As the demand for lithium-ion battery packs continues to surge—especially in electric vehicles (EVs), energy storage systems (ESS), and portable electronics—the importance of every step in the battery assembly line cannot be overstated. While much attention is given to testing, welding, and sorting, there’s a lesser known but critical process that plays a pivotal role in battery safety and structural integrity: battery extrusion.
What Is Battery Extrusion in Assembly?
In the context of lithium-ion battery manufacturing, extrusion doesn’t refer to material shaping, but rather to the pressing and binding of assembled battery cells into a compact, uniform module or pack. This step ensures that the cells are tightly pressed together, eliminating air gaps and preventing movement or vibration, which can lead to mechanical failure or compromised electrical connections over time.
The Semco SI-N PCEB: Built for Precision Pressing
The Semco SI-N PCEB Battery Extrusion Assembly Station is engineered specifically for shaping and strapping square aluminum shell batteries. It supports a wide range of battery module sizes, accommodating lengths from 180 to 1000 mm and heights from 120 to 260 mm. This versatility makes it suitable for a broad spectrum of applications, from small energy modules to large EV battery packs.
Equipped with pneumatic clamping and a robust pressure control system, the machine applies a controlled force of up to 1 ton when operating at a maximum air pressure of 0.6 MPa. The pressure sensor, with a high accuracy of ±5 kg, ensures uniform distribution across the battery pack, reducing the risk of cell deformation or misalignment.
Why Pressing Matters: Performance and Safety
Battery packs are subject to frequent mechanical stress, especially in mobile or automotive environments. Without firm structural cohesion, cells can shift, swell, or develop internal resistance inconsistencies. This leads to:
- Poor thermal management
- Reduced pack life
- Electrical imbalance
- Risk of short circuits or thermal runaway
Extrusion solves these problems by compressing the pack into a rigid, unified form, reducing gaps and securing every cell in place. It also prepares the pack for subsequent stages like welding, busbar installation, or casing—ensuring alignment is accurate and stable.
Operator-Friendly and Safe
Designed for single-person operation, the Semco extrusion station offers a smooth and structured workflow:
- Adjust frame to pack size
- Insert the battery
- Check polarity and engage pneumatic clamping
- Activate pressing via the push plate switch
- Safely remove the bound battery pack
Safety features like an emergency stop button, manual override options, and insulated materials (e.g., electric planks) make it secure for daily industrial use. Additionally, parts exposed to mechanical stress are made of oxidation-treated aluminum, ensuring long-term durability and resistance to rust or aging.
Maintenance and Reliability
To keep the station running efficiently, regular checks for air leakage, button responsiveness, and structural alignment are recommended. The design also emphasizes quick cleaning and easy troubleshooting, reducing downtime and enhancing productivity.
Closing the Gap in Battery Assembly
In today’s fast-evolving battery industry, small oversights in assembly can lead to big risks. The Semco Battery Extrusion Machine bridges that gap—offering a crucial step between cell alignment and final pack integration.
For manufacturers aiming to scale their production with quality, reliability, and safety at the core, extrusion isn’t optional—it’s essential.
