Shell sealing technology of lithium batteries for motorcycle starting
main content
As the core power unit of the ignition system of internal combustion engines, the sealing technology of the casing of the lithium battery for motorcycle starting directly determines the battery's waterproof, dustproof, shockproof performance and long-term cycle stability. Under complex working conditions such as high temperatures, vibrations, and rain erosion, the enclosure sealing system needs to simultaneously meet multiple requirements including lightweight, high mechanical strength, and chemical inertness.
Key technologies for sealing structure design
Multi-layer composite sealing system
The first layer (physical sealing) : Laser-welded aluminum shell joints, with a weld width of 0.2-0.5mm and an air tightness of 1×10⁻⁷ Pa·m³/s, which is three orders of magnitude better than traditional argon arc welding.
The second layer (elastic cushioning) : A 0.5mm silicone gasket is embedded between the cover plate and the shell, with a Shore hardness of 35A and a compression permanent set rate of less than 10% (150℃/72h).
The third layer (chemical protection) : The shell surface is sprayed with a 50μm polyurea coating, with a salt spray resistance of > 1000 hours (ASTM B117), and is resistant to acid rain erosion.
Modular sealed interface design
Double sealing of the terminal post: Between the copper terminal post and the shell, a fluororubber O-ring (6mm in diameter) + hot melt adhesive double sealing is adopted, with a contact resistance of less than 0.1mΩ and a leakage rate of less than 5×10⁻⁸ mbar·L/s.
Intelligent control of pressure relief valve: When the internal pressure exceeds 1.5MPa, the PTFE membrane ruptures to relieve pressure. After pressure relief, the self-healing coating (containing microcapsule epoxy resin) automatically seals the crack.
Sealing Performance Standards and Testing Techniques
Protection grade standard (IP code)
Ip67-level protection: The shell needs to undergo A 30-minute immersion test in a water depth of 1 meter, with an internal humidity of less than 5%RH and a leakage current of less than 1μA.
IP6K9K (Automotive grade) : Can withstand the impact of a high-pressure water gun at 80℃ (100bar), with a shell deformation of less than 0.1mm, meeting the water wading conditions of motorcycles.
Helium mass spectrometry leak detection technology
The micro-holes in the weld seam were precisely located by using the vacuum helium detection method (detection limit 1×10⁻¹² mbar·L/s). By optimizing the design of the detection chamber (such as patent CN217765378U), the helium residue is less than 1ppm, and the detection efficiency is increased by 50%.
Accelerated aging test
After the wet heat cycle (-40℃→85℃/95%RH, 1000 cycles), the retention rate of the peel strength of the shell sealant is > 90%, and the change in the leakage rate is < 5%.
Conclusion
The casing sealing technology of motorcycle starting lithium batteries is a culmination of material innovation, structural design and precise craftsmanship. From the atomic-level bonding of aluminum alloy laser welding to the dynamic adaptive sealing of silane glue, every breakthrough is redefining the reliability boundaries of batteries and laying a solid safety foundation for the power revolution of two-wheeled vehicles.
START-STOP LITHIUM battery
Enov start-stop battery is designed to provide excellent performance for high-demand start-stop vaehicles. It adopts the third-generation intelligent lithium platform architecture to achieve technological breakthroughs in core indicators such as cycle life, environmental adaptability and energy density. Compared with the traditional lead-acid battery system, the energy efficiency is increased by 210%, the cycle life is extended by 8-10 times, and the monthly self-discharge rate is controlled within 3%. Enov's unique low-temperature battery technology makes a breakthrough in achieving stable output in the whole climate domain from -30℃ to 65℃, maintaining more than 90% of the effective capacity release under extremely cold conditions (-30℃), and maintaining 90% of the capacity in high temperature environments (65℃).
The start-stop battery series products cover the mainstream voltage platform of 12V/24V/48V, and support flexible configuration of LFP (lithium iron phosphate) and NCM (lithium nickel cobalt manganese oxide) dual-material system. All models adopt modular design to support customization of different model specifications. Enuo engineering and technical team to provide full cycle technical service support, if you need, please contact us.
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