Custom High-Efficiency Liquid Cold Plate Aluminum Continuous Brazed Water Cooling Plate for EV Battery & Data Center
Engineered for mission-critical thermal management, our high-performance Liquid Cold Plates utilize advanced vacuum brazing and continuous brazing technology to deliver unmatched heat dissipation for high-power density electronics. Designed specifically for IGBT modules, EV battery packs, server CPUs, and 5G base stations, this aluminum cold plate ensures maximum surface contact and minimal thermal resistance. Whether you are dealing with thermal runaway prevention or edge computing overheating, our customizable pin-fin and serpentine channel designs provide a lightweight, leak-proof cooling solution that scales seamlessly from prototyping to high-volume mass production.
- Stamped Channels: Complex flow paths formed in seconds at low cost, ideal for high-volume scaling.
- Leak-Proof Construction: Solid-state sealed for permanent, maintenance-free operation with no internal contaminants.
- Custom Configurable: Size, port locations, mounting bosses, and surface treatments can be tailored to your module layout.
- Fast Sample Turnaround: Functional prototypes delivered in weeks, using the same production-ready process.
- Certification Support: Full documentation and material traceability to assist with UL 1973 and UL 9540A compliance.
| Item | Parameter / Description |
|---|---|
| Main Material | 3003 / 3003MOD / 6061 Aluminum Alloy |
| Tray Forming Process | High-Precision Progressive Die Stamping |
| Cooling Plate Joining | Vacuum Brazing (CAB – Controlled Atmosphere Brazing) |
| Structural Assembly | Self-Piercing Riveting (SPR) & Flow Drill Screws (optional) |
| Insulation & Damping | Closed-Cell Polyurethane (PU) In-Situ Foaming |
| Surface Finish | Electrostatic Powder Coating (Insulating, RAL options) |
| Ingress Protection | IP67 / IP6K9K (Powder coating + Foam seal design) |
| Coolant Compatibility | Water-Glycol, Dielectric fluids |
| Cooling Channel Integrity | Helium Mass Spectrometry Leak Test, <1*10⁻⁷ mbar·L/s |
| Salt Spray Resistance | ≥1,500 hours (per ASTM B117, with powder coat) |
| Dielectric Strength | 3000V DC (Coating + Foam combined insulation) |
| Customization | Connector openings, cell array mounting holes, sloped drainage |
| Compliance | Designed to UL 1973, UL 9540A, UN 38.3 test profiles |
We solve these problems by treating every cold plate order as a custom engineering project:
· Tailored to Your Module: Our engineering team works directly with your 3D module layout to optimize channel routing, port placement, and mounting features. No compromises, no wasted space.
· Full Certification Support: Every shipment includes complete material mill certificates, dimensional inspection reports, and individual helium leak test records. This documentation package directly supports your UL 1973 and UL 9540A submission.
· Consistent Manufacturing from Day One: We use the same precision stamping and sealing process for single prototypes as we do for 10,000-unit production runs. The thermal and mechanical performance you validate in the lab is what you get in the container.
· Optional Condensation Management: For installations in high-humidity climates, we offer integrated insulation layers and design features that mitigate cold surface sweating.
Send Trumony Aluminum your module dimensions and thermal requirements. Our engineering team will return a preliminary layout and quotation within 5 business days, ready to move into prototyping.
- For high-volume programs, stamped construction ensures the best unit economics without sacrificing thermal performance.
- For corrosive or coastal environments, select the optional trivalent chromium conversion coating.
- Share your module’s 3D model and thermal requirements, and our team will provide a simulated design and production-ready prototype in just a few weeks.
Absolutely. That is the core of our one-stop service. Share your heat load, space envelope, and target thermal performance. Our engineers will propose an initial flow channel design, run CFD simulations for your approval, and then move to prototype. We guide you from idea to serial production.
We have no fixed MOQ for the prototype and NPI (New Product Introduction) stage. For mass production, we work flexibly with your volumes. As a factory serving global clients, we comfortably handle everything from small pilot runs to millions of pieces annually.
Quality is built in from the start. We use vacuum brazing for high-integrity joints and 100% test every single plate with a helium mass spectrometer, achieving leak rates tighter than 1*10⁻⁹ Pa·m³/s. Additionally, we conduct pressure cycling and thermal shock tests on pre-production samples validated according to customer durability requirements.
Yes. Our manufacturing is certified to ISO 9001 and IATF 16949. Our materials and components comply with RoHS, REACH, and UL standards as required by your product. We are also experienced in supporting customers through final system-level UL 9540A or UN 38.3 certification by providing detailed design and material documentation.
We stand behind our workmanship. Our standard product warranty is 5 years when properly operated within specified parameters. In the rare event of an issue, our engineering team provides root cause analysis and works to resolve it immediately. For ongoing production, we maintain complete traceability records tied to each batch.
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Have questions about our products or want to discuss a custom order? Our team is ready to help you.