Battery Module Side Plate – Structural Support for EV & Energy Storage Module

Material Selection

• Weight Sensitivity: Aluminum is preferred for EV applications where reducing overall battery pack weight is critical.

• Mechanical Load: Steel is selected when modules are subjected to high vibration or mechanical impact.

• Thermal Management: Aluminum offers better heat dissipation, beneficial for high-current modules.

• Cost Efficiency: Steel provides a lower-cost option for stationary energy storage systems where weight is less critical.

• Electrical Insulation: Insulation coating is required when the side plate is in close proximity to busbars or cell terminals to prevent unintended electrical contact.

Welding Preparation

• Surface Preparation
  Aluminum oxides must be removed by mechanical brushing or chemical cleaning. Steel surfaces should be free of rust or zinc residues to prevent porosity.

• Joint Fit-Up
  Gap tolerance must be maintained at ≤0.1mm for laser welding and ≤0.3mm for resistance welding to ensure consistent penetration and fusion.

• Weld Point & Groove Design
  Weld points or adhesive grooves are precisely designed based on module strength requirements and assembly sequence.

• Hybrid Bonding
  When combining welding with adhesive, welding is performed first to avoid thermal degradation of the adhesive.