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Liquid Cooling Tube Liquid Cooling Tube, also known as liquid-cooling tubing / serpentine tubing, is composed of thermally conductive metals (typically copper or aluminium alloys) that have been extruded and corrugated to create an internal structure with a specific number of channels. These channels conform closely to the surface of the battery cells. Serpentine tubing functions as a heat exchanger component in indirect liquid cooling systems, utilizing the circulation of coolant within the channels to dissipate heat generated by the components. Typically, 1 to 2 rows of battery cells are sandwiched between every two serpentine flat tubes. This design effectively increases the heat exchange area on the side of the battery, resulting in a more uniform temperature distribution among individual cells during operation and reducing the temperature difference across the entire battery pack Serpentine tubing finds its primary application in which scenario? — Cylindrical battery side liquid cooling solutions Battery packs are composed of numerous battery cells arranged in a specific configuration. Therefore, when considering thermal management for batteries, the first aspect to account for is the inherent characteristics of the cells. For instance, square-shaped cells can be densely packed with a larger surface area, making them suitable for utilizing stamped liquid-cooling plates for bottom or side heat dissipation. On the other hand, cylindrical cells offer more diverse arrangement possibilities with larger gaps between cells. Hence, they are better suited for side heat dissipation using serpentine tubing that conforms to the curvature of the battery’s surface. With the increasing market demand for cost-effective products, a series of cylindrical cells like 2170, 4680, and 4695 have emerged. It is expected that large cylindrical cells will gradually replace a portion of the market share held by square and pouch cells in the future. Efficient heat dissipation solutions for cylindrical cells of…
Brazing refers to a welding method in which a filler material with a melting point lower than that of the workpieces, and the workpieces themselves, are heated simultaneously to the melting temperature of the filler material. This method involves using the liquid solder to fill the gaps in the solid workpieces, thus creating a metallic connection. During soldering, it is essential to first remove any oxide layers and oil residues from the contact surfaces of the base materials. This facilitates the capillary action of the solder once it melts, enhancing the solder’s wetting and capillary flow properties. Brazing Process The workpieces, which have been cleaned on the surfaces, are assembled in a lap joint configuration, and the solder is placed near or between the joint gaps. When the workpieces and the solder are heated to slightly above the solder’s melting point temperature (the workpieces remain unmelted), the solder melts and, aided by capillary action, is drawn into and fills the gaps between the solid workpieces. The liquid solder and the workpiece metals mutually diffuse and dissolve into each other, forming the brazed joint upon cooling. Advantages of Brazing Process 1. The brazing process can reach temperatures of 500-700 degrees, and the strength of the aluminum sheet increases after cooling following the brazing process. 2. A continuous tunnel-type brazing furnace can accommodate the welding of large components, with typical cold plate dimensions for 52 battery cells reaching 120*85. 3. Brazing can join different types of aluminum sheets, such as pure aluminum and aluminum alloy sheets, with a high-strength brazed layer. 4. Brazing can join thin and thick plates without producing weld seam protrusions. Disadvantages of Brazing Process 1. Brazing furnaces have large volumes and consume significant energy. 2. Brazing requires the use of flux, which may lead to environmental pollution. 3….
The carbon emissions generated by the electricity consumption of data center cooling and air conditioning systems are quite significant. Carbon reduction is one of the four main pathways to achieving carbon neutrality (carbon substitution, carbon reduction, carbon sequestration, and carbon recycling). In order to achieve energy efficiency and emissions reduction in data center cooling and air conditioning systems, the industry has conducted extensive research in various cooling methods, including aisle containment, wind barriers airflow organization heat pipes river water cooling dynamic glycol cooling cooling towers air-cooled chillers refrigerant pumps indirect evaporative cooling enthalpy wheels and direct natural cooling with fresh air Liquid cooling technology can directly utilize natural cooling, significantly reducing power consumption, and helping to reduce the carbon emissions of data centers. Cooling server chips presents a serious challenge, and the temperature of chip packaging shells continues to rise, reaching the limits of air cooling. With a specific heat capacity of 1000 to 3500 times that of air and thermal conductivity 15 to 25 times higher than that of air, liquid cooling is the preferred choice for higher heat density cooling.
