The heart of any lithium battery system is the careful packaging and framing that holds its essential components together. Let’s embark on a journey to explore the intricacies of lithium battery packaging, where every detail counts to ensure the performance, safety, and reliability of these powerhouses.
Anatomy of a Lithium Battery Pack
A lithium battery pack, as depicted in Figure 1, is a sophisticated assembly comprising several key elements: the lower frame, upper frame, lithium battery cells, high-voltage connection assembly, low-voltage connection assembly, and more.
Lower Frame Design
The lower frame, crucial in the structural integrity of the battery pack, often employs an innovative aluminum extrusion frame design. This approach is favored for its lightweight properties, aligning well with the escalating energy density requirements of modern vehicles. As seen in Figure 2, the aluminum extrusion process stands as the primary solution for achieving the desired lightweight design while maintaining structural integrity.
Upper Frame Design
In an era where integration reigns supreme, the upper frame leaps forward. Battery system frames are becoming increasingly intertwined with the vehicle chassis. The battery frame now directly adopts a die-cast chassis frame structure. Battery cells nestle within the die-cast chassis frame, forming a direct connection between the cells and the vehicle chassis itself.
Navigating the Challenges: Welding Pores and Gas Inspection
Welding plays a pivotal role in the construction of both upper and lower frames, but it’s not without its challenges. During welding, an alumina film can hinder the seamless fusion of metals, potentially leading to slag formation. Additionally, the oxide film might absorb moisture, exacerbating the formation of undesirable pores within the welds.
These leakage holes are typically minuscule in size, exhibit irregular cross-sections, and manifest in various pathways for air escape. Their appearance is often unpredictable and influenced by production techniques.
When it comes to gas inspection, several issues can arise:
Diverse Leakage: Identifying the root cause of leaks isn’t always straightforward.
Virtual Welding: Detecting virtual welds (improperly fused sections) can be challenging.
Temperature Effects: Temperature fluctuations can impact inspection results, introducing variability.
Solution: Helium Inspection
To combat these challenges, the industry turns to helium inspection. Box vacuum helium inspection equipment is a customized testing system meticulously designed to establish helium inspection conditions that align with the characteristics of the workpiece being examined. This approach ensures that every nook and cranny is examined for potential issues, guaranteeing the utmost safety, performance, and reliability of lithium battery packs.
In the intricate world of lithium battery packaging and framing, precision is paramount. These solutions, from lightweight aluminum frames to advanced inspection techniques, ensure that our lithium batteries continue to power the future with safety and efficiency at the forefront.
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About Semco – Semco University is an educational website that is catering to the needs of students and researchers. Offering information on Lithium-ion batteries. The resources and content are compiled from various sources including manufacturers, test labs, crowdsourcing, etc. Our motto is to provide a viable resource for companies, students, and enthusiasts interested in participating in the Li-ion Battery industry. Our initiative is to make people aware of the benefits, and opportunities of the revolutionary Lithium Batteries for multiple applications.
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