Balancing performance and manufacturability in battery cooling plates

With the rapid development of electric vehicles, energy storage systems, and high-efficiency rail transit, the performance of battery thermal management systems has become a key factor restricting the efficiency and safety of the entire system. As a core heat exchange unit in the thermal management system, the liquid cooling plate faces technical challenges in every aspect, from flow channel design to welding processes. How to achieve efficient heat exchange, lightweight structure, structural stability, and scalability under complex working conditions is a core issue widely discussed in the current industry.

Technical Challenge 1: Flow Channel Design and Thermal Uniformity Control

In practical applications, the uneven distribution of heat dissipation requirements for battery cells and frequent changes in operating conditions place strict demands on the design of micro-channels inside the liquid cooling plate. Overly dense channels can result in excessively high pressure drops, while those that are too sparse fail to ensure heat exchange efficiency. In a typical power battery pack, if the operating temperature difference between individual battery cells exceeds ±3°C, it will significantly affect cell life span and SOC consistency.

To address industry challenges, the technical team at XD THERMAL has independently developed a simulation system to model various cell arrangements, load conditions, and coolant properties, enabling thermal uniformity optimization early in product development. The engineering team introduced solutions such as multi-zone distribution adjustment, branched main channels, and gradient transition structures into flow channel design to improve the distribution balance of coolant in complex pathways. As a result, experimental measurements showed that for a cold plate installed on a 72 prismatic cell module, the temperature difference on the cell surface was only 2.4°C. This design not only reduces the risk of overheating but also enhances the overall pack’s operational uniformity, providing a more stable foundation for customers’ BMS algorithm optimization.

Technical Challenge 2: Balance Between Material Compatibility and Thermal Conductivity

Liquid cooling plates need to operate for long periods under conditions of high humidity, high corrosion, and high pressure, while also possessing good thermal conductivity and structural stability. Different application scenarios have significantly different requirements for material strength, corrosion resistance, and processability. The widely used aluminum alloy materials on the market often involve trade-offs between corrosion resistance and thermal conductivity.

Based on specific application needs, XD THERMAL selects various high-performance aluminum alloy series—for example, the 3 series for energy storage applications with high corrosion resistance requirements, and the 5 series for power battery systems requiring high strength. To improve the thermal conductivity of cooling plates, the company applies local additive manufacturing technology to enhance heat diffusion capability in key areas in some products.

Technical Challenge 3: Welding Quality and Sealing Reliability

The internal flow channel structure of liquid cooling plates is complex. Traditional brazing methods may be prone to defects such as air trap and welding blockage when dealing with multilayered and irregular structures, which can affect the sealing performance and mechanical strength of the cooling channels. In addition, deformation control during mass production is also a significant challenge. The FSW (Friction Stir Welding) process can achieve a qualified rate of up to 98.5%, but local thermal effects may still lead to deformation of ±0.4mm, while TIG (Tungsten Inert Gas) / CMT (Cold Metal Transfer) and other techniques in complex corners frequently have micro-leakage rates between 1% and 2%.

In response, XD THERMAL employs a combination of multiple welding processes, including friction stir welding (FSW), laser welding, and vacuum brazing, to match the processes to different product structures. For example, for cold plates used in large-size or high-pressure scenarios, FSW combined with laser spot welding is given priority to reduce thermal deformation; for precision structures, laser spot welding is used to achieve high positioning accuracy. The company has also developed a complete set of online air tightness detection and weld imaging technologies to ensure the consistency and safety of products leaving the factory. Verified results show that the annual pass rate of cold plate air tightness tests exceeds 99.7%, and typical plate differential pressure tests can withstand 0.6 MPa static pressure for 10 minutes without leakage.

Technical Challenge 4: Large-Scale Customization and Flexible Production

Battery systems are developing towards diversification and high integration, and liquid cooling plates are increasingly showing trends of non-standardization, small batches, and multiple interfaces. XD THERMAL addresses this from the source of the process, dividing the cold plate structure into standard functional areas and customized edge areas based on modular design concepts, thus achieving large-scale sharing of parts and standardization of key interfaces. At the same time, the company has introduced automated process sections and flexible fixture systems, effectively shortening model changeover time and improving customized response speed. According to feedback from the company’s production department manager, it is now possible to achieve integrated delivery of the entire process from design, simulation, sample processing to functional validation within as few as 15 working days.

In Conclusion

Every advancement in liquid cooling plate technology is backed by a systematic understanding of application scenarios, material properties, and manufacturing processes. With the continuous deepening of electrification, the role of thermal management systems is becoming increasingly central, especially as energy density rises and structural integration accelerates, resulting in ever-higher technical requirements for liquid cooling plates.

In the future, liquid cooling products will not be limited to “heat dissipation”, but will also take on more functional designs, such as structural support, sensor integration, and localized temperature control feedback. The industry will pay greater attention to simulation-driven design, extreme operating condition adaptability, and the integration of green manufacturing methods. Emerging centers of electrification like India are also accelerating the upgrading of local supply chains.

In recent years, XD THERMAL has assisted several Indian vehicle and battery pack enterprises in implementing cooling system solutions, including well-known brands such as Ashok Leyland and Tata Auto comp, demonstrating the adaptability and development potential of thermal management technology in different markets.

Thermal management is becoming a key pillar of innovation for new energy systems and is opening broader technological possibilities for the entire industry.

Company Details:

Name: XD THERMAL TECHNOLOGY CO., LTD

Website: https://www.xdthermal.com

Email: inquiry@xdthermal.com

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