The battery enclosure serves as the outer housing that accommodates all critical components of the battery pack, safeguarding elements such as battery modules, electrical systems, thermal management systems(TMS), battery management systems(BMS), and others from the effects of moisture, dust, and other harmful substances. Additionally, it provides impact resistance and protection against external collisions. It’s widely recognized that reducing the weight of the battery enclosure by around 10% can potentially increase the electric vehicle’s range by approximately 6%. The battery enclosure typically accounts for about 20-30% of the total system weight, making it a primary structural component. Consequently, achieving lightweight battery enclosures has become a major focus in improving battery systems while ensuring both the functionality and overall safety of the vehicle. R&D We have dedicated over two decades of experience and resources to our endeavors. With a team of 40+ engineers,who specialized in Metal Process, Thermal Design and Welding. We undertake hundreds of research and development projects every year. Simulation and Modeling We leverage state-of-the-art simulation software and hardware resources for comprehensive product testing and validation. Each product undergoes hundreds of hours of simulation and testing before entering production.(Design For Manufacturer, CFD and more) Testing and Validation Testing and validation are crucial steps in ensuring product quality and reliability. We possess a range of laboratory equipment capable of conducting complex performance and environmental tests. Including flow resistance, coolant temperature impact, burst pressure and so on. Manufacturing Production Our highly automated factories meet large-scale production demands while ensuring product consistency. Our data-driven quality control system maintains a product qualification rate of over 96%. https://youtu.be/kMC1ra-OpcE?si=78iyWORNkNLPOlaX With a comprehensive in-house manufacturing process, XD THERMAL can efficiently select various types of base plates or liquid cooling plates for small-scale thermal management. Coupled with multiple connection methods, our production process strikes a balance between strength and cost-effectiveness when creating…
Types of Liquid Cooling Plates Produced by XD Thermal Electric vehicle battery and energy storage system production facilities require precise temperature control through heating and cooling to optimize battery operations and associated equipment, thereby enhancing operational efficiency. XD Thermal offers professional research and development expertise along with advanced production technologies, delivering the comprehensive liquid cooling solutions to clients. Our solutions aid in the smooth initiation and continuous operation of facilities, ensuring a path to success in the future. Characteristics of a Great Liquid Cooling Plate High Quality-price Ratio Excellent Thermal Conductivity Stable and Safe Ease of Use What Is A Punching Brazed Liquid Cooling Plates? Punched and brazed liquid cooled plates（cold plate) are a special type of heat sink that allows the coolant to be directed directly to the heat source, and the coolant is circulated through the coolant to achieve precise temperature control and efficient heat dissipation. It combines the advantages of the stamping process and brazing technology by stamping the liquid cooling plate to form a certain internal piping or channel system for the flow of coolant (usually water or other cooling media), and then brazing the cooling structure to the heat dissipation surface using brazing technology, which can steadily and uniformly transfer heat from a heat source (such as a battery, a chip, an electronic component, or another), thus achieving effective thermal management. This enables stable and uniform heat transfer from the heat source (e.g. battery, chip, electronic component or other) and thus effective thermal management. Why Choose Punching Brazed Liquid Cooling Plates? Punching: The stamping process has the advantages of low cost and high production speed, and can efficiently produce large quantities of liquid-cooled panels. For example, with a production quantity of more than 1,000 sets, the finished product speed of stamping and brazing production…
New Energy Vehicle Pain Points Despite the rapid growth of electric vehicles, the persistent challenges faced by consumers, such as the difficulties in charging, long charging times, and limited driving range, have continued to hinder their development. These issues have repeatedly become hot topics, highlighting the critical obstacles that need to be addressed in the advancement of electric vehicle technology. Fully Liquid-cooled Supercharger The statement “5 minutes of charging for a 300-kilometer range” has now become a reality, seemingly addressing the issue of “slow charging” in electric vehicles. Liquid-cooled fast-charging technology, as a novel solution to the challenges of electric vehicle charging, has emerged as a focal point in the industry. Liquid-cooled fast charging employs a cooling system that utilizes liquid-cooled plates in the battery section and includes a liquid circulation channel between the cables and the charging gun. Within this channel, a cooling fluid is introduced to dissipate heat efficiently. This cooling fluid is circulated by a power pump, effectively removing the heat generated during the charging process. A fully liquid-cooled design offers superior