In the field of lithium battery custom processing, designing a reasonable battery structure and layout is a core element in ensuring product performance, safety, and applicability. This process requires comprehensive consideration of cell characteristics, application scenarios, space constraints, and thermal management requirements, achieving a balance between performance and cost through systematic design. The following analysis covers design principles, cell arrangement, electrical connections, thermal management, mechanical protection, space adaptation, and verification optimization.
The primary principle of lithium battery custom processing is to clearly define the core requirements of the application scenario. For example, portable devices have high requirements for battery energy density and volume, necessitating the selection of high-energy-density cells and optimized compact layout; while industrial equipment may prioritize cycle life and charge/discharge efficiency, requiring adjustments to the series and parallel connection of cells to balance performance. The design team needs to communicate deeply with the customer to extract key parameters (such as voltage, capacity, charge/discharge rate, and operating ambient temperature), using this as a basis to build the design framework and avoid rework due to unclear requirements.
The cell arrangement directly affects the energy density and safety of the battery pack. In lithium battery custom processing, cell arrangement must balance space utilization and heat dissipation efficiency. Common battery arrangement methods include series, parallel, and hybrid connections. Series connection can increase voltage, but cell consistency must be ensured to avoid the "weakest link" effect. Parallel connection can increase capacity, but a balancing circuit must be designed to prevent overcharging and over-discharging. For high-power applications, a modular design can be adopted, grouping the cells and managing each group independently, reducing the risk of fault propagation and facilitating later maintenance. Furthermore, the cell spacing needs to be adjusted according to heat dissipation requirements to avoid localized overheating and safety hazards.
Electrical connection design is a key technical aspect of lithium battery custom processing. Connection methods (such as welding, crimping, and bolting) must be selected comprehensively based on current magnitude, vibration environment, and cost. For example, ultrasonic welding or laser welding is preferred in high-current scenarios to reduce contact resistance; fatigue-resistant connectors are required in high-frequency vibration environments. Simultaneously, the circuit layout must follow the "short and straight" principle, reducing line length to lower internal resistance and energy loss, and avoiding intersections to prevent short-circuit risks. In addition, a reasonable fusing mechanism (such as PTC, fuses) and voltage monitoring points must be designed to achieve overcurrent and overvoltage protection, improving system safety.
Thermal management design is crucial for ensuring performance and lifespan in lithium battery custom processing. Cells generate heat during charging and discharging; poor heat dissipation can lead to capacity decay, shortened lifespan, and even thermal runaway. The design must select the appropriate heat dissipation method based on the cell's heating characteristics: for low-power applications, natural cooling can be used, improving heat dissipation efficiency by optimizing cell spacing and casing materials (such as thermally conductive plastics); for high-power applications, integrated liquid or air cooling systems are necessary, using coolant circulation or forced convection fans to remove heat. Additionally, thermally conductive silicone or phase change materials can be filled between cells to homogenize temperature distribution and prevent localized overheating.
Mechanical protection design aims to protect the battery pack from external impacts, vibrations, and environmental corrosion. In lithium battery custom processing, the casing material must possess high strength, corrosion resistance, and flame retardancy. Common materials include aluminum alloys, plastics (such as PC/ABS), and composite materials. Structurally, reinforcement ribs and cushioning pads enhance impact resistance, and a sealed design prevents moisture and dust intrusion. For automotive or outdoor applications, IP protection ratings (such as IP67) must be considered to ensure stable operation of the battery pack in harsh environments.
Space-adaptive design requires balancing performance and installation constraints. In lithium battery custom processing, customers often have specific requirements for battery size and shape (such as irregularly shaped batteries or ultra-thin designs). Design teams need to optimize space through cell selection (such as replacing cylindrical cells with pouch cells) and structural innovation (such as replacing wound cells with stacked cells). For example, in drone battery design, lightweight materials and compact layouts can be used to increase energy density within a limited space; in smart home devices, flat designs are needed to adapt to small installation spaces.
The structural and layout design of lithium battery custom processing needs continuous optimization through simulation analysis and field testing. Thermal simulation software (such as Fluent) is used to simulate cell temperature distribution and adjust the heat dissipation structure; mechanical simulation (such as ANSYS) is used to evaluate shock resistance and optimize the casing design. The testing phase requires charge-discharge tests, vibration tests, and high- and low-temperature cycling tests to verify the design reliability. For example, during testing, a custom battery pack was found to have excessively high local temperature rise. By adding thermal pads and optimizing the airflow design, the temperature difference was eventually controlled within 5°C, significantly improving performance stability.
