Aluminum battery shell are widely used in the current era of new energy. As we knows, Batteries generate a lot of heat during operation. and the aluminum battery shell can provide the protection of cooling, waterproofing, and corrosion resistance, so it can extend the battery’s lifespan.

Probably you are wondering how to design better drawings for aluminum battery case extrusions. and how to design the part of shape, size, corner radius, and thickness radius and so on.

Well, we have an answer for you – choose a better way to get a aluminum battery case extrusion model.

You should know that the size and shape design of the battery case are based on the spatial design of the battery, and it also needs to meet the requirements of the installation location.

Different shapes are suitable for different battery shell scenarios, as follows.

The square shape 

The square shape is the most widely used aluminum battery profile shell shape, and It is suitable for applications that require more heat sinks or ventilation holes.

As you know, batteries need good heat dissipation under high load conditions. Because of the square structure, the arrangement and layout of the internal components are more convenient.

Additionally, due to its right-angle frame, the square aluminum battery extrusion shell is easier to fix and assemble in the installation environment.

A square shape is also very suitable for applications with high heat dissipation performance and large spaces, such as high-performance industrial motors, electric vehicle motors, and equipment that requires frequent maintenance.

However, when you compare to the circular shape, you can find that the square shape has disadvantages compared to the circular shape. In terms of stress distribution, it may not be as stable as the circular shape, but by reinforcing the edges and corners in the design, its structural strength and durability can be effectively increased.

The Circle shape  

The circular shape is suitable for high-performance applications as it offers good heat dissipation and structural stability.

If your battery product has a symmetrical structure, when you design the shape of aluminum battery profile, using the circular shape aluminum battery profile is very appropriate. for the circular design can effectively distribute stress, circle shape shell reduce stress concentration, and increase the durability of the battery product’s protective casing.

What’s more, You can find that the circular frame can distribute and dissipate heat more evenly; its heat dissipation uniformity is better than that of a square frame.

In addition, the aluminum profile circular frame work in the high-vibration and high-load environments, it can maintain a stable structure, so it is suitable for demanding applications such as industrial motors and heavy equipment.

When an aluminum extrusion factory performs aluminum extrusion, the circular shape is relatively easy for the extrusion machine to handle due to its simple design. The precision in tolerance will not have significant deviations, and it is also easier to maintain and clean.

 Triangular Shape

The triangular battery aluminum profile is a type of aluminum material specifically used for manufacturing battery casings, with a triangular cross-section.

Stress distribution  

when you design the cross-section of an aluminum battery case, you should avoid stress concentration and uneven stress distribution, as these can easily lead to case rupture. At the same time, you can use appropriate curvature to effectively disperse stress.

In the extrusion molding of battery aluminum profiles, the factor that most affects the strength is the extrusion pressure during the extrusion process. For example, when extruding some aluminum profiles with heat sinks, the additional tensile stress on the head of the inter-tooth suspended tube caused by the excessive metal flow speed of the semi-solid structure heat sink can lead to the fracture of the inter-tooth suspended tube.

Therefore, when designing the mold structure of battery shell profiles, the goal should be to reduce the extrusion pressure , and improve the state of the inter-tooth suspended tube by adjusting the metal flow speed and force, thereby improving the strength of the mold.

Thickness design

For the wall thickness of the extrusion housing, it depends on the space of the product on one hand, and also depends on the load-bearing force on the other hand.

For the thickness of the screw-fixed support arm, thickness of the screw-fixed support arm. In some designs of screw-fixed support arms, you need to pay attention to the thickness of the fixed support arm. If the fixed support arm is too thin, the supporting screws are prone to breakage. Moreover, for extrusion profile factories, a too-thin support arm is prone to breakage during extrusion.

When a battery operates under high load, it requires a well-designed profile casing for heat dissipation. Generally, we provide heat sinks as a part of aluminum profile shell.

Here, we discuss the design of heat sinks for extruded aluminum profiles. We know that the heat sink of extruded aluminum profiles, including the fins and the baseplate, is integrated without joints. This has the advantage of uniform heat conduction within the radiator and a high thermal conductivity. Unfortunately, there are also disadvantages, as it is limited by the extrusion process. The dimensions of the profile and the spacing, thickness, and height of the fins and plates are restricted.

Heat Sink Material

When you choose aluminum profiles, you generally use 6061 or 6063 alloy materials, which have very good heat dissipation effects.6063 has better extrudability and surface treatment performance on the heat sink compared to 6061 aluminum profiles.

Shapes

flattened and wide, comb-like, fishbone-like, radial, or tree branch-like.

Number and position of heat sinks

When designing aluminum profiles for battery enclosures, it is necessary to add densely distributed and evenly arranged heat sinks. As shown in the circular aluminum profile above, This method can improve heat dissipation efficiency.

Generally speaking, the distance between heat sinks is short, and there is a groove between adjacent heat sinks, with a relatively large aspect ratio and significant wall thickness difference.

Typically, we consider the space between the teeth of the heat sinks to be semi-hollow, so it is necessary to ensure the strength of the heat sinks. Currently, there are some relatively mature mold structures, such as covered split-flow molds, cutting split-flow molds, and suspension bridge split-flow molds.

When the extrusion factory produces aluminum battery cases with heat sinks, products with smaller and symmetrical shapes are easier to extrude. If the depth-to-width ratio of the grooves between the heat sinks is very large, the production difficulty is very high.

For the heat sinks of battery aluminum profiles, the flow rate of each tooth should be as uniform as possible.

When designing heat sink profiles, increasing the number of diversion holes also increases the number of diversion bridges, making the distribution of metal flow rate and quantity more uniform. As the number of diversion bridges increases, the width of the diversion bridges decreases accordingly.

The thickness of the heat sink

We usually make the mistake of thinking that the thicker the heat sink, the better the cooling effect. However, the truth is that the cooling effect is proportional to the wind-facing surface. Excessive profile wall thickness does not guarantee better cooling effect; on the contrary, overly thick heat sinks can lead to a waste of resources.