heat dissipation, reduced noise levels, and extends equipment lifespan to 10-20 years or more. The use of fast-charging stations achieves a charging success rate of over 99%. The comprehensive liquid-cooled fast-charging architecture can cater to the charging requirements of various vehicle models, enabling on-the-spot charging, power sharing, and maximizing the fulfillment of vehicle charging needs. In the future, it will support smooth integration of both AC and DC power with energy storage, facilitating intelligent peak shaving, reducing the need for grid modifications, and enhancing the efficient utilization of electrical resources. The fully liquid-cooled fast charging system delivers a higher charging current and faster charging speeds. The output current of the charging station is constrained by the charging gun cable, which uses copper conductors for electrical…
Commercial Energy Storage VS Large-Scale Storage Industrial and commercial energy storage systems typically have smaller capacities and simpler system functionalities compared to large-scale storage facilities； The requirements for system control in industrial and commercial energy storage are lower than those in energy storage power stations. Additionally, some Power Conversion System (PCS) products in this category also incorporate Battery Management System (BMS) functionality； Regarding Energy Management Systems (EMS), industrial and commercial energy storage systems only require the configuration of charge and discharge times to achieve energy management, with lower functional demands compared to energy storage power stations. Batteries In the realm of industrial and commercial energy storage, there exists a relatively lower demand for rapid response times, influenced by factors such as cost, cycle life, and response time. Consequently, these applications predominantly employ energy-type batteries. Conversely, energy storage power stations utilize power-type batteries for frequency regulation. While many also use energy-type batteries, the necessity to provide auxiliary power services in frequency-regulation power stations imposes higher requirements on cycle life and response time, necessitating the selection of power-type batteries. Battery Management System (BMS) In the realm of industrial and commercial energy storage, the Battery Management System (BMS) for batteries offers the following functions:1.Overcharging, overdischarging, overcurrent, overtemperature, undervoltage, short-circuit protection.2.Voltage balancing during the charging process.3.Parameter configuration and data monitoring through backend software.Integration with various types of Power Conversion Systems (PCS) for intelligent management of the energy storage system. Battery Management System (BMS) In the realm of industrial and commercial energy storage: 1. Overcharging, overdischarging, overcurrent, overtemperature, undervoltage, short-circuit protection. 2. Voltage balancing during the charging process. 3. Parameter configuration and data monitoring through backend software.Integration with various types of Power Conversion Systems (PCS) for intelligent management of the energy storage system. For Energy Storage Power Stations: 1. Hierarchical and stratified unified management, resulting in…
The battery production process introduces inconsistencies between individual battery cells, which gradually become more pronounced during actual usage. The performance of batteries is influenced by factors such as charge-discharge cycles, ambient temperature, and discharge currents. As a result, practical battery performance may exhibit deviations from theoretical expectations. During operation, batteries tend to follow a ‘weaker gets weaker, and at a faster rate than the stronger’ trend. This undoubtedly poses significant challenges to battery thermal management and energy conversion. So, how difficult is it to achieve uniform battery temperature? In one-dimensional designs, where batteries are neatly arranged, the flow direction and battery temperature changes can be observed clearly as the cooling medium flows from left to right. (Temperature is lower near the cooling medium and higher away from it.) In two-dimensional designs, when multiple rows of batteries are staggered, it becomes less intuitive to determine the flow direction, speed of the cooling medium, and cooling conditions. Which battery experiences a higher temperature rise? Which battery exhibits greater temperature differences? This requires the use of fluid dynamics and heat transfer simulations to make informed judgments. In three-dimensional designs, one must take into account vehicle structure and battery cell arrangement (such as the irregular distribution seen in Tesla’s battery pack, as depicted in the diagram). This complexity adds considerable challenges to the design, simulation, and testing of thermal management systems. Batteries, despite being unassuming, are remarkably intricate devices. This becomes particularly evident in the realm of new energy vehicles, where they involve disciplines like measurement and control technology, energy conversion techniques, power transformation strategies, system integration, and manufacturing processes. Even though perfect cell uniformity may not exist, we continue to strive for minimal disparities in battery temperatures. This isn’t merely an isolated concern; it’s a systemic challenge that necessitates interdisciplinary collaboration…
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