Stamped Aluminum Battery Pack Lower Enclosure with Brazed Liquid Cooling Plate & PU Foam Insulation
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Product Overview Engineered by Trumony Aluminum Limited, this Battery Pack Lower Enclosure adopts a multi-process aluminum manufacturing approach that prioritizes production efficiency and consistent quality. Instead of conventional steel welding or expensive full-machining, we utilize high-precision stamping for the main tray structure, followed by a vacuum brazing process to create a leak-proof, integrated liquid cooling plate. Self-piercing riveting (SPR) is employed to assemble multi-layer structural reinforcements without thermal distortion, while a polyurethane (PU) foaming process delivers superior vibration damping and condensation prevention. Finally, an electrostatic powder coating finish delivers excellent insulation and corrosion resistance. This enclosure solution meets the demands of North American commercial and utility-scale energy storage projects, offering an ideal balance of thermal performance, lightweight design, and mass production scalability. 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 Commercial & Industrial (C&I) Storage Cabinets: Ideal for
100kW to 1MW systems where quiet, condensed-format enclosures are
required indoors and outdoors. How It Works The base of the battery module directly rests on the brazed cooling plate. As cells generate heat during operation, energy passes through a thermal interface layer into the coolant flowing inside the brazed aluminum plate, carrying the heat away to the HVAC chiller. Meanwhile, the PU foam bonded beneath the plate creates a thermal barrier to ambient humidity, preventing moisture formation inside the sealed enclosure. Mechanically, road shock or pack movement is absorbed by the foam core and the elastic riveted joints, rather than transmitting stress to the cell terminals. Finally, the powder-coated outer skin isolates the pack’s internal potential from the rack, preventing arc flash risks during installation and maintenance How To Choose Your Stamped Cooling Plate 1. Heat Load & Flow Rate: Determine total watts to dissipate
and available coolant flow (L/min). Our engineers use this to
calculate required channel cross-section and plate size. Simply reach out with your requirements. We return a comprehensive proposal including die design feasibility, CFD thermal report, and transparent cost breakdown for prototype, pilot, and mass production phases. 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: stamped aluminum battery tray battery pack lower enclosure with cooling PU foam insulated battery enclosure |
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Stamped Aluminum Battery Pack Lower Enclosure with Brazed Liquid Cooling Plate & PU Foam Insulation |