The aluminum block battery modules have more cells hold in one case with different arrangement for series and parallel config, like 1S12P, 2S6P, 3S4P etc., The top part of battery module is a plastic frame with several metal sheet bars built in, the pouch cell tabs will go through them and lay down, to have laser welding on metal sheet bars for the parallel and series config. Among battery modules here are soft-link busbars with screws for further connection. We build aluminum case for battery modules, because it has light weight, nice shell protection towards outside force, and good heat conduction when cells are in some high charge and discharge conditions. Bestgo made patents on modules design, they are easy for assembly and reliable in configuration, it simplifies the 3D design of the battery package structure, and makes the assembly process in production easier and quality control more reliable.

Here are some examples of Bestgo aluminum block modules.
For example, if one module has model name of BAB110-N-2S6P, BAB110 means it has 110mm thickness, N means chemistry of Li-NCM, 2S6P means cells arrange is 2 in series and 6 in parallel config.

For Li-NCM chemistry,
BAB110-N Series, with Li-NCM 3.7V 37Ah cells, can hold up to 12 cells. (Can use 32Ah cells to build smaller Ah modules)

BAB74-N Series, with Li-NCM 3.7V 37Ah cells, can hold up to 8 cells. (Can use 32Ah cells to build smaller Ah modules)

For LiFePO4 chemistry,
BAB110-F Series, with LiFePO4 3.2V 30Ah cells, can hold up to 12 cells.

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The cassette sheet battery modules hold the cells exactly with aluminum sheets like a sandwich way. Aluminum sheets can help cells improving the heat passion and enhance the strength of structure. On the two ends of module here are plastic units and metal sheets can be installed well, cells tabs will go through then and lay down on metal sheets for laser welding. The parallel and series connection will be directly done on the metal sheets. We can also separate the entire structure to several parts then use the busbars for connection, as cassette structure is easy to be extended in length direction. Our cassette sheet module structure has low height (about 100mm) and extensible size in design, they are best suitable for building battery packs as “skate structure” in low profile chassis of electric vehicles.

For Size calculation, The size of cassette sheet module can be easily calculated, the height of battery module is 102mm, the width of module is 370mm, the length of modules is depends on how many cassette sheets been used. Every sheet can hold 2 of 48Ah cells and has thickness of 24mm, here are 2 of extra plastic protection boards pressing those cassette sheets, plastic board has thickness of 12mm. So the length of cassette module is “numbers of aluminum sheets used * 24mm + 2 of plastic protection board * 12mm”. For example, a 51.8V 96Ah cassette sheet module, Here are 28 pcs of 3.7V 48Ah cells, which needs 14 aluminum sheets, so the module length is 14*24mm+2*12mm=360mm. If calculate for the 51.8V144Ah module, it will have the length of 528mm.

We use direct laser welding to build the battery modules made with prismatic aluminum cells. Those cells belong to VDA cells which used for high speed electric vehicles, which request high reliable connection in electricity, their terminals are aluminum nodes for laser welding with aluminum busbars. We use holding tools to put them together, then use high precision laser welding machine with big power to do the process, with big laser welding to melt down the aluminum, the battery terminals can firmly attach to the busbars, ensure the reliable connection in electricity. After that we will use ultrasonic detecting to check the welding is done all right well.