-cavity Prismatic Aluminum Case Power Battery. Intermediate annealing is performed between each step (depending on the material's hardening degree) to restore the material's ductility reserves. The final shaping station corrects the shell's perpendicularity and opening flatness. |
| Trimming and Flanging | The opening edge is precisely trimmed to remove the process allowance from the deep drawing process, followed by flanging. The height, angle, and radius tolerances of the flanging directly determine the fit clearance with the cover plate and the welding quality. |
| Cleaning and Drying | Multi-stage water-based cleaning combined with pure water rinsing removes all process residues. After hot air circulation drying, it enters a clean temporary storage area to prevent secondary contamination. |
| Airtightness verification | Helium mass spectrometry leak detection technology is used to test the airtightness of the casing. Helium, as a tracer gas, can detect leakage paths caused by micron-level defects, ensuring the airtightness baseline of the delivered casing. |
Material Advantages: A Delicate Balance of Purification and Alloying
High-purity food-grade aluminum alloy substrate
We select high-purity aluminum ingots from specific series, strictly limiting the content of impurity elements such as Fe, Cu, and Si. The extremely low impurity ratio prevents cracking of intermetallic compounds during deep drawing and eliminates the possibility of impurity ions dissolving and contaminating the electrolyte under high pressure.
Customized alloy formulation
Finding the optimal balance between purity and strength. By adding trace amounts of elements such as Mn and Mg, we significantly improve the yield strength of the casing without reducing thermal conductivity or deep-drawing performance, resisting long-term expansion stress within the battery cell.
Superior thermal conductivity and ductility
Compared to stainless steel casings, aluminum alloy has several times higher thermal conductivity and is nearly half the weight; simultaneously, its excellent elongation at break gives the casing better energy absorption characteristics, making the aluminum battery box less prone to instantaneous cracking during vehicle collisions.
Detailed Showcase – Key Features Easily Overlooked
Housing Opening Chamfer
A smooth transition of R0.5~R1.0 prevents scratching of the electrode insulation film during installation.
Bottom Rib Design
Raised cross or grid-like reinforcing ribs are stamped on the bottom of the Aluminum deep drawing stamping battery case to increase impact resistance and improve positioning stability during laser welding of the bottom cover.
Explosion-proof Valve Dustproof Film
A peelable blue protective film is affixed to the outside of the explosion-proof valve during transportation and assembly. This film should be removed before installation to prevent dust from entering and scratching the valve body.
Electrion Post Threaded Hole
M4/M5 threaded holes are pre-drilled on the top of the electrode post for screw fixing of the module busbar. The thread strength meets a torque requirement of 5 N·m without stripping.
contact us
If you are looking for a Lithium Ion Cell Aluminum Shell supplier with experience in new energy projects, deep drawing and forming capabilities, mold development capabilities, and large-scale manufacturing capabilities, we can provide an integrated technical support solution from engineering evaluation to mass delivery, based on your cell design, module structure, and mass production requirements.
Hot Tags: aluminum battery shell, China aluminum battery shell manufacturers, suppliers, factory, Aluminum Battery Cases, Lithium Cell Aluminum Shell, Lithium Ion Battery Aluminum Shell, new energy battery, Prismatic Cell Aluminum Battery Case, Rechargeable Aluminum Shell
You Might Also Like
Send Inquiry