Custom EV Battery Liquid Cooling Plate Progressive Stamping CAB Vacuum Brazing Aluminum Cooling Tray With PU Foam Insulation

Application

1. Electric Vehicle Traction Battery Packs
Our stamped cold plates are installed between prismatic or pouch cell modules to maintain optimal temperatures during highway driving and DC fast charging. The high flatness ensures maximum contact with cell surfaces, while robust brazed joints withstand years of vibration and thermal cycling.

2. Commercial & Utility-Scale Energy Storage (BESS)
For containerized and cabinet-type storage systems using high-capacity cells. Stamped plates with multi-parallel channels keep dozens of cells within a 2°C temperature band, extending system life beyond 10,000 cycles and meeting UL 9540A safety test requirements.

3. IGBT & SiC Power Module Cooling
Power inverters, motor controllers, and renewable energy converters demand compact cold plates that handle extreme heat flux. Our pin-fin stamped designs maximize surface area directly beneath semiconductor substrates, reducing junction temperatures and preventing thermal throttling.

4. Automotive Ancillary Electronics
On-board chargers, DC-DC converters, and ADAS compute units also benefit from our lightweight stamped plates, which integrate easily into tight vehicle packaging envelopes.

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.
2. Condensation Management: If your system operates in 80%+ relative humidity, specify the full PU foam injection package. This prevents cold-plate “sweating” and subsequent cell terminal corrosion.
3. Corrosion Class: For standard outdoor exposure, a polyester powder coat is sufficient. For coastal installations, we recommend a marine-grade epoxy powder primer prior to the topcoat.
4. Mounting Integration: Inform us of the exact mounting bushing type, as we can install stainless steel Helicoils or threaded inserts via heat-staking during the stamping process to ensure thread durability.
5. Custom Drain Paths: In the event of a coolant leak, we can stamp sloped drainage channels into the base metal, directing fluid safely away from high-voltage electronics towards a designated leak port.