XD Thermal uses all different workmanship to fit in with your engineering needs.
Hydroformed Cooling Plates
Hydroformed cooling plates is the type which most preffered in automotive industry. Suitable for massive production, balanced with cost and mechanical strength.
XD Thermal is a professional liquid cooling plates manufactuer in China, with rich experience in supplying cooling components for automotive OEMs and other fields which run Li-ion battery packs. We not only produce cooling parts, but also provide engineering service, including design, simulation and validation tests.
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SPEC
t1
t2
R1
R2
h1
h2
MATERIAL
3003/4343; 3003/4045
3003
/
/
/
/
THICKNESS
0.8, 1.0, 1.2, 1.5, 2.0
0.8, 1.0, 1.2, 1.5, 2.0, 2.5
3
5
2~6mm
3.8~8mm
Mates to be matedfor Your Cold Plate
There are multiple mating parts that work together with cooling plates and battery cells. Each part mated and assembled in every battery pack.
Over the past 4 years, your expertise in designing battery cooling plates has significantly enhanced our electric vehicle battery packs. Your ability to deliver customized solutions swiftly without compromising quality is unparalleled. The rapid and smooth handling of our orders, from placement to delivery, truly sets you apart. We deeply appreciate your exceptional service and look forward to continuing our successful partnership. Thank you for being a reliable pillar of our supply chain.
Elliot MeadowsBattery Mechanical Engineer
It’s rare to find a partner who can match our pace, especially with the super rapid development lead time. Your straightforward, no-nonsense approach makes the whole process smooth and reliable. Keep up the great work!
Jake WilliamsProject Leader
Great. It's been a year since we started working together, and I've got to say, your liquid cooling plates are top-notch! You've helped us up our game in the eVTOL. Since it is quite new application, your knowledge of battery thermal management helped us a lot in finalizing our first eVTOL project.
Melisa PomeroProcurement Manager
FAQs
If your question isn't here, feel free to drop us an email anytime!
Prismatic cells and pouch cells are usually assembled in a cluster, with a flat interface at bottom side or sometimes top side. Thus this two kinds of cells are compatible with XD Thermal cooling plates.
XD Thermal provides validation tests, by doing multiple tests, clients can have quantifiable data about burst pressure, anti-corrosion performance, flow resistance and so on.
Each cooling components manufactuered by XD Thermal will be tested with helium tester, which is a much accurate and sensitive testing method over water test.
Hydroformed cooling plates is taking the biggest share, as it is economical for massive product. However, in some specific areas, especially when high strength is required, extrusion and FSW are also preferred.
At XD THERMAL, our liquid cold plates are essential for efficient battery thermal management, ensuring optimal performance and safety. Engineered to automotive-grade standards, these plates prevent overheating, enhance durability, and maintain consistent temperature distribution across battery packs. With our commitment to quality, certified by IATF 16949, we guarantee products that meet strict industry requirements, delivering significant benefits to your battery systems. Choose XD THERMAL for superior protection and performance.
Table of Contents
What is liquid cooling plate?
Liquid cooling plates is considered as an active cooling components for battery packs, especially for Li-ion battery packs. Heat generated and accumulated while battery go through charging and discharging. Without heat management, battery life and performance would be seriously impacted. Thus liquid cooling plates is commonly deployed in today’s Li-ion battery packs.
What is liquid cooling?
Liquid cooling mainly uses water-glycol mixture or freon-like coolant. These fluids runs inside of cooling components, absorb heat from the interface where they run through. Fluids working mode: cool fluids go into components via inlets–> absorb heat –> go out of components via outlets–> fluids cooled down via external chiller –> again go into components.
What advantages does liquid cooling have?
Battery pack size can be more compacted; Cooling effectiveness much higher than air cooling; higher IP projection level; possibility of waste heat recycle; Compatible in wider range of climate.
What material is used in making battery cooling plates?
Aluminum is the most preferred material, because aluminum is lighter and recyclable. 3003, 3005, 6061, 6063 are some of the common aluminum alloys used. 3 series enjoy excellent anti-corrosion performance, in most 3 series coolign plates proejcts, it can withstand over 1000 hours of salt spray test. 6 series material is usually used in higher strength solution, some PDU cooling plates which is expected to bear weight load are mostly seen in 6 series.
How many kinds of liquid cold plates are there?
a) Hydroformed cooling plates, also called stamped cooling plates, it is most universal solution for most of Li-ion battery packs.
b) Extruded cooling plates. The main body of the parts is done by extrusion. Internal structure can be customized.
c) FSW cooling plates. FSW stands for Frinction Stir Welding. It is a very reliable way of joining separate metal pieces into one. FSW can maintain 70% of original metal’s mechanical strength.
d) Machining cooling plates. This kind of cooling plates are mainly used in developing proto samples. Investment of tooling is not needed, so usually machinning cooling plates can be finished with a shorter lead time.
e) Roll-bond cooling plates. Roll-bond plates were widely used in home appliance industry, for example refrigerators. The channels are made by high pressure air blowing.
