Lightweight Aluminum Liquid Cooling Plate for EV Battery Pack, ESS, GPU Server, Industrial IGBT Cooling
The booming market of new energy vehicles, grid energy storage and AI computing hardware has brought unprecedented high heat flux challenges, exposing obvious defects of traditional cooling solutions:
First, air cooling cannot cope with high-power fast charging batteries and dense GPU clusters. Limited heat dissipation leads to equipment overheating derating, reduced runtime efficiency and accelerated component aging. Second, low-quality generic cold plates use rough internal flow paths, causing severe temperature imbalance among battery cells, which raises thermal runaway risks and fails strict regional safety codes in US, Germany and Japan. Third, heavy copper cooling plates bring extra load to EV battery packs and push up overall project costs, which is not friendly for mass vehicle manufacturing. Fourth, many cooling plate suppliers lack stable mass production capacity, leading to delayed delivery and inconsistent product quality for overseas importers and system integrators. Fifth, most cooling manufacturers only supply standard sizes without flexible customization, forcing buyers to carry out secondary machining and waste labor & production cycles.
| Item | Technical Parameters |
|---|---|
| Base Material | 3003/6061 aluminum alloy |
| Main Processing Technology | microchannel extrusion, vacuum brazing, embedded tube forming |
| Applicable Coolant | water glycol antifreeze fluid, fluorinated cooling liquid |
| Cooling Performance | 3~5x higher heat dissipation efficiency than air cooling |
| Temperature Uniformity | ≤5℃ overall plate temperature difference |
| Working Pressure | 1.0–3.0MPa, customizable reinforced pressure version |
| Max Custom Size | 1300*2200mm, thickness 5–8mm adjustable |
| Quality Test | 100% air tightness & hydraulic pressure leakage test |
| Global Certifications | IATF16949, ISO9001, CE, RoHS, UL compliant |
| Customizable Items | Outline dimension, internal flow channel, inlet/outlet joints, installation holes, surface anti-corrosion coating |
Core Advantages
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Ultra-Thin & Lightweight, High Integration: Ultra-thin wall design, minimal overall thickness, no occupation of equipment internal space. Lightweight body effectively reduces the overall load of equipment, suitable for portable and miniaturized electronic products.
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Precision Uniform Cooling, No Local Overheating: Micro-precision internal flow channel design, uniform heat dissipation coverage, accurate control of component operating temperature. The temperature balance is excellent, which effectively solves the hot spot problem of precision chip heat dissipation.
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High Safety & Strong Compatibility: Insulated and electrically isolated overall design, safe and non-conductive, avoiding short circuit risk of electronic components. The interface is standardized, compatible with various small circulating cooling systems, and easy to install and fix.
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Exquisite Craft & Long Service Life: Adopts one-piece precision stamping process, no welding gap, stable sealing. The surface is smooth and wear-resistant, anti-oxidation and anti-fouling, adapting to long-term continuous working state of precision electronic equipment.
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The liquid cold plate functions as a compact heat exchanger integrated directly into the battery pack structure.
Thermal Interface: Battery cells transfer waste heat through a thermal interface material to the cold plate's flat contact surface. The high thermal conductivity of 3003 aluminum rapidly conducts this heat into the channel walls.
Fluid Dynamics: Coolant enters through the inlet port and is distributed into the stamped channel network. The channel geometry is designed via computational fluid dynamics to induce controlled turbulence at the target flow rate — typically 2–10 L/min per plate. This turbulent flow disrupts the thermal boundary layer that would otherwise insulate the channel walls, dramatically increasing heat transfer efficiency.
Heat Rejection: As coolant flows through the serpentine or parallel channel matrix, it absorbs thermal energy and exits at an elevated temperature through the outlet port. The heated fluid travels to an external radiator, chiller, or heat exchanger where the thermal energy is dissipated to ambient air before the cooled fluid recirculates.
Structural Integrity: The continuous brazed bond between the stamped top plate and the flat bottom plate forms a pressure vessel capable of withstanding pump pressures, thermal expansion stresses, and vibration loads encountered in automotive and stationary storage environments. Unlike gasketed or O-ring sealed plates, there are no elastomeric elements to deteriorate or relax over time.
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.
Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.