Power Battery Structural Components

# Power Battery Structural Components: Breaking Industry Pain Points, Company Solutions Lead the Way

## I. Insight into Industry Pain Points

With the rapid development of the new energy vehicle industry, power battery structural components, as core components, face multiple severe challenges. Firstly, **safety performance under pressure**. Under conditions such as charging - discharging cycles, high - temperature environments, and mechanical impacts, if micro - deformations or cracks occur in structural components, it is easy to trigger thermal runaway risks, threatening the safety of the entire vehicle. However, traditional structural designs and material selections struggle to ensure long - term structural integrity under complex working conditions. Secondly, **the contradiction between lightweight and strength**. To improve the range of new energy vehicles, battery pack lightweighting is required, but blindly reducing weight sacrifices structural strength. In scenarios such as vehicle driving vibration and collision, structural components are easily damaged, affecting the service life and reliability of the battery pack. Thirdly, **inefficient production collaboration**. Power battery structural components involve multiple links such as mold development, material processing, and surface treatment. The industry generally has problems of poor supply chain collaboration and slow information flow, resulting in long production cycles, high costs, and difficulty in quickly responding to the market's demand for battery iterations. Fourthly, **insufficient adaptability**. Different vehicle models and battery systems (such as ternary lithium, lithium iron phosphate) have different requirements for the size, interface, and heat dissipation design of structural components. The existing structural components with low standardization are difficult to flexibly adapt to diversified needs, increasing the integration difficulty for vehicle manufacturers.

## II. Decoding of Company Solutions

### (I) Safety Enhancement System

The company focuses on the core safety demands of structural components and adopts a **new composite structure design**. Through simulation of extreme working conditions such as battery thermal runaway and mechanical impact, the stress distribution of structural components is optimized. High - strength, high - temperature - resistant reinforcing ribs and buffer layers are embedded in key parts (such as cell brackets, shell frames). For example, a carbon fiber - reinforced composite material bushing is integrated inside the aluminum shell to improve the structure's resistance to deformation and cracking. At the same time, **high - purity, high - stability materials** are selected, and special heat treatment is performed on aluminum alloy profiles to refine the grain structure, enhancing the mechanical properties and corrosion resistance of the material itself, and reducing potential safety hazards from the source.

### (II) Lightweight - Strength Balance Solution

**Topology optimization technology** is applied. With the help of computer - aided design, redundant materials in non - stressed areas of structural components are accurately removed. For example, the battery tray is designed with a hollowed - out, grid - like structure, ensuring structural strength while reducing weight. An innovative **multi - material hybrid integration** process is also adopted. Lightweight and high - strength magnesium alloy is used for the cover plate with less force, high - strength steel is used for key connection parts, and an aluminum - steel composite structure is used for the shell, achieving the synergy of "lightweight + high rigidity". Compared with traditional single - material structural components, the weight is reduced by 15% - 20%, and the strength is increased by more than 10%.

### (III) Full - process Collaborative Intelligent Manufacturing

A **digital supply chain collaboration platform** is built, integrating resources such as mold factories, material suppliers, and processing workshops to achieve real - time sharing of order, design, and production data. In the mold development link, 3D printing rapid prototyping and mold flow analysis technology are adopted, reducing the mold development cycle by 30%. In the production process, an intelligent production line is introduced, equipped with a visual inspection and adaptive processing system, to monitor dimensional accuracy and surface quality in real - time, ensuring a good product rate of more than 99%. From order to delivery, the overall cycle is shortened by 25% compared to the industry average, efficiently responding to market demands.

### (IV) Customized Adaptation Service

A **modular + customized product matrix** is established. Generalized structural modules (such as standardized cell fixing frames, interface components) are pre - developed, and then module combination and local optimization design are quickly carried out according to the needs of customer vehicle models and battery systems. For the high - heat characteristics of ternary lithium batteries, the layout of structural components in the heat dissipation channel is optimized; for lithium iron phosphate battery packs, the low - temperature tolerance design of structural components is strengthened. Through the "general module + customized fine - tuning" mode, it can adapt to more than 80% of the design requirements of mainstream battery packs, reducing the integration difficulty and cost for vehicle manufacturers.