How a cooling plate is been made?
There are multiple types of cooling plates. However, there might be several steps which are in common.
Step 1 , Material preparation. For example shearing, extrusion, laser cutting and so on.
Step 2 , Flow channel/chamber processing. For example stamping, machining, pressure blowing.
Step 3 , Connector/accessories processing. For example, inlet & outlet, mounting beams.
Step 4 , Welding. For example, brazing, FSW, CMT.
Step 5 , Surface treatment. For example, polish, insulation coating.
Step 6 , Test and verification.
What is brazing, and what does it do in cooling plates production?
Yes, brazing is used for joinning channel plate and cover plate. The brazing process will make the aluminum material stay in a semi-melded condition, then channel plate and cover plate will attached to each other, and a strong joint between them will be created.
How many types of brazing will be used in cooling plates production?
There are three popular brazing ways.
First one is continuous brazing, or called corridor brazing. It is done in a long and open furnace.
Second one is vacuum brazing. It is done in a closed capsule-like chamber.
Third one is induction brazing. It is done near a heated circuit.
What brazing method should I use?
When eyeing on highest productivity, and shorter cycle time, continuous brazing suits you well.
When higher strength is required, and cooling plates is thicker in its dimension, go for vacuum brazing.
When bonding is required in a tiny area, induction brazing should be on your list.
What kind of connectors/inlets & outlets are recomended?
Connectors, sometimes also called inlets & outlets, are the places where cooling plates connecting to pipeline systems. Since connectors play the role of mating, so its dimension and shape should match its mating parts. We suggest following SAE, VDA or CQC standards. Under these standards’ connectors, pipelines can be easily assembled.
How connectors are made?
Usually connectors are made from CNC, stamping and die casting.
How to make insulation on top of cooling plates?
Below are the popular ways of cooling plates insulation.
Do insulation coating on external surface of cooling plates.
Attach insulation films on top of cooling plates.
Use thermal interface materials to do both heat transfer and insulation job.
Things you should know before designing a cooling plate
In order to make a robust cooling plate. There are certain ABCs to follow. For example, choose the right thickness of raw material when running pressure is at the higher side; When maintaining mechanical strength is at top priority, then try to avoid heat treatment in the production of cooling plates.
What is common running pressue for cooling plates?
Mostly it stays between 1-2 bars for most of cooling plates and its systems for passenger cars. For heavy duties or other utilities, running pressure would be higher.
Should I always go for as much as lower flow resistance?
The answer is no. Cooling plates job is do proper heat dissipation inside of battery packs. When flow resistance is way low, it will make fluid run much faster than it should be. Too fast speed means less time of heat exchange, heat transfer could not be sufficiently done.
What insulation level should I set?
2U+1K is the design guideline for most projects. Find nominal voltage of your battery pack, make it two times more then plus 1000 V. This standard suits most of the senarios.
What ultimate pressure can cooling plate withstand?
For hydroformed cooling plate, it usually higher than 12 bars.
For extruded coolingplate, it is usually higher than 50 bars.
What is the thermal interface material between cooling plates and cells?
Thermal interface material called TIM for short, it is a silicon based material which aims to fill invisible gap between cells and cooling plates. TIM could guarantee sufficient contact between cooling plates and cells, and at the same time TIM also become an efficient conductor of heat transfer.
The tests might required for a cooling plate project
Apart from regular products tests, cooling plates will have to go through a series of validation tests.
Anti-corrosion tests
Anti-corrosion tests will verify cooling plates’ durability in corrosion environment. External tests will be done with salt spray chamber. Internal tests will be done in circulation stations. Based on the materials’ selection, XD Thermal’s cooling plate will be durablemore than 1000 hours in corrosion tests.
Burst pressure
Burst pressure tests will help designers to locate cooling plate’s ultimate pressure resistance. One of the inlets or outlets will be sealed before testing, pressure with liquid will be injected from another port till cooling plate start cracking. Normally, hyroformed cooling plate will withstand 12bars – 20bars pressure; extruded cooling plate could withstand over 50 bars.
Flow resistance
Too much flow resistance will add unnecessary burden to the cooling system’s pump. At the same time, higher flow resistane means reduced flow speed, in most of the cases, cooling plates could not reach to heat dissipation target with too high flow resistance. So get flow resistance optimized and tested in development period if very important. Such tests can be done in a liquid circulation station.
How to install a cooling plate?
Horizontal Installation
Flat side to sky, to be mated with battery cells. In between cells and cooling plates, there usually be thermal interface materials( thermal pads or glues). Cooling plates sit on top of cushion pads, then mounted onto batter case beams.
Vertical installation
Cooling plate attached to left or right side of cluster of prismatic cells. Usually mounting hole will be deployed at top and bottom areas of cooling plates. Cooling plates will be mounted to end plates fromcluster of prismatic cells.
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