Custom EV Battery Liquid Cooling Plate Progressive Stamping CAB Vacuum Brazing Aluminum Cooling Tray With PU Foam Insulation
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Product Overview Trumony Aluminum Limited supplies high-performance liquid cooling plates for battery modules in commercial and utility-scale energy storage. We combine progressive die stamping and controlled atmosphere vacuum brazing to deliver thermally efficient, leak-proof plates that are ideal for volume production. Flow channels are precision-stamped into 3003 aluminum sheet, ensuring consistent geometry and flatness for optimal cell contact. The stamping route provides uniform quality and avoids the high cost of machining. A cover plate is then vacuum-brazed to the base, forming a continuous metallurgical bond with no flux or residue. Every plate passes a 100% helium leak test (<1×10⁻⁷ mbar·L/s), providing a permanent, maintenance-free seal. The brazed aluminum construction offers low thermal resistance and maintains cell-to-cell temperature variation within ±1.5°C. The plates work with water-glycol, up to 3 bar pressure, and across -40°C to +85°C. This tight temperature control extends battery life and reduces thermal risk. An optional trivalent chromium coating adds corrosion protection without impacting heat transfer. Plates are fully customizable—mounting bosses, tie-rod clearances, connector ports, and coolant fittings are integrated to match your module layout. Trumony provides full material certifications and test reports supporting UL 1973 and UL 9540A compliance. We deliver functional prototypes in weeks using the same production-ready process, and scale smoothly to annual volumes in the multi-gigawatt-hour range. Cause – Why Your Battery Pack Needs a Superior Lower Enclosure
· Thermal runaway propagation: Without integrated cooling, heat
builds up between cells, accelerating degradation and creating
safety hazards. Solution – The Trumony Aluminum Integrated Lower Enclosure · Built-in Liquid Cooling Gallery: Serpentine flow channels are
CNC-machined into the thick aluminum baseplate, allowing direct
contact with the module thermal interface. This ensures cell
temperatures stay within a tight ±2°C band. Parameter Details
Application 1. Electric Vehicle Traction Battery Packs 2. Commercial & Utility-Scale Energy Storage (BESS) 3. IGBT & SiC Power Module Cooling 4. Automotive Ancillary Electronics How It Works Stamped aluminum liquid cooling plates operate on a closed-loop liquid circulation principle. Coolant enters through an inlet fitting, flows through the stamped channel network beneath the heat-generating components, absorbs waste heat, and exits through an outlet to an external heat exchanger. The stamping process forms the intricate channel geometry directly into the aluminum sheet — creating raised features like dimples or chevrons that disturb the fluid boundary layer and enhance convective heat transfer. The cover plate is then joined via continuous brazing, where the assembly passes through a furnace with precisely controlled temperature and inert atmosphere. The brazing filler metal (typically a clad layer on the sheet) melts and forms a metallurgical bond along every contact point, creating a single, leak-proof structure. Because every plate undergoes identical automated processing, thermal performance is exceptionally consistent from the first unit to the millionth. How To Choose Your Stamped Cooling Plate 1. Production Scale vs. Geometry: If your pack design is confirmed
and you need over 2,000 units per year, the stamped + brazed route
offers the best unit economics. If you still iterate frequently,
ask about our hybrid aluminum prototyping options. FAQ Q1: I don’t have a finalized design. Can you help from the concept
stage? 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. Q2: What is the minimum order quantity (MOQ) for custom liquid
cooling plates? 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. Q3: How do you ensure zero leaks in a water-cooled battery pack? 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. Q4: Do you hold certifications for the North American and Asian
markets? 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. Q5: What kind of warranty and after-sales support do you offer for
your cooling plates? 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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| Product Tags: Custom EV battery liquid cooling plate Aluminum cooling tray with PU foam Progressive stamping CAB vacuum brazing |
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