Plastic lithium battery cases measuring 120x120x90mm are critical for protecting lithium-ion cells from physical damage, environmental factors, and thermal issues. These cases, often made of ABS or polycarbonate, ensure safe energy storage in applications like solar power systems, medical devices, and industrial equipment. Their standardized sizing simplifies integration while offering customization options for vents, terminals, and mounting systems.
How to Prevent Lithium-Ion Battery Fires and Explosions
How Do Dimensions Impact the 120x120x90mm Battery Case’s Functionality?
The 120x120x90mm dimensions balance compactness with capacity, fitting 100-200Ah lithium cells. This size optimizes space efficiency in tight installations like drones or robotics while maintaining structural integrity. Precise internal ribbing prevents cell movement, reducing short-circuit risks. The 90mm height accommodates standard BMS (Battery Management System) layouts, ensuring seamless compatibility with most lithium battery configurations.
Why Choose Plastic Over Metal for Lithium Battery Enclosures?
Plastic offers 40% lighter weight than aluminum cases, reducing overall system mass. It resists corrosion from humidity or chemicals, unlike metal, and provides innate electrical insulation. Advanced polymers like flame-retardant ABS (UL94 V-0 rated) maintain stability at -30°C to 80°C. Plastic also allows complex geometries for custom vents, cable glands, and snap-fit assemblies impossible with sheet metal fabrication.
Top 5 best-selling Group 14 batteries under $100
| Product Name | Short Description | Amazon URL |
|---|---|---|
|
Weize YTX14 BS ATV Battery  |
Maintenance-free sealed AGM battery, compatible with various motorcycles and powersports vehicles. | View on Amazon |
|
UPLUS ATV Battery YTX14AH-BS  |
Sealed AGM battery designed for ATVs, UTVs, and motorcycles, offering reliable performance. | View on Amazon |
|
Weize YTX20L-BS High Performance  |
High-performance sealed AGM battery suitable for motorcycles and snowmobiles. | View on Amazon |
|
Mighty Max Battery ML-U1-CCAHR  |
Rechargeable SLA AGM battery with 320 CCA, ideal for various powersport applications. | View on Amazon |
|
Battanux 12N9-BS Motorcycle Battery  |
Sealed SLA/AGM battery for ATVs and motorcycles, maintenance-free with advanced technology. | View on Amazon |
Modern plastic formulations now incorporate glass-fiber reinforcement to achieve tensile strengths exceeding 80 MPa, rivaling some aluminum alloys while maintaining weight advantages. The inherent dielectric properties eliminate the need for secondary insulation coatings required in metal enclosures. Injection molding techniques enable precise wall thickness control (±0.2mm tolerance) for optimal weight distribution. Unlike metal cases that require welding or riveting, plastic enclosures can be produced with integrated hinge systems and tamper-proof latches in single manufacturing cycles.
What Safety Standards Govern Plastic Lithium Battery Cases?
These cases must meet UN38.3 (vibration/shock resistance), IEC 62133 (fire containment), and IP67 waterproof standards. Critical features include flame arrestors in venting systems, 1.5mm minimum wall thickness, and UL-certified self-extinguishing materials. Some manufacturers incorporate built-in pressure relief valves that activate at 15-20 psi to prevent catastrophic failure during thermal runaway events.
Compliance with IEC 62619 mandates specific material behavior during thermal stress tests, requiring plastics to maintain structural integrity after 150 hours at 85°C with 85% relative humidity. UL 2596 certification ensures proper containment of electrolyte leaks through specialized channeling designs. Recent updates to NFPA 855 require battery enclosures to limit heat release rates below 25kW/m² during failure scenarios, achieved through advanced intumescent additives in polymer formulations.
Which Industries Rely on 120x120x90mm Battery Cases?
| Industry | Application | Key Requirement |
|---|---|---|
| Telecom | 5G Microcell Backup | IP65 rating, -40°C operation |
| Marine | Navigation Systems | ISO 8846 ignition protection |
| Medical | Portable MRI Machines | FDA-compliant materials |
| Renewables | Solar Storage | UV-resistant polymers |
How Does Customization Enhance Plastic Battery Case Utility?
Top manufacturers offer CNC-machined terminal slots (M6-M12 bolt sizes), dual-material overmolding for gaskets, and laser-etched labeling areas. Advanced options include integrated coolant channels for liquid thermal management and RFID tags for inventory tracking. Some cases feature modular designs allowing daisy-chaining of multiple units via interlocking grooves rated for 500+ mating cycles.
What Are the Environmental Considerations for These Cases?
Leading producers use 30% recycled ABS (PCR content) without compromising UL94 ratings. End-of-life cases can be shredded and reprocessed at 240-260°C extrusion temperatures. The 120x120x90mm size aligns with EU Battery Directive 2023 requirements for standardized disassembly, with snap-fit designs enabling tool-free separation of plastic, metal, and cell components for recycling.
How to Install and Maintain 120x120x90mm Battery Cases?
Installation requires torque-controlled tightening of terminals (typically 2-4 N·m) using anti-oxidant paste. For maintenance, conduct quarterly inspections of O-rings (replace if hardness exceeds 80 Shore A) and apply dielectric grease to connectors. Storage recommendations include keeping cases at 40-60% SOC (State of Charge) in environments below 50°C to prevent polymer stress cracking.
“The 120x120x90mm plastic case has become the de facto standard for mid-capacity lithium systems. Recent advancements like carbon-fiber reinforced nylon (20% weight reduction) and 3D-printed gasket channels are game-changers. We’re now seeing cases with embedded strain gauges that monitor cell swelling—critical for predictive maintenance in mission-critical applications.”
– Dr. Elena Voss, Battery Systems Engineer, 2023 Energy Storage Summit Keynote
The 120x120x90mm plastic lithium battery case combines precise engineering with material science to address modern energy storage challenges. From its IP67-rated seals to customizable thermal management features, this enclosure format supports safe, efficient power delivery across industries while meeting evolving sustainability mandates through recyclable materials and modular designs.
FAQs
- Can these cases withstand extreme temperatures?
- Yes—premium variants operate reliably from -40°C to 125°C using PPS (polyphenylene sulfide) construction.
- Are threaded inserts available for mounting?
- Most manufacturers offer M4-M8 threaded brass inserts molded directly into case walls with 200+ N pullout strength.
- How do I verify case authenticity?
- Look for laser-etched QR codes linked to material certificates and UL file numbers on genuine products.