Are you frustrated by liquid cooling plates that corrode quickly, reduce efficiency over time, or fail under harsh conditions? Do you worry that untreated plates might lead to unexpected equipment breakdowns, compromised safety, or an unprofessional appearance that impacts your brand’s reputation? These challenges are common among companies that rely on untreated cooling plates, risking both performance reliability and long-term cost efficiency in critical applications.
Surface treatment on liquid cooling plates prevents corrosion, enhances heat transfer, improves durability, ensures electrical safety, delivers a professional finish, and enables consistent performance in challenging environments.
Let’s dive deeper into each method, supported by data, industry standards, and real-world success stories and hopefully inspire your choices
As mentioned earlier, effective surface treatment maximizes heat transfer, protects against corrosion, and improves overall battery pack longevity, directly influencing EV reliability and operational costs.
Studies indicate that well-treated cooling plates can enhance thermal efficiency by up to 20%, prolonging battery life and reducing maintenance. This ensures consistent performance even under extreme temperatures, humidity, and load cycles.
According to a 2022 report in a leading automotive engineering journal, proper surface treatments can cut failure rates by 15-25% over a battery’s operational lifespan. As EV manufacturers face rigorous safety and performance regulations—such as UNECE R100 or IEC 62660—investing in the right surface treatment ensures robust, reliable performance and reduced downtime.
From traditional approaches to cutting-edge finishes, multiple treatment options exist to address corrosion, conductivity, and cost-effectiveness in various EV scenarios.
Popular choices include anodising (durable oxide layers), electroplating (enhanced conductivity), polymer and ceramic coatings (corrosion prevention), epoxy spraying (chemical resistance), and UV coating (scratch resistance). Each method aligns with distinct operational and environmental requirements.
Epoxy spraying is favored for its robust chemical resistance and stable adhesion, often essential in high-humidity environments. UV coatings, hardened by ultraviolet light, provide a smooth, durable finish with low environmental impact. A 2023 European battery consortium study highlighted UV coatings’ stable dielectric properties, making them a rising star for EV cooling plates needing both aesthetic and functional longevity.
Choosing the right method involves balancing advantages—like enhanced conductivity or corrosion protection—against potential drawbacks in cost, complexity, and maintenance needs.
Anodising: Affordable, corrosion-resistant, but slightly less conductive.
Electroplating: Highly conductive, but more intricate and costly.
Coatings (Polymer/Ceramic): Strong corrosion barriers, moderate cost.
Epoxy Spraying: Excellent chemical resistance, requires precise application.
UV Coating: Scratch-resistant, stable, slightly higher initial investment.
Industry standards like ISO 9227 (for corrosion testing) and IATF 16949 (for quality management systems) guide material selection. Engineering experts often consult SAE technical papers to benchmark performance. For instance, high-performance EVs may prefer electroplating for maximum conductivity, while epoxy or UV treatments may excel in harsh climates where corrosion and abrasion pose significant risks.
A tailored approach involves assessing operating conditions, regulatory requirements, cost constraints, and sustainability goals before finalizing the surface treatment method.
Consider climate (humidity, salt exposure), battery design (power density, energy capacity), and lifetime targets. Factor in total lifecycle costs, including installation, maintenance, and potential downtime. Engaging an experienced supplier ensures that chosen methods meet both technical and financial criteria.
For EV fleets operating in monsoon-prone regions, epoxy spraying’s robust chemical resistance may be indispensable. High-performance racing EVs might lean towards electroplating for peak thermal conductivity under intense loads. Consulting engineering consultants with global project experience allows evaluating multiple methods through cost-benefit analyses and predictive simulations to optimize long-term value.
XD THERMAL’s integrated capabilities, global experience, and engineering know-how ensure clients receive data-driven, validated, and customized surface treatment solutions.
With over 300 successful battery cooling projects and IATF 16949-certified processes, XD THERMAL employs in-house testing labs equipped with thermal imaging and corrosion chambers. We deliver end-to-end solutions—from R&D and design through validation and mass production—to meet diverse international standards.
Our facilities integrate extrusion lines, machining centers, and various surface treatment options under one roof. Advanced CAE simulations help predict performance under real-world conditions. We align with global standards, like ASTM B117 for salt spray testing, ensuring every solution meets or exceeds client expectations. By partnering with XD THERMAL, clients benefit from comprehensive engineering support, reduced lead times, and strategic cost savings.
Choose a surface treatment aligned with performance, cost, and compliance goals. XD THERMAL’s global expertise and certified processes ensure durable, efficient, and custom EV battery cooling solutions.
EN 
DE 
ES 
KO 