In the growing demand for energy storage, customizing a suitable die-cast aluminum battery case has become the focus of many enterprises and users. When facing the choice of energy storage battery cases, we often find that stretched or extruded aluminum cases are not used in many cases. So, how exactly can we customize die-cast aluminum battery cases? This article will intensely discuss the methods of customizing die-cast aluminum battery cases and analyze multiple aspects such as performance, manufacturing process, and cost to teach you to create the die-cast aluminum battery case that best meets your needs.
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1. It is high-strength and capable of withstanding external impacts such as collisions and squeezes during storage, transportation, and use.
2. Good toughness, able to absorb impact energy, and remain stable in unique environments such as significant temperature changes.
3. Strong seismic resistance, effectively buffering vibrations during transportation and use and protecting the battery's internal structure.
1. Waterproof, preventing water from entering and causing battery short circuits and corrosion.
2. Dustproof, avoiding dust and impurities from affecting battery operation.
3. Moisture-proof, preventing the battery from getting damp in humid environments.
4. Corrosion-resistant, capable of withstanding the erosion of corrosive substances in different environments.
1. Good thermal conductivity, timely conducting the heat generated during battery charging and discharging.
2. To improve heat dissipation efficiency, heat sinks, ventilation holes, etc., should have a reasonable heat dissipation design.
1. Good flame retardancy, preventing the spread of fire in case of battery failure.
2. They have specific explosion-proof performance and can withstand pressure to protect surrounding people and equipment.
1. Good insulation, preventing short circuits caused by contact between the battery and external conductive objects.
2. Have specific electromagnetic shielding performance, reducing the electromagnetic interference of the battery to external equipment and preventing external interference to the battery.
1. High precision to ensure a good fit with the battery's internal components.
2. Good machinability, meeting different design requirements with high manufacturing efficiency and stable quality.
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Battery Type: Different types of batteries have different characteristics, sizes, shapes, dimensions, weights, and performances. Understanding the battery type in use helps determine the battery case's size and internal structure design.
Size Requirements: Determine the battery case's external dimensions according to the batteries' size and quantity. At the same time, consider the limitations of the battery case in the installation space to ensure that the battery case can be successfully installed in the predetermined position.
Installation Method: There are multiple installation methods for battery cases, such as fixed type, detachable type, wall-mounted type, etc. According to the actual application scenario and requirements, select the appropriate installation method.
1. Structural Design
Adapt to Battery Shape: Design the battery case structure according to the battery shape and quantity to ensure the battery can be placed safely and stably.
Emphasize Sealing: When designing, consider waterproof and dustproof. Adopt appropriate sealing structures, such as rubber sealing rings and sealants, to prevent moisture and dust from entering the battery case.
Optimize Heat Dissipation: Since battery charging and discharging will generate heat, the battery case should have good heat dissipation performance. Heat dissipation efficiency can be improved by designing heat sinks, ventilation holes, etc.
2. Wall Thickness Selection
Comprehensive Consideration Factors: Wall thickness selection should comprehensively consider factors such as battery case size, strength requirements, and manufacturing processes. Too thin a wall thickness will make the battery case insufficient in strength and prone to deformation and damage; too thick a wall thickness will increase material costs and manufacturing difficulties.
Refer to Standards and Specifications: When choosing wall thickness, relevant standards and specifications can be referred to. You can also consult the die-casting engineer of the shine-choose company to determine the most suitable wall thickness.
3. Reinforcement Layout
Enhance Strength and Stiffness: Reinforcements can improve the strength and stiffness of the battery case and reduce the risk of deformation and damage. The layout of reinforcements should be reasonably designed according to the battery case structure and stress conditions.
When customizing die-cast battery cases, aluminum alloy, zinc alloy, and magnesium alloy are commonly available materials for die-casting factories. The following is a comparison of their advantages in die-cast battery cases:
1，Aluminum Alloy
Lightweight: Reduces the weight of the overall equipment, which is beneficial for transportation and installation. It has significant advantages in scenarios with strict weight requirements, such as electric vehicles.
High strength: Can effectively protect the battery and withstand external impacts without being easily deformed or damaged.
Excellent thermal conductivity: Conducts the heat generated during battery charging and discharging in time to maintain the appropriate operating temperature of the battery and improve battery performance and lifespan.
Relatively good corrosion resistance: Stable performance in most environments and not readily corroded.
2，Zinc Alloy
Excellent casting performance: Strong fluidity, easy-to-fill complex mold shapes, suitable for manufacturing battery cases with complex shapes.
High dimensional accuracy: The produced battery case fits closely with the battery, helping to improve overall stability.
Good surface treatment: Multiple surface treatments (such as electroplating and spraying) can be performed with good appearance and corrosion resistance.
Lower cost: In some cases, the price is lower than that of aluminum and magnesium alloy.
3，Magnesium Alloy
Extremely lightweight: It is the lightest among the three alloys and is suitable for highly lightweight applications.
High specific strength: It has higher strength under the same weight and can reliably protect the battery.
Good shock absorption: Effectively absorbs and buffers external impacts and protects the battery from being affected by vibrations.
Relatively good electromagnetic shielding performance: It can provide specific electromagnetic shielding in environments sensitive to electromagnetic interference.
In conclusion, die-cast battery cases of aluminum, zinc, and magnesium alloy have advantages. When choosing, factors such as application requirements, cost budget, and performance requirements must be comprehensively considered to select the most suitable material.
1. Provide the standards and methods for choosing suppliers, such as production capacity, quality control system, technical strength, etc.
2. Check what product cases the factory has done, preferably products of the same type.
3. Find a supplier who can respond efficiently and has a positive attitude.
This article has comprehensively discussed the relevant content of customizing die-cast aluminum battery cases. Energy storage battery cases have various requirements, covering aspects such as mechanical properties, protective performance, thermal management, safety performance, electrical performance, and manufacturing processes.
Before customization, clearly define requirements such as battery type, size, and installation method. During the design process, consider factors such as structure, wall thickness, and reinforcement layout. In material selection, aluminum alloy, zinc alloy, and magnesium alloy each have their advantages, and multiple factors need to be comprehensively considered to make a decision.
Finding a supplier cannot be ignored. Attention should be paid to its production capacity, quality control, technical strength, product cases, and service attitude. Considering all the above aspects, a die-cast aluminum battery case that meets the requirements can be customized to ensure the regular operation of energy storage batteries and balance cost and performance.
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